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D50C-5
Doosan D50C-5 Manuals
Manuals and User Guides for Doosan D50C-5. We have
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Doosan D50C-5 manuals available for free PDF download: Service Manual, Operation & Maintenance Manual, Disassembly/Assembly
Doosan D50C-5 Operation & Maintenance Manual (350 pages)
LIFT TRUCKS
Brand:
Doosan
| Category:
Forklifts
| Size: 5.95 MB
Table of Contents
Table of Contents
3
Information Section
4
Foreword
4
Safety Section
6
Important Safety Information
6
Safety
7
General Hazard Information
12
Operation Information
13
Before Starting the Lift Truck
13
Maintenance Information
16
Operator Restraint System (if Equipped)
19
Avoiding Lift Truck Tipovers
23
Safety Rules
25
How to Survive in a Tipover (if Operator Restraint System Equipped)
30
General Section
32
Specifications
32
Noise and Vibration
40
Capacity Chart
41
Capacity Chart (with Side Shifter)
43
Serial Number
55
Operator's Warning and Identification Plate
57
Operation Section
59
Operator's Station and Monitoring Systems
59
Seat Switch System (if Equipped)
63
Lift Truck Controls
64
Refueling
67
Before Starting the Engine
70
Starting the Engine
72
After Starting the Engine
74
Lift Truck Operation
110
Mono-Ped Control System (Option)
112
Auto Shift Controller ASC - 200 (if Equipped)
113
Operating Techniques
116
Parking the Lift Truck
120
Lift Fork Adjustment
121
Storage Information
122
Transportation Hints
123
Towing Information
124
Maintenance Section
125
Inspection, Maintenance and Repair of Lift Truck Forks
125
Tire Inflation Information
129
Torque Specifications
130
Cooling System Specifications
132
Fuel Specifications
134
Lubricant Specifications
136
Lubricant Viscosities and Refill Capacities
139
First 250 Service Hours or a Month Maintenance Intervals
140
Maintenance Intervals
140
Adjust
143
Test Fuel System for Leaks (LP Engine Only)
143
When Required
144
Priming the Fuel System (Diesel Engine Only)
146
Seat, Hood Latch & Support Cylinder - Check, Lubricate
146
Fuses, Bulbs & Circuit Breaker - Change, Reset
147
Fuse & Relay (LP Engine Only)
148
Circuit Breaker
148
Tires and Wheels - Check, Inspect
149
Carriage Roller Extrusion - Check, Adjust
150
Every 10 Service Hours or Daily
151
Inspect Engine for Fluid Leaks
151
Engine Oil Level - Check
151
Coolant Level - Check, Clean
151
Air Cleaner Indicator - Check
152
Walk - Around Inspection - Inspect
153
Mast Channels - Lubricate
154
Transmission Oil Level - Check
154
First 50 - 100 Service Hours or a Week
155
Engine Oil & Filter (Diesel Engine Only) - Change
155
Transmission Oil, Oil Filter & Strainer - Clean, Change
156
Drive Axle Oil - Check, Clean, Change
158
Parking Brake - Test, Adjust
159
First 250 Service Hours or a Month
161
Hydraulic Return Filter - Change
161
Every 250 Service Hours or Monthly
162
Air Intake System - Check, Clean
162
Brake Oil Level - Check
163
Hydraulic Oil Level - Check
165
Drive Axle Oil Level - Check
165
Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate
166
Carriage Side Rollers - Lubricate
167
Steering Mechanism - Check, Lubricate
167
Battery Terminal - Clean, Inspect
168
Engine Oil & Filter - Change
168
Wheel Bolts and Nuts - Inspect
169
Every 500 Service Hours or 3 Months
170
Belts (Diesel Engine Only) - Check, Adjust
170
Mast Hinge Pins - Lubricate
