Doosan GC15S-5 Operation & Maintenance Manual
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Doosan GC15S-5 Operation & Maintenance Manual

Doosan GC15S-5 Operation & Maintenance Manual

Lift trucks
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See also: Service Manual
SB2354E00
Operation &
Maintenance Manual
LIFT TRUCKS
GC15S-5, GC18S-5, GC20SC-5
0703

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Summary of Contents for Doosan GC15S-5

  • Page 1 SB2354E00 Operation & Maintenance Manual LIFT TRUCKS GC15S-5, GC18S-5, GC20SC-5 0703...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Information Section Maintenance Section Foreword ..............2 Inspection, Maintenance and Repair of Lift Truck Forks ................ 92 Torque Specifications ..........96 Safety Section Cooling System Specifications....... 98 Fuel Specifications..........100 Important Safety Information ........4 Lubricant Specifications ........101 Safety .................5 Lubricant Viscosities and Refill Capacities ..

  • Page 4: Information Section

    Photographs or illustrations guide the operator Literature Information through correct procedures of checking, operation This manual should be stored in the operator's and maintenance of the DOOSAN operator restraint compartment in the literature holder or seat back system. literature storage area.
  • Page 5 Hours or 3 Months”, also service those items listed under “Every 250 Service Hours or Monthly” and “Every 10 Service Hours or Daily”. Environment Management Note that DOOSAN Infracore VHEICLE B.G. is ISO 14001 certified which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS &...

  • Page 6: 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 7: Safety

    See your dealer for new labels. accordance with local regulations. Training Required To Operate or DOOSAN lift trucks are manufactured according to Service Warning the regulations and standards laid down in EU Machinery Directive 98/37/EC and EMC directive 89/336/EC.
  • Page 8 Safety Section Do not allow anyone to stand or pass under the General Warnings to Operator elevated portion of any machine. 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.
  • Page 9 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 10 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 4. This design has been tested with an impact of appropriate value.
  • Page 11 Safety Section Applying the parking brake puts the transmission in NEUTRAL. The parking brake must be applied when leaving the lift truck and when starting the engine. If the operator leaves the seat without applying the parking brake, an audible alarm will sound.
  • Page 12 Safety Section Always use the overhead guard. The overhead General Hazard Information guard is intended to protect the lift truck operator from overhead obstructions and from falling objects. A truck that is used for handing small objects or uneven loads must be fitted with a load backrest. If the lift truck must be operated without the overhead guard in place due to low overhead clearance, use extreme care.

  • Page 13: Operation Information

    DOOSAN dealer. We would like to Make sure all hydraulic controls are in the HOLD draw your attention to the fact that any secondary position.
  • Page 14 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 Obey all traffic rules and warning signs. equipped) and all other devices are working properly.
  • Page 15 Safety Section Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers.

  • Page 16: Maintenance Information

    Pressure air can cause personal injury. When using To avoid possible weakening of the Falling Objects pressure air for cleaning, wear a protective face Protective Structure (FOPS), consult a DOOSAN shield, protective clothing and protective shoes. dealer before altering, by adding weight to, welding on, or cutting or drilling holes into the structure.

  • Page 17: Burn Prevention

    Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant Coolant mixtures are flammable. At operating temperature, the engine coolant is hot Fuel leaked or spilled onto hot surfaces or electrical and under pressure. The radiator and all lines to components can cause a fire.
  • Page 18 Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your DOOSAN dealer for repair or replacement. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks.

  • Page 19: Operator Restraint System (If Equipped)

    If a label is on a part misused equipment. that is replaced, make sure a new label is installed on the replaced part. See you DOOSAN Lift Truck Stand behind the tread and use a self-attaching dealer for new labels.
  • Page 20 Safety Section WARNING Do not place your hand or fingers under the seat. Injury may occur as the seat moves up and down. The “Survive in tipover” warning is located on the overhead guard. It shows the proper use of the operator restraint system.
  • Page 21 Safety Section Weight adjustment If Optional Suspension Seat (Weight Adjusting Type) Equipped Pull the weight adjustment lever upwards and move right or left side. Forward and Backward Adjustment 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 22 On visual inspection, fastenings must be intact, otherwise, contact the safety manager. WARNING Your DOOSAN truck comes equipped with a 1. Grip the plate (connector) of the belt and insert DOOSAN operator restraint system. Should it the plate into the slot of the buckle until a snap become necessary to replace the seat for any is heard.
  • Page 23 Safety Section The belt will automatically retract when released. WARNING Hold the plate of the belt and allow the belt to If you fasten the belt across your abdomen, the slowly retract. belt may injure your abdomen in an accident. 1.

