Doosan D15S-5 Manuals

Doosan D15S-5 Manuals

Manuals and User Guides for Doosan D15S-5. We have 2 Doosan D15S-5 manuals available for free PDF download: Service Manual, Specifications Systems Operation Testing & Adjusting

Doosan D15S-5 Service Manual

Doosan D15S-5 Service Manual (242 pages)

Brand: Doosan | Category: Engine | Size: 16.8 MB

Table of Contents

Important Safety Information
3
Table of Contents
5
Index

6
Introduction

7
- About the Manual
  7
- How to Use the Manual
  7
- Generic Symbols
  8
- Definition of Terms
  9
- Illustrations
  10
General Engine Information

11
- External Engine Components
  11
- Engine Specifications
  13
Troubleshooting Logic

14
Coolant System

55
- Cooling System Components and Flow
  55
- Pressure Caps
  58
- Water(Coolant) Pump
  59
- Thermostat
  62
- Gauges, Overfueling and Laoding
  63
- Cooling System Replacement Procedures
  64
- Belt Tensioner Replacement
  64
- Fan Pulley Replacement
  64
- Fan Hub Replacement
  65
- Water Pump Replacement
  66
- Cup Plug Replacement
  69
Fuel System

70
- Fuel System Components and Flow
  70
- Fuel System Malfunction Diagnosis
  71
- Air in the Fuel System
  72
- Fuel Water Separator/Filter Unit
  73
- Injection Pump
  74
- Governor Malfunctions
  74
- Fuel Control Lever Travel and Adjustment
  75
- VE Pump Adjustment Screws
  75
- Manual Shut down Levers
  76
- Advance Timing Mechanism
  76
- Electrical Shut off Valves
  77
- Injection Pump Timing
  79
- High Pressure Fuel Line
  80
- Injectors
  81
- Fuel Drain Manifold
  83
Air System

100
- Air System Flow
  100
- Diagnosing Air System Malfunctions
  101
- Air Flow Restriction
  101
- Damage from Non-Filtered Air
  102
- Pressure Side Air Leaks
  102
- Exhaust Leaks
  103
- Malfunctioning Turbocharger
  103
- Oil Consumption and Leaks
  104
- Turbocharger Noise
  105
- Rotor Assembly Clearance Measure
  106
- Intake Air Restriction
  114
Lubricating System

115
- Lubricating System Flow
  115
- Lubricating Oil Pump
  115
- Pressure Regulating Valve
  115
- Oil Coolers
  116
- Oil Filters
  116
- Oil Filters Bypass Valve
  116
- Low Oil Pressure
  118
- Oil Level
  118
- Oil Filter
  119
- Oil Gauge
  119
- Oil Suction Tube
  119
- Bearings and Oil Pump
  119
- Incorrect Oil Pump
  120
- Oil Dilution
  120
- Coolant Diluted Oil
  120
- Fuel Diluted Oil
  121
- Oil Leaks
  125
Electrical System

136
- Electrical System Description/Operation
  136
- Electrical System Spec
  138
- Starting Motor
  139
- Engine Cranking Speed too Slow
  141
- Alternator
  142
- Fuel Shut off Valve Check
  145
- Oil Pressure Switch
  145
Base Engine Components