170
Tilt Cylinders - Check, Adjust, Lubricate
171
Crosshead Rollers - Inspect
172
Carriage Side Rollers Thrust (if Equipped) - Lubricate
172
Carriage Sideshifter (if Equipped) - Lubricate
172
Parking Brake - Test, Adjust
173
Circulation Pump Belt (OCDB & LP Engine Only. if Eguipped) - Check, Adjust
173
Drive Axle Oil & Strainer (OCDB Only) - Check, Clean, Change
173
Inching & Brake Control Shaft - Lubricate
174
Horn & Lights (if Equipped) - Check
174
Inspect Vacuum Lines and Fittings (LP Engine Only)
174
Fuel Trim Valve(FTV) Inspection (G643E Engine Only)
175
Inspect Electrical System (LP Engine Only)
175
Overhead Guard - Inspect
175
Steer Suspension - Inspect
175
Every 1000 Service Hours or 6 Months
176
Fuel Filters - Change
176
Air Intake System - Change
176
Fuel Lines & Fittings - Check
177
Hydraulic Return Filter - Change
178
Air Breather - Change
178
Transmission Oil, Oil Filter & Strainer - Clean, Change
178
Lift Chains - Test, Check, Adjust
178
Universal Joint - Inspect
181
Every 1500 Service Hours or 9 Months
182
Drive Axle Oil (Shoe Brake Only) - Check, Clean, Change
182
Inspect Ignition System (LP Engine Only)
182
Replace Spark Plugs (LP Engine Only)
182
Replace LP Fuel Filter Element (LP Engine Only)
183
Fuel Filter (LP Engine Only)
183
Disassembly
183
Testing Fuel Lock-Off Operation (LP Engine Only)
184
Every 2000 Service Hours or Yearly
185
Steer Wheel Bearings - Reassemble
185
Cooling System - Clean, Change
186
Fork - Inspect
187
Every 2500 Service Hours or 15 Months
189
Hydraulic Oil - Check, Clean, Change
189
Inspect Battery System
189
Checking the TMAP Sensor (LP Engine Only)
190
Inspect for Intake Leaks (LP Engine Only)
190
Replace PCV Valve and Breather Element - Change (LP Engine Only)
190
Replace Oxygen Sensor (G643E Engine Only)
190
Index Section
191
Index
191
Table of Contents
197
Information Section
198
Foreword
198
Safety Section
200
Important Safety Information
200
Safety
201
Warning Signs and Labels
201
General Hazard Information
206
Operation Information
207
Before Starting the Lift Truck
207
Maintenance Information
210
Operator Restraint System (if Equipped)
213
If Optional Suspension Seat (Weight Adjusting Type) Equipped
214
Avoiding Lift Truck Tipovers
217
Safety Rules
219
How to Survive in a Tipover (if Operator Restraint System Equipped)
224
General Section
226
Specifications
226
Noise and Vibration
228
Capacity Chart
229
Capacity Chart (with Side Shifter)
230
Capacity Chart
231
Capacity Chart (with Side Shifter)
232
Serial Number
233
Operator's Warning and Identification Plate
234
Operation Section
236
Operator's Station and Monitoring Systems
236
Seat Switch System (if Equipped)
240
Lift Truck Controls
241
Refueling
244
Before Starting the Engine
246
Starting the Engine
248
After Starting the Engine
250
Lift Truck Operation
274
Mono-Ped Control System (Option)
276
Auto Shift Controller ASC - 200 (if Equipped)
277
Operating Techniques
280
Parking the Lift Truck
284
Lift Fork Adjustment
285
Storage Information
286
Transportation Hints
287
Towing Information
288
Maintenance Section
289
Inspection, Maintenance and Repair of Lift Truck Forks
289
Tire Inflation Information
293
Torque Specifications
294
Cooling System Specifications
296
Fuel Specifications
298
Lubricant Specifications
299
Lubricant Viscosities and Refill Capacities