  • Page 24: Avoiding Lift Truck Tipovers

    Safety Section Avoiding Lift Truck Tipovers Stability and Center of Gravity Lift Truck Stability The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the Counterbalanced lift truck design is based on the bal- combined CG of the truck and load.
  • Page 25 If the CG moves outside of the line 1. Capacity/Nameplates originally attached to on either side of the stability base, the lift truck will forklifts sold by DOOSAN shall not be tip to the side. removed, altered or replaced without DOO- SAN’s approval.

  • Page 26: 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. Only properly trained and authorized personnel Never put any part of body into the mast structure should operate forklift trucks.
  • Page 27 Safety Section Do not overload. Always handle loads within the Do not raise anyone on the forks of your lift truck. Do not let other people ride on the truck. rated capacity shown on the capacity plate. Lift trucks are designed to carry loads, not people. Do not add extra counterweight to the truck.
  • Page 28 Safety Section Do not elevate the load with the mast tilted forward. Do not permit anyone to stand or walk under the load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards. cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
  • Page 29 Safety Section Do not drive in forward direction when loads restrict Do not stack or turn on ramps. 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 30 Safety Section Mop up spilt fuel and do not forget to close the fuel Do not operate your truck close to another truck. Always keep a safe distance from other trucks and tank before restarting the engine. make sure there is enough distance to stop safely. Park your lift truck in authorized areas only.

  • Page 31: How To Survive In A Tipover

    Safety Section How to Survive in a Tipover WARNING Hold on tight. 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 follows instructions provided. Always use operator restraint system.
  • Page 32 Safety Section Lean away from the direction of fall. Lean forward.

  • Page 33: General Section

    General Section Specifications CHARACTERISTICS Manufacturer DOOSAN DOOSAN DOOSAN Model GC15S-5(TIER-3) GC18S-5(TIER-3) GC20SC-5(TIER-3) Capacity at rated load center lb/kg 3000/1500 3500/1750 4000/2000 Load center distance inch/mm 24/500 24/500 24/500 Power type electric, diesel, gasoline, lp-gas Operator type stand-on, rider-seated Rider - seated...
  • Page 34 General Section...

  • Page 35: Noise And Vibration

    General Section Noise and Vibration Sound Pressure Level at Whole-body Vibration Operator’s ear (Leq.) Level according to EN12053 according to EN13059 Model Guaranteed Sound (m/s dB(A) Mean Uncertainty GC15/18S-5, GC20SC-5...

  • Page 36: 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. Power Shift Transaxle Serial Number •______________________________ Lift Truck Serial Number •______________________________ Side Shift Serial Number (If Equipped) •______________________________ 2.0 liter Spark –...

  • Page 37: 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. Operator's Warning Plate Lift Truck Capacity Rating Do not exceed allowable lift truck working capacity load ratings.
  • Page 38 General Section Mast Abbreviations Attachment Abbreviations (includes Special Forks) STD - Standard Mast (single inner member, low free lift) Special Carriage - increased width, height or outreach FF - Full Free Lift Mast (single inner member with high free lift duplex cylinder) SSS - Shaft-type Sideshift Carriage FFT -...

  • Page 39: Operation Section

    Operation Section Operator's Station and Monitoring Systems Instrument Panel Your lift truck may not have the same indicator or warning lights as shown in the illustrations. Due to the various options available, typical instrument panels are shown. However, the symbols on the indicators and lights on your panel identify what those particular items are. Also, the symbol for each of the items is identified and an explanation of their function and location is described on the following pages.
  • Page 40 Operation Section 1. Engine Oil Pressure Indicator Light - Check the cooling system for a malfunction. Both Indicates insufficient engine oil pressure. tenth & ninth will flash out of phase when the coolant The light will come on when the ignition temperature reaches approximately 106°C (223°F) switch is turned to the ON position.
  • Page 41 Operation Section 13. Transmission Neutral Position Light Electrical Disconnect Switch (If Indicates neutral position Equipped) transmission. 14. Brake Fluid Oil Light (If Equipped) - The light is ON when the brake fluid oil of brake reservoir comes down to low level position.

  • Page 42: Seat Switch System (If Equipped)

    If seat or seat switch replacement becomes neutral. necessary, be sure to use genuine DOOSAN Before exiting the lift truck, the parking brake Infracore lift truck parts. Lift trucks should never be operated without an operational should always be applied.
  • Page 43 Operation Section Engine Compartment Circuit Breaker 1. The engine compartment is accessible by Circuit Breaker - Protects the main pulling the latch and raising the hood and seat electrical circuits. To reset the circuit assembly. breaker, push the button in. It is Located in the engine compartment.
  • Page 44 Operation Section Seat NOTE : Seat arrangements may vary. Basic operation will be similar. Seat adjustment should be checked at the beginning of each shift and when operators change. Lock the seat into position before operating, to prevent an unexpected seat change. Adjust seat to allow full brake pedal travel with operator's back against seat back.

