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).

Vehicle System Disassembly & Assembly9
Mast
Remove Mast
Start By :
a. Remove carriage.
1. Fully lower mast.
2. Fasten a hoist to the mast as shown.
3. Tilt the mast forward. Disconnect hydraulic lines
(1).
4. Bend back the tab on clip (4).
5. Remove bolt (3), clip (4) and block (2).
WARNING
Tilt cylinders can drop when pin (6) is removed.
To avoid component damage or personal injury,
support tilt cylinder while removing pin (6).
6. Remove retaining bolts (5). Remove pin (6).
7. Repeat Steps 4, 5 and 6 for the other side of the
mast.
8. Start the engine. Operate the control lever for the
tilt cylinders until the rods are fully retracted.
9. Remove the mast from the frame of the vehicle.
The weight of the mast is approximately 2600 to
4400 kg (5732 to 9700 lb).

Vehicle System Disassembly & Assembly10
Install Mast
1. Install the mast on the frame of the vehicle. The
weight of the mast is approximately 2600 to 4400
kg (5732 to 9700 lb).
2. Start the engine. Operate the control lever for the
tilt cylinders until the holes in the cylinder rods are
aligned with the holes in the mast.
3. Install two pins (6). Install bolts (5) and retainers
to hold both pins in place.
4.Install bolts (3), clip (4) and block (2) on each side.
Torque bolts (3) to 800 ± 100 N•m (590 ± 74 lb•ft).
5. Bend back the tabs on clips (4) against the bolt
heads.
6. Connect hydranlic lines (1).
NOTE : If lift cylinders were removed from the mast,
adjust both lift chains to equal tension. Run the mast
to full lift. If mast does not kick to either side no
shims are required. If mast does kick to one side
disconnect cylinder from support assembly on that
side. Add shims, reassemble and repeat. Repeat
process until “kicking” is corrected. Do not exceed 3
mm (.12 in) of shims.
End By :
a. Install bracket assembly carriage.

Vehicle System Disassembly & Assembly11
STD Mast
Disassembly
Start By :
a. Remove mast.
1. Remove hose (1) and bracket (2).
2. Remove hose (3), flow protector (4) and flow
regulating and bracket assembly (5) from outer
mast channel.
3. Bend back the plate (7) supporting nut (6) not to
be loosened. Remove nut (6), plate (7), spacers
(8), pad-rubber (9) and clamp assembly(10) if
they were installed.
4. Remove grease pipe if it was installed.
5. Remove bolt (12) and washers.
6. Remove bolts (13), washers and nuts.
7. Attach hoist to lift cylinder (14).
8. Remove lift cylinder (14). The weight of the
cylinder is 171 to 400 kg (377 to 881 lb). Mark for
identification and remove the shims at top of
cylinder (14).
NOTE : At installation, adjust both lift chains with the
same tension. Run the mast to full lift. If mast does
not kick to either side, no shimming is required. If
mast does kick to one side, disconnect cylinder from
support assembly on that side. Add shims to
reassemble Repeat this process until “kicking” is
corrected.

Vehicle System Disassembly & Assembly12
9. Remove pads (15) and shims from the outer mast
channel.
10.Remove the snap-ring from the outer mast pin.
Remove roller assemblies (16) from the outer
mast channel.
NOTE : Place identification marks on all roller
assemblies (16) to assure proper installation.
11.Remove bolts (17), washers, roller and bracket
assembly (18) and shims from the outer mast
channel.
NOTE : Mark and separate the shims and roller and
bracket assemblies (18) removed from each side for
identification at assembly.
12.Remove snap-ring (19) from the inner mast pin.
Remove roller assemblies (20) from the inner
mast channel.
NOTE : Place identification marks on all roller
assemblies (20) to assure proper installation.
13.Remove bolts (21), washers, roller and bracket
assembly (22) and shims from the inner mast
channel.
14.Remove chains from the outer mast.
15.Repeat steps 10 through 13 for the other side.
16.Fasten a hoist to outer mast (23). Use a lift truck
to separate inner mast (24) from outer mast (23).
The weight of outer mast (23) is about 1230kg
(2771lb) and The weight of inner mast (24) is
about 910kg (2006lb).

Vehicle System Disassembly & Assembly13
17.Remove snap-ring (24), bearing (25) from roller
(26) if needed.
18.Remove bolt (27), washer and grease fitting. Tap
the shaft and remove shaft (28), spacers (30),
and roller (29) from the bracket if needed.
19.Check the condition of bushing (30) in the roller
(29). Replace the bushing (30) with new one if
worn or damaged.
20.Support crosshead assembly (32) with a hoist
and remove eight bolts, washers (31) and
crosshead assembly (32) from the inner mast
channel.
21.Remove retaining bolts, washers (33) and pins
(34) and then remove chain sheaves (35).
22.Remove snap-ring (37) and bearing (38) from
the wheel if needed.

