Doosan D110S-5 with OCDB User manual

SB4013E01
Nov. 2006
Specifications
Systems Operation
Disassembly & Assembly
Lift Trucks Power Train-Drive Axle
D11 S-5
D13 S-5
D16 S-5
D1 (EM 83- 34~UP)
D12 (EM 84- 23~UP)
D15 (EM 86- 23~UP)

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.
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.
WARNING
1

Power Train Index
Index
Specifications
Axle for D100/120 & D110/130S-5 Truck-Wheel
end Torque Chart .......................................................5
Axle for D150 & D160S-5 Truck-Wheel end
Torque Chart ..............................................................6
Systems Operation
Drive Axle...................................................................7
Standard Single Reduction Carriers ..........................8
Disassembly & Assembly
Brakes......................................................................62
Differential ..................................................................9
Wheel end................................................................43
Axle for D100/120 & D110/130S-5 Truck .............45
Axle for D150 & D160S-5 Truck...........................53
3

Power Train Specifications5
Specifications
Axle for D100/120 & D110/130S-5 Truck-Wheel End Torque Chart
Item Fastener Torque Value
1Wheel rim nut 500 lb•ft (680 N•m)
2pinion shaft set screw 35 lb•ft (47 N•m)
3Oil fill/level/drain plug 35 lb•ft (47 N•m)
4planetary spider-to-wheel hub slotted head screw Hand tighten(no specification)
5Spindle and brake spider mounting 310-400 lb•ft (420-542 N•m)
6Camshaft bracket clamp 35-50 lb•ft (47-68 N•m)
7Camshaft bracket to spider 85-115 lb•ft (115-156 N•m)
8Wheel bearing adjusting nut Refer to instructions on page 50

Power Train Specifications6
Axle for D150 & D160S-5 Truck-Wheel End Torgue Chart
Item Fastener Torque Value
1Wheel rim nut 500 lb•ft (680 N•m)
2Lock plate screw 20-30 lb•ft (27-41 N•m)
3Planetary spider cover 35-50 lb•ft (48-68 N•m)
4Wheel bearing adjusting nut Refer to instrucitions on page 59
5Planetary spider-to-wheel hub slotted head screw Hand tighten (no specification)
6Camshaft bracket to spider 85-115 lb•ft (115-156 N•m)
7Camshaft bracket clamp 35-50 lb•ft (47-68 N•m)
8Spindle and brake spider mounting 375-430 lb•ft (508-583 N•m)

Power Train Systems Operation7
Systems Operation
Drive Axle
The planetary axles incorporate a single reduction
carrier/differential assembly with hypoid gearing. The
final reduction is of planetary spur designed gearing
built into the wheel hubs.
The axles have only cast housings.
The Planetary Axles permit the hypoid gearing of the
carrier and the axle shafts to carry only a nominal
torsional load. At the same time, they provide the
highest practical numerical gear reduction at the
wheels.
•The hypoid pinion and differential assembly of the
first reduction are supported by tapered roller
bearings.
•The pinion bearing preload is adjusted and
maintained by a hardened precision spacer
between the inner and outer bearings.
•The differential tapered bearing preload is adjusted
and maintained by the positioning of the threaded
adjusting rings in the carrier leg and cap bores.
•The teeth of the floating sun gear mesh with teeth
of the planetary spur gears.
•The planetary gears rotate on planetary shafts
which are mounted on a spider. The planetary gear
teeth in turn mesh with teeth of the floating ring
gear.
•Power is transmitted by the hypoid gear set in the
carrier to the axle shafts and the sun gear of the
final reduction, through the revolving planetary
gears, and into the planetary spider which drives
the wheel hub.

