Doosan D50S-5 Operation & Maintenance Manual
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Doosan D50S-5 Operation & Maintenance Manual

Doosan D50S-5 Operation & Maintenance Manual

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See also: Service Manual
SB2356E03
Operation &
Maintenance Manual
FORKLIFTS
D50S-5, D60S-5, D70S-5
D80S-5, D90S-5
G50S-5, G60S-5, G70S-5
Original Instruction
1304

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Summary of Contents for Doosan D50S-5

  • Page 1 SB2356E03 Operation & Maintenance Manual FORKLIFTS D50S-5, D60S-5, D70S-5 D80S-5, D90S-5 G50S-5, G60S-5, G70S-5 Original Instruction 1304...

  • Page 2: Table Of Contents

    Table of Contents Table of Contents Information Section Maintenance Section Foreword ..............2 Inspection, Maintenance and Repair of Lift Truck Forks ............... 133 Tire Inflation Information ........137 Safety Section Torque Specifications ..........138 Cooling System Specifications ......140 Fuel Specifications ..........142 Important Safety Information ........

  • Page 3: Information Section

    WARNING been removed for illustrative purposes. Continuing improvement and advancement of Your DOOSAN truck comes equipped with an product design might have caused changes to your operator restraint system. Should it become lift truck which are not included in this publication.
  • Page 4 Information Section Operation Environment Management The Operation Section is a reference for the new Note that DOOSAN INDUSTRIAL VEHICLE operator and a refresher for the experienced one. DIVISION 14001 certified which This section includes a discussion of gauges, harmonized with 9001.

  • Page 5: Safety Section

    The warnings in this publication and on the product are therefore not all inclusive. Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must be sure that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 6: Safety

    U.S.A., operate this lift truck in accordance with local regulations. Training Required To Operate or Service Warning DOOSAN lift trucks are manufactured according to the regulations and standards laid down in EU Machinery Directive 98/37/EC and EMC directive 2004/108/EC. Please refer to the Directives 89/655/ EC and 89/391/EC and its amendments for the safe use of DOOSAN lift trucks.
  • Page 7 Safety Section General Warnings to Operator 10. Be sure operating surface can safely support machine. 11. Operate machine and attachments only from operator's position. 12. Do not handle unstable or loosely stacked loads. 13. Use minimum tilt when picking up or depositing a load.
  • Page 8 Safety Section Pressure Warning No Standing On Forks Warning, No Standing Under Forks Warning WARNING WARNING Contents under pressure may be hot. Allow to cool before opening. Do not stand or ride on the forks. Do not stand or ride on a load or pallet on the forks. Do not stand or walk under the forks.
  • Page 9 Safety Section Overhead Guard Must Be In Place Moving Fan Warning Warning WARNING WARNING To avoid personal injury, stay clear of moving fan. Operation without this device in place may be hazardous. This guard conforms to A.N.S.I.B56.1 and F.E.M. Section IV. This design has been tested with an impact of appropriate value.
  • Page 10 Safety Section WARNING When leaving machine apply parking brake! Parking brake is not automatically applied. Alarm will sound if parking brake is not applied. WARNING Correct adjustment is necessary to provide adequate braking. See MAINTENANCE section for adjustment procedures. The lift truck may creep at engine idle and can cause damage, injury or death.

  • Page 11: General Hazard Information

    Safety Section Do not raise loads any higher than necessary and General Hazard Information never raise a load higher than 1830 mm (72 in) with the overhead guard removed. Always use load backrest extension when the carriage or attachment does not fully support the load.

  • Page 12: Operation Information

    Adjust the seat so that full brake pedal travel can be please contact your DOOSAN dealer. We would like obtained with the operator's back against the to draw your attention to the fact that any secondary seatback.
  • Page 13 Safety Section Operate the lift truck and controls only from the Operating the Lift Truck operator's station. Always keep the lift truck under control. Make sure the lift truck horn, lights, backup alarm (if equipped) and all other devices are working Obey all traffic rules and warning signs.
  • Page 14 Safety Section some trailers, extra supports may be needed to prevent upending or corner dipping. Be certain dock plates are in good condition and properly placed and secured. Do not exceed the rated capacity of dock boards or bridge plates. Lift Truck Parking When leaving the operator station, park the lift truck in authorized areas only.

  • Page 15: Maintenance Information

    Block the drive wheels when parking on an To avoid possible weakening of the Falling Objects incline. Protective Structure (FOPS), consult a DOOSAN dealer before altering, by adding weight to, welding Pressure Air on, or cutting or drilling holes into the structure.
  • Page 16 Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant mixtures Coolant are flammable. At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to Fuel leaked or spilled onto hot surfaces or electrical heaters or the engine contain hot water or steam.
  • Page 17 If the tires were originally inflated with air, tubes and hoses. Leaks can cause fires. Contact nitrogen is still preferred for adjusting the pressure. your DOOSAN dealer for repair or replacement. Nitrogen mixes properly with air. Check lines, tubes and hoses carefully. Do not use Nitrogen inflated tires reduce the potential of a tire your bare hand to check for leaks.

  • Page 18: Operator Restraint System (If Equipped)

    If a label is on a part that is replaced, make sure a new label is installed on the replaced part. See you DOOSAN Lift Truck dealer for new Seat Adjustment labels. The most effective method of preventing serious...
  • Page 19 Safety Section If Optional Suspension Seat Equipped Weight adjustment Pull the weight adjustment lever upwards and move Forward and Backward Adjustment right or left side. Adjust to driver’s weight in 7 steps (50 ~ 110 kg) The seat can be adjusted by pushing the lever on the right side of seat.
  • Page 20 WARNING Your DOOSAN truck comes equipped with a DOOSAN operator restraint system. Should it become necessary to replace the seat for any 1. Grip the plate (connector) of the belt and pull the reason, it should only be replaced with another belt from the retractor.
  • Page 21 Safety Section Release the Seat Belt WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. Push the button of the buckle to release the belt. The belt will automatically retract when released. Hold the plate of the belt and allow the belt to slowly retract.

  • Page 22: Avoiding Lift Truck Tipover

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipover Lift Truck Stability The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the combined CG of the truck and load. The lift truck Counterbalanced lift truck design is based on the has moving parts and, therefore, has a CG that balance of two weights on opposite sides of a...
  • Page 23 If forklifts sold by DOOSAN shall not be removed, the CG moves forward of the front axle, the lift truck altered or replaced without DOOSAN’s approval. will tip forward. If the CG moves outside of the line 2.

  • Page 24: Safety Rules

    Safety Section Safety Rules Do not operate a lift truck unless you are in the operator’s seat. Keep hands and feet inside the operator’s compartment. Do not put any part of the body outside of the operator’s compartment. Never Only properly trained and authorized personnel put any part of body into the mast structure or should operate forklift trucks.
  • Page 25 Safety Section Do not overload. Always handle loads within the Do not raise anyone on the forks of your lift truck. rated capacity shown on the capacity plate. Do not let other people ride on the truck. Lift trucks Do not add extra counterweight to the truck. An are designed to carry loads, not people.
  • Page 26 Safety Section Do not elevate the load with the mast tilted forward. Do not permit anyone to stand or walk under the Do not tilt the elevated loads forwards. load or lifting mechanism. The load can fall and This will cause the lift truck to tip over forward. cause injury or death to anyone standing below.
  • Page 27 Safety Section Do not stack or turn on ramps. Do not drive in forward direction when loads restrict Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
  • Page 28 Safety Section Park your lift truck in authorized areas only. Fully Do not operate your truck close to another truck. lower the forks to the floor, put direction lever in Always keep a safe distance from other trucks and NEUTRAL position, engage the parking brake, and make sure there is enough distance to stop safely.
  • Page 29 Safety Section An unloaded forklift may be easier to tip over than a operate forklifts near flammable loaded truck. combustible materials. When traveling without a load, the risk of lateral avoid discoloration, deformation overturn is greater. combustion of materials (such as lumber, veneer board, paper products and other similar items), always park at least 30 cm (12 inches) away from them.

