Doosan D110S-5 D130S-5 D160S-5 Service Manual – SB4217E/SB4225E00 PDF

Description

The Doosan D110S-5 D130S-5 D160S-5 Service Manual – SB4217E/SB4225E00 PDF is a 916-page service reference covering the major mechanical, hydraulic, electrical, power-train, engine, operating, and maintenance information assembled for these Doosan lift truck models. Dated November 2006, the manual set identifies the D110S-5, D130S-5, and D160S-5 and brings together service forms for safety, torque specifications, two engine families, the drive axle, three-speed powershift transmission, vehicle systems, hydraulic and electrical schematics, and operation and maintenance.

File Details

• Manual type: Service Manual
• Brand: Doosan
• Models: D110S-5, D130S-5, D160S-5
• Engine coverage: DE08TS Tier II and DL06 Tier III
• Language: English
• Pages: 916
• File format: PDF
• Service manual form: SB4217E
• Service Manual Contents form: SB4225E00
• Date: Nov. 2006

Engine Service Coverage

This Doosan D110S-5 D130S-5 D160S-5 service manual contains substantial engine material rather than a brief maintenance summary. The DE08TS section includes specifications, system operation, testing and adjusting, preventive maintenance, diagnostic flow charts, disassembly, inspection and measurement of major parts, reassembly, component service, special tools, and an appendix of service data. The manual identifies the DE08TS as a six-cylinder, water-cooled, turbocharged, direct-injection engine and includes both 140 PS and 160 PS performance information. Technician procedures extend through cylinder head work, valve and rocker gear, camshaft, crankshaft, pistons and connecting rods, cylinder liners, timing gears, lubrication, cooling, fuel injection, and turbocharger service.

A separate DL06 Tier III engine section is also included for the D110S-5, D130S-5, and D160S-5. It covers specifications, technical information, engine systems, service procedures, diagnostics, special tools, and disassembly and assembly. The DL06 material includes electronic diagnostic information using EDIA, fault-code diagnosis, fuel-system and engine-control information, cooling and lubrication work, and turbocharger service. Having both engine families in the same PDF is useful when identifying the correct service path for the truck configuration being repaired.

Power Train, Drive Axle and Transmission

The power-train portion goes beyond basic removal notes. The drive axle section is organized around specifications, system operation, and disassembly and assembly, including axle and wheel-end torque information, planetary drive-axle operation, carrier and differential work, brakes, hubs, bearings, and associated axle components. The drive-axle material specifically identifies the D110S-5, D130S-5, and D160S-5.

Transmission coverage includes the three-speed powershift transmission 3WG 116/161. The system-operation section explains transmission operation and electronic control functions, while the fault-code material provides diagnostic references for the transmission control system. A dedicated disassembly and assembly section covers special tools, torque limits, hydraulic control components, clutches, gearshift system parts, input and output components, and reassembly procedures. This gives a technician both the operating logic needed for diagnosis and the mechanical procedures needed when the unit must be opened and serviced.

Vehicle Systems, Hydraulics and Brakes

The vehicle-systems material is built around specifications, system operation, testing and adjusting, and component disassembly and assembly. Coverage includes the hydraulic control valve, triple-section hydraulic pump, priority valve, hydraulic oil filtration, lift and tilt cylinders, flow regulator valve, mast, lift chains, carriage, power steering, steer axle, steering gear, and air brake system. Testing and adjusting procedures address hydraulic-system performance, relief pressure checks, mast and carriage adjustment, chain adjustment and wear, cylinder drift, steering pressure and air removal, braking efficiency, governor adjustment, and related setup work.

The disassembly and assembly portion provides illustrated procedures for major truck assemblies such as the carriage, mast, lift and tilt cylinders, air brake components, hydraulic pump and filter, steering column and gear, steering cylinder, steer axle, steering knuckle and bearings, tires and rims, and counterweight. This makes the manual useful for jobs that cross system boundaries, such as diagnosing a hydraulic lifting complaint and then carrying the repair through pump, valve, cylinder, mast, or carriage service.

Hydraulic and Electrical Schematics

Dedicated schematic forms are included for the D110S-5, D130S-5, and D160S-5. The hydraulic schematic identifies the lift, tilt, and auxiliary circuits, giving a direct system-level reference when tracing oil flow or checking connections. The electrical schematic section includes diagrams for engine starting and charging, lighting and warning systems, and monitoring circuits. These diagrams complement the component procedures and can be used while tracing wiring, relays, switches, senders, interlocks, gauges, and related electrical functions shown in the manual.

