Doosan D25G Diesel Forklift Manuals

Manuals and User Guides for Doosan D25G Diesel Forklift. We have 3 Doosan D25G Diesel Forklift manuals available for free PDF download: Service Manual, Disassembly/Assembly, Specifications Systems Operation Testing & Adjusting

Doosan D25G Service Manual (1209 pages)

Brand: Doosan | Category: Forklifts | Size: 50 MB

Table of Contents
17
About the Manual
19
Symbols
20
Illustrations
21
Engine Identification
22
Specifications
23
Engine Diagrams
24
Troubleshooting Symptoms
35
Engine Acceleration or Response Poor
36
Engine will Not Crank or Cranks Slowly
38
Engine Difficult to Start or will Not Start Exhaust Smoke) (Continued)
42
Engine Has Poor Respones
43
Engine Stops During Operation
44
Engine Runs Rough or Misfires
45
Engine Power Output Low
46
Engine Power Output Low (Continued)
47
Excessive Exhaust (Black Smoke)
48
Excessive Exhaust (White Smoke)
49
Lubricating Oil Consumption Excessive
50
Lubricating Oil Contaminated
51
Fuel Consumption Is Excessive
52
Coolant Contamination
53
Coolant Loss
54
Lubricating Oil Pressure Is Low
55
Oil Level Rises
56
Coolant Temperature above Normal
57
Excessive Noise
58
Excessive Noise (Continued)
59
Engine Vibration Excessive
60
Complete Engine
61
Engine Assembly
80
Engine System
109
Bearing, Main
114
Bearing, Thrust
119
Camshaft
121
Camshaft Bushings
124
Camshaft Gear
126
Connecting Rod
127
Crankshaft
134
Crankshaft Gear, Front
139
Crankshaft Pulley
140
Crankshaft Seal, Front
142
Crankshaft Seal, Rear
143
Cylinder Block
144
Gear Cover, Front
148
Idle Gear, Camshaft
150
Piston
153
Piston Rings
156
Piston and Connecting Rod Assembly
160
Gear Train Backlash, Front
170
Camshaft Thrust Bearing
171
Cylinder Head
172
Rocker Levers
178
Rocker Levers Assembly
180
Rocker Lever Cover
183
Push Rods or Tubes
184
Tappet
185
Complete Engine
187
Testing and Adjusting the Fan Belt Tansion
189
Fuel System
190
Injector
195
Lubricating System
200
Lubricating Oil Pressure Regulator (Main Rifle)
202
Lubricating Oil Suction Tube (Block-Mounted)
205
Cooling System
206
Coolant Thermostat
208
Coolant Thermostat Housing
209
Cooling System
210
Cooling System Diagnostics
213
Engine Compression
219
Specifications
222
Rocker Arm Shaft, Push Rod and Tappets
223
Cylinder Head
224
Cylinder Block
225
Camshaft and Camshaft Bushing
226
Crankshaft
227
Timing Gear
228
Flywheel
229
Cylinder
230
Piston
231
Connecting Rod, Piston Ring and Piston Pin
232
Oil Pump
233
Regulator Valve
234
Thermostat
235
Capscrew Markings and Torque Values
236
Capscrew Markings and Torque Values - U.S Customary
237
Fraction, Decimal, Millimeter Conversions
238
Newton-Meter to Foot-Pound Conversion Chart
239
Tap-Drill Chart - U.S. Customary and Metric
240
Weight and Measures - Conversion Factors
241
Special Tools
242
Information Section
1032
Foreword
1032
Safety Section
1034
Important Safety Information
1034
Safety
1035
Warning Signs and Labels
1035
No Riders Warning
1038
Parking Brake
1039
General Hazard Information
1040
Operation Information
1041
Maintenance Information
1044
Operator Restraint System(if Equipped)
1047
Avoiding Lift Truck Tipover
1051
Safety Rules
1053
How to Survive in a Tipover
1058
General Section
1060
Specifications
1060
Capacity Chart
1066
Capacity Chart(with Side Shifter)
1068
Serial Number
1070
Operator's Warning and Identification Plate
1073
Operation Section
1074
Operator's Station and Monitoring Systems
1074
Seat Switch System (if Equipped)
1078
Lift Truck Control
1080
Refueling
1083
Before Starting the Engine
1086
Starting the Engine
1088
Lift Truck Operation
1091
Operating Techniques
1127
Parking the Lift Truck
1131
Lift Fork Adjustment
1132
Storage Information
1133
Transportation Hints
1134
Towing Information
1135
Maintenance Section
1136
Inspection, Maintenance and Repair of Lift Truck Forks
1136
Tire Inflation Information
1140
Torque Specifications
1141
Cooling System Specifications
1143
Fuel Specification
1145
Lubricant Information
1147
Lubricant Viscosities and Refill Capacities
1149
Maintenance Intervals
1150
When Required
1154
Every 10 Service Hours or Daily
1161
First 50 - 100 Service Hours or a Week
1166
First 250 Service Hours or a Month
1171
Every 250 Service Hours or Monthly
1172
Every 500 Service Hours or 3 Months
1178
Every 1000 Service Hours or 6 Months
1186
Every 1500 Service Hours or 9 Months
1192
Every 2000 Service Hours or Yearly
1195
Every 2500 Service Hours or 15 Months
1202
Every 3000 Service Hours or 18 Months
1205
Index
1206