  • Page 30: How To Survive In A Tipover (If Operator Restraint System Equipped)

    Safety Section How to Survive in a Tipover (If Operator Restraint System Equipped) WARNING In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided.
  • Page 31 Safety Section Lean away from the direction of fall. Lean forward.

  • Page 32: General Section

    (Manseok-dong) 468, Injung-ro, Dong-Gu, Incheon, Korea 401-010 Authorized Representative, Compiler of Technical File According to 2006/42/EC and Keeper of Technical File According to 2000/14/EC Doosan Industrial Vehicle Europe N.V, Mr. Y.W. Chung Europark Noord 36 A 9100 Sint-Niklaas BELGIUM herewith declare...

  • Page 33: Specifications

    General Section Specifications CHARACTERISTICS 3 Speed, TIER-Ⅱ Manufacturer DOOSAN DOOSAN MODEL D50S-5 D60S-5 Capacity at rated load center 5000 6000 Load center distance Power type electric,diesel,gasoline,LPG diesel diesel Operator type stand-on, rider-seated rider-seated rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear...
  • Page 34 General Section 3 Speed, TIER-Ⅱ DOOSAN DOOSAN DOOSAN D70S-5 D80S-5 D90S-5 7000 8000 9000 diesel diesel diesel rider-seated rider-seated rider-seated 3000 3100 3100 60x180x1200 70x180x1200 70x180x1200 410x2032 410x2092 410x2092 15/10 15/10 15/10 3647 3970 4040 2108 2230 2230 2500 2835...
  • Page 35 General Section Specifications CHARACTERISTICS 3 Speed, TIER-Ⅲ Manufacturer DOOSAN DOOSAN MODEL D50S-5 D60S-5 Capacity at rated load center 5000 6000 Load center distance Power type electric,diesel,gasoline,LPG diesel diesel Operator type stand-on, rider-seated rider-seated rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear...
  • Page 36 General Section 3 Speed, TIER-Ⅲ DOOSAN DOOSAN DOOSAN D70S-5 D80S-5 D90S-5 7000 8000 9000 diesel diesel diesel rider-seated rider-seated rider-seated 3000 3100 3100 60x180x1200 70x180x1200 70x180x1200 410x2032 410x2092 410x2092 15/10 15/10 15/10 3647 3970 4040 2108 2230 2230 2500 2835...
  • Page 37 General Section Specifications CHARACTERISTICS Manufacturer MODEL Capacity at rated load center Load center distance Power type electric,diesel,gasoline,LPG Operator type stand-on, rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS Lift with STD maximum fork height with rated load two stage mast free lift thickness x width x length Forks...
  • Page 38 General Section 2 Speed, TIER-Ⅱ DOOSAN DOOSAN DOOSAN D50S-5 D60S-5 D70S-5 5000 6000 7000 diesel diesel diesel rider-seated rider-seated rider-seated 3000 3000 3000 60x150x1200 60x180x1200 60x180x1200 350x2032 410x2032 410x2032 15/10 15/10 15/10 3507 3568 3647 2108 2108 2108 2500 2500...
  • Page 39 General Section Specifications CHARACTERISTICS Manufacturer MODEL Capacity at rated load center Load center distance Power type electric,diesel,gasoline,LPG Operator type stand-on, rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS Lift with STD maximum fork height with rated load two stage mast free lift thickness x width x length Forks...
  • Page 40 General Section 2 Speed, TIER-Ⅲ DOOSAN DOOSAN DOOSAN D50S-5 D60S-5 D70S-5 5000 6000 7000 diesel diesel diesel rider-seated rider-seated rider-seated 3000 3000 3000 60x150x1200 60x180x1200 60x180x1200 350x2032 410x2032 410x2032 15/10 15/10 15/10 3507 3568 3647 2108 2108 2108 2500 2500...
  • Page 41 General Section Specifications CHARACTERISTICS TIER-Ⅱ Manufacturer DOOSAN DOOSAN MODEL G50S-5 G60S-5 Capacity at rated load center 5000 6000 Load center distance Power type electric,diesel,gasoline,LPG Operator type stand-on, rider-seated rider-seated rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS Lift with STD...
  • Page 42 General Section TIER-Ⅱ TIER-Ⅲ DOOSAN DOOSAN DOOSAN DOOSAN G70S-5 G50S-5 G60S-5 G70S-5 7000 5000 6000 7000 rider-seated rider-seated rider-seated rider-seated 3000 3000 3000 3000 60x180x1200 60x150x1200 60x180x1200 60x180x1200 410x2032 350x2032 410x2032 410x2032 15/10 15/10 15/10 15/10 3647 3507 3568 3647...
  • Page 43 General Section Specifications CHARACTERISTICS Manufacturer MODEL Capacity at rated load center Load center distance Power type electric,diesel,gasoline,LPG Operator type stand-on, rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS Lift with STD maximum fork height with rated load two stage mast free lift thickness x width x length Forks...
  • Page 44 General Section NON_CERTI DOOSAN DOOSAN DOOSAN G50S-5 G60S-5 G70S-5 5000 6000 7000 rider-seated rider-seated rider-seated 3000 3000 3000 60x150x1200 60x180x1200 60x180x1200 350x2032 410x2032 410x2032 15/10 15/10 15/10 3507 3568 3647 2108 2108 2108 2500 2500 2500 4340 4340 4340 2455...
  • Page 45 General Section Specifications 3 Speed, Interim TIER-Ⅳ CHARACTERISTICS Manufacturer DOOSAN DOOSAN MODEL D50S-5 D60S-5 Capacity at rated load center 6000 Load center distance Power type electric,diesel,gasoline,LPG diesel Operator type stand-on, rider-seated rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS...
  • Page 46 General Section 3 Speed, Interim TIER-Ⅳ DOOSAN DOOSAN DOOSAN D70S-5 D80S-5 D90S-5 7000 8000 9000 diesel diesel diesel rider-seated rider-seated rider-seated 3000 3100 3100 60x180x1200 70x180x1200 70x180x1200 410x2032 410x2092 410x2092 15/10 15/10 15/10 3647 3970 4040 2108 2230 2230 2500...
  • Page 47 General Section Specifications CHARACTERISTICS Manufacturer MODEL Capacity at rated load center Load center distance Power type electric,diesel,gasoline,LPG Operator type stand-on, rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS Lift with STD maximum fork height with rated load two stage mast free lift thickness x width x length Forks...
  • Page 48 General Section 2 Speed, Interim TIER-Ⅳ DOOSAN DOOSAN DOOSAN D50S-5 D60S-5 D70S-5 6000 7000 diesel diesel rider-seated rider-seated 3000 3000 60x180x1200 60x180x1200 410x2032 410x2032 15/10 15/10 3568 3647 2108 2108 2500 2500 4340 4340 2455 2455 1333 1333 3331 3380...