  • Page 45: Lift Truck Controls

    Operation Section Lift Truck Controls Direction Control Lever Transmission Inching Control Pedal 1. Forward - Push the lever forward for Inching Control Pedal - Pushing down on FORWARD direction travel. the inching pedal, modulates the hydraulic pressure to the clutch packs, permitting 2.
  • Page 46 Operation Section Service Brake Pedal Parking Brake Lever Pull the lever BACK to engage the parking Push DOWN on the brake pedal to slow brake. or stop the lift truck. Push the lever FORWARD to release the RELEASE the brake pedal to allow the lift parking brake.
  • Page 47 Operation Section Tilt Control Sideshift Attachment Control (If Equipped) 1. Mast Tilt Back - Pull the lever BACK smoothly to tilt the mast backward. 1. Sideshift Left - Push the lever FOR- WARD to shift the carriage to the left. 2.

  • Page 48: Refueling

    Operation Section Refueling Changing LP-Gas Tanks WARNING 1. Park the lift truck on level ground, with the parking brake applied, the transmission in Only trained, authorized personnel should fill or NEUTRAL, the forks lowered and the engine exchange LP-Gas tanks. running at low idle.
  • Page 49 Operation Section 11. Position the replacement tank so that the locating pin(dowel) is in place. The LP-Gas tank must not extend past the counterweight. 12. Clamp the tank securely 13. Connect the fuel supply line. 6. Check to be sure that the LP-Gas warning plate 14.

  • Page 50: Before Starting The Engine

    Operation Section Before Starting the Engine 5. Inspect the carriage, forks or attachments for Walk-Around Inspection wear, damage and loose or missing bolts. Make a thorough walk-around inspection before 6. Inspect the tires and wheels for cuts, gouges, mounting the lift truck or starting the engine. Look foreign objects, inflation pressure and loose or for such items as loose bolts, debris buildup, oil or missing bolts.
  • Page 51 Operation Section Typical Example 13. Observe the fuel level gauge after starting the truck. Add fuel if necessary. 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.

  • Page 52: Starting The Engine

    Operation Section Starting the Engine Prestart Conditions Gasoline Engine NOTE : The engine will not start unless the transmission directional control lever is in NOTICE the NEUTRAL position. Do not leave the key in ON position when engine is not running. Do not engage the starter more than 10 seconds at any one time 1.
  • Page 53 Operation Section LP-Gas Engine Diesel Engine Starting a Cold Diesel Engine WARNING 1. Turn the key to the ON position. The start preheat light will come ON. The preheat light will LP - Gas fuel is flammable and can cause stay approximately seven...
  • Page 54 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 55: After Starting The Engine

