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GC18S-5
Doosan GC18S-5 Service Manual
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Service Manual
A2300 Diesel Engine
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
SB4106E01
2
Table of Contents
Default Chapter
3
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
Engine Diagrams
14
Problem Isolation and Correction
14
Troubleshooting Logic(List of Symptoms)
15
Coolant Temperature above Normal
34
Coolant Temperature below Normal
37
Lubricating Oil Pressure Low
40
Excessive Fuel Consumption
49
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 GC18S-5 Specifications
General
Model
GC18S-5
Category
Forklifts
Load Capacity
1800 kg
Power Source
Diesel
Lift Height
3000 mm
Tire Type
Pneumatic
Overall Width
1150 mm
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