Daewoo D35S-2 Operation & Maintenance Manual
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Daewoo D35S-2 Operation & Maintenance Manual

Daewoo D35S-2 Operation & Maintenance Manual

Tier ii & stage ii certified lift trucks
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SB2301E06
Operation &
Maintenance Manual
LIFT TRUCKS
D35S-2, D40S-2, D45S-2, D50C-2
G35S-2, G40S-2, G45S-2, G50C-2
D40SC-2, D45SC-2, D50SC-2
G40SC-2, G45SC-2, G50SC-2
D35S-2, D40S-2, D45S-2, D50C-2
D40SC-2, D45SC-2, D50SC-2
G35S-2, G40S-2, G45S-2, G50C-2
(TIER II & STAGE II CERTIFIED TRUCK)
0510

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Summary of Contents for Daewoo D35S-2

  • Page 1 SB2301E06 Operation & Maintenance Manual LIFT TRUCKS D35S-2, D40S-2, D45S-2, D50C-2 G35S-2, G40S-2, G45S-2, G50C-2 D40SC-2, D45SC-2, D50SC-2 G40SC-2, G45SC-2, G50SC-2 D35S-2, D40S-2, D45S-2, D50C-2 D40SC-2, D45SC-2, D50SC-2 G35S-2, G40S-2, G45S-2, G50C-2 (TIER II & STAGE II CERTIFIED TRUCK) 0510...
  • Page 2 WARNING Do not start, operate or service this machine unless you have read and understood these instructions and received proper training. Unsafe or improper use of the machine may cause serious injury or death. Operators and maintenance personnel must read this manual and receive training before operating or maintaining the machine.

  • 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 ............... 100 Tire Inflation Information........104 Safety Section Torque Specifications........... 105 Cooling System Specifications ......107 Fuel Specifications ..........109 Important Safety Information........

  • Page 4: Information Section

    Information Section Foreword Literature Information This manual should be stored in the operator's Photographs or illustrations guide the operator through compartment in the literature holder or seat back correct procedures checking, operation literature storage area. maintenance of the DOOSAN operator restraint system. This manual contains safety, operation, trans-portation, SAFE and EFFICIENT OPERATION of a lift truck lubrication and maintenance information.
  • Page 5 Information Section Maintenance The Maintenance Section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by servicing intervals. Items without specific intervals are listed under “When Required” topics. Items in the “Maintenance Intervals” chart are referenced to detailed instructions that follow.

  • Page 6: Safety Section

    Safety Section Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons must also have the necessary training, skills and tools before attempting to perform these functions.

  • Page 7: Safety

    Safety Section Safety The safety rules and regulations in this section are Warning Signs and Labels representative of some, but not all rules and regulations noted under the Occupational Safety and Health Act There are several specific safety signs on your lift truck. (OSHA) and are paraphrased without representation Their exact location and description of the hazard are that the OSHA rules and regulations have been...
  • Page 8 Safety Section General Warnings to Operator 14. Use extreme care when handling long, high, or wide loads. 15. Forks should be completely under load and spread apart as far as load permits. 16. Machine should be equipped with overhead guard or equivalent protection.
  • 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 Warning Brake Pedal Adjustment Warning WARNING WARNING Operation without this device in place may be Improper adjustment could result in injury or death. hazardous. This guard conforms to A.N.S.I.B56.1 It has to be adjusted by drawing dimension on free and F.E.M.
  • Page 11 Safety Section Parking brake No Riders Warning WARNING To avoid personal injury, allow no riders. A lift truck is designed for only one operator and no riders. Pull the lever BACK to engage the parking brake. Push the lever FORWARD to release the parking brake.

  • Page 12: General Hazard Information

    Safety Section General Hazard Information Do not raise loads any higher than necessary and 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. The load backrest extension is intended to prevent the load or any part of the load from falling backwards into the operator's station.

