Doosan D15S-5 Specifications Systems Operation Testing & Adjusting Download

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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

Summary of Contents for D15S-5

Page 1: ...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...

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Page 3: ...ollowing 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...

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Page 5: ...lic 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 syste...

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Page 7: ...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 T...

Page 8: ...tion 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 cm rev 1 19 in rev Sideshift Cylinder 1 Torque for head 270 35 N m 200 25 lb...

Page 9: ...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 l...

Page 10: ...s 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...

Page 11: ...5 mm 400334 00015 GC15 18S 5 6 10 392 5 mm 73 mm D518224 6 10 392 5 mm 82 mm A252107 1 Adjust pivot eye to dimension Y with cylinder open extended 2 Torque for bolt 95 15 N m 70 10 lb ft 3 With mast...

Page 12: ...hicle Systems Specifications 10 Steering Wheel 1 Torque for steering wheel nut 75 to 88 N m 55 to 65 lb in Priority Valve Flow Load sensing Relief valve no adjustment opens at 8 285 350 kPa 1 200 50 p...

Page 13: ...th internal pump gear gerotor 2 and drive 3 as shown 4 Tighten bolts in sequence shown Tighten to a first torque of 14 1 2 8 N m 125 25 lb in Tighten to a final torque of 28 2 2 8 N m 250 25 lb in 5 T...

Page 14: ...ations 12 Forward and Reverse Control Group 1 Torque for bolts four 3 4 to 3 9 N m 30 to 34 5 lb in 2 Torque for bolts two 2 8 to 3 4 N m 25 to 30 lb in Brake SHOE 1 Torque for wheel cylinder bolts 1...

Page 15: ...ne shutdown system will interrupt the fuel supply to the engine thereby saving the engine from the critical damage 1 Low engine oil pressure The warning MIL lamp will turn on when the oil pressure dro...

Page 16: ...Vehicle Systems Specifications 14 Diagram of Delayed Engine Shutdown System G424I E G424F E ENGINE LP TRUCK G424I E G424F E ENGINE GAS DF TRUCK...

Page 17: ...15 Low Oil Pressure Fault Low engine oil pressure 521 52 Transmission Oil Temperature Excessive transmission oil temperature 933 Diagnostic Fault Codes DFC PROBABLE FAULT FAULT ACTION CORRECTIVE ACTI...

Page 18: ...Vehicle Systems Specifications 16 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424I E LP...

Page 19: ...Vehicle Systems Specifications 17 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424I E GAS DF E G OIL PR E G CHECK ENG GND NEAR COILS...

Page 20: ...Vehicle Systems Specifications 18 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424F E LP...

Page 21: ...Vehicle Systems Specifications 19 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G424F E GAS DF...

Page 22: ...l shift feature Transmission is automatically shifted to the neutral when the operator leaves the seat with the engine running and the direction lever in forward or reverse To restore the lift truck r...

Page 23: ...chematic SOL_VALVE_UNLOAD SOL_VALVE_LIFT LOCK INDICATOR AS SEAT BELT SWITCH SEAT SWITCH AIR CLEANER SWITCH FUSE CIRCUIT BREAKER IGNITION SW DIR SWITCH RELAY CREEPING SPEED PILOT BUZZER FWD BATTERY FUS...

Page 24: ...controller SW3 and GND 12V is no problem 1 Buzzer warning 2 Neutral light 3 No drive operation 1 Seat switch open 2 Relay REV FWD Creep speed defect 3 Directional switch defect 4 Wiring defect 5 FWD R...

Page 25: ...Unload Solenoid 3 Check continuity of wire from solenoid lift lock 2 or solenoid unload 2 to controller ISO3691 VALVE 4 Check continuity of wire from solenoid lift lock 1 or solenoid unload 1 to cont...

Page 26: ...w protector primary 3 lift cylinder primary 4 flow protector secondary standard 5 side shift cylinder 6 control valve 7 solenoid valve for lift lock 8 tilt cylinder 9 relief valve auxiliary 10 solenoi...

Page 27: ...he operator leaves a seat for more than 3 seconds or a start key is off the solenoid valve becomes off which leads to block the lowing flow passage Once a start key is on and operator sits on seat the...

Page 28: ...Vehicle Systems Systems Operation 26 Control Valve External View 4 Spool I C Truck Valve Circuit Schematic 4 Spool I C Truck Valve...

Page 29: ...nection as well as a diagnostic inlet pressure gage port new feature to be added When the operator is not seated the solenoid valve is in the normally open position which helps divert flow from the pu...

Page 30: ...nction with a lift lock check valve When the operator is not seated the solenoid valve is not energized which ensures that pressures are equalized across the lift lock valve closed and prevents loweri...

Page 31: ...normally closed solenoid valve Important Note Before opening the secondary needle valve make sure personnel and equipment are safely positioned to avoid accidents Be careful to operate this secondary...

Page 32: ...ing notches and cylinder head Simultaneously the high pressure acts on the end of the tilt lock plunger to move it towards the spring end of the spool This plunger movement opens additional spool mete...

Page 33: ...ion In general one work port is pressurized by high pressure oil from the parallel passage past the load check valve past the metering notches and to the cylinder Simultaneously oil from the other wor...

Page 34: ...Vehicle Systems Hydraulic System Operation 32 Outlet Section The outlet section contains the tank port and the secondary relief valve with built in anti cavitation feature...

Page 35: ...lows through piston 11 of the main relief valve The pressure oil opens pilot valve 14 This lets the oil flow go through spring chamber 13 to passage 7 The oil then returns to tank When the pilot valve...

Page 36: ...f mast operation are filled The fluid is pulled from a hydraulic tank 11 to a hydraulic pump 10 Pump supplies a fluid through a hydraulic hose 15 to a priority valve 12 When the steering unit 1 is neu...

