Doosan D15S-5 User manual

Vehicle System
Specification
Systems Operation
Testing & Adjusting
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
SB4365E01
June. 2011

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.
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 Systems Index
3
Index
Specification ............................................5
Control Valve............................................................5
Hydraulic Pump ........................................................6
Sideshift Cylinder......................................................6
Lift Cylinders.............................................................7
Standard................................................................7
Full Free Triple and Full Free Lift Primary ............7
Full Free Lift Secondary........................................8
Full Free Triple Lift Secondary..............................8
Tilt Cylinder...............................................................9
Steering Wheel.......................................................10
Priority Valve...........................................................10
Steering Unit...........................................................11
Forward and Reverse Control Group .....................12
Brake – SHOE........................................................12
Delayed Engine Shutdown System........................13
Operation ............................................................13
Diagram of Delayed Engine Shutdown System..14
Trouble shooting of Delayed Engine Shutdown
System ................................................................15
Diagnostic Fault Codes.......................................15
Delayed Engine Shutdown System Schematic...16
Delayed Engine Shutdown System Schematic...16
Delayed Engine Shutdown System Schematic...17
OSS (Operator Sensing System) ...........................20
Operation ............................................................20
Symbols of OSS..................................................20
Operator Sensing System Schematic.................21
Trouble shooting of Operator Sensing System...22
Hydraulic System Operation.................24
Hydraulic Schematic ...........................................24
Control Valve..........................................................26
External View......................................................26
Circuit Schematic................................................26
Inlet Section ........................................................27
Lift Section ..........................................................28
Tilt Section ..........................................................30
Auxiliary Section..................................................31
Outlet Section......................................................32
Relief Valve.........................................................33
Hydraulic Steering system......................................34
Hydraulic Schematic ...........................................34
Steering Cylinder.................................................35
Steering Unit ...................................................... 36
Brake System ........................................................ 38
Master Cylinder.................................................. 38
Shoe Type Brakes.............................................. 39
Parking Brake..................................................... 39
Testing and Adjusting ...........................41
Troubleshooting..................................................... 41
Visual Checks .................................................... 41
Performance Tests............................................. 41
Hydraulic System and Mast ............................... 42
Steering System................................................. 47
Brake System..................................................... 48
Lift Cylinders Air Removal.................................. 50
Hydraulic System................................................... 51
Relief Valve Pressure Check ............................. 51
Lift Relief Valve Check and Adjusment.............. 52
Tilt and Auxiliary Relief Valve Check and
Adjusment.......................................................... 53
Steering System .................................................... 53
Steer Wheel Bearing Adjustment -Pneumatic.... 53
Steer Axle Stop Adjustment-Pneumatic............. 54
Steer Wheel Bearing Adjustment-Cushion ........ 54
Steer Axle Stop Adjustment-Cushion................. 55
Steering System Air Removal............................ 55
Steering System Pressure Check...................... 56
Brake System ........................................................ 58
Brake System Air Removal................................ 58
Pedal Adjustment for Brake & Inching............... 58
Parking Brake Test............................................. 60
Parking Brake Adjustment.................................. 60

Vehicle Systems Specifications
5
Specification
Control Valve
CONTROL VALVE
MODEL MAST
RELIEF PRESSURE
Main Relief Pressure-lift Auxiliary Pressure-tilt,attachment
psi kPa psi kPa
D15S,G(C)15S-5 STD/FF/FFT 2,550±35 17,600±250
2,040±50 14,000±350
D18S,G(C)18S-5 STD/FF/FFT 2,880±35 19,860±250
D20SC,G20SC-5 STD/FF/FFT 3,125±35 21,550±250
(1) Torque for nuts that hold control valve sections together.................................24 to 28 N•m (18 to 21 lb•ft)
(2) Torque for nuts that hold control valve sections together.................................24 to 28 N•m (18 to 21 lb•ft)
(3) Torque for main and auxiliary relief valve .........................................................44 to 49 N•m (32 to 36 lb•ft)
(4) Torque for cap screw that hold spool cap...........................................................10 to 15 N•m (7 to 11 lb•ft)

Vehicle Systems Specifications
6
Hydraulic Pump
Rotation is counterclockwise when seen from drive
end.
Type of pump : Gear
For test, use SAE 10W oil at 65°C (150°F)
Pump output....................19.5 cm³/rev (1.19 in³/rev)
Sideshift Cylinder
(1) Torque for head ...............................270±35 N•m
(200±25 lb•ft)
(2) Torque for piston nut ........................260±25 N•m
(190±20 lb•ft)

Vehicle Systems Specifications
7
Lift Cylinders
Standard
(1) Put Pipe Sealant on the last three threads of
bleed screw and tighten to a torque of... 6±1N•m
(53±9 lb•in)
NOTE : All seals to be lubricated with hydraulic oil.
Full Free Triple and Full Free Lift
Primary
(1) Put Pipe Sealant on the last three threads of
bearing.
(2) Put Pipe Sealant of the last three threads of
bleed screw (not shown) and tighten to a torque
of.........................................6±1 N•m (53±9 lb•in)
NOTE : All seals to be lubricated with hydraulic oil.

Vehicle Systems Specifications
8
Full Free Lift Secondary
(1) Put Pipe Sealant on the last three threads of
bearing.
(2) Put Pipe Sealant on the last three threads of
bleed screw and tighten to a torque of................
..........................................6±1 N•m (53±9 lb•in)
NOTE : All seals to be lubricated with hydraulic oil.
Full Free Triple Lift Secondary
(1) Put Pipe Sealant on the last three thread of
bearing.
(2) Put Pipe Sealant on the last three thread of bleed
screw and tighten to a torque of..........................
..........................................6±1 N•m (53±9 lb•in)
NOTE : All seals to be lubricated with hydraulic oil.