    Operation Section 4. The diesel engine water in fuel filter indicator After Starting the Engine light(4), will not come ON with the engine running, unless water in fuel filter exceeds Observe all indicator lights and gauges frequently 100cc. Stop the engine immediately and drain during operation, to make sure all systems are the water if the light comes ON.
  • Page 56 Operation Section Electronic Controlled Spark-Ignition Engines G420FE Engine EMS (Engine management system) of G420F(E) (SECM) uses two heated exhaust gas oxygen engine engine is a closed loop system utilizing a 3- sensors (HEGO) in the exhaust system to monitor way catalytic muffler to reduce the emission level in exhaust gas content.
  • Page 57 Operation Section G420F Engine EMS (Engine management system) of G420F engine engine is an open loop LP system and/or closed loop gasoline system. 3-way catalytic muffler is not used for this system. LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM. Manifold pressure from the TMAP, rpm from the crank position sensor and throttle position is used by the SECM to calculate load.
  • Page 58 Operation Section Basic Troubleshooting(LP) The MI-07 systems are equipped with built-in fault basic checks that should be made before referring diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
  • Page 59 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Difficult to Start 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”...
  • Page 60 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Will Not Run Fill fuel container Continuously Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for a “click”...
  • Page 61 Operation Section Problem Probable Cause Corrective Action Clogged fuel filter Repair/replace as required Will Not See Maintenance Accelerate/Hesita Section, LP Fuel Filter replacement tion During Acceleration Faulty vapor connection between Check connection Verify no holes in hose pressure regulator/converter Clamps must be tight and the mixer Look for kinked, pinched and/or collapsed hose...
  • Page 62 Operation Section Problem Probable Cause Corrective Action Fuel Lock-off malfunction Repair/replace Fuel Lock-off Engine Stalls See Engine Service Manual Faulty vapor connection between Check connection Verify no holes in hose pressure regulator/converter Clamps must be tight and the mixer Look kinked, pinched and/or...
  • Page 63 Operation Section Problem Probable Cause Corrective Action Incorrect Idle speed control See Advanced Diagnostics & See Engine Rough Idle Service Manual Incorrect timing or spark control Engine Mechanical See Engine Service Manual Incorrect Idle speed control See Advanced Diagnostics & See Engine High Idle Speed Service Manual Throttle sticking...
  • Page 64 Operation Section Problem Probable Cause Corrective Action Air/Fuel Mixer malfunction Check mixer Excessive Fuel See Engine Service Manual Consumption/LP Air filter clogged Check air filter G Exhaust Smell Clean/replace as required Vacuum leak Check system vacuum hoses from regulator to FTV and mixer Repair/replace as necessary Pressure regulator malfunction/fuel Test pressure regulator operation...
  • Page 65 Operation Section Advanced Diagnostics Displaying Fault Codes (DFC) from SECM Memory MI-07 systems are equipped with built-in fault diagnostics. Detected system faults To enter code display mode you must turn OFF the displayed by the Malfunction Indicator Lamp (MIL) ignition key. Now turn ON the key but do not start as Diagnostic Fault Codes (DFC) or flash codes, the engine.
  • Page 66 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) PROBABLE FAULT FAULT ACTION * CORRECTIVE 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 INJ1 wiring for an open circuit Inj1Open SECM (Signal) A5 to Injector 1 Pin A...
  • Page 67 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check coolant system for radiator blockage, proper coolant level and for ECTOverTempFault leaks in the system. Engine coolant temperature is (1) TurnOnMil Possible ECT short to GND, check ECT high.
  • Page 68 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TPS1RangeLow Check throttle connector connection and TPS1 sensor voltage out of TPS1 sensor for an open circuit or short to range low, normally set if the TurnOnMil (22)
  • Page 69 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TPS2AdaptHiMin Learned WOT end of TPS2 None sensor range lower than expected TPS1AdaptLoMax Learned closed throttle end None of TPS1 sensor range higher than expected TPS2AdaptLoMax Learned closed throttle end of...
  • Page 70 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK MAPTimeRangeHigh Check TMAP connector and MAP signal wiring Manifold Absolute Pressure for a shorted circuit Sensor Input is High, normally TMAP Pin 4 to SECM Pin B18 (signal) set if the TMAP pressure TMAP Pin 1 to SECM Pin B1 (sensor GND) signal wire has become...
  • Page 71 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check TMAP connector and IAT signal wiring IATRangeHigh for a shorted circuit Intake Air Temperature TMAP Pin 2 to SECM Pin B12 (signal) Sensor Input is High normally TMAP Pin 1 to SECM Pin B1 (sensor GND) set if the IAT temperature...
  • Page 72 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A6 (EST4) to OEM ignition EST4_Open system. See application manual. EST4 output open, possibly Verify GND on ignition module TurnOnMil...
  • Page 73 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check coil driver wiring and connector for shorts SECM Pin A10 (EST2) to ignition module EST2_Short Pin D (4-pin connector) EST2 output shorted high or Verify GND on ignition module low, EST2 signal shorted to TurnOnMil...
  • Page 74 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK EST7_Short EST7 output shorted high or low, EST7 signal shorted to None ground or power or defective spark module EST8_Short EST8 output shorted high or low, EST8 signal shorted to None ground or power or defective...
  • Page 75 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check ETC driver wiring for a shorted circuit HbridgeFault_ETC SECM Pin A17 to ETC + Pin 1 Electronic Throttle Control SECM Pin A18 to ETC - Pin 4 •...
  • Page 76 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 XDRP +5 Vdc to TMAP Pin 1 XDRG GND Verify transducer power at the SECM with a multimeter SensVoltRangeLow...
  • Page 77 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION FIRST PROBABLE FAULT FAULT ACTION * CHECK APP2RangeLow APP2 sensor voltage out of range Check foot pedal connector • Check APP2 signal at SECM PIN low, normally set if the APP2 signal TurnOnMil (65) has shorted to ground, circuit has...
  • Page 78 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check FTV1 for an open wire or FTV connector LSDFault_Dither1 being disconnected Dither Valve 1 Fault, signal FTV1 Pin 1 (signal) to SECM Pin A1 has opened or shorted to TurnOnMil FTV1 Pin 2 (power) to SECM (DRVP) Pin A23...
  • Page 79 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK GasFuelAdaptRangeHi Check dual dither valves, e.g. plugged valve or In LPG mode, system had hose. TurnOnMil (73) to adapt lean more than Check for plugged orifice(s).
  • Page 80 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 772 (e.g. faults pertaining to FTVs, Pre-Cat O2, Post GasPostO2FailedRich (1) TurnOnMil Cat O2 sensor) Pre-catalyst O2 sensor (2) DisableGasPost Look for leaks in exhaust, catalytic converter,...
  • Page 81 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 852 (e.g. faults pertaining to Injectors, MAP, LiqPostO2FailedLean (1) TurnOnMil IAT, Pre-Cat O2, Post Cat O2 sensor) Pre-catalyst O2 sensor indicates (2) DisableLiqPost Look for leaks in exhaust, catalytic converter,...
  • Page 82 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TransOilTemp (1) TurnOnMil Refer to drivetrain manufacturer’s Excessive transmission oil (2) DelayedEngine transmission service procedures. temperature Shutdown ServiceFault4 Service Interval 4 has been Replace Pre-catalyst HEGO sensor TurnOnMil Replace Post-catalyst HEGO sensor...

