Doosan D20G Manuale utente

Vehicle System

Specification

System Operation

Testing & Adjusting

D20G, D25G, D30G with B3.3 Engine

D20G, D25G, D30G with 4TNE98 Engine

G20G, G25G, G30G with G424F Engine

G20G, G25G, G30G with G424FE Engine

SB4219E01

Jan. 2008

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 avail-able.

WARNING

Vehicle System Index3

Index

Specification..................................5

Hydraulic Control Valve.........................................5

Hydraulic Pump ....................................................6

Lift Cylinder...........................................................6

Standard........................................................6

Full Free Triple and Full Free Lift....................7

Tilt Cylinder...........................................................8

Mast .....................................................................9

Carriage................................................................9

Lift Relay Group - Full Free Lift ...........................11

Lift Relay Group - Full Free Triple Lift..................12

Lift & Tilt Mounting Group....................................13

Steering Wheel...................................................14

Steering Gear.....................................................15

Steer Axle and Wheel .........................................16

Steer Wheel Mounting.........................................17

Shoe Brake.........................................................17

System Operation ....................... 18

Hydraulic System................................................18

Basic Schematic - Standard.........................18

Optional Schematic with hyd. locking system

...20

Hydraulic Control Valve................................22

Steering System.................................................27

Steering Cylinder .........................................27

Steering Gear..............................................28

Brake System.....................................................30

Master Cylinder............................................30

Shoe Type Brake.........................................31

Automatic Adjustment..................................31

Parking Brake..............................................31

Testing and Adjusting................ 32

Troubleshooting ..................................................32

Visual Checks ..............................................32

Performance Tests.......................................32

Hydraulic Oil Temperature (Too Hot)............32

Hydraulic System and Mast..........................33

Hydraulic Pump............................................36

Hydraulic Control Valve................................37

Steering System...........................................38

Brake System...............................................39

Parking Brake...............................................40

Hydraulic System................................................41

Relief Valve Pressure Check........................41

Lift Cylinder Air Removal (Only FFT & FFL

Mast)............................................................43

Delayed Engine Shutdown System......................44

Operation.....................................................44

Diagram of Delayed Engine Shutdown System

....................................................................45

Trouble shooting of Delayed Engine Shutdown

System.........................................................46

Diagnostic Fault Codes ................................46

Delayed Engine Shutdown System Schematic

....................................................................47

Delayed Engine Shutdown System Schematic

....................................................................47

Delayed Engine Shutdown System Schematic

....................................................................48

OSS (Operator Sensing System).........................49

Operation.....................................................49

Symbols of OSS...........................................49

Operator Sensing System Schematic ...........50

Trouble shooting of Operator Sensing System

....................................................................51

Mast and Carriage...............................................53

Mast Adjustment...........................................53

Carriage Adjustment.....................................58

Chain Adjustment.........................................59

Chain Wear Test..........................................60

Carriage and Mast Height Adjustment ..........61

Forks Parallel Check....................................61

Vehicle System Index4

Tilt Cylinder Alignment........................................62

Drift Test.............................................................63

Steering System.................................................64

Steer Wheel Bearing Adjustment..................64

Steering Axle Stop Adjustment.....................65

Steering Knuckle Bearing Preload Adjustment

....................................................................65

Steering System Pressure Check.................66

....................................................................66

Brake System.....................................................67

Brake System Air Removal ..........................67

Brake Adjustment.........................................67

Parking Brake Test ......................................71

Parking Brake Adjustment............................71

Vehicle System Specification5

Specification

Hydraulic Control Valve

(1) Torque for bolts that hold control valve sections

together .....................40 ± 3 N·m (360±24 lb·in)

(2) Adjust main system relief valve pressure for lift

and tilt as shown above. See “Relief valve

pressure check” in Testing &Adjusting.

(3) Adjust auxiliary relief value pressure for the

attachment as shown above. See “Relief valve

pressure check” in Testing &Adjusting.

(4) Torque for screws..........6 ± 2 N·m (53±20 lb·in)

CONTROL VALVE

ITEM psi kPa bar Kgf/㎠

USA LIFT

TILT (2,630±35) 18,100±250

(181±2.5) (185±2.5)

2.0t NON - EU

NON - USA LIFT

TILT (3,130±35) 21,550±250

(216±2.5) (220±2.5)

USA LIFT

TILT (2,840±35) 19,500±250

(195±2.5) (199±2.5)

2.5t NON - EU

NON - USA LIFT

TILT (3,130±35) 21,550±250

(216±2.5) (220±2.5)

USA LIFT

TILT (3,130±35) 21,550±250

(216±2.5) (220±2.5)

3.0t NON - EU

NON - USA LIFT

TILT (3,130±35) 21,550±250

(216±2.5) (220±2.5)

ALL ALL Aux (2,040±35) 14,000±250

(140±2.5) (143±2.5)

Vehicle System Specification 6

Hydraulic Pump

(1) Tighten mounting bolts to a torque of

.................................55 ±10 N·m (440±90 lb·in)

(2) Apply Loctite #262.

A372287 for D20/25/30G with B3.3 engine.

Nominal displacement...............................32mL/rev

Rated pressure..............................................25Mpa

Rotation is counter clockwise when seen from drive

end.

Type of pump : Gear

D514289 for D20/25/30G with 4TNE98 Engine.

Displacement..........................................26.5㎤/rev

Rotation is counter clockwise when seen from drive

end.

Type of pump : Gear

A601502 for G20/25/30G

Rotation is counter clockwise when seen from drive

end.

Type of pump : Gear

Displacement.............................................29ml/rev

Lift Cylinder

Flow rate of flow protector

FFL and FFT Mast

D700495....................................45 to 53 liter/min

A215044..................................90 to 106 liter/min

STD Mast

A371156....................................85 to 90 liter/min

Standard

(1) Put pipe sealant on the last three threads of cap.

(2) Torque for setscrew ........6 ±1 N·m ( 53 ±9 lb·in)

NOTE : All seals to be lubricated with hydraulic oil.

Vehicle System Specification7

Full Free Triple Lift and Full Free Lift

Primary

(1) Put pipe sealant on the last three threads of cap.

NOTE : All seals to be lubricated with hydraulic oil.

Full Free Triple Lift And Full Free Lift

Secondary

(1) Put pipe sealant on the last three threads of cap.

NOTE : All seals to be lubricated with hydraulic oil.

Vehicle System Specification 8

Tilt Cylinder

TILT CYLINDER

Model Tilt Gp

Part No.

Forward Tilt

Angle*

Backward

Tilt Angle*

Cyl. Stroke (X)

mm (in)

Cyl. Closed (Z)

mm (in)

A375282 6° 12° 167 (6.57) 514 (20.24)

A375322 6° 6° 110 (4.33) 571 (22.48)

A375324 6° 4° 92 (3.62) 589 (23.19)

D20G, G20G

D25G, G25G

D30G, G30G A375335 6° 10° 148 (5.83) 533 (20.98)

* Permissible tolerance of 1/2°

(1) Adjust pivot eye to dimension (Z) with cylinder

closed.

(2) Torque for bolt............ 95 ±15 N·m (70 ±10 lb·ft)

(3) Torque for head.............................270 ±30 N·m

(200 ±22 lb·ft)

(4) Torque for piston nut......................270 ±30 N·m

(200 ±22 lb·ft)

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