User Manuals: Doosan D90S-5 Diesel Forklift

Manuals and User Guides for Doosan D90S-5 Diesel Forklift. We have 5 Doosan D90S-5 Diesel Forklift manuals available for free PDF download: Service Manual, Operation & Maintenance Manual, Specifications Systems Operation Testing & Adjusting Disassembly & Assembly

Doosan D90S-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 D90S-5 Operation & Maintenance Manual (204 pages)

Brand: Doosan | Category: Forklifts | Size: 9 MB

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

Doosan D90S-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 D90S-5 Operation & Maintenance Manual (204 pages)

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

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 D90S-5 Specifications Systems Operation Testing & Adjusting Disassembly & Assembly (68 pages)

Brand: Doosan | Category: Control Unit | Size: 4 MB

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
- 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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User Manuals: Doosan D90S-5 Diesel Forklift

Doosan D90S-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

Vehicle Communication Function

PC Utility

Appendix

Doosan D90S-5 Operation & Maintenance Manual (204 pages)

Table of Contents

Operation & Maintenance Manual

Information Section

Safety Section

General Section

Operation Section

Maintenance Section

Maintenance Intervals

Notice

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

Doosan D90S-5 Service Manual (152 pages)

Table of Contents

1 General Information

2 Technical Information

3 Maintenance

4 Commissioning and Operation

5 Maintenance of Major Components

6 Special Tool List

Appendix

Doosan D90S-5 Operation & Maintenance Manual (204 pages)

Table of Contents

Table of Contents

Every 250 Service Hours or