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D80S-5
Doosan D80S-5 Manuals
Manuals and User Guides for Doosan D80S-5. We have
5
Doosan D80S-5 manuals available for free PDF download: Service Manual, Operation & Maintenance Manual, Specifications Systems Operation Testing & Adjusting Disassembly & Assembly
Doosan D80S-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
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Doosan D80S-5 Operation & Maintenance Manual (204 pages)
Brand:
Doosan
| Category:
Forklifts
| Size: 9.11 MB
Table of Contents
Operation & Maintenance Manual
2
Table of Contents
2
Information Section
3
Foreword
3
Safety Section
5
Important Safety Information
5
Safety
6
Warning Signs and Labels
6
General Hazard Information
11
Operation Information
12
Maintenance Information
15
Operator Restraint System (if Equipped)
18
Avoiding Lift Truck Tipover
22
Safety Rules
24
How to Survive in a Tipover (if Operator Restraint System Equipped)
30
General Section
32
Declaration of Conformity
32
Specifications
33
Noise &Vibration
49
Capacity Chart - Without Side Shifter
50
Capacity Chart - with Side Shifter
52
Serial Number
54
Operator's Warning and Identification Plate
56
Operation Section
58
Operator's Station and Monitoring Systems
58
Seat Switch System
68
Lift Truck Controls
68
Refueling
73
Before Starting the Engine
76
Starting the Engine
79
After Starting the Engine
82
Lift Truck Operation
118
Auto Shift Controller ASC-202/204/208 (if Equipped)
120
Operating Techniques
125
Parking the Lift Truck
129
Lift Fork Adjustment
130
Storage Information
131
Transportation Hints
132
Towing Information
133
Maintenance Section
134
Inspection, Maintenance and Repair of Lift Truck Forks
134
Tire Inflation Information
138
Torque Specifications
139
Cooling System Specifications
141
Fuel Specifications
143
Lubricant Specifications
145
Maintenance Intervals
149
Notice
153
Engine Valve Lash (Diesel E/G Only) - Check, Adjust
153
Priming the Fuel System (Diesel Engine Only)
153
Test Fuel System for Leaks (LP Engine Only)
154
Fuel Tank Filter Cap & Screen - Clean
155
Seat - Check, Lubricate
155
Fuses, Bulbs & Circuit Breaker - Change, Reset
156
Tires and Wheels - Inspect, Check
157
Radiator Cap - Clean, Change
158
Carriage Roller Extrusion - Adjust
158
Brake Oil (OCDB) - Check
159
When Required
153
Every 10 Service Hours or Daily
160
Inspection Engine for Fluid Leaks
160
Engine Oil Level - Check
160
Coolant Level - Check
160
Air Cleaner Indicator - Check
161
Inspect Foot Pedal Operation (LP Engine Only)
162
Inspect Engine for Exhaust Leaks
162
Walk-Around Inspection - Inspect
162
Mast Channels - Lubricate
163
Transmission Oil Level - Check
164
First 50-100 Service Hours or a Week
165
Engine Oil & Oil Filter (Diesel E/G Only) - Change
165
Transmission Oil & Oil Filter - Change
166
Drive Axle Oil - Change
168
Parking Brake - Test, Adjust
170
First 250 Service Hours or a Month
172
Hydraulic Return Filter - Change
172
Every 250 Service Hours or Monthly
173
Air Intake System - Check, Clean
173
Engine Oil & Filter(LP Engine Only) - Change
176
Hydraulic Oil Level - Check
177
Drive Axle Oil Level - Check
177
Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate
178
Steering Mechanism - Check, Lubricate
179
Battery Terminal - Clean, Inspect
180
Wheel Bolts & Nuts - Inspect
180
Every 500 Service Hours or 3 Months
181
Belts (Diesel E/G Only) - Check, Adjust
181
Mast Hinge Pins - Lubricate
181
Tilt Cylinders - Check, Adjust, Lubricate
182
Crosshead Rollers - Inspect
182
Transmission Oil Filter (2 Speed Only) - Change
182
Parking Brake - Test, Adjust
182
Drive Axle Oil (OCDB) - Change
182
Horn and Lights(if Equipped) - Check
183
Overhead Guard - Inspect
183
Steer Suspension - Inspect
183
Universal Joint - Inspect, Lubricate
183
Engine Oil & Filter(Diesel Engine Only) - Change
184
Inspect Vacuum Lines and Fittings (G643(E) Engine Only)
184
Fuel Trim Valve(FTV) Inspection (G643E Engine Only)
184
Inspect Electrical System (G643E Engine Only)
184
Every 1000 Service Hours or 6 Months
185
Carburetor (LP - Gas Engine Only) - Adjust, Clean
185
Fuel Filter - Check, Clean, Change
185
Air Intake System - Change
185
Inspect Coolant Hoses (LP Engines Only)
186
LP Regulator/Converter Inspection (LP Engine Only)
186
Fuel Lines & Fittings - Check