  • Page 49: Noise &Vibration

    By-stander position at Operator's ear (Leq.) Power Level (AS 3713) by new AS 3713 prEN 12053 Drive-By Lifting Mode Directive 2000/14/EC D50S-5, D60S-5 W/O Cabin 83.7 85.8 81.3 78.3 D70S-5, D80S-5 D90S-5 With Cabin 87.5 89.6 (3 speed, Tier-Ⅱ)

  • Page 50: Capacity Chart - Without Side Shifter

    General Section Capacity Chart - Without Side Shifter MODEL A. FFT 4550mm MAST B. FFT 5000mm MAST C. FFT 5600mm MAST D. FFT 6050mm MAST A. FFT 4550mm MAST B. FFT 5000mm MAST C. FFT 5600mm MAST D. FFT 6050mm MAST A.
  • Page 51 General Section Capacity Chart - Without Side Shifter MODEL A-FFT 4350~5400mm MAST B-FFT 5850mm MAST A-FFT 4350~5400mm MAST B-FFT 5850mm MAST...

  • Page 52: Capacity Chart - With Side Shifter

    General Section Capacity Chart - With Side Shifter MODEL A. FFT 4550mm MAST A. 3000 ~ 4000 mm (118 in - 158 in) B. FFT 5000mm MAST MFH MAST C. FFT 5600mm MAST B. 4500 mm (177 in) MFH MAST D.
  • Page 53 General Section Capacity Chart - With Side Shifter MODEL A-FFT 4350mm MAST A-STD 3100~3600mm MAST B-FFT 4800mm MAST B-STD 4100mm MAST C-FFT 5400mm MAST C-STD 4600mm MAST D-FFT 5850mm MAST D-STD 5100mm MAST E-STD 5600mm MAST A-STD 3100~3600mm MAST A-FFT 4350mm MAST B-STD 4100mm MAST B-FFT 4800mm MAST...

  • Page 54: Serial Number

    General Section Serial Number Serial Number Locations For quick reference, record your lift truck's serial numbers in the spaces provided below the photographs. Interim TIER-4 Diesel Engine Serial Number (V3800) .______________________________ Typical Example Lift Truck Serial Number .______________________________ Typical Example G50/60/70S-5 4.3 liter GM Vortec Engine Serial Number (G643) .______________________________...
  • Page 55 General Section D50/60/70S-5(2 speed), G50/60/70S-5 D50/60/70/80/90S-5(3 speed) Transmission Serial Number .______________________________ DRIVE AXLE Serial Number (OCDB type) .______________________________ D50/60/70S-5(2 speed), G50/60/70S-5 Transmission Serial Number .______________________________ ID6OM001 DRIVE AXLE Serial Number (Shoe type) .______________________________ D50/60/70/80/90S-5(3 speed), G50/60/70S-5 Transmission Serial Number .______________________________ OM001 Side shifter Serial Number (If equipped) .______________________________...

  • Page 56: Operator's Warning And Identification Plate

    General Section Operator's Warning and Identification Plate Familiarize yourself with the Operator’s WARNING Plate and IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES. DO NOT exceed Capacity as equipped load ratings. Identification, Lift Capacity and WARNING Attachment Plate The load capacity of lift truck should never be exceeded.
  • Page 57 General Section Below are abbreviations that may appear on the Attachment Abbreviations Identification, Lift Capacity and Attachment Plate (includes Special Forks) and their meanings. Mast Abbreviations Special Carriage-increased width, height or outreach Standard Mast STD - SSS - Shaft-type Sideshift Carriage (single inner member, low free lift) HSS - Hook-type Sideshift Carriage (ITA)

  • Page 58: Operation Section

    Operation Section Operator’s Station and Monitoring Systems 1. Horn Switch 2. Steering Handwheel 3. Turn Signal Lever 4. Instrument Panel 5. Parking Brake Lever 6. Lift Lever 7. Tilt Lever 8. Direction Control Lever 9. Engine Ignition Start Switch 10. Accelerator Pedal 11.
  • Page 59 Operation Section 5. Hour Counter Instrument Panel 1. Engine Ignition Start Switch Indicates the total number of hours the engine and the lift The key switch is a four position truck have operated. The hour switch. Position meter will operate when the ACCESSORY ON.
  • Page 60 Operation Section 9. Light Switch Switch Light Clearance Lamp Tail Lamp License plate Lamp Instrument Lamp Head Lamp O : means “lights on” X : means “lights off” These lamps light up regardless of position of the ignition switch. 10. Hazard Lamp Switch Push the button to active the hazard lamp.
  • Page 61 Operation Section Warning Light - Kubota V3800 ( Interim TierⅣ)
  • Page 62 Operation Section 1. Upper Indicator Light 12. Transmission Neutral Position Light 2. Air Cleaner Indicator Light 13. Engine Malfunction Indicator Light 3. Alternator Indicator Light 14. Directional Turning Indicator Lights 4. Diesel Engine Start Preheat Indicator Light 15. Brake Fluid Oil & Drive axle Oil Light 5.
  • Page 63 Operation Section (13) Engine Malfunction Indicator Lamp (18) DPF : Regeneration Engine control systems are equipped with Blinking of the light indicates the quantity built-in fault diagnostics. Detected system of PM loaded on DPF is required of faults can be displayed by the Malfunction regeneration.
  • Page 64 Operation Section DPF Switch Steering Column Tilting Angle Adjustment This switch used performing Typical Example operation relevant to DPF regeneration. If The tilting angle of the steering wheel is adjustable the light of the same logo of the top within a range of 15 degrees to suit individual switches on the instrument panel turns on, operators.
  • Page 65 Operation Section 1. D50/60/70S-5 (2 Speed) Fuse Box Rated Description Capacity Engine Start Alternator, ECU, Fuel, Iso3691 Valve T/M Solenoid Valve Control Sys. Cabin Relay Coil, Aircon Relay Coil Gague Panel, Strobe Light Horn Spare Rear Lamp, Turn Signal Lamp Clearance Lamp Head Lamp(Hi Beam), Head Lamp(Low Beam)
  • Page 66 Operation Section 5. D50/60/70/80/90S-5 TIER-4 Interim (2/3 SPEED) 3. G50/60/70S-5 (2 Speed) Rated Description Capacity Engine Start ECU(Engine Control Unit) Main Relay Coil, Iso3691 Valve, Alternator T/M Solenoid Valve Control Sys. Cabin Relay Coil, Aircon Relay Coil Gague Panel, Stop Lamp, Strobe Light Horn ECU power Head Lamp Relay Coil, Rear Lamp, Turn...
  • Page 67 Operation Section Circuit Breaker Typical Example Diesel Engine Truck Circuit Breaker protects the main electrical circuit. It is located in the engine compartment on the left side. To reset the circuit breaker, push the button in. If the button comes back out, have the electrical circuits checked.

  • Page 68: Seat Switch System

    The directional lever, however, will 4. If seat or seat switch replacement becomes remain in that forward or reverse location although necessary, be sure to use genuine DOOSAN internally the transmission will have shifted into Infracore lift truck parts. Lift trucks should never neutral.
  • Page 69 Operation Section Lift Truck Controls WARNING “LOCK” the direction control lever. Whenever machine is parked, "LOCK" the direction control Direction Control Lever lever in "NEUTRAL" to prevent accidental machine movement. Transmission Display (3 Speed Only) A transmission display is to the right of the steering wheel on the dash.
  • Page 70 Operation Section Automatic Transmission Switch (3 Inching Switch (3 Speed Only) Speed Only) This switch changes over the modes of the inching Automatic speed range: control pedal, inching and no-inching. . FORWARD: 3 speeds. . REVERSE: 3 speeds. DR In this position, the "NO INCHING" mode is selected.
  • Page 71 Operation Section Transmission Inching Control Service Foot Brake Pedal Pedal Typical Example Typical Example Push DOWN on the brake pedal to slow or stop the lift truck. Inching Control Pedal - Pushing down on the inching pedal, modulates the hydraulic pressure to the clutch packs, permitting RELEASE the brake pedal to allow the lift disc slippage.
  • Page 72 Operation Section Parking Brake Lever Tilt Control NOTICE Do not engage the parking brake while the lift truck is moving unless an emergency exists. The use of the parking brake as a service foot brake in regular operation will cause severe damage to the parking brake system.

