Introduction & Update of Pro-5 IC 5-9 ton

Truck

(D50/60/70S-5, D80/90S-5, G50/60/70S-5)

Doosan Industrial Vehicle

ST1041_IC07Intro_02
 Contents

1. Model to Market
2. Brief of New Points
3. Basic Configuration
4. Scope of Change
5. Design feature

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1. Model to Market

Model Engine Market Remark

• All overseas market • 2 Speed Transmission

DB58S • Korea (Up to 2009) 3 Speed Transmission
Diesel
(Tier-2)
D50/70S-5
D80/90S-5
• North America, Europe • Introduction ; Dec. 2008
D439E • Korea • 2 Speed Transmission
Diesel
(Tier-3) 3 Speed Transmission

• North America • Base Engine ; GM643

G643E
LP Fuel system ; WG MI-
(Tier-3) 07
G50/70S-5

• Korea • Base Engine ; GM643

G643 • All overseas market Fuel system ; WG MI-
LP
(Non Certified) 04
except NA

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2. Brief of New Points

New Style • Aligned New Style on All New IC trucks

Operator’s compartment • Convenience and Deluxe

Regulation • Electronic controlled Engine

- Tier-3 ; G643E, D439E
- Non-certified ; G643

Improved Function • PTO on Transmission

• Lift & Tilt Locked Control Valve (ISO 3691, Standard)
• Operator Sensing System (OSS, Standard)
• Engine Shut Down (LP only, Standard)
• Transaxle -> Transmission + U-joint + Drive axle

Serviceability • Tool Free Side Panel

• Integrated Electric Components (Relay, Fuse)
• Brake Oil Reservoir with Level sender

* PTO ; Power Take-out

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3. Basic Configuration

Group Maker / Model (Type) Remark

Engine D50/70S-5 Doosan / DB58S • Tier-2
D80/90S-5 Hyundai / D439E • Tier-3
G50/70S-5 GM / G643(E) • Non-certified (Tier-3)
• MI-04 (07) LP Fuel System
- Engine Shut-down System (07)
- Ground Speed Control (Optional)
Cooling Radiator Soldering Type
Oil cooler • Only for OCDB (Standard)
Power train Transmission Power Shift Type • 2 Forward / 2 Reverse
• Almost same to D(G)35/45S-5
• Auto Shift Controller (Optional)
Auto Shift Type • 3 Forward / 3 Reverse
(ZF / 3WG94) • Only for D50/90S-5
Drive axle • Almost same to D(G)35/45S-5
Service Oil Cooled Disc • Almost same to D(G)35/45S-5
Brake Brake
Shoe Brake
Hydraulic Pump Gear pump • PTO on Transmission (Triple pumps)
Control valve - 4 • Pilot Control Valve separately
4. Design feature (1. Electronic Engine Control System for G50S-5)

G643 Engine with MI-04 Engine Management System

• Improved Engine power & Fuel

consumption
• Engine Service Tool
• Truck speed limit by SECM (Optional)
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4. Design feature (2. Power train)

Former truck (2006) New truck

¾ Transaxle -> Drive axle + U-joint + Transmission

* Less Vibration
* Better Serviceability
¾ Transmission ; PTO and Pump changed
* Refer to the next page.
¾ Drive axle ; Brake disc & Plate are changed (OCDB)
* Brake disc & Plate ; same with D/G15-5 & D/G35-5
* Oil ; Not changed (MOBIL FLUID 424, TOTAL TRANSMISSION MP)
¾ Parking brake ; Separated Drum type

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4. Design feature (2. Power train)

J-TYPE HOOK

U-JOINT

CHARGING PUMP

Side PTO for Hydraulic pump

PARKING BRAKE
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4. Design feature (3. Transmission)

Former truck (2006) New truck

Charging
Hyd.
¾ PTO ; Engine -> Transmission pump
pump
* Better Serviceability
* Less Noise from U-joint
¾ Charging pump ; Inside of Converter housing -> Outside
* More Output
* Better Engagement between Converter and Pump (Ring gear)
* Better Serviceability
¾ Control valve ; Improve Jerking start
¾ Clutch and Bearing area ; Not changed

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4. Design feature (3. Transmission)

Transmission Control valve

¾ 1st. Design change ; 2005 year

* 3 Solenoids (F, R, ½) -> 4 Solenoids (F, R, 1st, 2nd)
* Positioned inside -> Positioned outside
¾ 2 . Design change ; 2007 year
nd

* Smooth starting against the jerking mode

¾ Design feature is same with D(G)35S-5

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4. Design feature (3. Transmission)