Power Train Systems Operation
Standard Single Reduction
Carriers Without Differential
Lock
The single reduction carrier models are front
mounted into the axle housing. These carriers have a
hypoid drive pinion and ring gear set and bevel gears
in the differential assembly.
Astraight roller bearing (spigot) is mounted on the
head of the drive pinion. All other bearings in the
carrier are tapered roller bearings.
When the carrier operates, there is normal differential
action between the wheels all the time.
8

Power Train Disassembly & Assembly9
Disassembly & Assembly
Removal of the Differential
Carrier from Axle Housing
To prevent serious eye injury, always wear safe eye
protection when performing vehicle maintenance
or service.
1. Make sure vehicle is on level surface.
2. Raise the end of vehicle where the axle to be
serviced is mounted. Use a jack or other lifting
tool, and place safety stands under each side of
the axle.
Do not work under a vehicle supported only by a
jack. Jacks can slip or fall over resulting in serious
personal injury. Always use safety stands.
3. Place jack stands under each spring seat of the
axle to hold vehicle in the raised position.
4. Remove the plug from bottom of axle housing and
drain the axle lubricant from the housing assembly.
5. Disconnect the driveline universal joint from the
pinion input yoke on the carrier.
6. Remove both axle shafts from the wheel ends. To
disassemble the axle shaft, refer to wheel end
section of this manual.
WARNING
WARNING

Power Train Disassembly & Assembly
Carrier Removal from Axle
1. Place a hydraulic roller jack under the differential
carrier to support the assembly.
2. Remove all but the top two carrier to housing stud
nuts and washers.
3. Loosen the top two carrier-to-housing fasteners
and leave attached to the assembly. The fasteners
will hold the carrier in the housing.
4. Loosen the differential carrier in the axle housing.
Use a leather mallet to hit the mounting flange of
carrier at several points.
5. After the carrier is loosened, remove the top two
fasteners.
CAUTION : When using a pry bar be careful not to
damage the carrier or housing flange. Damage to
these surfaces will cause oil leaks.
6. Carefully remove the carrier from the axle housing
using the hydraulic roller jack. Use a pry bar that
has a ruound end to help remove the carrier from
the housing.
7. Lift the differential carrier by the input yoke and
place the assembly in a repair stand. Use a lifting
tool for this procedure. Do not lift by hand.
10

Power Train Disassembly & Assembly
Remove the Differential and
Ring Gear from the Carrier
NOTE : Before working on the differential carrier,
inspect the hypoid gear set for damage. If inspection
shows no damage, the same gear set can be used
again. Measure the backlash of the gear set and
make a record of the dimension. During differential
reassembly, adjust the backlash to the original
recorded dimension when the gear set is installed
into the carrier.
1. Loosen the jam nut on the thrust screw.
2. Remove the thrust screw and jam nut from the
differential carrier.
3. Rotate the differential carrier in the repair stand
until the ring gear is at the top of the assembly.
4. Mark one carrier leg and bearing cap to correctly
match the parts during carrier assembly. Mark the
parts using a center punch and hammer.
11

Power Train Disassembly & Assembly
5. Remove the cotter keys that hold the two bearing
adjusting rings in position.
6. Remove the capscrews and washers that hold the
two bearing caps on the carrier. Each cap is held
in position by two capscrews and washers.
7. Remove the bearing caps and bearing adjusting
rings from the carrier.
8. Safely lift the main differential and ring gear
assembly from the carrier. Place the assembly on
a work bench.
12

Power Train Disassembly & Assembly
Disassemble the Differential
and Ring Gear Assembly
1. If the matching marks on the case halves of the
differential assembly are not visible, mark each
case half with a center punch and hammer. The
purpose of the marks is to match the plain half and
flange half correctly when the carrier is
reassembled.
2. Remove the capscrews and washers that hold the
case halves together.
Do not hit steel parts with a steel hammer during
removal and disassembly procedures. Striking
parts with a hammer can cause the parts to break
and result in serious personal injury.
3. Separate the case halves. If necessary, use a
brass, plastic or leather mallet to loosen the parts.
4. Remove the differential spider (cross), four pinion
gears, two side gears and six thrust washers from
inside the case halves.
5. If the ring gear needs to be replaced, remove the
bolts, nuts, and washers that hold the gear to the
flange case half.
WARNING
13