  • Page 83: Lift Truck Operation

    Operation Section Lift Truck Operation Power Shift Transaxle WARNING 1. Start the engine. See topic "Starting the Engine." A lift truck with the engine running but without an operator can move slowly (creep) if the transmission is engaged. This could result in personal injury. Always place the transmission control lever in the NEUTRAL (center) position and apply the parking brake before dismounting the lift truck.
  • Page 84 Operation Section Inching NOTE : The purpose of the inching pedal is to provide precise lift truck inching control at very slow travel speed and high engine rpm. This is used for fast hydraulic lift, during load approach, pick up or load positioning.

  • Page 85: Operating Techniques

    Operation Section Operating Techniques Inching into Loads Lifting the Load 1. Lift the load carefully and tilt the mast back a short distance. 1. Move the lift truck slowly FORWARD into position and engage the load. The truck should be square with load, forks spaced evenly 2.
  • Page 86 Operation Section Traveling with the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. 1. Move the lift truck into the unloading position. 1. Travel with the load uphill on upgrades and downgrades. 2.
  • Page 87 Operation Section Turning 3. Deposit the load and BACK away carefully to disengage the forks. 1. When turning sharp corners, keep close to the inside corner. Begin the turn when the inside drive wheel meets the corner. 4. Lower the carriage and forks to the travel position or to the park position.
  • Page 88 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 89: Parking The Lift Truck

    Operation Section Parking the Lift Truck Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor. Block the drive wheels when parking on an incline. 5. Turn the key in the ignition switch to the OFF position and remove the key.

  • Page 90: Lift Fork Adjustment

    Operation Section Lift Fork Adjustment WARNING When adjusting the fork spread, be careful not to pinch your hand between forks and the carriage slot. Hook-on type Fork 1. Move up the hook pin to the free position. 2. Raise the hook pin in each fork to side the fork on the carriage bar.

  • Page 91: Storage Information

    Operation Section Storage Information • The machine should be operated at least once a Before Storage week. Fill the cooling system, if cooling water is Before storing your lift truck, clean and inspect as discharged, and mount the battery. Start the the following procedures.

  • Page 92: Transportation Hints

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

  • Page 93: Towing Information

    Block the lift truck wheels to prevent movement Consult your DOOSAN Lift Tuck dealer for towing a before releasing the brakes. The lift truck can disabled lift truck.

  • Page 94: 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 and ISO Standard 2330 - Fork Arms-Technical...
  • Page 95 Maintenance section • Repetitive Overloading Causes of Fork Failure Repetitive cycling of loads which exceeds the Improper Modification or Repair fatigue strength of the material can lead to fatigue failure. The overload could be caused by loads in Fork failure can occur as a result of a field excess of the rated fork capacity and by use of the modification involving welding, flame cutting or forks tips as pry bars.
  • Page 96 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 97 Maintenance section 4. A fork should be load tested before being 12 Months Inspection returned to service on completion of repairs authorized and done in accordance with the Forks should be inspected, at a minimum, every 12 manufacturer’s recommendations. months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked Most manufacturers and standards require the every six months.

  • Page 98: Torque Specifications

    Maintenance section Torque for Standard Bolts, Nuts, Torque Specifications and Taperlock Studs Metric Hardware Most of the nuts, bolts, studs, and threaded holes in NOTICE your lift truck are metric. In this manual we provide specifications in both metric and U.S. customary The two charts below give general torques for measurement.
  • Page 99 Maintenance section Torque for Metric Fasteners Torques for Taperlock Studs NOTICE Standard Taperlock Stud Thread Size Torque Inch Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or N•m lb•ft incorrect fasteners will cause lift truck damage 8 + 3 6 + 2 or malfunction and may even result in personal...

  • Page 100: Cooling System Specifications

    Filling at over 20 liters (5 U.S. gallons) per minute can cause air pockets in the cooling system. NOTICE After draining and refilling the cooling system, DOOSAN recommends that the coolant mixture operate the engine with the radiator cap removed contain a minimum of 30% antifreeze or equivalent. until...
  • Page 101 Use the chart below to assist in determining the number of heating and cooling cycles. concentration of antifreeze to use. DOOSAN prefers the use of distilled water or deionized water to reduce the potential and severi- Antifreeze Concentrations ty of chemical insolubility.