Jerking improved

Changed 1st Orifice

(dia. 2.7 -> 1.8 mm)

Changed Spring

Inching spool
Power is
압압1

9.8 kgf/cm2
압압2

-00:00:39. kgf/cm2
Serial No : transmitted 압압1 압압2
Serial No :
9.7 kgf/cm2 00:00:08.6 kgf/cm2
20.0
20.0
17.5
17.5
15.0
15.0
12.5
12.5
10.0
10.0
7.5
7.5
5.0
5.0
2.5
2.5
0.0
0.0
-2.5
-2.5
-5.0
-5.0
-7.5

Disc & Plate are

-7.5
6.5 7.0 7.5 8.0 8.5
압압 1 s 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5
압압 1 s

contacted

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4. Design feature (3. Transmission)

Schematic

4. Solenoid valve

3. Accumulator valve

2. Inching valve

1. Relief valve

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4. Design feature (3. Transmission)

Inside

1. Input shaft
(Forward)

2. Output shaft 3. Counter shaft

(Reverse)

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5. Design feature (3. Transmission)

Inside

PTO Gear

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4. Design feature (4. Drive axle)

Axle part

Shoe Brake Oil Cooled Disc Brake

¾ Except Service Brake, almost same between OCDB and Shoe type.
- Parking brake, Differential, Hub reduction
¾ OCDB and Brake Shoe are almost same with the old model.
¾ Almost same feature with D(G)35S-5

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5. Design feature (4. Drive axle)

Piston

Disc &
Plate
Bushing Spring
BOLT

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4. Design feature (4. Drive axle)

Parking brake

<- Mounted Condition

External veiw ->

<- Uncovered view

Sectional view ->

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4. Design feature (4. Drive axle)

Parking brake - Adjustment

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4. Design feature (5. Cooling for OCDB Axle)

Cooling circuit for OCDB

Lubrication
Pump

Cooler-
Drive axle
Drive axle

Cooling
Fan

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5. Design feature (6. Hydraulic system)

1st.
Priority valve Steering
2nd.
Steering unit
Reducing valve
Power steering cylinder
Reducing valve
Pump 1
Lifting, Tilting & Attachment

Pump 2
Control valve

Pump 3 Lift cylinder, Tilt cylinder

Service braking

Master cylinder

Brake piston, Disc & Plate

Wheel cylinder
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5. Design feature (6. Hydraulic system)

¾ Hyd. Pump (# 3)
¾ Priority valve (# 5)
for dividing the oil flow
¾ Pilot Control valve (# 11)
for the less force
¾ Main Control valve (# 36)
¾ Pressure Reducing valve (# 6)
from 140 Kg/cm^2 to 25 Kgf/cm^2
¾ Unload Solenoid valve (# 22)
connected to Seat switch for OSS
¾ Needle valve (# 13)
for lowering the mast manually
(Max. 3 turns)
¾ Flow control valve (# 37)
for limiting the oil flow (0.8GPM)
¾ Master cylinder
¾ Flow Regulator (# 14)
for limiting the lowering speed
¾ Flow Protector (# 15, # 21)
against the sudden lowering
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5. Design feature (6. Hydraulic system)

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5. Design feature (7. Hydraulic pump)

Steering
Unit ¾ Triple pump
Control - Less overheating
Valve - Improve Locking at dual operating
Priority
Valve
Master ¾ Better Serviceability
Cylinder
T/M
Triple Pump < For D50/70S-5 (2 speed) >

< For G50/70S-5 (2 speed) > < For D50/90S-5 (3 speed) >

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4. Design feature (8. Lifting circuit)

Major Different Points

• Increase the efficiency and decrease the heating
• Triple pump • Improve the performance
• Pilot Control Valve • Easy to operate the control levers with less force
• Decrease the vibration at relief
Lift CYL.

Main Control Valve

Pilot Control Valve

Main Control Valve

Steering
Unit Brake
Master Cylinder

Pump+P/Valve

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5. Design feature (8. Lifting circuit)

Needle Valve
for lowering the forks
manually (Max 3 turns)

Pressure Reducing Valve

For reducing the pressure
Unload Solenoid Valve
for activating OSS function

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5. Design feature (9. Main Control Valve)

Main Relief Valve

(Lift & Tilt)

Auxiliary
Relief Valve

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5. Design feature (10. Steering)

Load Sensing Line

< Location of Pressure port >

• Relief pressure ; 14,000 (+500,-0) KPa

2,035 (+70,0) psi

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5. Design feature (10. Tilting Cabin)

¾ Separate hydraulic system

¾ Totally electric

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End of Document

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