301
First 250 Service Hours or a Month Maintenance Intervals
302
Maintenance Intervals
302
When Required
306
Test Fuel System for Leaks (LP Engine Only)
306
Seat, Hood Latch & Support Cylinder - Check, Lubricate
306
Fuses, Bulbs & Circuit Breaker - Change, Reset
307
Fuse & Relay (LP Engine Only)
308
Circuit Breaker
308
Tires and Wheels - Check, Inspect
309
Carriage Roller Extrusion - Check, Adjust
310
Every 10 Service Hours or Daily
311
Inspect Engine for Fluid Leaks
311
Engine Oil Level - Check
311
Coolant Level - Check, Clean
311
Air Cleaner Indicator - Check
312
Walk - Around Inspection - Inspect
313
Mast Channels - Lubricate
314
Transmission Oil Level - Check
314
First 50 - 100 Service Hours or a Week
315
Transmission Oil, Oil Filter & Strainer - Clean, Change
315
Drive Axle Oil - Check, Clean, Change
317
Parking Brake - Test, Adjust
318
First 250 Service Hours or a Month
320
Hydraulic Return Filter - Change
320
Every 250 Service Hours or Monthly
321
Air Intake System - Check, Clean
321
Hydraulic Oil Level - Check
323
Drive Axle Oil Level - Check
323
Brake Oil Level - Check
323
Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate
324
Carriage Side Rollers - Lubricate
325
Steering Mechanism - Check, Lubricate
325
Battery Terminal - Clean, Inspect
326
Engine Oil & Filter - Change
326
Wheel Bolts and Nuts - Inspect
327
Every 500 Service Hours or 3 Months
328
Mast Hinge Pins - Lubricate
328
Tilt Cylinders - Check, Adjust, Lubricate
328
Crosshead Rollers - Inspect
329
Carriage Side Rollers Thrust (if Equipped) - Lubricate
329
Carriage Sideshifter (if Equipped) - Lubricate
330
Parking Brake - Test, Adjust
330
Circulation Pump Belt (OCDB & LP Engine Only. if Eguipped) - Check, Adjust
330
Drive Axle Oil & Strainer (OCDB Only) - Check, Clean, Change
331
Horn & Lights (if Equipped) - Check
332
Inspect Vacuum Lines and Fittings (LP Engine Only)
332
Fuel Trim Valve(FTV) Inspection (G643E Engine Only)
332
Inspect Electrical System (LP Engine Only)
332
Overhead Guard - Inspect
333
Steer Suspension - Inspect
333
Every 1000 Service Hours or 6 Months
334
Air Intake System - Change
334
Fuel Lines & Fittings - Check
335
Hydraulic Return Filter - Change
335
Air Breather - Change
335
Transmission Oil, Oil Filter & Strainer - Clean, Change
335
Lift Chains - Test, Check, Adjust
335
Universal Joint - Inspect
337
Every 1500 Service Hours or 9 Months
338
Drive Axle Oil (Shoe Brake Only) - Check, Clean, Change
338
Inspect Ignition System (LP Engine Only)
338
Replace Spark Plugs (LP Engine Only)
338
Replace LP Fuel Filter Element (LP Engine Only)
339
Fuel Filter (LP Engine Only)
339
Disassembly
339
Testing Fuel Lock-Off Operation (LP Engine Only)
340
Every 2000 Service Hours or Yearly
341
Steer Wheel Bearings - Reassemble
341
Cooling System - Clean, Change
342
Fork - Inspect
343
Every 2500 Service Hours or 15 Months
345
Hydraulic Oil - Check, Clean, Change
345
Inspect Battery System
345
Checking the TMAP Sensor (LP Engine Only)
346
Inspect for Intake Leaks (LP Engine Only)
346
Replace PCV Valve and Breather Element - Change (LP Engine Only)
346
Replace Oxygen Sensor (G643E Engine Only)
346
Index Section
347
Index
347
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Doosan D50C-5 Service Manual (366 pages)
Brand:
Doosan
| Category:
Engine
| Size: 16.51 MB
Table of Contents
Table of Contents