  • Page 13: Operation Information

    Safety Section Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully. Clean your shoes and wipe your hands before mounting. Face the lift truck when mounting and dismounting. Use both hands face the lift truck when mounting and dismounting.
  • Page 14 Safety Section Operating the Lift Truck Make sure no one is standing and/or working on, underneath or close to the lift truck before operating the Always keep the lift truck under control. lift truck. Obey all traffic rules and warning signs. Operate the lift truck and controls only from the operator's station.
  • 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

    Safety Section Maintenance Information Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying debris before Perform all maintenance unless otherwise specified as striking any object. follows ; Falling Objects Protective Structure(FOPS) Park the lift truck in authorized areas only.
  • Page 17 Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant mixtures are Coolant flammable. At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or Fuel leaked or spilled onto hot surfaces or electrical the engine contain hot water or steam.
  • Page 18 Safety Section Fire Extinguisher Tire Information Have a fire extinguisher-type BC and 1.5KG minimum Explosions of air-inflated tires have resulted from heat- capacity-on rear overhead guard leg with latch and induced gas combustion inside the tires. The heat, know how to use it. Inspect and have it serviced as generated by welding or heating rim components, recommended on its instruction plate.

  • Page 19: Operator Restraint System (If Equipped)

    Safety Section Operator Restraint System (If Dry nitrogen(N ) gas is recommended for inflation of tires. If the tires were originally inflated with air, nitrogen Equipped) is still preferred for adjusting the pressure. Nitrogen Warning Signs and Labels mixes properly with air. Your DOOSAN lift truck has the following tipover Nitrogen inflated tires reduce the potential of a tire warning decals.
  • Page 20 Safety Section WARNING Do NOT place your hand or fingers under the seat. Injury may occur as the seat suspension mechanism moves up and down. NOTICE Before getting on the truck, adjust the level of the suspension using the grip in the rear of the seat. The “Survive in tipover”...
  • Page 21 Safety Section If Optional Suspension Seat (weight Seat Belt adjusting type) Equipped The Operator Restraint System, Prevents the operator from jumping from the operator’s compartment in the event of a forward or side tipover. The system is designed to keep the operator on the seat and in the operator’s compartment in the event of a tipover.
  • Page 22 Safety Section WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 3. In the event of a tipover, the seat and restraint system should be inspected for damage and replaced, if necessary. NOTE: Operator restraints shall be examined at the regular truck...

  • Page 23: Avoiding Lift Truck Tipovers

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipovers 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 Counterbalanced lift truck design is based on the the truck and load.
  • Page 24 Safety Section Lift Truck Stability Base The location of the CG in the vertical direction is the same as the horizontal dimension. Remember that, unless otherwise indicated, the capacity load shown on the nameplate is for a standard lift truck with standard backrest, forks and mast, and having no special-purpose attachment.

  • Page 25: Safety Rules

    Safety Section Safety Rules Do not operate a lift truck unless you are in the operator's seat. Only properly trained and authorized personnel should Keep arms, legs and head inside the confines of the operate forklift trucks. Wear a hard hat and safety shoes operator's area.
  • Page 26 Safety Section Do not raise anyone on the forks of your lift truck unless Do not overload. Always handle loads within the rated using an approved safety cage. capacity shown on the capacity plate. Do not let other people ride on the truck. Do not add extra counterweight to the truck.
  • Page 27 Safety Section Do not permit anyone to stand or walk under the load or Do not elevate the load with the mast tilted forward. lifting mechanism. The load can fall and cause injury or Do not tilt the elevated loads forwards. death to anyone standing below.
  • Page 28 Safety Section Do not stack or turn on ramps. Do not drive in forward direction when loads restrict your Do not attempt to pick-up or deposit a load unless the lift visibility. Operate your lift truck in reverse to improve truck is level.
  • Page 29 Safety Section Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully lower Always keep a safe distance from other trucks and the forks to the floor, put direction lever in NEUTRAL make sure there is enough distance to stop safely.