  • Page 73: Refueling

    Operation Section Refueling Diesel Engine Equipped WARNING Explosive fumes present during refueling. Do not smoke in refueling areas. Lift truck should be refueled only at designated safe locations. Safe outdoor locations are preferable Typical Example to those indoors. Stop the engine and get off the lift truck during 2.
  • Page 74 Operation Section Changing LP Tanks WARNING Only trained, authorized personnel should fill or exchange LP tanks. Personnel engaged in filling of LP containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves. Do not refuel or store LP powered lift trucks near any underground entrance, elevator shafts or any other place where LP could collect in a pocket 4.
  • Page 75 Operation Section WARNING LP tank must extend past counterweight. 9. Check to be sure that the LP warning plate is in position on the lift truck, and is legible. 10. Check to be sure the replacement tank is of the correct type.

  • Page 76: Before Starting The Engine

    Operation Section Before Starting the Engine 7. Inspect the overhead guard for damage and Walk-Around Inspection loose or missing mounting bolts. 8. Inspect the hydraulic system for leaks, worn Make a thorough walk-around inspection before hoses or damaged lines. mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or 9.
  • Page 77 Operation Section 11. Measure the engine crankcase oil level with the dip stick. Maintain the oil level between the MAX. and MIN., (or FULL and ADD) notches on the dip stick. Typical Example Diesel Engine(Tier-ⅣInterim) Typical Example Diesel Engine Typical Example LP Engine 10.
  • Page 78 Operation Section WARNING Personal injury may occur from accidents caused by improper seat adjustment. Always adjust the operator's seat before starting the lift truck engine. Seat adjustment must be done at the beginning of each shift and when operators change. Typical Example 14.

  • Page 79: Starting The Engine

    Operation Section Starting the Engine Starting a Warm Diesel Engine Prestart Conditions 1. Turn the ignition key to the ON position and then NOTE: The engine will not start unless the to START position, without waiting for the transmission directional control lever is in preheat light to go OFF.
  • Page 80 Always connect the external power source cables in parallel with the lift truck battery cables : POSITIVE(+) to POSITIVE(+) and NEGATIVE(-) to NEGATIVE(-). Attach ground cable last, remove first. All lift trucks equipped with DOOSAN built internal combustion engines are NEGATIVE(-) ground.
  • Page 81 Operation Section Use of Jumper Cables 10. Connect one end of the negative (-) jumper cable to the other terminal (negative) of the When auxiliary start receptacles are not available, boost battery. use the following procedure. 11. Make final connection of negative (-) cable to the 1.

