User Manuals: Doosan D45S-5 Pneumatic Forklift Truck

Manuals and User Guides for Doosan D45S-5 Pneumatic Forklift Truck. We have 4 Doosan D45S-5 Pneumatic Forklift Truck manuals available for free PDF download: Service Manual, Operation & Maintenance Manual, Disassembly/Assembly

Doosan D45S-5 Operation & Maintenance Manual (350 pages)

LIFT TRUCKS

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

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
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

Doosan D45S-5 Service Manual (366 pages)

Brand: Doosan | Category: Engine | Size: 16 MB

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 D45S-5 Service Manual (152 pages)

Brand: Doosan | Category: Engine | Size: 24 MB

Important Safety Information
3
Table of Contents
7
1 General Information

9
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
- 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

Doosan D45S-5 Disassembly/Assembly (62 pages)

Vehicle System

Brand: Doosan | Category: Forklifts | Size: 17 MB

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

Doosan Categories

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User Manuals: Doosan D45S-5 Pneumatic Forklift Truck

Doosan D45S-5 Operation & Maintenance Manual (350 pages)

Table of Contents

Table of Contents

Information Section

Safety Section

General Section

Operation Section

Maintenance Section

First 250 Service Hours or a Month Maintenance Intervals

Every 10 Service Hours or Daily

First 50 - 100 Service Hours or a Week

First 250 Service Hours or a Month

Every 250 Service Hours or Monthly

Every 500 Service Hours or 3 Months

Every 1000 Service Hours or 6 Months

Every 1500 Service Hours or 9 Months

Every 2000 Service Hours or Yearly

Every 2500 Service Hours or 15 Months

Index Section

Table of Contents

Information Section

Safety Section

General Section

Operation Section

Maintenance Section

First 250 Service Hours or a Month Maintenance Intervals

When Required

Every 10 Service Hours or Daily

First 50 - 100 Service Hours or a Week

First 250 Service Hours or a Month

Every 250 Service Hours or Monthly

Every 500 Service Hours or 3 Months

Every 1000 Service Hours or 6 Months

Every 1500 Service Hours or 9 Months

Every 2000 Service Hours or Yearly

Every 2500 Service Hours or 15 Months

Index Section

Doosan D45S-5 Service Manual (366 pages)

Table of Contents

General

General

Timing System

Cylinder Head Assembly

Crankcase

Cylinder Block Assembly

Intake and Exhaust System

Turbocharger

Intake Manifold

Exhaust Manifold

Lubrication System

Oil Pump

Oil Cooler

Cooling System

Water Pump

General

Charging System

Alternator

Starting System

Preheating System

General

Engine Control System-Electronic

Engine Control Unit (ECU)

ECU Circuit Diagram

Intake Air Temperature Sensor

Intake Air Pressure Sensor

Coolant Temperature Sensor

Camshaft Position Sensor

Crankshaft Position Sensor

Rail Pressure Sensor

Supply Control Valve

Fuel Delivery System-Electronic

Fuel Filter

Injector

Common Rail Assembly

Injection Pump-Electronic

Check before Use

Hardware

Basic Usage of G-Scan

Configuration