  • 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. -29-...

  • Page 32: General Section

    General Section Specifications CHARACTERISTICS 1 Manufacturer UNIT DOOSAN DOOSAN DOOSAN 2 Model D35S-2 G35S-2 D40S-2 G40S-2 D45S-2 G45S-2 3 Capacity at rated load center 3500 4000 4500 4 Load center distance 5 Power type electric, diesel, gas, LP-GAS diesel LP-GAS...
  • Page 33 General Section DOOSAN DOOSAN DOOSAN D40SC-2 G40SC-2 D45SC-2 G45SC-2 D50SC-2 G50SC-2 4000 4500 5000 diesel LP-GAS diesel LP-GAS diesel LP-GAS rider - seated rider - seated rider - seated X2/2 X2/2 X2/2 3000 3000 3000 50 X 150 X 1050 50 X 150 X 1050 50 X 150 X 1200 8/10...
  • Page 34 General Section Specifications CHARACTERISTICS UNIT DOOSAN DOOSAN 1 Manufacturer G35S-2(TIER l l) G40S-2(TIER l l) 2 Model 3500 4000 3 Capacity at rated load center 4 Load center distance LP-GAS LP-GAS 5 Power type electric, diesel, gas, LP-GAS rider-seated ri d er-seated 6 Operator type stand-on, rider seated 7 Tire type...
  • Page 35 General Section DOOSAN DOOSAN G45S-2(TI E R l l) G50C-2(TI E R l l) 4500 5000 LP-GAS LP-GAS rider - seated rider - seated X2/2 X2/2 3000 3050 50 X 150 X 1200 60 X 150 X 1200 8/10 8/10 3190 3235 1445...
  • Page 36 General Section Specifications CHARACTERISTICS 1 Manufacturer UNIT DOOSAN DOOSAN DOOSAN 2 Model D35S-2(TIER II) D40S-2(TIER II) D45S-2(TIER II) 3 Capacity 3500 4000 4500 at rated load center 4 Load center distance 5 Power type diesel diesel diesel electric, diesel, gas, LP-GAS...
  • Page 37 General Section DOOSAN DOOSAN DOOSAN DOOSAN D40SC-2(TIER II) D45SC-2(TIER II) D50SC-2(TIER II) D50C-2 4000 4500 5000 5000 diesel diesel diesel diesel rider - seated rider - seated rider - seated ri d er - seated X2/2 X2/2 X2/2 x2/2 3000 3000 3000 3050...

  • Page 38: Noise And Vibration

    General Section Noise and Vibration Noise Noise Level [Unit : dB(A)] Sound Pressure Level at Sound Pressure Level at By- Guaranteed Sound Model Power Level(L Operator’s ear(Leq) stander position (AS 3713) by new directive 2000/14/EC AS3713 prEN12053 Dri v e-By Lifting Mode W/O Cabin 83.4...

  • Page 39: Capacity Chart

    General Section Capacity Chart -37-...
  • Page 40 General Section Capacity Chart -38-...

  • Page 41: Capacity Chart (With Side Shifter)

    General Section Capacity Chart (with Side Shifter) -39-...
  • Page 42 General Section Capacity Chart (with Side Shifter) -40-...
  • Page 43 General Section Capacity Chart -41-...
  • Page 44 General Section Capacity Chart -42-...
  • Page 45 General Section Capacity Chart (with Side Shifter) -43-...
  • Page 46 General Section Capacity Chart (with Side Shifter) -44-...
  • Page 47 General Section Capacity Chart -45-...
  • Page 48 General Section Capacity Chart (with Side Shifter) -46-...

  • Page 49: 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. 4.3 liter GM Vortec Engine Serial Number(G643) •______________________________ Lift Truck Serial Number •______________________________ 4.3 liter GM Vortec Engine Serial Number(G643E) •______________________________ 5.8 liter Diesel Engine(TIER I) Serial Number •______________________________...
  • Page 50 General Section DRIVE AXLE Serial Number •______________________________ Side Shifter Serial Number(If Equipped) •______________________________ -48-...