Vehicle System Disassembly & Assembly14
Assembly
Tools Needed A B C
Vernier Calipers 1
Inside Vernier Calipers 1
Mast Gauge 1
1. Make sure all parts are clean and free of dirt and
foreign material.
2. Check all parts for damage. If damaged, use new
parts for replacement.
3. Install bearing (38) and snap ring (37) into the
wheel if they were removed.
4. Install chain sheaves (35), pins (34), washers and
retaining bolts (33) that hold pins (34) to the
crosshead assembly.
5. Put crosshead assembly (32) in position and
install washers and bolts (31). Adjust crosshead
assembly (32) of which distance difference (X)
between left hand and right hand should be within
1.5mm(.06 in) from side of the inner beam.
Tighten bolts.
6. When crosshead assembly (32) is assembled,
distance difference (Y) between left hand and
right hand should be within 1.5 mm (.06 in) from
front of the inner beam.
7. Install new bushes (30) into the roller.

Vehicle System Disassembly & Assembly15
8. Install the shaft, spacers and roller (29) to the
bracket.
Install bolt (27) and washer using Loctite No.242.
Install grease fitting (28) to the shaft. Be careful
for assembling direction.
Typical Example
9. To shim the inner mast (lower) side roller, move
gauge (C) up and down inside outer mast channel
(8) to find the narrowest point across the outer
mast channels in track where the side roller travel.
Measure the channel lap which is the distance
between the outer rail upper face and inner rail
lower face. Record this measurement. The
channel lap is to be shown in the below table.
MFH 3.0~4.5 M 5.0~6.0 M
CHANNEL
LAP 1115 mm 1315 mm
10.Install the inner mast channel side roller and
bracket assemblies (22) without shims on the
inner mast.
11.Measure the distance between inner mast side
rollers with tool (A). Add shims between one of
side rollers to be 0.2~0.8 mm (.008~.031 in)
clearance.
12.Divide the shims into two groups to have the
same thickness and install them on each side of
the inner channel behind side roller and bracket
assemblies (22).
13.To shim outer mast (upper) side roller(18),
measure outside of the inner mast channel (24)
to find the widest point across the inner mast
channels in the track where side roller (18) travel
using tool (A). Record this measurement.
14.Install the outer mast channel side roller and
bracket assemblies (18) without shims on the
outer mast.
15.Measure the distance between outer mast side
rollers (18) with tool (B). Add shims between one
of side rollers to be 0.2~0.8 mm (.008~.031 in)
clearance.

Vehicle System Disassembly & Assembly16
NOTE : Assemble after spray to anti-seizing
lubricant, Molybdenum disulfide type between
bearing and roller.
16.Assemble the bearings and snap rings into the
rollers if they were removed. Install roller
assemblies (20) on the inner mast pin. Install
snap rings (19).
17.Install roller assemblies (16) on the outer mast
pin. Install the snap rings.
18.Use a hoist and nylon strap to install inner mast
(24) into outer mast channel (23).
The weight of outer mast (23) is about 1230kg
(2771lb) and The weight of inner mast (24) is
about 910kg (2006lb).
19.Place the shims between wear pads (15) and the
inner mast. Clearance (X) between outer roller
(16) and inner mast flange is to be 0.0 to 1.0 mm
(.0 to .04 in).
20.Slide the mast completely together.
21.Install the chains on each side of the outer mast.
22.Fasten a hoist and nylon strap to lift cylinder (14)
and put lift cylinder (14) and shims in position.
Install bolts (13), washers and nut.
23.Install bolts (12) and washers on the inner mast.
Apply the Loctite No.242 to thread of bolts (12).

Vehicle System Disassembly & Assembly17
24.Install clamp assembly (10), pad-rubber (9),
spacers (8), plate (7) and nut (6). Bend plate (7)
supporting nut (6) not to be loosened.
NOTICE
Make lift cylinders vertical by adjusting pad-rubber
(9) and U-clamp assembly (10).
25.Install grease pipe if it was removed.
26.Install the flow regulating and bracket assembly
(5), flow protector (4) and hose (3).
27.Install bracket (2) and hose (1).
End By :
a. Install mast.

Vehicle System Disassembly & Assembly
18
FFT Mast
NOTE: Since many things for FFT are same for STD,
please also refer to the instruction for STD.
1. Remove the mast chassis
a) Remove tilt pin from the (1) & tilt cylinder
b) Remove hinge pin (2)
c) Remove mast from chassis
2. Remove fork & carriage
( How to same the STD mast)
a) Remove fork(1) - Remove cover & shaft
b) Remove carriage(2)- Remove carriage chain
anchor
Tilt
Chain anchor
Shaft
Cover