Power Train Disassembly & Assembly
Observe all WARNINGS and CAUTIONS provided
by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components during assembly
and installation procedures.
6. Separate the case half and ring gear using a
press. Support the assembly under the ring gear
with metal or wood blocks and press the case half
through the gear.
7. If the differential bearings need to be replaced,
remove the bearing cones from the case halves.
Use a bearing puller or press.
Remove the Drive Pinion and
Bearing Cage from Carrier
1. Fasten a yoke bar to the input yoke. When the nut
is removed, the bar will hold the drive pinion in
position.
2. Remove the nut and washer from the drive pinion.
3. Remove the yoke bar.
4. Remove the yoke from the drive pinion. If the yoke
is tight on the pinion, use a puller for removal.
5. Remove the capscrews and washers that hold the
bearing cage in the carrier.
WARNING
14

Power Train Disassembly & Assembly
Do not hit steel parts with a steel hammer during
removal and disassembly procedures. Striking
parts with a hammer can cause the parts to break
and result in serious personal injury.
CAUTION : Do not use a pry bar to remove the
bearing cage from the carrier. A pry bar can damage
the bearing cage, shims and carrier.
6. Remove the drive pinion, bearing cage and shims
from the carrier. If the bearing cage is tight in the
carrier, hit the bearing cage at several points
around the flange area with a leather, plastic or
rubber mallet.
7. If the shims are in good condition, keep the shims
together for use later when the carrier is
assembled.
8. If shims are to be discarded because of damage,
first measure the total thickness of the pack. Make
a note of the dimension. This dimension will be
requried to calculate the depth of the drive pinion
in the carrier when the gear set is installed.
Disassemble the Drive Pinion
and Bearing Cage
Observe all WARNINGS and CAUTIONS provided
by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components during assembly
and installation procedures.
WARNING
WARNING
15

Power Train Disassembly & Assembly
1. Place the drive pinion and bearing cage in a press.
The pinion shaft must be toward the top of the
assembly.
2. Support the bearing cage under the flange area
with metal or wood blocks.
3. Press the drive pinion through the bearing cage.
NOTE : The inner bearing cone and bearing spacer
will remain on the pinion shaft.
4. If a press is not available, use a leather, plastic or
rubber mallet to drive the pinion through the
bearing cage.
CAUTION : Be careful when removing the seal. Do
not damage the wall of bore. Damage to the bore
wall can result in oil leaks.
NOTE : When the oil seal has been removed, always
replace it with a new seal during component
reassembly.
5. If the pinion oil seal is mounted directly in the outer
bore of the bearing cage, remove the seal at this
time.
Be careful that you do not damage the mounting
surfaces of the bearing cage.
Observe all WARNINGS and CAUTIONS provided
by the press manufacturer conerning press
operation to avoid serious personal injury and
possible damage to components during assembly
and installation procedures.
6. If the pinion bearings need to be replaced, remove
the inner and outer bearing cups from the inside of
cage. Use a press and sleeve, bearing puller or a
small drift hammer.
WARNING
16

Power Train Disassembly & Assembly
7. If the pinion bearings need to be replaced, remove
the inner bearing cone from the drive pinion with a
press or bearing puller. The puller must fit under
the inner race of the cone to remove the cone
correctly without damage.
8. If the spigot bearing needs to be replaced, place
the drive pinion in a vise. Install a soft metal cover
over each vise jaw to protect the drive pinion.
9. Remove the snap ring from the end of drive pinion
with snap ring pliers that expand.
10. Remove the spigot bearing from the drive pinion
with a bearing puller.
17

Power Train Disassembly & Assembly
Assemble the Drive Pinion,
Bearings and Bearing Cage
To prevent serious eye injury, always wear safe eye
protection when performing vehicle maintenance
or service.
Observe all WARNINGS and CAUTIONS provided
by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components during assembly
and installation procedures.
1. Place the bearing cage in a press.
2. Support the bearing cage with metal or wood
blocks.
3. Press the bearing cup into the bore of bearing
cage until cup is flat against bottom of bore. Use a
sleeve of the correct size to install bearing cup.
NOTE : Use the same procedure above (steps 1, 2
and 3) for both bearing cups.
4. Place the drive pinion in a press, gear head (teeth)
toward the bottom.
5. Press the inner bearing cone on the shaft of the
drive pinion until the cone is flat against the gear
head. Use a sleeve of the correct size against the
bearing inner race.
WARNING
WARNING
18