Doosan D55C-5 - User Manual

Other manuals for Doosan D55C-5

Service Manual366 pages

Disassembly/Assembly62 pages

Questions and Answers

C
Christopher RodriguezAug 9, 2025
Why is there excessive black smoke coming from my Doosan Engine?
- A
  Angelica TaylorAug 9, 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.
J
Jessica LopezAug 16, 2025
What to do if my Doosan D55C-5 has low output?
- H
  Holly JonesAug 16, 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
Thomas MorganAug 25, 2025
How to fix unusual sound or vibration in my Doosan D55C-5 Engine?
- A
  Austin HendersonAug 25, 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.
G
Gloria LoganAug 31, 2025
What causes excessive white smoke from a Doosan D55C-5 Engine?
- B
  Bonnie HaleAug 31, 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.

Summary

Safety Warnings

Safety Section

Important Safety Information

Crucial safety rules and precautions to prevent accidents and injury.

Safety Rules and Regulations

Warning Signs and Labels

Describes various warning signs and their locations on the lift truck.

General Warnings to Operator

Lists essential operational warnings and precautions for safe lift truck use.

System-Specific Safety Warnings

Component Safety Warnings

Operational Safety Warnings

General Hazard Information

Before Starting the Lift Truck Checks

Operating the Lift Truck Safely

Guidelines for safe and controlled lift truck operation.

Loading or Unloading Trucks;Trailers Precautions

Maintenance Information Guidelines

Fire or Explosion Prevention

Tire Information and Safety

Operator Restraint System Safety

Information regarding warning signs, labels, and seat adjustment for restraint systems.

Seat Belt Safety Procedures

Guidelines for inspecting seat belt condition and proper fastening.

General Safety Rules

General safety rules for operating forklift trucks.

General Operational Safety Rules

Specific safety rules for forklift operation, including seat position and movement.

Tipover Survival Instructions

Instructions on how to react and survive in the event of a tipover.

General Section

Specifications

Detailed technical specifications for various lift truck models.

Operator Plates and Capacity Rating

Capacity Charts

Charts showing load capacity based on load center and mast height.

Capacity Charts with Side Shifter

Load capacity charts considering the use of a side shifter.

Lift Truck Capacity Rating Explanation

Explanation of how lift truck capacity is determined and rated.

Operation Section

Operator’s Station and Monitoring Systems

Instrument Panel Indicators

Starting the Engine Procedures

Steps for starting the engine, including prestart conditions and procedures for Diesel and LP engines.

After Starting the Engine Checks

G643 E Engine System Overview

Basic Troubleshooting Guide

Basic checks for engine or drivability problems before advanced diagnostics.

Engine Starting Troubleshooting

Troubleshooting steps for engine cranking, starting difficulties, and running continuously issues.

Engine Performance Troubleshooting

Fuel Consumption and Exhaust Issues

Advanced Diagnostics (G643 E Only)

Information on reading and displaying diagnostic fault codes from the SECM.

MI-07 Diagnostic Fault Codes

Lists MI-07 diagnostic fault codes, probable faults, actions, and corrective actions.

MI-07 Diagnostic Fault Codes (Continued)

Continues the list of MI-07 diagnostic fault codes and their corrective actions.

Lift Truck Controls

Primary Controls Operation

Mono-Ped Control System (Option)

Auto Shift Controller ASC - 200 (If Equipped)

Overview of the autoshift controller system, its purpose, and features.

Operating Techniques

Inching into Loads

Step-by-step guide to inching the lift truck into position for loads.

Lifting the Load Safely

Procedures for safely lifting loads using the mast and forks.

Traveling With the Load

Guidelines for traveling with a load, including load height and visibility.

Unloading Procedures

Steps for safely unloading a load from the forks.

Parking the Lift Truck

Lift Fork Adjustment

Procedures for adjusting fork spread and ensuring they are locked.

Machine Lifting and Tiedown Information

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.

Causes of Fork Failure

Fork Inspection Procedures

Guidelines for initial and daily inspection of forks for safety.

Cooling System Specifications

Fuel Specifications

General guidelines for fuel use and tank filling for diesel and LP engines.

Lubricant Specifications

Lubricant Viscosities and Refill Capacities

Tables for oil viscosities and refill capacities for various components.

Maintenance Intervals Guide

Lists all maintenance tasks grouped by service intervals.

When Required Maintenance Tasks

Every 10 Service Hours or Daily Tasks

Procedures for daily checks including engine fluid leaks, oil, and coolant levels.

First 50 - 100 Service Hours or a Week Tasks

Procedures for initial engine oil/filter and transmission oil/filter service.

Parking Brake Test and Adjustment

Procedure for testing and adjusting the parking brake to hold capacity load on a 15% grade.

First 250 Service Hours or a Month Tasks

Procedure for changing the hydraulic return filter.

Every 250 Service Hours or Monthly Tasks

Primary Filter Element Cleaning

Hydraulic Oil Level Check

Drive Axle Oil Level Check

Brake Oil Level Check

Mast, Carriage, Lift Chains, & Attachments Service

Steering Mechanism Check and Lubrication

Tilt Cylinders Service

Circulation Pump Belt Check and Adjustment

Drive Axle Oil & Strainer Service (OCDB Only)

Procedures for checking, cleaning, and changing drive axle oil and strainer for OCDB.

Fuel Trim Valve (FTV) Inspection (G643 E Engine only)

Overhead Guard Inspection

Steer Suspension Inspection

Air Intake System - Change

LP Regulator;Converter Inspection (LP Engine Only)

Hydraulic Return Filter Change

Transmission Oil, Filter & Strainer Service

Procedures for cleaning and changing transmission oil, filter, and strainer.

Lift Chains Service

Carriage Chain Adjustment

Mast Chain Adjustment

Drive Axle Oil Service (Shoe Brake Only)

Procedures for checking, cleaning, and changing drive axle oil for shoe brake types.

Ignition System Inspection (LP Engine Only)

Spark Plug Replacement (LP Engine Only)

Replace LP Fuel Filter Element (LP Engine Only)

Procedure for replacing the LP fuel filter element.

Testing Fuel Lock-off Operation (LP Engine Only)

Steer Wheel Bearings Reassembly

Step-by-step instructions for reassembling steer wheel bearings.

Cooling System Clean and Change

Procedures for cleaning and changing the cooling system fluid.

Fork Inspection

Guidelines for inspecting forks for cracks, wear, and damage.

Hydraulic Oil Check, Clean, Change

Procedures for checking, cleaning, and changing hydraulic oil.

Inspect Battery System

TMAP Sensor Check (LP Engine Only)

Intake Leak Inspection (LP Engine Only)

PCV Valve and breather element Replacement (LP Engine Only)

Oxygen Sensor Replacement (G643 E Engine Only)

Procedure for replacing oxygen sensors when indicated by MIL.

Doosan D55C-5 Specifications

General

Brand	Doosan
Model	D55C-5
Category	Engine
Language	English

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