150
- Operation and Description
  150
- Cylinder Head and Valve Train
  151
- Front Gear Housing and Gear Train
  152
- Front Crankshaft Seal
  152
- Camshaft, Tappets and Push Rods
  152
- Flywheel Housing and Flywheel
  153
- Piston and Rod Assemblies
  154
- Crankshaft and Main Bearings
  156
- Oil Pan
  158
- Base Engine Component
  158
- Air and Fuel System
  159
- Compression Check
  160
- Piston Ring Seal
  160
- Valce Sealing
  160
- Valve Seal Wear
  162
- Front Gear Housing and Gear Train
  163
- Rocker Levers
  164
- Piston and Rod Assembly
  165
- Crankshaft and Main Bearings
  167
- Cylinder Block
  168
- Flywheel Housing and Flywheel
  168
- Base Engine Componen Specifications
  170
- Gear Train
  171
- Camshaft
  171
- Tappets
  171
- Pistons
  172
- Connecting Rod
  173
- Crankshaft
  173
- Cylinder Block
  173
- Cylinder Bore
  174
- Base Engine Components
  175
- Rocker Levers
  176
- Rocker Levers Assembly
  181
- Valve Clearance
  181
- Four Cylinder Engine
  181
- Camshaft and Tappet
  182
- Camshaft Inspection
  183
- Camshaft Bushing Inspection
  184
- Tappet Inspection
  185
- Gear Housing or Gasket
  188
- Flywheel Ring Gear and Rear Sel
  189
- Brass Drift Pin
  189
- Flywheel
  190
- In Chassis Overhaul
  191
- Cylinder Head Removal
  192
- Main Bearing Preliminary Inspection
  193
- Main Bearing
  196
- Piston and Rod
  198
- Piston, Pin and Connecting Rod
  199
- Piston Ring Gap
  204
- Piston Rings
  204
- Piston and Rod Assembly
  206
- Cylinder Head and Gasket
  209
- Cylinder Head
  213
- Valves
  216
- Valve Seats
  218
- Cylinder Head
  222
- Hydraulic Pump Drive Gear and Shaft
  223
- Balancer-Remove
  223
- Balancer-Install
  224
Engine Replacement and Testing

225
- Engine Replacement
  225
- Engine Removal
  225
- Engine Installation
  227
- Engine Testing
  229
Specifications

230
- General Engine
  230
- Fuel System
  230
- Lubricating Oil System
  230
- Cooling System
  231
- Air Intake System
  231
- Exhaust System
  231
- Electrical System
  231
- Drive Belt Tension
  231
- Capscrew Markings and Torque Values
  232
- Fraction, Decimal, Millimeter Conversions
  235
- Newton-Meter to Foot-Pound Conversions
  236
- Pipe Plug Torque Values
  236
- Weights and Measures-Conversion Factors
  237
Special Tools

239
- Special Tool List
  239

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Doosan D15S-5 Specifications Systems Operation Testing & Adjusting

Doosan D15S-5 Specifications Systems Operation Testing & Adjusting (64 pages)

Brand: Doosan | Category: Forklifts | Size: 2.35 MB

Table of Contents

Table of Contents
5
Specification

7
- Control Valve
  7
- Hydraulic Pump
  8
- Sideshift Cylinder
  8
- Lift Cylinders
  9
- Tilt Cylinder
  11
- Steering Wheel
  12
- Priority Valve
  12
- Steering Unit
  13
- Forward and Reverse Control Group
  14
- Brake - SHOE
  14
- Delayed Engine Shutdown System
  15
- OSS (Operator Sensing System)
  22
  - Operation
    22
  - Symbols of OSS
    22
  - Operator Sensing System Schematic
    23
  - Trouble Shooting of Operator Sensing System
    24
Hydraulic System Operation

26
- Hydraulic Schematic
  26
- Control Valve
  28
  - External View
    28
  - Circuit Schematic
    28
  - Inlet Section
    29
  - Lift Section
    30
  - Tilt Section
    32
  - Auxiliary Section
    33
  - Outlet Section
    34
  - Relief Valve
    35
- Hydraulic Steering System
  36
  - Hydraulic Schematic
    36
  - Steering Cylinder
    37
  - Steering Unit
    38
- Brake System
  40
  - Master Cylinder
    40
  - Shoe Type Brakes
    41
  - Parking Brake
    41
Testing and Adjusting

43
- Troubleshooting
  43
  - Visual Checks
    43
  - Performance Tests
    43
  - Hydraulic System and Mast
    44
  - Steering System
    49
  - Brake System
    50
  - Lift Cylinders Air Removal
    52
- Hydraulic System
  53
- Steering System
  55
- Brake System
  60
  - Brake System Air Removal
    60
  - Pedal Adjustment for Brake & Inching
    60
  - Parking Brake Test
    62
  - Parking Brake Adjustment
    62

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