Doosan D110S-5 with OCDB Quick start guide

Vehicle System
Disassembly & Assembly
D110S-5 with OCDB
D130S-5 with OCDB
D160S-5 with OCDB
SB4376E01
Aug.2012

Vehicle System Index1
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
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, lubrication, 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.

Vehicle System Index3
INDEX
Forks........................................................5
Remove & Install Forks.....................................5
Carriage...................................................6
Remove & Install Carriage.................................6
Carriage Rollers......................................7
Remove & Install Carriage Rollers.....................7
Disassemble & Assemble Carriage Rollers........7
Disassemble & Assemble Carriage....................8
Mast .........................................................9
Remove Mast....................................................9
Install Mast......................................................10
STD Mast........................................................11
Disassembly................................................11
Assembly........................................................14
FFT Mast.........................................................18
Lift Cylinder...........................................20
Removal & Installation.....................................20
Disassembly....................................................22
Assembly........................................................24
Tilt Cylinder...........................................25
Removal & Installation.....................................25
Disassembly & Assembly ................................26
Brake Assembly....................................29
Removal & Installation.....................................29
Remote Control Valve ..........................31
Replacing the parts .........................................31
Attachment Carriage ............................33
Lift Cylinder and Mast..........................33
Hydraulic Pump ....................................35
Removal & Installation.....................................35
Start-up Instructions & Recommendations.......36
Rotation & Ports Indication...........................36
Start-up :......................................................36
Removal of Air in Pump – Motor line................36
Pump & Cartridge Breakdown Drawing............37
Disassembly....................................................38
Reassembly ....................................................43
Seal Driver......................................................48
Dimension of Protective Cone .........................48
Hydraulic Oil Filter................................49
Removal & Installation.....................................49
Disassembly & Assembly ................................49
Universal Joint......................................50
Removal & Installation.....................................50
Disassembly & Assembly.................................51
Steering Wheel & Gear.........................52
Steering Wheel................................................52
Removed & Disassembly of Steering Gear.......52
Assembly of Steering Gear..............................54
Steer Axle ..............................................58
Removal & Installation.....................................58
Steering Cylinder..................................60
Removal & Installation.....................................60
Disassembly & Assembly.................................62
Steering Knuckle, Kingpin And Bearings
................................................................64
Removal & Installation.....................................64
Steer Tire And Rim................................67
Removal & Installation.....................................67
Removal of Wheel Bearing ..............................67
Installation of Wheel Bearing............................68
Drive Tire And Rim................................69
Removal & Installation.....................................69
Counterweight.......................................70
Removal of Air.......................................71
Pump – Motor line............................................71
After changing main pump ...............................71
Air in Brake system..........................................72
Removal of the High Pressure in accumulator..72
Emergency Lowering.......................................73
Removal and installation of Engine and
Transmission...................................................74

Vehicle System Disassembly & Assembly5
Forks
Remove & Install Forks
1. Pull out pin assembly (1) from the fork.
2. Remove two bolts, washers (2) and plate (3).
3. Support the fork with strap and hoist. Remove
shaft (4). Remove strap and hoist from the fork.
The weight of the fork is 217 to 465 kg (477 to
1025 lb).
4. Tilt the mast at full forward direction. Lower the
carriage until fork is separated from the carriage.
Drive the truck at backward direction.
5. Repeat steps 1 through 4 for the other fork.
6. Install the forks in the reverse order of removal.

Vehicle System Disassembly & Assembly6
Carriage
Remove & Install Carriage
Start By :
a. Remove forks.
1. Completely lower carriage and inner mast.
2. Attach a hoist to the carriage as shown.
3. Lift the carriage with the hoist until the chains and
hoses hang loosely.
4. Put identification marks on sideshift cylinder
hoses if equipped. Disconnect two hoses.
5. Remove the cotter pin and pin (2) from both of the
lift chains.
6. Start the engine. Raise the mast until the inner
mast clears the carriage.
7. Remove the carriage. The weight of the carriage
is 936 kg (2063 lb).
NOTE : The following steps are for installation of the
carriage. See the topic entitled Carriage Adjustment
in the Testing and Adjusting Manual before installing
the carriage on the mast.
8. Attach a hoist to the carriage as shown.
9. Start the engine. Raise the mast until the carriage
will go under the inner mast.
10.Move the carriage in position under the mast.
11.Completely lower the mast over the carriage
making sure the rollers are properly aligned
inside the inner mast.
12.Connect two hoses. If necessary, raise the
carriage slightly with the hoist.
13.Pull the chains into position on the carriage.
Install pin (2) and the cotter pin in both of the lift
chains.
14.Make an adjustment to the lift chains. See the
topic entitled Chain Adjustments in the Testing
and Adjusting Manual.
End By :
a. Install forks.

Vehicle System Disassembly & Assembly7
Carriage Rollers
Remove & Install Carriage Rollers
Start By :
a. Remove carriage.
1. Remove the snap ring (1) that holds the roller in
place.
2. Remove load roller (2) from the carriage.
NOTE : The following steps are for installation of the
carriage rollers.
3. Put the load roller in position on the carriage.
4. Install the snap ring that holds the roller in place.
End By :
a. Install carriage.
Disassemble & Assemble Carriage
Rollers
Tools Needed A B
Bearing Cup Puller Attachment 1
Puller Assembly 1
Ratchet Box Wrench 1
Bearing Installer 1
Start By :
a. Remove carriage rollers (load).
1. Remove snap ring (1) from the roller.
2. Remove bearing (2) from the roller using the tool
group (A).
NOTE : The following steps are for the assembly of
the carriage rollers.
3. Put (pack) clean grease in the bearings for the
load roller.
4. Install bearing (2) in the roller using tool (B).

Vehicle System Disassembly & Assembly8
5. Install snap ring (1) in the roller.
End By :
a. Install carriage rollers (load)
Disassemble & Assemble Carriage
Start By :
a. Remove carriage
Tools Needed A
Bearing Cup Puller Attachment 1
1. Remove snap ring (1) with tool (A).
2. Remove roller (2) from the pin of the carriage.
3. Remove bolts (4), washers, roller and bracket
assembly (3) and shims (5) from carriage
assembly.
4. Disassemble the roller and bracket assembly (3)
as follows:
a. Remove grease fitting (6).
b. Remove bolt (7) and washer that hold shaft (8)
in bracket.
NOTE : When assembly, apply Loctite No.242 to
bolt thread.
c. Tap the shaft (8) and remove shaft from
bracket.
d. Remove spacers (9) and roller (10).
e. Remove bushings (11) from roller (10).
Replace the bushings with new ones if worn or
damaged.
NOTE : Assemble carriage in the reverse order of
disassembly.
End By :
a. Install carriage.
b. Make an adjustment to the carriage (see Carriage
Adjustment in Testing and Adjusting).