  • Page 51: 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 Identification, Lift Capacity and Attachment Plate Located on the cowl to the right side of the steering column.
  • Page 52 General Section Mast Abbreviations Attachment Abbreviations (Includes Special Forks) STD - Standard Mast (single inner member, low free lift) SC - Special Carriage-increased width, height or FF - Full Free Lift Mast (single inner member with high outreach free lift duplex cylinder) SSS - Shaft-type Sideshift Carriage FFT - Triple Lift Mast (two inner members) with either low or full free lift characteristics.

  • Page 53: 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 54 Operation Section 1. Engine Oil Pressure Indicator Light - & ninth will flash out of phase when the coolant Indicates insufficient engine oil pressure. The temperature reaches approximately 106℃(223℉) on all light will come on when the ignition switch is engine.
  • Page 55 Operation Section 13. Transmission Neutral Position Light - Indicates the neutral position of transmission. 14. Drive Axle Oil Indicator Light (OCDB only) - Indicates too hot drive axle oil. The light will be ON when the ignition switch is in the ON position and must go OFF when the engine is running.
  • Page 56 Operation Section Engine Compartment 1. The engine compartment is accessible by pulling the latch and raising the hood and seat assembly. NOTE: Unlock latch before pulling if key equipped. 2. The hood and seat assembly is held up by a support cylinder.
  • Page 57 Operation Section Circuit Breaker Electrical Disconnect Switch (If Equipped) Typical Example Diesel Engine Truck 1. ON-Connects the battery for electrical power to all electrical circuits. 2. OFF-Disconnects the battery from all electrical circuits. Seat NOTE: Seat arrangements may vary. Basic operation will be similar.

  • Page 58: Seat Switch System (If Equipped)

    Operation Section Seat Switch System (If Equipped) NOTICE 1. Prior to operating the lift truck, be sure to understand and check the SEAT SWITCH SYSTEM. 2. While in normal operation and on level ground, select a direction with the derectional lever and with the park brake released.

  • Page 59: Lift Truck Controls

    Operation Section Lift Truck Controls Direction Control Lever Transmission Inching Control Pedal Inching Control Pedal - Pushing down on the inching pedal, modulates the hydraulic pressure 1. Forward - Push the lever forward for to the clutch packs, permitting disc slippage. FORWARD direction travel.
  • Page 60 Operation Section Service Brake Pedal Parking Brake Lever Pull the lever BACK to engage the parking Push DOWN on the brake pedal to slow or stop brake. the lift truck. Push the lever FORWARD to release the RELEASE the brake pedal to allow the lift truck parking brake.
  • Page 61 Operation Section Tilt Control Sideshift Attachment Control (If Equipped) 1. Mast Tilt Forward - Push the lever FORWARD smoothly to tilt the mast forward. 1. Sideshift Left - Push the lever FORWARD to shift the carriage to the left. 2. Mast Hold - When the lever is released it will return to the HOLD or center position.