5
General
9
General Precautions for Servicing
13
General
18
Specification
22
Tightening Torque
26
Special Tool
30
Diagnosis
32
Adjustment
34
Timing System
35
Removal
37
Inspection
41
Replacement
44
Installation
45
Cylinder Head Assembly
51
Removal
53
Disassembly
56
Inspection
57
Replacement
61
Reassembly
63
Installation
65
Crankcase
67
Removal
68
Installation
69
Cylinder Block Assembly
71
Removal
73
Disassembly
76
Inspection
77
Reassembly
83
Installation
84
Intake and Exhaust System
88
Troubleshooting
89
Turbocharger
91
Removal
93
Inspection
94
Installation
95
Intake Manifold
97
Removal
98
Installation
99
Exhaust Manifold
100
Removal
101
Installation
102
Lubrication System
103
Specification
107
Troubleshooting
109
Adjustment
111
Oil Pump
113
Disassembly
115
Oil Cooler
116
Disassembly
117
Reassembly
118
Cooling System
119
Specification
120
Trouble Shooting
122
Water Pump
124
Removal
125
Inspection
126
Installation
127
General
128
Service Standards
130
Troubleshooting
131
Charging System
133
Adjustment
134
Alternator
138
Disassembly
139
Inspection
141
Reassembly
142
Starting System
143
Inspection
144
Preheating System
146
General
147
Sealant
148
Engine Control
150
Fuel Tank and Fuel Line
151
Troubleshooting Procedure
152
Troubleshooting Procedure
156
Engine Control System-Electronic
169
Engine Control Unit (ECU)
172
ECU Circuit Diagram
177
Removal
179
Inspection
180
Intake Air Temperature Sensor
186
Intake Air Pressure Sensor
187
Coolant Temperature Sensor
188
Installation
189
Camshaft Position Sensor
190
Crankshaft Position Sensor
191
Rail Pressure Sensor
192
Supply Control Valve
193
Fuel Delivery System-Electronic
194
Fuel Filter
195
Injector
196
Cleaning
197
Replacement
198
Injector Replacement
199
Installation
200
Common Rail Assembly
201
Injection Pump-Electronic
202
Check before Use
205
Safety Warning and Caution before Use
206
Hardware
210
Introduction of Components
213
Basic Usage of G-Scan
214
Power ON/OFF
217
Description for Main Components of H/W
219
Description for Layout of S/W Screen
224
Connecting the DLC Cable
228
Self Test Adapter
231
Configuration
232
User Information
240
Version
243
Self Test
245
STEP-B Test
249
Vehicle Communication Function
252
Fault Code Searching
259
DTC Analysis
262
Data Analysis
270
Actuation Test
282
Vehicle S/W Management
284
ECU Upgrade
288
Carb Obd-II
301
Flight Record
307
PC Utility
327
How to Use PC Utility
336
Appendix
354
O/S Update
358
Doosan D50C-5 Service Manual (152 pages)
Brand:
Doosan
| Category:
Engine
| Size: 24.02 MB
Table of Contents
Important Safety Information
3
Table of Contents
7
1 General Information
9
Engine Specifications
9
D50/60/70/80/90S-5 (3 Speed)
9
Performance Curve
10
Performance Curve (ECRFD), D35/40/45S-5, D50/55C-5
11
Performance Curve (ECRFE), D50/60/70S-5 (2 Speed)
12
Engine Assembly
13
Engine Assembly View (ECRFA), D50/60/70/80/90S-5 (3 Speed)
13
Engine Assembly View (ECRFD), D35/40/45S-5, D50/55C-5
14
Engine Assembly Views (ECRFE), D50/60/70S-5 (2 Speed)
15
Safety Regulations
16
General Notes
16
Regulations Designed to Prevent Accidents
16
Regulations Designed to Prevent Damage to Engine and Premature Wear
17
Regulations Designed to Prevent Pollution
18
General Repair Instructions
19
2 Technical Information
20
Engine Model and Serial Number
20
Engine Type
21
Cylinder Block
21
Piston Con-Rod / Crankshaft