  • Page 82: After Starting The Engine

    Operation Section NOTE: At an oil temperature in the shifting circuit After Starting the Engine lower than -12°C, the transmission must be warmed-up for some minutes. This must be Observe all indicator lights and gauges frequently carried out in Neutral with an increased during operation, to make sure all systems are engine speed (about 1500 rpm).
  • Page 83 Operation Section Electronic Controlled Spark-Ignition Engines G643E Engine EMS (Engine management system) of G643E uses two heated exhaust gas oxygen sensors engine is a closed loop system utilizing a catalytic (HEGO) in the exhaust system to monitor exhaust muffler to reduce the emission level in the exhaust gas content.
  • Page 84 Operation Section G643 Electronic Controlled LP Engines (If Equipped) General Description LP Fuel Line Key switch Fault Light Fuel Lock Fuel Filter Main Foot Pedal Relay Converter Coolant Line Vacuum Air Cleaner Mixer Line DBW Throttle TMAP Ignition Coil SECM Coolant Temperature Sensor Muffler Engine speed is monitored by the SECM through a...
  • Page 85 Operation Section Basic Troubleshooting The EMS systems are equipped with built-in fault checks that should be made before referring to the diagnostics. Detected system faults can be Advanced Diagnostics section, if engine or drivability displayed by the Malfunction Indicator Lamp (MIL) problems are encountered.
  • Page 86 Operation Section Problem Probable Cause Corrective Action Engine Cranking No VR Sensor Signal Verify the VR signal is present but Will Not Start See Advanced Diagnostics Difficult to Start Fuel container almost empty LPG Vapor from liquid outlet Fill fuel container Do not exceed 80% of liquid capacity Excess flow valve closed...
  • Page 87 Operation Section Problem Probable Cause Corrective Action Will Fuel container almost empty LPG Vapor from liquid outlet Continuously Fill fuel container Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for a “click” sound Slowly open liquid valve Clogged fuel filter Repair/replace as required...
  • Page 88 Operation Section Problem Probable Cause Corrective Action Will Clogged fuel filter Repair/replace as required Accelerate/Hesitat See Maintenance Section, LP Fuel During Filter replacement Acceleration Faulty vapor connection between Check connection the pressure regulator/converter Verify no holes in hose and the mixer Clamps must be tight Look for kinked, pinched and/or collapsed hose...
  • Page 89 Operation Section Problem Probable Cause Corrective Action Engine Stalls Fuel Lock-off malfunction Repair/replace Fuel Lock-off See Engine Service Manual Faulty vapor connection between Check connection the pressure regulator/converter Verify no holes in hose and the mixer Clamps must be tight Look for kinked, pinched and/or collapsed hose Pressure regulator freezes...
  • Page 90 Operation Section Problem Probable Cause Corrective Action Rough Idle Incorrect Idle speed control See Advanced Diagnostics & See Engine Service Manual Incorrect timing or spark control Engine Mechanical See Engine Service Manual High Idle Speed See Advanced Diagnostics & See Engine Incorrect Idle speed control Service Manual Throttle sticking...
  • Page 91 Operation Section Problem Probable Cause Corrective Action Excessive Fuel Air/Fuel Mixer malfunction Check mixer Consumption/LPG See Engine Service Manual Exhaust Smell Air filter clogged Check air filter Clean/replace as required Check system vacuum hoses from regulator Vacuum leak to FTV and mixer Repair/replace as necessary Pressure regulator Test pressure regulator operation...
  • Page 92 Operation Section Mixer Idle Screw / Power Valve Adjust (G643 Engine Only) Forklift have Unstable Idle RPM, You can adjust • idle screw. Idle Screw turn to rich side (turn in screw) Forklift have Poor High Speed Performance, you • can adjust power valve, power valve turn to rich side.
  • Page 93 Operation Section Reading Diagnostic Fault Codes Advanced Diagnostics (G643 Engine Only) All MI-04 fault codes are two digit codes. When the fault codes are retrieved (displayed) the MIL will flash for each digit with a short pause (0.5 seconds) Advanced Diagnostics between digits and a long pause (1.2 seconds) between fault codes.
  • Page 94 Operation Section Displaying Fault Codes (DFC) From SECM Memory To enter code display mode you must turn OFF the ignition key. Now turn ON the key but Do not start the engine. As soon as you turn the key to the ON position you must cycle the foot pedal by depressing it to the floor and then fully releasing the pedal (pedal maneuver).
  • Page 95 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check NONE NONE None, used as a beginning and end of the fault list identification Signifies the end of one pass through the fault list ECTSensorInputLow Stored Fault Code Check ECT sensor connector and...
  • Page 96 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check ETCSticking Engine Shutdown Check for debris or obstructions inside the throttle body Throttle plate sticking inside the Check throttle-plate shaft throttle body or the ETC driver signal is open bearing wear Check the ETC driver wiring for...
  • Page 97 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Check TMAP connector and MAP MapSensorInputHigh Disable Throttle signal wiring for a shorted circuit TMAP sensor failure or shorted circuit IATSensorInputLow Stored Fault Code Check TMAP connector and IAT signal wiring for a shorted circuit TMAP sensor failure or shorted...
  • Page 98 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check BatterySensorInputLow Stored Fault Code Check battery voltage Perform maintenance check on Battery voltage measured below (MIL Only) electrical connections to the battery +8.0 VDC and chassis ground Check battery voltage during starting and with the engine...
  • Page 99 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Measure transducer power at the XDRPSensorInputHigh Engine Shutdown TMAP connector with a multimeter +5VDC Transducer power supplied by the SECM to the sensors is above +5.20VDC Verify transducer power at the SECM with a multimeter Verify transducer power at ETC with...
  • Page 100 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Pedal2SensorInputLo MIN power Limit Check foot pedal connector APP2 sensor failure or shorted circuit Pedal2SensorInputHi MIN power Limit Check foot pedal connector APP2 signal disconnected, open circuit or sensor malfunction (Expected faults...
  • Page 101 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Engine measured Air/Fuel ratio at AFRTrimValveLowerDC Stored Fault Code the O2 sensor is excessively lean. FTV duty cycle at lower (lean) (MIL, Disable Adaptive limit learns) If LP fuel in LP tank is not enough,...
  • Page 102 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Note : If LP fuel in LP tank is not O2SensorSwitching Stored Fault Code enough, this fault code can be set. O2 sensor is not switching across (MIL, Disable Adaptive If LP tank is frozen, this fault code the reference AFR voltage...
  • Page 103 Operation Section Reading Diagnostic Fault Codes Advanced Diagnostics (G643E Engine Only) All MI-07 fault codes are three-digit codes. When the fault codes are retrieved (displayed) the MIL will MI-07 systems are equipped with built-in fault flash for each digit with a short pause (0.5 seconds) diagnostics.
  • Page 104 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK NONE None, used as end of the fault list Signifies the end of one pass NONE identification through the fault list Check ECT sensor connector and wiring for a short to GND ECTRangeLow...
  • Page 105 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION* FIRST CHECK CrankSyncFault Check Crankshaft sensor connections Loss of synchronization on SECM (SIGNAL) Pin B5 to Crank the crankshaft sensor, sensor Pin 3 None normally due to noise on the SECM (Sensor GND) Pin B1 to Crank...
  • Page 106 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check the throttle connector and pins for corrosion. To check the TPS disconnect the TPS2AdaptLoMin throttle connector and measure the Learned closed throttle end None resistance from:...
  • Page 107 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 (signal) MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1 Manifold Absolute Pressure (sensor GND)
  • Page 108 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK MAPRangeHigh Check TMAP connector and MAP Manifold Absolute Pressure signal wiring for a shorted circuit Sensor Input is High, TMAP Pin 4 to SECM Pin B18 (signal) normally set if the TMAP TMAP Pin 1 to SECM Pin B1 pressure signal wire has...
  • Page 109 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A9 (EST1) to OEM ignition EST1_Open system. See application note. EST1 output open, possibly Verify GND on ignition module Pin A TurnOnMil...
  • Page 110 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK ETCSpringTest Electronic Throttle Control Spring Return Test has failed. The SECM will perform a safety test of the throttle return spring following engine shutdown.
  • Page 111 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check battery and charging system voltage Check battery voltage during starting and with the engine running Check voltage regulator, alternator, and charging system SysVoltRangeHigh Check battery and wiring for...
  • Page 112 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Usually associated with additional ETC MediumOverspeed faults (1) TurnOnMil Engine speed has exceeded Check for ETC Sticking or other ETC (2) MediumRevLimit the second level (2 of 3) of faults...
  • Page 113 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK APP1AdaptHiMin Learned full pedal end of None APP1 sensor range lower than expected APP2AdaptHiMin Learned full pedal end of None APP2 sensor range lower than expected APP1AdaptLoMax...
  • Page 114 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK LSDFault_CrankDisable Crank Disable Fault, signal has opened or shorted to None ground or power or defective crank disable relay Check fuel lock off valve for an open wire or connector being disconnected LSDFault_LockOff or signal shorted to GND...
  • Page 115 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check that Post-catalyst O2 sensor connections are OK. O2 (signal) Pin 3 to SECM Pin B19 O2 Pin 2 (HEATER GND) to SECM (DRVG GNG) Pins A16, B17 O2 Pin 1 (HEATER PWR) to Post O2 Heater Relay.
  • Page 116 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Correct other faults that may contribute to 772 (e.g. faults pertaining to FTVs, GasPostO2FailedRich (1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor) Pre-catalyst O2 sensor (2) DisableGas Look for leaks in exhaust, catalytic...
  • Page 117 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK FuelTempRangeLow Check fuel temp sensor connector and Fuel Temperature Sensor wiring for a short to GND Input is Low normally set if SECM (signal) Pin B14 to FTS Pin 1 the fuel temperature sensor TurnOnMil...

  • Page 118: Lift Truck Operation

    Operation Section Lift Truck Operation Power Shift Transmission / Drive WARNING Axle A lift truck with the engine running but without an operator can move slowly (creep) if the transmission is left engaged. 1. Start the engine. See item "Starting the Engine" This could result in personal injury.
  • Page 119 Operation Section Inching WARNING Watch the road carefully for any obstacle when driving the truck. Do not go fast over bumps, pot NOTE: The purpose of the inching pedal is to holes or other rough grounds, otherwise the provide precise lift truck inching control at engine might go OFF by a severe impact.

  • Page 120: Auto Shift Controller Asc-202/204/208 (If Equipped)

    Operation Section Auto Shift Controller ASC-202/204/208 (If Equipped) Product Description Adjustments The Autoshift controller is an electrical control system, specially designed for use on forklift trucks with internal combustion engines. Its primary purpose is to prevent the operator from operating the truck outside of the design parameters, e.g.
  • Page 121 Operation Section • Direction Inhibit Point (SW2) Diagnostics Features Auto Shift allows you to set the Direction Inhibit Speed, the maximum travel speed at which the transmission can be reversed. For adjustment of direction inhibit speed, the SW2 switch is used on the printed circuit board.
  • Page 122 Operation Section • Display for Troubleshooting Operation Display Description Remark This system can be basically operated in two Automatic operation preselected modes, automatic mode and manual High speed s/w input Lever input test mode. Forward s/w input Lever input test NOTE: In ASC-204 factory-setting...
  • Page 123 Operation Section Manual Mode (Fail-Safe mode) WARNING In case that the controller is broken down or you When you want to change the travel direction, don't want to use the functions of the Auto Shift you must press down on the service brake pedal Controller, you can select Manual Mode.
  • Page 124 Operation Section Typical Example of ASC-204 NOTE: In ASC-204 factory-setting controller, automatic mode is selected for both direction inhibit and two-speed auto shift control as a default on the PCB(Printed Circuit Board).In ASC-202 factory-setting controller, manual mode(Fail-Safe Mode) is selected as a default for direction inhibit while automatic mode is selected as a default for two-speed auto shift control.