  • Page 62: Refueling

    Operation Section Refueling Diesel Engine Equipped WARNING Explosive fumes may be present during refueling. Do not smoke in refueling areas. Lift truck should be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors. Stop the engine and get off the lift truck during refueling.
  • Page 63 Operation Section Changing LP-Gas Tanks WARNING Only trained, authorized personnel should fill or exchange LP-Gas tanks. Personnel engaged in filling of LP-Gas containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves. Do not refuel or store LP-Gas powered lift trucks near any underground entrance, elevator shafts or any other place where LP-Gas could collect in a 2.
  • Page 64 Operation Section WARNING The LP-Gas tank must not extend past the counterweight. 12. Clamp the tank securely. 13. Connect the fuel supply line. 14. Open the fuel valve by slowly turning the valve counterclockwise. If the fuel valve is opened too quickly, a back pressure check valve will shut off the fuel supply.
  • Page 65 Operation Section Before Starting the Engine Walk-Around Inspection Make a thorough walk-around inspection before mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or coolant leaks. Check condition of tires, mast, carriage, forks or attachments.
  • Page 66 Operation Section Typical Example LP-Gas Engine Truck 13. Observe the fuel level gauge after starting the truck. Add fuel if necessary 10. Inspect the engine compartment for oil, coolant and fuel leaks. 14. In case of LPG truck, if needed, change LPG Fuel Tank as the procedure of changing LP-Gas tanks in Refueling Section.
  • Page 67 Operation Section Starting the Engine Prestart Conditions Diesel Engine Starting a Cold Diesel Engine NOTE: The engine will not start unless the transmission directional control lever is in the NEUTRAL position. 1. Turn the key to the ON position. The start preheat indicator light will come ON.
  • Page 68 Operation Section LP-Gas Engine Starting From a 12 Volt External Source WARNING WARNING LP - Gas fuel is flammable and can cause personal injury. Sparks occurring near the battery could cause vapors to explode. Inspect LP - Gas fuel lines and fitting for leaks. Always connect the external power source ground Inspect tank for secure mounting.

  • Page 69: After Starting The Engine

    Operation Section After Starting the Engine Observe all indicator lights and gauges frequently during 5. The engine coolant temperature gauge pointer operation, to make sure all systems are working (5), will be in the green band with the engine properly. All of the indicator lights will come ON with the running, unless the coolant temperature is ignition switch in the ON position before the engine is excessive.
  • Page 70 Operation Section G643E Electronic Controlled LP Engines (If Equipped) General Description The MI-04 is a closed loop system utilizing a catalytic engine control module (SECM) uses a heated exhaust muffler to reduce the emission level in the exhaust gas. gas oxygen sensor (HEGO) in the exhaust system to In order to obtain maximum effect from the catalyst, an monitor exhaust gas content.
  • Page 71 Operation Section Basic Troubleshooting Below are basic checks that should be made before referring to the Advanced Diagnostics section, if engine The MI-04 systems are equipped with built-in fault or drivability problems are encountered. diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) and are covered in Locating a problem in a propane engine is done exactly the Advanced Diagnostics section.
  • Page 72 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 Reset excess flow valve...
  • Page 73 Operation Section Problem Probable Cause Corrective Action Will Not Run 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”...
  • Page 74 Operation Section Problem Probable Cause Corrective Action Will Not Clogged fuel filter Repair/replace as required Accelerate/Hesitatio n During See Maintenance Section, LP Fuel Acceleration Filter replacement Faulty vapor connection between Check connection the pressure regulator/converter and Verify no holes in hose the mixer Clamps must be tight Look for kinked, pinched and/or...
  • Page 75 Operation Section Problem Probable Cause Corrective Action Engine Stalls Fuel Lock-off malfunction Repair/replace Fuel Lock-off See G643E Engine Service Manual Faulty vapor connection between Check connection the pressure regulator/converter and Verify no holes in hose the mixer Clamps must be tight Look for kinked, pinched and/or collapsed hose Pressure regulator freezes...
  • Page 76 Operation Section Problem Probable Cause Corrective Action Rough Idle Incorrect Idle speed control See Advanced Diagnostics & See G643E Engine Service Manual Incorrect timing or spark control Engine Mechanical See Engine Service Manual High Idle Speed Incorrect Idle speed control See Advanced Diagnostics &...
  • Page 77 Operation Section Problem Probable Cause Corrective Action Excessive Fuel Air/Fuel Mixer malfunction Check mixer Consumption/LPG Exhaust Smell See G643E Engine Service Manual Air filter clogged Check air filter Clean/replace as required Vacuum leak Check system vacuum hoses from regulator to FTV and mixer Repair/replace as necessary Pressure regulator malfunction/fuel...
  • Page 78 Operation Section Reading Diagnostic Fault Codes Advanced Diagnostics All MI-04 fault codes are two digit codes. When the fault Advanced Diagnostics codes are retrieved (displayed) the MIL will flash for The MI-04 systems are equipped with built-in fault each digit with a short pause (.5 seconds) between diagnostics.
  • Page 79 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 80 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check NONE None, used as a beginning and end of NONE the fault list identification Signifies the end of one pass through the fault list Stored Fault Code Check ECT sensor connector and ECTSensorInputLow...
  • Page 81 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Engine Shutdown Check for debris or obstructions inside ETCSticking the throttle body Throttle plate sticking inside the throttle body or the ETC driver Check throttle-plate shaft for bearing signal is open wear...
  • Page 82 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Disable Throttle Check TMAP connector and MAP MapSensorInputHigh signal wiring for a shorted circuit TMAP sensor failure or shorted circuit Stored Fault Code Check TMAP connector and IAT IATSensorInputLow signal wiring for a shorted circuit...
  • Page 83 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Stored Fault Code Check battery voltage BatterySensorInputLow Battery voltage measured below (MIL Only) Perform maintenance check electrical connections to the battery +8.0 VDC and chassis ground Check battery voltage during starting and with the engine...
  • Page 84 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Engine Shutdown Measure transducer power at the XDRPSensorInputHigh TMAP connector with a multimeter +5VDC Transducer power supplied by the SECM to the sensors is Verify transducer power at the SECM above +5.20VDC with a multimeter...
  • Page 85 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check MIN power Limit Check foot pedal connector Pedal2SensorInputLo APP2 sensor failure or shorted circuit MIN power Limit Check foot pedal connector Pedal2SensorInputHi APP2 signal disconnected, open circuit or sensor malfunction (Expected faults...
  • Page 86 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Stored Fault Code Engine measured Air/Fuel ratio at the AFRTrimValveLowerDC O2 sensor is excessively lean. FTV duty cycle at lower (lean) limit (MIL, Disable Adaptive learns) If LP-Gas fuel in LP tank is not enough, this fault code can be set.
  • Page 87 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Stored Fault Code Note : If LP-Gas fuel in LP tank is not O2SensorSwitching enough, this fault code can be set. If O2 sensor is not switching across (MIL, Disable Adaptive LP tank is frozen, this fault code can the reference AFR voltage...