  • Page 102: Fuel Specifications

    LP-Gas is “Liquefied Petroleum Gas”. The exact composition of LP-Gas varies slightly between different parts of the country and different refineries. HD5 is recommended for DOOSAN forklift trucks. Remember LP-Gas is heavier than air and will sink to the lowest spot possible. Avoid areas near floor drains or lubrication pits where escaped fuel may collect.

  • Page 103: Lubricant Specifications

    Drain the fluid, retighten all hydraulic suction line clamps, purge and refill the system. Consult your DOOSAN Lift Truck Consult the EMA Lubricating Oils Data Book for a dealer for purging instructions.
  • Page 104 Maintenance section Transmission Oil (TDTO) Drive Axle Oil NOTE : Failure to follow the recommendation will cause shortened life due to excessive gear NOTICE wear. This oil is formulated for transmissions and • Shoe Brake drive trains only, and should not be used in Select oil that meets below specifications.
  • Page 105 Maintenance section Brake Fluid Lubricating Grease (MPGM) Use Multipurpose Molybdenum Grease (MPGM) for all lubrication points. If MPGM grease can not be used, a multipurpose type grease which contains 3% to 5% molybdenum disulfide can be used. NLGI No.2 grade is suitable for most tempera- tures.

  • Page 106: Lubricant Viscosities And Refill Capacities

    Maintenance section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities LUBRICANT VISCOSITIES Refill Capacities (Approximate) FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment °C °F Compartment Liters U.S. Gal. or System or System Viscosities Min Max Min Max Engine Crankcase w/Filter Engine Crankcase +104 G420E LP-Gas 10W30...

  • Page 107: Maintenance Intervals

    Maintenance section Drive Axle Oil Level - Check ........ 121 Maintenance Intervals Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate..............122 Steering Mechanism - Check, Lubricate ..... 122 NOTICE Battery Terminal - Clean, Inspect ......123 Brake Oil Level - Check........123 All maintenance and repair, except every 10 Engine Oil Filter - Change........
  • Page 108 Maintenance section Every 2500 Service Hours or 15 Months Hydraulic Oil - Change, Check, Clean ....141 Inspect Battery System ........142 Replace Oxygen Sensor (G420F(E) Engine Only) ................142 Checking the TMAP Sensor (G420F(E) Engine Only) ..............143 Inspect for Intake Leaks (G420F(E) Engine Only) ................

  • Page 109: 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. Fuses & Relay Change Operator's Seat, Hood Latch and Support Cylinder - Check, NOTE : If a fuse filament separates, use only the same type and size fuses for replacement.

  • Page 110: Tire And Wheels - Inspect, Check

    25 mm (1 inch). If the thickness is less than 25 mm (1 inch), the tire must be replaced. Consult your DOOSAN dealer. Do not try to replace the tire yourself. Inspect the wheels. They should have no...

  • Page 111: Test Fuel System For Leaks

    Maintenance section Test Fuel System for Leaks Check Points 1. Obtain a leak check squirt bottle or pump spray bottle. 2. Fill the bottle with an approved leak check solution. 3. Spray a generous amount of the solution on the fuel system fuel lines and connections, starting at the storage container.

  • Page 112: Wheel Bolts - Inspect

    Maintenance section Wheel Bolts - Inspect Carriage Roller Extrusion – Adjust Inspect Tightness - Drive Wheels 1. Set the mast vertical. 2. Lower the carriage completely. 3. On full free lift and full free triple lift models, the bottom of the inner mast must be flush with the bottom of the stationary mast.

  • Page 113: 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. 5. Inspect the operator's compartment for loose Walk-Around Inspection – Inspect items and cleanliness.

  • Page 114: Inspect Engine For Fluid Leaks

    Maintenance section Inspect Engine for Fluid Leaks Coolant Level - Check 1. Start the engine and allow it to reach operating WARNING temperatures. 2. Turn the engine off. At operating temperature, the engine coolant is hot and under pressure. 3. Inspect the entire engine for oil and/or coolant leaks.

  • Page 115: Air Intake System - Check

    Maintenance section Inspect Foot Pedal Operation WARNING • Verify foot pedal travel is smooth without Pressure air can cause personal injury. sticking. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. WARNING Maximum air pressure must be less than 205 When the acceleration pedal harness is connected kPa (30 psi) for cleaning purposes.

  • Page 116: Mast Channels - Lubricate

    Maintenance section Mast Channels - Lubricate Transmission Oil Level - Check Checking Oil Level WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Start and operate the lift truck until the engine reaches normal operating temperature.