  • Page 125: Operating Techniques

    Operation Section Operating Techniques Lifting the Load Inching into Loads 1. Lift the load carefully and tilt the mast back a short distance. Typical Example Typical Example 1. Move the lift truck slowly FORWARD into 2. Tilt the mast further back to cradle the load position and engage the load.
  • Page 126 Operation Section Traveling with the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. Typical Example 1. Move the lift truck into the unloading position. Typical Example 1. Carry the load as low as possible but maintain clearance.
  • Page 127 Operation Section Turning Typical Example 3. Deposit the load and BACK away carefully to 1. When turning sharp corners, keep close to the disengage the forks. inside corner. Begin the turn when the inside drive wheel meets the corner. Typical Example 4.
  • Page 128 Operation Section Lifting Drums or Round Objects Operating in Hot Weather Keep the following points in mind when you operate the lift truck in hot weather. 1. Check the radiator. Clogging can cause the overheating. Clean them out regularly with a blast of compressed air.

  • Page 129: Parking The Lift Truck

    Operation Section Parking the Lift Truck WARNING Blocking the wheels will prevent unexpected lift truck movement, which could cause personal injury. 5. Turn the ignition key switch to the OFF position and remove the key. Typical Example Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor.

  • Page 130: Lift Fork Adjustment

    Operation Section Lift Fork Adjustment WARNING WARNING When adjusting the fork spread, be careful not to Make sure the forks are locked before carrying a pinch your hand between forks and the carriage load. slot. For load stability, always adjust the forks as wide as possible.

  • Page 131: Storage Information

    Operation Section Storage Information 5. Cover components such as the breather and air Before Storage cleaner which may be caught with humidity. 6. The machine should be operated at least once a week. Fill the cooling system, if cooling water is Before storing your lift truck, clean and inspect as discharged, and mount the battery.

  • Page 132: Transportation Hints

    Remove ice, snow or other slippery material from width, and length of a load. the shipping vehicle and the loading dock. Contact your DOOSAN Lift Truck dealer for shipping instructions for your lift truck. Typical Example Always block the trailer or the rail car wheels before loading the lift truck.

  • Page 133: Towing Information

    Operation Section Consult your DOOSAN Lift Truck dealer for towing a Towing Information disabled lift truck. WARNING Personal injury or death could result when towing a disabled lift truck incorrectly. Block the lift truck wheels to prevent movement before releasing the brakes. The lift truck can roll free if it is not blocked.

  • Page 134: Maintenance Section

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for Users also refer International inspection, maintenance and repair of lift truck forks. Organization For Standardization-ISO Technical It also provides general information on the design Report 5057-Inspection and Repair of Fork Arms and application of forks and the common cause of Standard...
  • Page 135 Maintenance Section Wear Causes of Fork Failure Improper Modification or Repair Forks are constantly subjected to abrasion as they slide on floors and loads. The thickness of Fork failure can occur as a result of a field the fork blade is gradually reduced to the point modification involving welding, flame cutting or other where it may not be capable of handling the similar processes which affect the heat treatment...
  • Page 136 Maintenance Section Fork Inspection First Installation 1. Inspect forks to ensure they are the correct size for the truck on which they will be used. Make sure they are the correct length and type for the loads to be handled. If the forks have been previously used, perform the "12 Month Inspection".
  • Page 137 Maintenance Section With the fork restrained in the same manner as 12 Months Inspection its mounting on the lift truck, apply the test load twice, gradually and without shock. Maintain the Forks should be inspected, at a minimum, every 12 test for 30 seconds each time.

  • Page 138: Tire Inflation Information

    Maintenance Section Tire Inflation Information Tire Shipping Pressure Tires Inflation The tire inflation pressures shown in the following chart are cold inflation shipping pressures. Shipping WARNING Ply Rating Or Size Pressure Strength Index Personal injury or death could result when tires 8.25 x 15 14PR are inflated incorrectly.

  • Page 139: Torque Specifications

    Maintenance Section Torque Specifications Torques for Standard Bolts, Nuts and Taperlock Studs Metric Hardware - This lift truck is almost totally metric design. Specifications are given metric U.S.Customary NOTICE measurement. Metric hardware must be replaced with metric The following charts give general torques for bolts, hardware.
  • Page 140 Maintenance Section Torques for Taperlock Studs Torques for Metric Fasteners Thread Size Standard Taperlock Stud Torque NOTICE Inch N•m lb•ft Be very careful never to mix metric with U.S. 8 ± 3 6 ± 2 customary (standard) fasteners. Mismatched or incorrect fasteners will cause lift truck damage or 5/16 17 ±...

  • Page 141: Cooling System Specifications

    Cooling system problems can arise without a thermostat. NOTICE DOOSAN recommends that the coolant mixture contain a minimum of 30% antifreeze or equivalent. Never add coolant to an overheated engine, engine damage can result. Allow the engine to cool first.
  • Page 142 DOOSAN prefers the use of distilled water or dissolved solids and undissolved chemical inhibitors deionized water to reduce the potential and severity in the cooling system.

  • Page 143: Fuel Specifications

    Drain the water and sediment from main fuel storage additives may cause poor engine performance. tank before it is refilled. This will help prevent water Consult your Doosan representative for more and/or sediment from being pumped from the fuel information.
  • Page 144 Doosan approves the use of bio-diesel fuels that do not exceed a blend of 5% (by volume) of FAME with LP Specifications 95% (by volume) of approved mineral oil derived diesel fuel.

  • Page 145: Lubricant Specifications

    Shortened engine life will result. NOTICE Failure to follow the oil recommendations can cause NOTE: Multi-grade oils blended shortened engine life due to carbon deposits or DOOSAN transmissions. excessive wear. Multi-grade oils which use high molecular weight polymers viscosity index...
  • Page 146 Maintenance Section Drive Axle Oil Brake Oil (Only for OCDB) As brake oil for oil cooled disc brake system (OCDB), NOTE : Failure to follow the recommendation will use the oil that has the same specifications with cause shortened life due to excessive gear hydraulic oil.
  • Page 147 NOTICE Use MPGM for heavily loaded bearings and joints where an extreme pressure grease will maximize the life of DOOSAN equipment. This NLGI No. 2 grade is suitable for most temperatures. If MPGM is not available, use a multipurpose type grease which contains 3 to 5% molybdenum.
  • Page 148 Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities D50/60/70 LUBRICANT VISCOSITIES D50/60/70/ Refill Capacities G50/60/ FOR AMBIENT (OUTSIDE) TEMPERATURES 80/90S-5 (Approximate) 70S-5 (3 speed) °C °F (2 speed) Compartment Viscositie Compartment Liters Liters Liters or System Min Max Min or System Tier-Ⅱ...

  • Page 149: Maintenance Intervals

    Maintenance Section Maintenance Intervals First 50-100 Service Hours or a Week NOTICE Never exceed the Maintenance Intervals specified in Engine Oil & Oil Filter (Diesel E/G Only) - Change the manual. Defects and/or damage to the important ................. 164 functional components may be resulted in. Transmission Oil &...
  • Page 150 Maintenance Section Every 1000 Service Hours or 6 Months Every 3000 Service Hours or 18 Months Carburetor (LP - Gas Engine Only) - Adjust, Clean DPF Maintenance –Ash Cleaning ......199 ................. 184 Fuel Filter - Check, Clean, Change ....... 184 Air Intake System - Change ........
  • Page 151 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Air Cleaner Indicator Check Air Intake System Change Air Intake System Check, Clean Battery Terminal Clean, Inspect Belts (Diesel E/G Only) Check, Adjust Brake Oil (OCDB) Check Carburetor (LP - Gas Engine Only) Adjust, Clean Carriage Roller Extrusion Adjust...
  • Page 152 Maintenance Section FIRST EVERY Quick Reference to Maintenance Schedule ITEMS SERVICES PAGE Inspect for Intake Leaks (LP Engine Only) Inspect Ignition System (LP Engine Only) Inspect Throttle Assembly (LP Engine Only) Inspect Vacuum Lines Fittings (G643(E) Engine only) Inspection Engine for Fluid Leaks Lift Chains - Test, Check, Adjust LP Regulator/Converter Inspection (LP Engine Only)

  • Page 153: When Required

    Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Valve Lash (Diesel E/G Priming the Fuel System (Diesel Only) - Check, Adjust Engine Only) Bleeding the Fuel System NOTICE...