  • Page 88: Lift Truck Operation

    Operation Section Lift Truck Operation Power Shift Transaxle 1. Start the engine. See topic “Starting the Engine.” 5. Release the service brake. 6. Push down on the accelerator pedal to obtain the desired travel speed. Release the pedal to decrease 2.
  • Page 89 Operation Section 7. To change the lift truck direction of travel, release 11. To stop the lift truck when traveling in either the accelerator pedal. direction, release the accelerator pedal. 8. Push down on the service brake pedal to reduce the 12.

  • Page 90: Auto Shift Controller Asc - 200 (If Equipped)

    Operation Section Auto Shift Controller ASC - 200 (If Equipped) Product Description Adjustments The Autoshift controller is an electrical control system, specially designed for use on forklift trucks with internal ( Low-High Shift Point ) ( Direction Inhibit Point ) combustion engines.
  • Page 91 Operation Section Diagnostics Features Display for Troubleshooting Display Description Remark Automatic operation High speed s/w input Lever input test Forward s/w input Lever input test Reverse s/w input Lever input test This information is input for signal diagnostics. This test is used to verify operation of direction control lever.
  • Page 92 Operation Section Manual Mode (Fail-Safe mode) In case that the controller is broken down or you don’t WARNING want to use the functions of the Auto Shift Controller, you can select Manual Mode. In Manual Mode, you can When you want to change the travel direction, you operate your lift truck in the same manner as any lift must press down on the service brake pedal to truck without Auto Shift Controller.