Page 37: ...the hydraulic tank A check valve is installed into the port of steering unit connected to hydraulic line 9 to prevent a fluid back to priority valve right after a turn is made Relief valve in priorit...

Page 38: ...ics are met The steering unit has two main sections control section A and pump or metering section B These two sections work together to send oil to the steering cylinder Oil from the priority valve g...

Page 39: ...e causes a rotation of gear 5 inside gear 6 This rotation of the gear sends a controlled metered flow of pilot oil back through body 11 This oil flows to port 9 or 10 and then to the steering cylinder...

Page 40: ...ter cylinder and push brake liquid through outlet into the brake lines When floating piston seats on seal the liquid that is pushed by piston goes around cup seal out through loading piston and outlet...

Page 41: ...put it in position against the drum Automatic Adjustment Brakes with automatic adjustment are adjusted on the reverse braking action In this example the drum rotation is counterclockwise in reverse wh...

Page 42: ...end lock 5 away from nut 6 Adjust nut 6 so lever 4 is against stop 3 3 Tighten nut 6 finger tight and bend lock 5 to hold in place 4 Loosen nut 2 5 Tighten screw 1 to a torque of 5 6 to 6 8 N m 50 to...

Page 43: ...Visual Checks A visual inspection of the hydraulic system and its components is the first step when a diagnosis of a problem is made Lower the carriage to the floor and follow these inspections 1 Meas...

Page 44: ...e control valve check valves that do not seat correctly or poor adjustment or fit in the control valve spools 3 Cycle times in the lift and tilt circuits Cycle times that are too long are the result o...

Page 45: ...The lift spool in the control valve has a restriction caused by foreign material and does not operate freely 3 The lift cylinder flow regulator valve has a restriction 4 Air in the hydraulic system P...

Page 46: ...ted Problem Safety lift lock doesn t work Safety lift lock function Once the operator leaves a seat more than 3 seconds or a start key is off the lift cylinder doesn t lower even though lift spool is...

Page 47: ...luid Probable Cause 1 Low Level of the oil in the tank 2 There is a restriction in the pump inlet line 3 There is air leakage in the pump inlet line 4 The viscosity of the oil is wrong 5 The pump has...

Page 48: ...bable Cause 1 The relief valve is not correctly set or will not move in base and or is worn 2 There is air in the system 3 Dirt or foreign particles between relief valve control poppet and its seat 4...

Page 49: ...uit Problem Oil leakage at the pump Probable Cause 1 Loose hose connections 2 Defective shaft seal Problem Low oil pressure Probable Cause 1 Low oil level 2 Priority valve relief valve spring weak 3 R...

Page 50: ...drag Probable Cause 1 Brake shoe adjustment not correct 2 Brake pedal adjustment not correct 3 Mechanical resistance at the pedal or shoe 4 Restriction in brake line 5 Bad wheel cylinder Problem Peda...

Page 51: ...lining 4 Air in the brake hydraulic system 5 Bad master cylinder 6 Linkage is not in correct adjustment or is bent Problem Not braking evenly or rough feeling of braking chatter Probable Cause 1 Linin...

Page 52: ...lower when the bleed screw is loose 4 Lift the forks high enough to put a load on all stages of the lift cylinders The illustrations shown are of a full free triple lift mast Lift Cylinder Air Removal...

Page 53: ...re any fitting plug hose or component is loosened tightened removed or adjusted Always move the lift truck to a clean and level location away from the travel of other machines Be sure that other perso...

Page 54: ...indication is the pressure that opens the relief valve at the end of lift cylinder stroke 3 The correct pressure setting is shown in the chart 4 If an adjustment to the relief valve setting is necess...

Page 55: ...rrect pressure setting is shown in the chart 4 If an adjustment to the relief valve setting is necessary loosen locknut 7 Relief valve Adjustment 7 Locknut 8 Stud 5 Turn stud 8 clockwise to increase o...

Page 56: ...irection until the steering cylinder internal stop is reached 4 Adjust stop bolt 1 5 Tighten nut 2 Turn the steer wheel the opposite direction and do the same procedure for the opposite stop bolts Thi...

Page 57: ...ull Be ready to add oil when the engine is started Do not let oil level go below the outlet to the pump 2 Start the engine and keep at low idle Add oil immediately to the tank or reservoir as needed N...

Page 58: ...cause personal injury Before any steering system hydraulic lines or components are disconnected make sure all hydraulic pressure is released in the steering system Move the steer wheels to the left a...

Page 59: ...e indication on pressure gauge 6 b If the indication is approximately the pressure shown in Step 5 then the steering gear has a hydraulic failure c If the indication is too low or too high then the pr...

Page 60: ...ssure is still on the brake pedal then let the pedal return to the original position 3 Do Step 2 again as many times as necessary until the brake fluid is free of air 4 Use the procedure in Steps 2 an...

Page 61: ...the gap D for engaging brake pedal by inching pedal D should be approx 9 5mm 5 The distance E between the shaft center and its mounting bracket should be 82 5mm 6 The stroke of inching spool should b...

Page 62: ...do the steps in parking Brake Adjustment Parking Brake Adjustment Parking Brake Adjustment 1 Screw 2 Nut 3 Stop 4 Lever 5 Lock 6 Nut NOTICE Turn the adjustment screw clockwise to tighten Turning the...

Page 63: ...0 to 60 lb in 7 Loosen screw 1 1 2 to 1 5 turns hold in this position and tighten nut 2 Parking Brake Adjustment 7 Switch Assembly 8 Screws 8 Loosen screws 8 9 Adjust switch assembly 7 until switch ac...

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