Руководство по эксплуатации погрузчиков doosan

• 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

Brand: Doosan
|
Category: Forklifts
|
Size: 9.11 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

  • 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

• 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

Brand: Doosan
|
Category: Forklifts
|
Size: 5.54 MB

Brand: Doosan
|
Category: Control Unit
|
Size: 4.58 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

    • 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