186
Inspect Mixer Assembly (LP Engine Only)
186
Inspect Throttle Assembly (LP Engine Only)
186
Hydraulic Oil, Return Filter, Strainer & Breather - Check, Clean, Change
187
Transmission Oil & Filter (3 Speed, ZF 3WG116) - Change
188
Transmission Oil (2 Speed Only) - Change
188
Lift Chains - Test, Check, Adjust
188
Every 1500 Service Hours or 9 Months
191
Drive Axle Oil (Shoe Brake Only) - Change
191
Inspect Ignition System (LP Engine Only)
191
Replace Spark Plugs (LP Engine Only)
191
Replace LP Fuel Filter Element (LP Engine Only)
192
Testing Fuel Lock-Off Operation (LP Engine Only)
193
Every 2000 Service Hours or Yearly
194
Steer Wheel Bearings - Reassemble
194
Transmission Oil & Filter (3 Speed, ZF 3WG94) - Change
194
Cooling System - Clean, Change
195
Fork - Inspect
196
Every 2500 Service Hours or 15 Months
198
Inspect Battery System
198
Checking the TMAP Sensor (LP Engine Only)
198
Inspect for Intake Leaks (LP Engine Only)
199
Replace PCV Valve and Breather Element - Change (LP Engine Only)
199
Replace Oxygen Sensor (G643E Engine Only)
199
Every 3000 Service Hours or 18 Months
200
Index
201
Doosan D80S-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 D80S-5 Operation & Maintenance Manual (204 pages)
Brand:
Doosan
| Category:
Forklifts
| Size: 5.54 MB
Table of Contents
Table of Contents
2
Information Section
3
Foreword
3
Safety
6
Warning Signs and Labels
6
General Hazard Information
11
Safety Rules
24
How to Survive in a Tipover (if Operator Restraint System Equipped)
30
General Section
31
Capacity Chart - - with
50
Operation Section
57
Seat Switch System
67
Lift Truck Controls
68
Refueling
72
After Starting the Engine
81
Parking the Lift Truck
128
Plate
132
Inspection, Maintenance and Repair of Lift Truck
133
Tire Inflation Information
137
Torque Specifications
138
Cooling System Specifications
140
Specifications
143
Every 250 Service Hours or
149
Adjust Adjust
151
When Required
152
Radiator Cap - Clean, Change
157
Brake Oil (OCDB) - Check
158
Daily
159
Every 10 Service Hours or Daily
159
Air Cleaner Indicator - Check
160
Engine Oil Level - Check
160
Mast Channels - Lubricate
162
Transmission Oil Level - Check
163
First 250 Service Hours or a Month
171
Clean
174
Check
175
Inspect
175
Leaks
175
Hydraulic Oil Level - Check
176
Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate
177
Lubricate
178
Inspect
179
Wheel Bolts & Nuts - Inspect
179
Belts (Diesel E/G on E/G Only) - Ly) - Check, Adjust
180
Crosshead Rollers - Inspect
181
Lubricate
181
Check
182
Drive Axle Oil (OCDB) - Change
182
Parking Brake - Test, Adjust
182
Engine Oil & Filter(Diesel Engine Only) - Change
183
Fuel Trim Valve(FTV) Inspection
183
Inspect Vacuum Lines and Fittings (G643(E) Engine
183
Overhead Guard - Inspect
183
Universal Joint - Inspect, Lubricate
183
Index
201
Months
201
Service Service Hours Hours or or Monthly
201
Doosan D80S-5 Specifications Systems Operation Testing & Adjusting Disassembly & Assembly (68 pages)
Brand:
Doosan
| Category:
Control Unit
| Size: 4.58 MB
Table of Contents
Table of Contents
4
Specification
6
General Tightening Torque
6
Drive Axle Specification
7
Torque Converter
8
Transmission Pump
8
Drive Axle Mounting
9
Differential
9
Wheel Bearing and Drive Wheel
9
Brake Assembly
10
Brake Drum Diameter
11
U - Joint
11
System Operation
12
General Information
12
Power Shift Transmission
13
General Information
13
Power Flow at Low Speed Forward
14
Power Flow at High Speed Forward
15
Power Flow at Low Speed Reverse
16
Power Flow at High Speed Reverse
17
Transmission Control Valve
18
Cross-Section View
18
Hydraulic Schematic
19
Differential and Drive Axles
21
Differential
21
Wheel Hub
21
Brake Components
22
Shoe Brake
22
Brake Adjuster
22
Ocdb
23
Testing and Adjusting
24
Troubleshooting
24
Visual Checks
24
Checks During Operation
24
Check List During Operation
24
Check List from Operation Noise
26
Check List from Pressure Test
27
Differential
28
Transmission Pressure
29
Converter Stall Test
30
Shimming of Transmission Shaft
31
Wheel Brake Adjustment
31
Inching Pedal Adjustment
33
Disassembly and Assembly
36
Drive Shaft and Universal Joint
36
Engine, Torque Converter and Transmission
37
Transmission Control Valve
41
Transmission
44
Drive Axle
55
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