  • Page 154: Test Fuel System For Leaks (Lp Engine Only)

    Maintenance Section Draining the Water From the Fuel Filter Test Fuel System for Leaks (LP Engine Only) Diesel Engine Only Check Points Typical Example <DB58S> Obtain a leak check squirt bottle or pump spray bottle. Fill the bottle with an approved leak check solution.

  • Page 155: Fuel Tank Filter Cap & Screen - Clean

    Maintenance Section Fuel Tank Filter Cap & Screen - Seat - Check, Lubricate Clean Park the lift truck with the forks lowered, parking brake applied, transmission in neutral and the engine stopped. Typical Example Check the operation of the seat adjuster rod. Make sure that the seat slides freely on its track.

  • Page 156: Fuses, Bulbs & Circuit Breaker - Change, Reset

    Maintenance Section Fuse & Relay ( LP Engine Only) Fuses, Bulbs & Circuit Breaker - Change, Reset Fuses NOTE: If a fuse filament separates, use only the same type and size fuses for replacement. If the filament in a new fuse separates. have the circuits and instruments checked.

  • Page 157: Tires And Wheels - Inspect, Check

    Maintenance Section Bulbs Check Inflation and Damage Bulbs are identified as follows Inspect tires for wear, cuts, gouges and foreign objects. Look for bent rims and correct seating of [Diesel Engine] locking ring. 1. Bulb-head lamp halogen(24V-70/75W) Check tires for proper inflation. See "Tire Inflation 2.

  • Page 158: Radiator Cap - Clean, Change

    Maintenance Section Clean Outside of Radiator Core Radiator Cap - Clean, Change WARNING Clean Pressure Cap Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

  • Page 159: Brake Oil (Ocdb) - Check

    Maintenance Section Brake Oil (OCDB) – Check Only for Oil Cooled Disc Brake The brake reservoir is located on the left side of the steering column. 1. Remove the filter cap. 2. Maintain the brake fluid level to the fluid level mark on the brake system reservoir.

  • Page 160: Every 10 Service Hours Or Daily

    Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspection Engine for Fluid Leaks Coolant Level – Check WARNING 1.

  • Page 161: Air Cleaner Indicator - Check

    Maintenance Section 2. Remove the radiator cap. Fill radiator to the top Air Cleaner Indicator – Check of the filter neck. Inspect radiator cap. Replace if damaged. Install the radiator cap. Service Indicator Typical Example Typical Example Diesel Engine Truck 3.

  • Page 162: Inspect Foot Pedal Operation (Lp Engine Only)

    Maintenance Section Inspect Foot Pedal Operation (LP 3. Inspect the hydraulic system for leaks, worn Engine Only) hoses or damaged lines. 4. Look for transmission and driveaxle leaks on the 1. Verify foot pedal travel is smooth without sticking. lift truck and on the ground. WARNING When acceleration...

  • Page 163: Mast Channels - Lubricate

    Maintenance Section Mast Channels – Lubricate Typical Example Diesel Engine(Tier-Ⅲ) Typical Example The channels on the roller-type mast require a break-in period. Apply a light film of lubricant on the channels where the rollers ride. This will prevent metal peel until the rollers set a pattern. LP Engine 8.

  • Page 164: Transmission Oil Level - Check

    Maintenance Section 4. Shift the transmission into NEUTRAL. Engage Transmission Oil Level – Check the parking brake. WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 5. Loosen dipstick counter-clockwise, remove and clear it.

  • Page 165: First 50-100 Service Hours Or A Week

    Maintenance Section First 50-100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Oil & Oil Filter (Diesel E/G Only) - Change The percentage of sulfur in the fuel will affect the engine oil recommendations.

  • Page 166: Transmission Oil & Oil Filter - Change

    Maintenance Section Transmission Oil & Oil Filter – Change WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Park the lift truck level, with the forks lowered, Typical Example Diesel Engine Truck (DB58S) parking brake engaged, transmission in NEUTRAL and the engine stopped.
  • Page 167 Maintenance Section Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5 Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5 2. Wash the strainer (screen) , spring and drain 4. Rotate the oil filter counter clockwise to remove plug in clean, nonflammable solvent. Dry the strainer, spring and drain plug. [D50/60/ 70S-5 (2 Speed), G50/60/70S-5 Only] •...

  • Page 168: Drive Axle Oil - Change

    Maintenance Section Drive Axle Oil - Change Park the lift truck on a level surface, parking brake applied, transmission in neutral. WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5 Shoe Brake Type...
  • Page 169 Maintenance Section Oil Cooled Disc Brake (OCDB) Type Park the lift truck on a level surface. Apply the parking brake. Place the directional control level in NEUTRAL and stop the engine. Typical Example 8. Remove planetary hub level/drain/fill plugs. Allow the oil to drain completely out. Reinstall the planetary hub plugs.

  • Page 170: Parking Brake - Test, Adjust

    Maintenance Section Parking Brake - Test, Adjust WARNING To prevent personal injury, the operator must be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move. NOTE: Be sure area around the lift truck is clear of personnel and obstructions.
  • Page 171 Maintenance Section To Adjust Park the lift truck level, with the forks lowered, transmission in NEUTRAL, the engine stopped and the wheels securely blocked. Typical Example 1. Release the parking brake 2. Turn the adjustment knob, clockwise to tighten the brake. 3.

  • Page 172: First 250 Service Hours Or A Month

    Maintenance Section First 250 Service Hours or a Month You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. 4. Clean filter housing with clean, Hydraulic Return Filter – Change nonflammable solvent.

  • Page 173: Every 250 Service Hours Or Monthly

    Maintenance Section Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Servicing Filter Element Air Intake System - Check, Clean Precleaner (If Equipped) NOTICE Never service filter with the engine running.
  • Page 174 Maintenance Section Diesel Engine Truck (Dual Element) 10. Start the engine and observe the position of the indicator. If the indicator shows RED after the installation of the primary element, install another clean or a new element or, replace the secondary element.
  • Page 175 Maintenance Section Cleaning Primary Filter Elements Water-280 kPa (40 psi) Maximum Pressure WARNING Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

  • Page 176: Engine Oil & Filter(Lp Engine Only) - Change

    Maintenance Section 10. Fill the crankcase. See " Refill Capacities ". Engine Oil & Filter(LP Engine Only) - Change 11. Start the engine and allow the oil to fill the filter and passages. 12. Check for oil leaks. LP Engine Crankcase 1.

  • Page 177: Hydraulic Oil Level - Check

    Maintenance Section Hydraulic Oil Level – Check Drive Axle Oil Level – Check WARNING WARNING At operating temperature, the hydraulic tank is Hot oil and components can cause personal hot and under pressure. injury. Do not allow hot oil or components to contact skin.

  • Page 178: Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate

    Maintenance Section Oil Cooled Disc Brake (OCDB) Type Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate Park the lift truck on a level surface. Apply the parking brake. The engine is at the low idle. Place the directional control level in NEUTRAL. 1.

