Doosan D50S-5 User manual

Power Train
Specification
System Operation
Testing & Adjusting
Disassembly & Assembly
D50S-5, D60S-5, D70S-5, D80S-5, D90S-5
G50S-5, G60S-5, G70S-5
Two Speed Transmission
Drive Axle (OCD , SHOE)
SB4274E00
Sep. 2007

1
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read
and understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING"
as shown below.
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, Iubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DOOSAN dealers have the most
current information available.
WARNING

Power Train Index3
Index
Specification
General Tightening Torque ...................................5
Drive Axle Specification........................................6
Torque Converter..................................................7
Transmission Pump..............................................7
Drive Axle Mounting..............................................8
Differential ............................................................8
Wheel Bearing and Drive Wheel ...........................8
Brake Assembly....................................................9
Brake Drum Diameter.........................................10
U - joint...............................................................10
System Operation
General Information............................................11
Power Shift Transmission....................................12
General Information.........................................12
Power Flow at Low Speed Forward..................13
Power Flow at High Speed Forward.................14
Power Flow at Low Speed Reverse..................15
Power Flow at High Speed Reverse.................16
Transmission Control Valve................................17
Cross-Section View..........................................17
Hydraulic Schematic........................................18
Differential and Drive Axles.................................20
Differential .......................................................20
Wheel Hub.......................................................20
Brake Components.............................................21
Shoe Brake......................................................21
Brake Adjuster.................................................21
OCDB..............................................................22
Testing and Adjusting
Troubleshooting..................................................23
Visual Checks..................................................23
Checks During Operation.................................23
Check List During Operation ............................23
Check List From Operation Noise.....................25
Check List From Pressure Test........................26
Differential .......................................................27
Transmission Pressure.......................................28
Converter Stall Test............................................29
Shimming of Transmission Shaft.........................30
Wheel Brake Adjustment.....................................30
Inching Pedal Adjustment....................................32
Disassembly and Assembly
Drive Shaft and Universal Joint............................35
Engine, Torque Converter and Transmission.......36
Transmission Control Valve.................................40
Transmission.......................................................43
Drive Axle ...........................................................54

Power Train Specification5
Specification
General Tightening Torque
GENERAL TIGHTENING TORQUE FOR
BOLTS, NUTS AND TAPERLOCK STUDS
The following charts give the standard torque values for bolts, nuts
and taperlock studs of SAE Grade 5 of better quality. Exceotions
are given in other sections of Service Manual where needed.
THREAD DIAMETER STANDARD TORQUE
inches millimeters lb•ft. N•m*
Standard thread
Use these torques for bolts and nuts with standard
threads (conversions are approximate).
1/4 6.35 9 ± 3 12 ±4
5/16 7.94 18 ±5 25 ±7
3/8 9.53 32 ±5 45 ±7
7/16 11.11 50 ±10 70 ±15
1/2 12.70 75 ±10 100 ± 15
9/16 14.29 110 ±15 150 ±20
5/8 15.88 150 ±20 200 ±25
3/4 19.05 265 ±35 360 ±50
7/8 22.23 420 ±60 570 ±80
1 25.40 640 ±80 875 ±100
1 1/8 28.58 800 ±100 1100 ±150
1 1/14 31.75 1000 ±120 1350 ±175
1 3/8 34.93 1200 ±150 1600 ±200
1 1/2 38.10 1500 ±200 2000 ±275
Use these torques for bolts and nuts on hydraulic
valve bodies.
5/16 7.94 13 ±2 20 ±3
3/8 9.53 24 ±2 35 ±3
1/16 11.11 39 ±2 50 ±3
1/2 12.70 60 ±3 80 ±4
5/8 15.88 118 ± 4 160 ±6
Taperlock stud
Use these torques for studs with Taperlock threads
1/4 6.35 6 ±2 8 ±3
5/16 7.94 13 ±4 17 ±5
3/8 9.53 26 ±4 35 ±5
7/16 11.11 33 ±7 45 ±10
1/2 12.70 48 ±7 65 ±10
9/16 14.29 65 ±11 90 ±15
5/8 15.88 80 ±11 110 ±15
3/4 19.05 125 ±15 170 ±20
7/8 22.23 190 ±22 260 ±30
1 25.40 300 ±30 400 ±40
1 1/8 28.58 370 ±30 500 ±40
1 1/4 31.75 480 ±37 650 ±50
1 3/8 34.93 550 ±37 750 ±50
1 1/2 38.10 640 ±37 870 ±50
*1 newton meter(N•m) is approximately the same as 0.1 mkg.