21
Engine Timing
21
Valves
22
Lubrication System
22
Recommend of Lubricating Oil
23
Oil Cooler
24
Oil Filter
24
Air Cleaner
25
Fuel System
25
Injection Pump
26
Fuel Filter
26
Fuel Requirements
26
How to Select Fuel Oil
27
Cooling System
28
Anti-Freeze
29
Cooling Water
29
V-Belt Tension Check and Adjust
31
Valve Clearance and Adjustment
32
Cylinder Compression Pressure
33
Injection Nozzle
34
Battery
34
Starting Motor
34
Diagnosis and Remedy
35
Engine Inspection
44
Stopping Engine
44
General Engine Inspection Cycle36
44
Use of Original Parts for Repair and Replacement
45
3 Maintenance
46
Engine Disassembly
46
Major Part Fixing Nuts and Bolts
46
Main Structure Parts (1)
57
Main Structure Parts (2)
59
Rocker Arm Disassembly
61
Cylinder Head Disassembly
62
Piston and Connecting Rod Disassembly
63
Engine Inspection
65
Cylinder Block
65
Cylinder Head
65
Valve Stem and Valve Guide Clearance
66
Valve Spring
70
Tappet
71
Push Rod
71
Rocker Arm Correction
72
Idler Gear and Shaft
73
Camshaft
73
Cylinder Liner
75
Cylinder Block
76
Piston
79
Maintenance of Cylinder Block, Cylinder Liner and Piston
82
Connecting Rod
83
Crankshaft
85
Flywheel and Flywheel Housing
89
Engine Reassembly
90
Piston and Connecting Rod Assembly
90
Cylinder Head Assembly Parts
92
Rocker Arm and Shaft Assembly
95
Main Components
96
Major Component Assembly
102
External Parts
106
4 Commissioning and Operation
111
Preparation
111
Starting
111
Starting and Operation
112
Operation of a New Engine (Break-In)
112
Check Points for Break-In
112
Inspections after Starting
114
Operation in Winter Time
114
Prevention against the Freeze of Cooling Water
114
Prevention against Excessive Cooling
114
Lubricating Oil
115
Starting of Engine in Winter
115
Tuning the Engine
115
Maintenance and Care
116
Periodical Inspection and Maintenance
116
Exchanging of Lubrication Oil
116
Oil Level
116
Oil Exchange Procedure
116
Replacement of Oil Filter Cartridge109
117
Cooling System
118
Coolant Draining
118
Cleaning of the Cooling Inside System Circuit
119
Valve Clearance and Adjustment
119
Injection Timing
121
Tightening the Cylinder Head Bolts
124
Fuel Injection Pump
124
Feed Pump Strainer
125
Separator (Add if Necessary)
125
Air Bleeding
125
Belts
126
5 Maintenance of Major Components
129
Lubrication System
129
Oil Pump
129
Oil Cooler
131
Cooling System
132
Water Pump
132
Thermostat
136
Fuel System
137
Fuel Filter
137
Injection Nozzle
138
Injection Pump Calibration
142
Precautions for Operation
145
Walk-Around Check and Servicing
146
Diagnostics and Troubleshooting139
147
6 Special Tool List
148
Appendix
150
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Doosan D50C-5 Disassembly/Assembly (62 pages)
Vehicle System
Brand:
Doosan
| Category:
Forklifts
| Size: 17.53 MB
Table of Contents
Table of Contents
5
Overhead Guard
8
Tilt Cylinders
9
Secondary Lift Cylinders
11
Primary Lift Cylinder
14
Hydraulic Control Value
17
Washing
19
Assembling
20
Relief Valve Maintenance
22
Steering Wheel
31
Steering Unit
32
Brake Hydraulic Booster
41
Tie Rods
45
Steering Knuckles, Kingpins, and Bearings
46
Steer Axle
47
Steering Cylinder
48
Tires and Rims (Steer)
50
Hydraulic Control Valves
51
Hydraulic Pump
52
General Instruction
53
Counterweight
58
Hydraulic Oil Filter Assembly
59
Engine
60
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