Doosan D40S-5 User Manual

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SB2355E01

Operation &

Maintenance Manual

LIFT TRUCKS

D35S-5, D40S-5, D45S-5, D50C-5, D55C-5

G35S-5, G40S-5, G45S-5, G50C-5, G55C-5

D40SC-5, D45SC-5, D50SC-5, D55SC-5

G40SC-5, G45SC-5, G50SC-5, G55SC-5

0705

https://www.forkliftpdfmanuals.com/

Table of Contents

Other manuals for Doosan D40S-5

Service Manual366 pages

Disassembly/Assembly62 pages

Questions and Answers:

T
Timothy AllenAug 6, 2025
Why is there excessive black smoke coming from my Doosan Engine?
- Y
  yjohnsonAug 6, 2025
  Excessive black smoke from your Doosan Engine may be due to several reasons. The air cleaner element might be clogged, so try replacing or cleaning it. There could be restrictions in the air duct, which you should check and correct. Another potential cause is leakage at the intake manifold, so inspect and fix that as well. The turbocharger could be seized up and not rotating, or the turbine and compressor blades might be damaged or in contact with each other, requiring disassembly, repair, or replacement. Finally, the exhaust piping could be deformed or clogged; check and correct it.
D
Denise SmithAug 14, 2025
What to do if my Doosan D40S-5 has low output?
- K
  Kelly SmithAug 14, 2025
  If your Doosan Engine has low output, start by checking for gas leaks in the exhaust system and correct them. Also, the air cleaner element may be restricted, so replace or clean it. The turbocharger could be fouled or damaged, requiring disassembly, repair, or replacement. Lastly, check for leakage at the discharge port on the compressor side and correct it.
T
tylerthomasAug 20, 2025
How to fix unusual sound or vibration in my Doosan Engine?
- E
  Elizabeth GreenAug 20, 2025
  If your Doosan Engine is making unusual sounds or vibrating, the rotor assembly might be coming into contact, or the rotor rotation may be unbalanced, either of which would require disassembly, repair, or replacement. Also, the engine could be seized up, which would also require disassembly, repair, or replacement. Check if each joint loosened and correct.
N
nholderAug 28, 2025
What causes excessive white smoke from a Doosan D40S-5 Engine?
- C
  Caitlin CarsonAug 28, 2025
  Excessive white smoke from a Doosan Engine can be caused by an oil leak into the turbine and compressor, which requires disassembly, repair, or replacement. It may also be due to a worn or damaged seal ring because of excessive bearing wear, also requiring disassembly, repair, or replacement.

Doosan D40S-5 Specifications

General

Number of Cylinders	4
Fuel System	Direct Injection
Fuel Type	Diesel
Compression Ratio	17.5:1
Aspiration	Naturally Aspirated
Engine Type	4-cycle, Water-cooled, Diesel
Oil Capacity	8.5 L (9.0 qt)

Summary

Foreword

Literature Information

Information about the manual's content, storage, and updates.

Safety Section

Important Safety Information

Crucial safety precautions to prevent accidents, injury, or death during operation.

General Warnings to Operator

Key operational safety warnings for the lift truck operator.

Safety Rules

Essential rules for safe operation, including personal protective equipment and general conduct.

How to Survive in a Tipover (If Operator Restraint System Equipped)

Instructions on how to react and protect oneself in the event of a lift truck tipover.

General Section

Specifications

Technical details and performance data of various lift truck models.

Capacity Chart

Load capacity charts for different models and mast configurations.

Serial Number Locations

Guidance on locating serial numbers for the lift truck and its components.

Operation Section

Operator’s Station and Monitoring Systems

Description of instrument panel indicators, gauges, and warning lights.

Lift Truck Controls

Explanation of the function and operation of various lift truck controls.

Starting the Engine

Step-by-step guide for starting diesel and LP engines, including prestart conditions.

Operating the Lift Truck

Instructions on safe travel, load handling, and maneuvering techniques.

Parking the Lift Truck

Guidelines for properly parking the lift truck in authorized areas.

Storage Information

Procedures for preparing the lift truck for short-term and long-term storage.

Towing Information

Recommendations for safely towing a disabled lift truck.

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

Guidelines for inspecting, maintaining, and repairing lift truck forks.

Maintenance Intervals

Schedule of recommended maintenance tasks based on operating hours or time intervals.

When Required

Maintenance tasks that should be performed based on specific conditions or issues.

Every 10 Service Hours or Daily

Daily checks and lubrication for optimal engine and system performance.

First 50 - 100 Service Hours or a Week

Initial maintenance for engine oil, filter, transmission, and drive axle.

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