  • Page 179: Steering Mechanism - Check, Lubricate

    Maintenance Section Lubricate Mast Side Rollers Steering Mechanism - Check, Lubricate Typical Example Typical Example 1. Lubricate the 2 fittings on the inner mast. 1. Lubricate the steer axle king pins, total of four fittings. Two on the right side and two on the left Lubricate Carriage Side Rollers side.

  • Page 180: Battery Terminal - Clean, Inspect

    Maintenance Section Battery Terminal - Clean, Inspect Wheel Bolts & Nuts - Inspect Inspect Tightness WARNING Batteries give off flammable fumes that can Steer Wheels explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.

  • Page 181: Every 500 Service Hours Or 3 Months

    Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Belts (Diesel E/G Only) - Check, Adjust Typical Example NOTICE Typical Example...

  • Page 182: Tilt Cylinders - Check, Adjust, Lubricate

    Maintenance Section Tilt Cylinders - Check, Adjust, Crosshead Rollers - Inspect Lubricate 1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make Chassis Pivot Eyebolts sure the chain is tracking over the rollers properly.

  • Page 183: Horn And Lights(If Equipped) - Check

    Maintenance Section Horn and Lights(If Equipped) – Steer Suspension – Inspect Check 1. Inspect the suspension mounting bolts. Tighten Typical Example suspension each four mounting bolts(total eight 1. Press horn button, to determine if horn is bolts), if necessary, to 240±40N m(177±29 •...

  • Page 184: Engine Oil & Filter(Diesel Engine Only) - Change

    Maintenance Section Engine Oil & Filter (Diesel Engine Fuel Trim Valve (FTV) Inspection Only) – Change (G643E Engine only) Visually inspect the Fuel trim valve(3) for Diesel Engine Crankcase abrasions or cracking. Replace as necessary. See topic, "Engine Oil & Filter (Diesel E/G Only) - To ensure the valve is not leaking a blow-by test Change"...

  • Page 185: Every 1000 Service Hours Or 6 Months

    Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. 2. Remove fuel filter cartridge assembly. Carburetor (LP - Gas Engine Only) - Adjust, Clean 3.

  • Page 186: Inspect Coolant Hoses (Lp Engines Only)

    Maintenance Section LP Regulator/Converter Inspection (LP Engine Only) NOTICE Visually inspect the pressure regulator/converter Always replace the secondary element. Do not housing(2) for coolant leaks. Refer to the attempt to reuse it by cleaning. pressure regulator/converter section of the service manual if maintenance is required. 3.

  • Page 187: Hydraulic Oil, Return Filter, Strainer & Breather - Check, Clean, Change

    Maintenance Section Hydraulic Oil, Return Filter, Strainer & Breather - Check, Clean, Change WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 6. Remove the breather. Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL 7.

  • Page 188: Transmission Oil & Filter (3 Speed, Zf 3Wg116) - Change

    Maintenance Section 19. Start the engine and operate the hydraulic Lift Chains - Test, Check, Adjust controls, and the steering system, through a few cycles to fill the lines. Look for oil leaks. Lift Chain Wear Test 20. Stop the engine and check the oil level. With all Inspect the part of the chain that is normally cylinders retracted, maintain the oil level to the operated over the cross head roller.
  • Page 189 Maintenance Section Check for Equal Tension Carriage Chain Adjustment - STD Mast Typical example for carriage chain of STD mast Typical example Make sure that carriage height is correct. If correct, Lift the carriage and the mast high enough for adjust chain for equal tension.
  • Page 190 Maintenance Section Carriage Chain Adjustment - FFT Mast Chain Adjustment - FFT Typical example for carriage chain of FFT mast Typical example for FFT mast Make sure that mast height is correct. If correct, Make sure that carriage height is correct. if correct, adjust chain for equal tension.

  • Page 191: Every 1500 Service Hours Or 9 Months

    Maintenance Section Every 1500 Service Hours or 9 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Drive Axle Oil (Shoe Brake Only) - Replace Spark Plugs (LP Engine Change Only)

  • Page 192: Replace Lp Fuel Filter Element (Lp Engine Only)

    Maintenance Section Fuel Filter - Disassembly Replace LP Fuel Filter Element (LP Engine Only) Park the lift truck in an authorized refueling area with the forks lowered, parking brake applied and the transmission in Neutral. 1. Close the fuel shutoff valve on the LP-Fuel tank. Run the engine until the fuel in the system runs out and the engine stops.

  • Page 193: Testing Fuel Lock-Off Operation (Lp Engine Only)

    Maintenance Section Testing Fuel Lock-off Operation (LP Engine Only) Start engine. Locate the electrical connector for the fuel lock Disconnect the electrical connector. The engine should run out of fuel and stop within a short period of time. Turn the ignition key switch off and re-connect the fuel lock-off connector.

  • Page 194: Every 2000 Service Hours Or Yearly

    Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Steer Wheel Bearings - Reassemble Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL and the engine stopped.

  • Page 195: Cooling System - Clean, Change

    Maintenance Section Cooling System - Clean, Change WARNING At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand.

  • Page 196: Fork - Inspect

    (L). Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer for further information. 2. Check the angle between the upper face of the blade and the front face of the shank.
  • Page 197 Maintenance Section Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage. 5.

  • Page 198: Every 2500 Service Hours Or 15 Months

    Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspect Battery System Checking the TMAP Sensor (LP Engine Only) Clean battery outer surfaces with a mixture of baking soda and water.

  • Page 199: Inspect For Intake Leaks (Lp Engine Only)

    Maintenance Section Inspect for Intake Leaks (LP Replace Oxygen Sensor (G643E Engine Only) Engine Only) 1. Visually inspect the intake manifold, throttle assembly (4), and manifold adapters (3), for looseness and leaks. Repair as necessary. Replace PCV Valve and breather element - Change (LP Engine Only) 1.

  • Page 200: Every 3000 Service Hours Or 18 Months

    Maintenance Section Every 3000 Service Hours or 18 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures DPF Maintenance –Ash Cleaning WARNING Ash cleaning services is recommended by the designated repair shop, if not, it can lead to damage of the product and system.

  • Page 201: Index

    Index Section Index Carburetor (LP - Gas Engine Only) - Adjust, Clean ................. 184 12 Months Inspection ..........136 Carriage Roller Extrusion - Adjust ......157 Causes of Fork Failure........... 134 Center of Gravity (CG) ..........21 Changing LP Tanks..........73 Changing Primary Element........
  • Page 202 Index Section Engine Oil & Oil Filter (Diesel E/G Only) - Change ................. 164 Engine Oil (DEO and EO) ........144 Hand Placement Warning .......... 7 Engine Oil Level - Check........159 Horn and Lights(If Equipped) – Check ....182 Engine Valve Lash (Diesel E/G Only) - Check, How to Survive in a Tipover (If Operator Restraint Adjust ...............
  • Page 203 Index Section Lift Truck Stability ............. 21 Only for D50/60/70/80/90S-5 (3 Speed, ZF 3WG94) Lifting Drums or Round Objects ......127 ................. 193 Lifting the Load ............124 Only for D50/60/70S-5 (2 Speed), G50/60/70S-5 Literature Information ..........2 ................175,187 Load Backrest Must Be In Place Warning ....
  • Page 204 Index Section Transmission Oil & Oil Filter – Change ....165 Seat Switch System..........67 Transmission Oil (2 Speed Only) – Change ..187 Seat ................66 Transmission Oil (TDTO) ........144 Serial Number Locations .......... 53 Transmission Oil Filter (2 Speed Only) – Change ... 181 Serial Number ............

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