Doosan D25G Specifications Systems Operation Testing & Adjusting (74 pages)

Vehicle System with B3.3/4TNE98/G424F/G424FE Engine

Brand: Doosan | Category: Trucks | Size: 3 MB

Table of Contents
5
Index

6
Specification

7
- Hydraulic Control Valve
  7
- Hydraulic Pump
  8
- Lift Cylinder
  8
  - Standard
    8
  - Full Free Triple and Full Free Lift
    9
- Tilt Cylinder
  10
- Mast
  11
- Carriage
  11
- Lift Relay Group - Full Free Lift
  13
- Lift Relay Group - Full Free Triple Lift
  14
- Lift & Tilt Mounting Group
  15
- Steering Wheel
  16
- Steering Gear
  17
- Steer Axle and Wheel
  18
- Steer Wheel Mounting
  19
- Shoe Brake
  19
System Operation

20
- Hydraulic System
  20
- Steering System
  29
  - Steering Cylinder
    29
  - Steering Gear
    30
- Brake System
  32
  - Master Cylinder
    32
  - Shoe Type Brake
    33
  - Automatic Adjustment
    33
  - Parking Brake
    33
Testing and Adjusting

34
- Troubleshooting
  34
  - Visual Checks
    34
  - Performance Tests
    34
  - Hydraulic Oil Temperature (too Hot)
    34
  - Hydraulic System and Mast
    35
  - Hydraulic Pump
    38
  - Hydraulic Control Valve
    39
  - Steering System
    40
  - Brake System
    41
  - Parking Brake
    42
- Hydraulic System
  43
  - Relief Valve Pressure Check
    43
  - Lift Cylinder Air Removal (Only FFT & FFL Mast)
    45
- Delayed Engine Shutdown System
  46
- OSS (Operator Sensing System)
  51
  - Operation
    51
  - Symbols of OSS
    51
  - Operator Sensing System Schematic
    52
  - Trouble Shooting of Operator Sensing System
    53
- Mast and Carriage
  55
  - Mast Adjustment
    55
  - Carriage Adjustment
    60
  - Chain Adjustment
    61
  - Chain Wear Test
    62
  - Carriage and Mast Height Adjustment
    63
  - Forks Parallel Check
    63
- Tilt Cylinder Alignment
  64
- Drift Test
  65
- Steering System
  66
- Brake System
  69
  - Brake System Air Removal
    69
  - Brake Adjustment
    69
  - Parking Brake Test
    73
  - Parking Brake Adjustment
    73

Doosan D25G Disassembly/Assembly (87 pages)

Vehicle System with B3.3 Engine, with 4TNE98 Engine, with G424F Engine, with G424FE Engine

Brand: Doosan | Category: Forklifts | Size: 5 MB

Table of Contents
5
Hood (with Seat) Assembly
7
Overhead Guard
8
Forks
9
Backrest
9
Carriage
9
Mast
15
Standard Lift Cylinder
30
Secondary Lift Cylinder
33
Primary Lift Cylinder
36
Tilt Cylinder
39
Hydraulic Pump
44
Steering Wheel
53
Steering Unit
54
Brake Master Cylinder
64
Steer Wheel & Bearing
66
Steering Knuckle, Kingpin, and Bearing
68
Steer Axle
69
Steering Cylinder
71
Hydraulic Control Valve
75
Counterweight
82
Engine
83

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