Power Train Specification6
Drive Axle Specification
Shoe Type
Differential 2.636 / D(G) 50/70S-5
3.100 / D80/90S-5
Planetary 4
Gear Ratio
Total 10.545 / D(G) 50/70S-5
12.400 / D80/90S-5
Axle Oil SAE #80 or #90
Drive Axle
Oil Volume 12.5 L
Service Brake Shoe Brake
Brake Oil AZOLLA - ZS10
Brake
Parking Brake Drum Brake
Gear Type Spiral Bevel Gear
Differential Differential Type 4 Pinions
OCDB Type
Differential D(G)50/70S-5 : 2.636
D80/90S-5 : 3.100
Planetary 4
Gear Ratio
Total D(G)50/70S-5 : 10.545
D80/90S-5 : 12.400
Axle Oil MOBIL #424
Drive Axle
Oil Volume 12.5 L
Service Brake Oil Cooled Disk Brake
Brake Oil AZOLLA - ZS10
Brake
Parking Brake Drum Brake
Gear Type Spiral Bevel Gear
Differential Differential Type 4 Pinions

Power Train Specification7
Torque Converter
(1) Torque for bolts (plate to torque converter)
.....................................45 ± 7 N∙m (33 ± 5 lb•ft)
Apply LOCTITE NO. 277 sealant to threads of
bolts.
(2) Torque for bolts (plate to flywheel)
.....................................25 ± 7 N•m (18 ± 5 lb•ft)
(3) End play of turbine hub (new) .
............................... 0 to 0.99 mm (0 to 0.039 in)
Maximum end play of turbine hub (worn)
.............................................1.65 mm (0.065 in)
(4) Torque for bolts (torque converter to PTO gear)
.....................................20 ± 3 N•m (15 ± 2 lb•ft)
Apply LOCTITE NO. 277 sealant to threads of
bolts.
NOTE : For Torque values not given, see the page
of specifications for general tightening torques.
Transmission Pump
(1) Clearance between outside of drive gear and
crescent 0.36 to 0.43 mm (0.014 to 0.017 in)
(2) Clearance between inside of driven gear and
crescent 0.25 to 0.33 mm (0.010 to 0.013 in)
(3) Gear end play....................... 0.025 to 0.064 mm
(0.0010 to 0.0025 in)
4
1
2
3

Power Train Specification8
Drive Axle Mounting
(1) Torque for nuts.....800 ± 50 N•m (590 ± 37 lb•ft)
Apply LOCTITE NO. 271 sealant to threads of
bolts.
Differential
1. Apply Loctite No.271 to threads of bolt. Torque
for bolts that hold bevel gear to differential
housing is....................132 ± 5 N•m (98 ± 4 lb•ft).
2. Apply Loctite No.271 to threads of bolts. Torque
for bolts is......................59 ± 5 N•m (43 ± 4 lb•ft).
3. Apply Loctite No.271 to threads of bolts.
Torque for bolts.......... 157 ± 5 N•m (116 ± 4 lb•ft)
Consider same marking on brackets to the
housing.
4. Apply Loctite No.271 to threads of bolts.
Torque for bolts................10 ± 2 N•m (7 ± 2 lb•ft)
5. Apply Loctite No.271 to threads of bolts.
Torque for bolts.......... 177 ± 5 N•m (130 ± 4 lb•ft)
6. Torsional backlash of bevel gear...0.18~0.23 mm
Wheel Bearing and Drive Wheel
Shoe Axle
OCDB Axle

Power Train Specification9
Slotted nut adjustment
a. Tighten slotted nut (1) slightly by hand.
b. Tighten slotted nut (1) to 640 N•m (472 lb•ft).
c. Rotate wheel hub several times.
d. Turn back slotted nut (1) slightly and retighten
until bearing friction torque reaches to 10~14
N•m (7.4 to 10.3 lb•ft).
e. Apply Loctite No.271 on the threads of bolt (2).
Secure slotted nut (1) with bolt (2) with tightening
torque of 19~24 N•m (14~18 lb•ft).
f. Assemble thrust washer (3) with Loctite # 609.
g. Torque for Spindle bolt (5) ...............118 ± 5 N•m
(87 ± 4 lb•ft)
h. Torque for Service piston bolt (6) ....15 ± 0.1 N•m
(11 ± 0.01 lb•ft)
i. Torque for wheel nut (7)................550 ± 50 N•m
(406 ± 37 lb•ft)
Brake Assembly
Torque for bolts (1).......19 to 22 N•m (14 to 16 lb•ft)
Torque for bolts (2)...... 120 ± 20 N•m (90 ± 15 lb•ft)
ICPS0005S
1
2