  • Page 117: 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. Parking Brake - Test, Adjust Transmission Oil & Strainer - Change, Clean NOTE : Be sure area around the lift truck is clear of personnel and obstructions.

  • Page 118: Drive Axle Oil - Change

    Maintenance section 6. Shift the transmission into NEUTRAL. Engage Drive Axle Oil - Change the parking brake. Park the lift truck on a level surface. Apply the 7. Remove the dip stick. Observe the oil level. parking brake. Place the directional control lever in NEUTRAL.
  • Page 119 Maintenance section 8. Clean and reinstall the level/fill plug. 9. Remove the wood blocking and lower the carriage. 10. Operate the lift truck for a few minutes and check oil level again. See the topic, “Drive Axle Oil Level - Check” in “Every 250 Service Hours or Monthly”...

  • Page 120: 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. Hydraulic Return Filter - Change WARNING Hot oil and components can cause personal injury.

  • Page 121: 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. 3. Clean and inspect the element or replace with a Air Intake System - Check, Clean new element.
  • Page 122 Maintenance section Air-205 kPa (30 psi) Maximum Pressure Cleaning Primary Filter Elements 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 123: Hydraulic Oil Level - Check

    Maintenance section Hydraulic Oil Level - Check Drive Axle Oil Level - Check Park the lift truck on a level surface. Apply the parking brake. Place the directional control lever in WARNING NEUTRAL. At operating temperature, the hydraulic tank is hot and under pressure.

  • Page 124: Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate

    Maintenance section Mast, Carriage, Lift Chains & Steering Mechanism - Check, Attachments - Inspect, Lubricate Lubricate 1. Operate the lift, tilt and attachment controls. Listen for unusual noises. These may indicate a need for repair. 2. Inspect for loose bolts and nuts on the carriage. Remove any debris from the carriage and mast.

  • Page 125: Battery Terminal - Clean, Inspect

    Maintenance section Battery Terminal - Clean, Inspect Brake Oil Level - Check WARNING Batteries give off flammable fumes that can explode. Do not smoke when observing the battery elec- trolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear protective glasses when working with batteries.

  • Page 126: Engine Oil Filter - Change

    Maintenance section Engine Oil Filter - Change 7. Before installing a new filter element, apply a small amount of clean engine oil to the filter 1. Operate lift truck a few minutes to warm oil. element gasket. Park the lift truck with the forks lowered, parking brake applied, transmission in neutral 8.

  • Page 127: 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 - Check, Adjust Tilt Cylinders - Check, Adjust, Lubricate Chassis Pivot Eyebolts - Lubricate 1.

  • Page 128: Mast Hinge Pin - Lubricate

    Maintenance section Mast Hinge Pin - Lubricate Cylinder Rod Extension-Adjust NOTE : The following description is for forward tilt. For cylinder rod back tilt, the collar should be stationary by the tilt eye. If it is not, the O-ring inside the collar may need to be replaced.

  • Page 129: Inching & Braking Control Shaft - Lubricate

    Maintenance section Horn & Lights (If Equipped) - Parking Brake - Test, Adjust Check See topic, “Parking Brake - Test, Adjust” in “First 50-100 Service Hours.” Inching & Braking Control Shaft - Lubricate 1. Press horn button, to determine if horn is operational.

  • Page 130: Inspect Vacuum Lines And Fittings (G420F(E) Engine Only)

    Maintenance section Inspect Vacuum Lines and Inspect Electrical System Fittings (G420F(E) Engine Only) (G420F(E) Engine Only) 1. Visually inspect vacuum lines and fittings for Check for loose, dirty or damaged connectors physical damage such as bittleness, cracks and and wires on the harness including: Fuel lock- kinks.

  • Page 131: 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. Hydraulic Return Filter, Breather 4. Remove the return filter from tank top plate assembly.

  • Page 132: Lift Chains - Test, Check, Adjust

    Maintenance section Lift Chains - Test, Check, Adjust Check for Equal Tension Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller. When the chain bends over the roller, the movement of the parts against each other causes wear.
  • Page 133 Maintenance section Carriage Chain Adjustment 4. Set the mast vertical and raise the carriage and check equal chain tension. If not equal, repeat Make sure that carriage height is correct. If correct, the same procedure as step 1 through step 3. adjust the chain for equal tension.

  • Page 134: Transmission Oil & Strainer - Clean, Change

    Maintenance section 3. Make adjustment anchor nuts(3),(4) for equal chain tension. 4. Raise the inner mast and check equal chain tension. If not equal, repeat the same procedure as step 1 through step 3. 5. Put LOCTITE No. 242 tread lock on the threads of the anchor nuts(3),(4) after the adjustment is completed.