Operation and Maintenance Information

The operation and maintenance section adds the information needed to service the truck in the context of its normal use. It contains safety information, specifications and capacity information, operator controls and monitoring systems, starting and operating procedures, parking, fork adjustment, storage, transportation and towing information, plus a detailed maintenance section. Maintenance topics include fork inspection, tire inflation, torque specifications, cooling-system and fuel specifications, lubricant specifications and viscosities, refill capacities, and service intervals ranging from daily checks through scheduled 2000-hour or yearly work.

Chapters Covered

• Service Manual Contents – form listing and included service publications
• Safety – general repair precautions, machine support, lifting, hot fluids, pressurized lines, electrical isolation, welding, guards, and service safety
• Torque Specifications – metric and inch fasteners, taperlock studs, O-ring face-seal fittings, flared fittings, hose clamps, air-conditioning fittings, and tapered pipe threads
• DE08TS Tier II Engine – Specification, System Operation, Testing & Adjusting – specifications, performance curves, engine assembly, preventive maintenance, diagnosis, disassembly, inspection, reassembly, cooling, lubrication, fuel injection, turbocharger, special tools, and appendix data
• DE08TS Tier II Engine – Disassembly & Assembly – engine and transmission removal, starter, alternator, fuel injection components, intake and exhaust, cooling, oil system, cylinder head, pistons, crankshaft, camshaft, timing components, and related assemblies
• DL06 Tier III Engine – specifications, technical information, engine systems, testing and adjustment, disassembly and assembly, electronic diagnostics, special tools, and engine assembly
• Drive Axle – specifications, axle system operation, differential/carrier and planetary reduction information, brakes, wheel ends, bearings, and disassembly and assembly
• Three-Speed Powershift Transmission 3WG 116/161 – System Operation – operating functions, electronic controls, inching, driving preparation, diagnostics, display information, and fault codes
• Three-Speed Powershift Transmission 3WG 116/161 – Disassembly & Assembly – torque limits, special tools, control system, clutches, gearing, shafts, bearings, hydraulic parts, and reassembly
• Vehicle Systems – Specifications – hydraulic control valve, pump and universal joint, oil filter mounting, priority valve, tilt and lift cylinders, mast, chains, carriage, steering, and air brake data
• Vehicle Systems – System Operation – hydraulic system, lift and tilt circuits, mast and carriage, steering, and air brake operation
• Vehicle Systems – Testing & Adjusting – hydraulic troubleshooting, pressure checks, mast and carriage setup, chain wear and adjustment, cylinder checks, steering tests, braking tests, and tilting operation
• Vehicle Systems – Disassembly & Assembly – forks, carriage, mast, lift and tilt cylinders, air brake components, hydraulic pump, filter, steering gear and axle, tires and rims, and counterweight
• Hydraulic Schematic – D110S-5, D130S-5, D160S-5 lift, tilt, and auxiliary hydraulic circuits
• Electric Schematic – starting and charging, lighting and warning, monitoring, interlock, and related electrical circuits
• Operation & Maintenance – safety, truck specifications, capacity information, controls, operating procedures, lubrication, refill information, inspection, and scheduled maintenance intervals

Taken as a complete reference, the manual connects system theory to inspection, adjustment, diagnosis, removal, disassembly, measurement, repair, reassembly, and scheduled maintenance. That breadth is especially valuable when a fault is not isolated to one component: an engine performance problem can be followed through fuel, air, cooling, lubrication, turbocharger, or electronic diagnosis; a lifting problem can be traced through hydraulic supply, valves, cylinders, chains, mast and carriage; and a travel complaint can be approached through transmission controls, fault codes, drive axle, brakes, or steering information.

Service and Repair with the Correct Reference at Hand

The Doosan D110S-5 D130S-5 D160S-5 Service Manual – SB4217E/SB4225E00 PDF supports a wide range of workshop tasks, from routine inspection and adjustment to engine overhaul work, transmission and axle service, hydraulic diagnosis, steering and brake repairs, mast and carriage work, electrical troubleshooting, and scheduled maintenance. Procedures, specifications, torque information, service limits, diagnostic charts, and schematics help the technician work from the values and sequences provided for these machines rather than relying on memory or generic repair information.

IMAGES PREVIEW

Delivery is by instant PDF download after purchase. There is no physical book and no shipping delay. The file can be opened on compatible phones, tablets, laptops, and desktop computers, and pages can be printed when a paper reference is more convenient at the machine or workbench.