  • Page 135: Inspect Coolant Hoses (Lp, Dual Fuel Engines Only)

    Maintenance section Inspect Coolant Hoses (LP, Dual Fuel Lines & Fittings - Check Fuel Engines Only) Visually inspect fuel lines and fittings for physical damage. Replace as required. 1. Visually inspect coolant hoses and clamps. Remember to check the two coolant lines that connect to the pressure regulator/converter.

  • Page 136: 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. Replace LP Fuel Filter Element Drive Axle Oil (Shoe Brake) - (LP-Gas, Dual Fuel Engine Only) Change Park the lift truck in an authorized refueling area...

  • Page 137: Fuel Filter (Lp - Gas Engine Only)

    Maintenance section Fuel Filter (LP - Gas Engine Only) Testing Fuel Lock-off Operation (LP-Gas Engine Only) Disassembly 1. Start engine. 2. Locate the electrical connector for the fuel lock 3. Disconnect the electrical connector. 4. The engine should run out of fuel and stop within a short period of time.

  • Page 138: 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 - Repack 11. Install the inner bearing. 12.

  • Page 139: 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 filler cap is cool enough to touch with your bare hand.
  • Page 140 Maintenance section NOTICE Hold the drain port when the radiator drain valve is turned because the tank and the drain port are separated. 4. After draining the coolant completely, close the radiator drain valve and the block drain plug, fill the engine and the radiator full with a radiator cleaner, and clean the engine and the radiator.

  • Page 141: Fork - Inspect

    2. Check the angle between the upper face of the blade allowable difference. Contact your local and the front face of the shank. The fork should be DOOSAN Lift Truck Dealer further withdrawn from service if angle (C) exceeds 93 information.
  • Page 142 Maintenance section at both ends of the carriage and in the path of the bottom fork hook. The load backrest extension may be used in place of the stop blocks in some cases. Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork.

  • Page 143: 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. Hydraulic Oil - Change, Check, 5. Start the engine and operate the hydraulic con- trols, and the steering system, through a few Clean cycles to fill the lines.

  • Page 144: Inspect Battery System

    Maintenance section Inspect Battery System Replace Oxygen Sensor (G420F(E) Engine Only) 1. Clean battery outer surfaces with a mixture of baking soda and water. G420F(E) Engine 2. Inspect battery outer surfaces for damage and replace as necessary. 3. Remove battery cable and clean, repair and/or replace as necessary.

  • Page 145: Checking The Tmap Sensor (G420F(E) Engine Only)

    Maintenance section Checking the TMAP Sensor Inspect for Intake Leaks (G420F(E) (G420F(E) Engine Only) Engine Only) 1. Verify that the TMAP sensor (F) is mounted 1. Visually inspect the intake manifold, throttle tightly into the manifold adapter (E), with no assembly (2), and manifold adapters (3), for leakage.

  • Page 146: Replace Spark Plugs (G420F(E) Engine Only)

    Maintenance section Replace Spark Plugs (G420F(E) Engine Only) 1. Disconnect Battery Cables. 2. Remove the ignition wiring harness. 3. Remove the ignition coil assy. 4. Remove spark plugs. 5. Gap the new spark plugs to the proper specifications. G420F(E) Engine : 0.7 ~ 0.8 6.

  • Page 147: 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. Timing Belt - Change See the “Service Manual” for the procedure and specifications.

  • Page 148: Index

    Index Section Index Circuit Breaker ............. 108 Cleaning Primary Filter Elements ....... 120 12 Months Inspection ..........95 Coolant Information ..........98 Coolant Level - Check ......... 112 Coolant Water ............99 Cooling System – Clean, Change ...... 137 Accelerator Pedal ...........44 Cooling System Specifications......
  • Page 149 Index Section Inching into Loads..........83 Inspect Battery System........142 Fasten the Seat Belt..........20 Inspect Coolant Hoses (LP, Dual Fuel Engines Fatigue..............93 Only) ..............133 Fire or Explosion Prevention........15 Inspect Electrical System (G420F(E) Engine Only) First 250 Service Hours or a Month ....118 ................
  • Page 150 Index Section Lubricant Viscosities..........104 Parking Brake - Test, Adjust .......115, 127 Lubricant Viscosities and Refill Capacities ..104 Parking Brake Lever ..........44 Lubricating Grease (MPGM)....... 103 Parking the Lift Truck..........87 Power Shift Transaxle ........... 81 Power Shift Transaxle(PTA18) ......115 Pressure Air............
  • Page 151 Index Section Test Operation ............. 115 Testing Fuel Lock-off Operation (LP-Gas Engine Only) ..............135 Tilt Control...............45 Tilt Cylinders - Check, Adjust, Lubricate.... 125 Tilting Steering Column..........42 Timing Belt - Change........... 145 Timing Belt for Counterbalance Shaft - Change 145 Tire and Wheels - Inspect, Check ......

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