  • Page 93: 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. Typical Example 1. Move the lift truck slowly FORWARD into position Typical Example and engage the load. The lift truck should be square with load, forks spaced evenly between pallet 2.
  • Page 94 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. Travel with the load uphill on upgrades and downgrades.
  • Page 95 Operation Section Turning Typical Example 1. When turning sharp corners, keep close to the 3. Deposit the load and BACK away carefully to inside corner. Begin the turn when the inside drive disengage the forks. wheel meets the corner. Typical Example 2.
  • Page 96 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 overheating. Clean them out regularly with a blast of compressed air, also, check for leakage of water.

  • Page 97: 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 98: 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 99: Storage Information

    Operation Section Storage Information Before Storage To Operate the Lift Truck After a Long Time Storage Before storing your lift truck, clean and inspect as the following procedures. Remove covers and antirust from each of the components and exposed parts. Wipe away grease, oil, etc.

  • Page 100: Transportation Hints

    Operation Section Transportation Hints Lift Truck Shipping Machine Lifting and Tiedown Information Check travel route for overpass clearances. Make sure there is adequate clearance if the lift truck being transported is equipped with a high mast, overhead guard or cab. NOTICE Improper lifting or tiedowns can allow load to shift and To prevent the lift truck from slipping while loading, or...

  • Page 101: Towing Information

    Operation Section Towing Information The different situation requirements cannot be given as WARNING minimal towing lift truck capacity is required on smooth level surfaces to maximum on inclines or poor surface Personal injury or death could result when towing a conditions.

  • Page 102: Maintenance Section

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for Users may also refer to the International Organization inspection, maintenance and repair of lift truck forks. It For Standardization - ISO Technical Report 5057 - also provides general information on the design and Inspection and Repair of Fork Arms and ISO Standard application of forks and the common cause of fork...
  • Page 103 Maintenance Section Causes of Fork Failure Repetitive Overloading Repetitive cycling of loads which exceeds the fatigue Improper Modification or Repair strength of the material can lead to fatigue failure. The overload could be caused by loads in excess of the Fork failure can occur as a result of a field modification rated fork capacity and by use of the forks tips as pry involving welding, flame cutting or other similar...
  • Page 104 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 105 Maintenance Section 12 Months Inspection Check the fork arm before and after the second application of the test load. It shall not show any Forks should be inspected, at a minimum, every 12 permanent deformation. months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six Consult the fork manufacturer for further information as months.

  • Page 106: Tire Inflation Information

    Maintenance Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures. Shipping Ply Rating or Size Pressure Strength Index 7.00X12 Steer 8.25X15 Drive 300X15 Drive 7.50X16 Drive dual Standard tire, ply rating and inflation pressures.

  • Page 107: Torque Specifications

    Maintenance Section Torque Specifications Metric Hardware Torque for Standard Bolts, Nuts, and Taperlock Studs Most of the nuts, bolts, studs, and threaded holes in your lift truck are metric. In this manual we provide specifications in both metric and U.S. customary measurement.
  • Page 108 Maintenance Section Torques for Taperlock Studs Torque for Metric Fasteners Standard Taperlock Stud Torque Thread Size NOTICE 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 or 8 ±...

  • Page 109: Cooling System Specifications

    Maintenance Section Cooling System Specifications Coolant Information Filling at over 20 liters (5 U.S. gallons) per minute can cause air pockets in the cooling system. NOTE: The following information is generic and valid for lift trucks. After draining and refilling the cooling system, operate the engine with the radiator cap removed until the Engine operating temperatures have increased to coolant reaches normal operating temperature and the...
  • Page 110 Maintenance Section Coolant Water Antifreeze Hard water, or water with high levels of calcium and magnesium ions, encourages the formation of insoluble NOTICE chemical compounds by combining with cooling system additives such as silicates and phosphates. DOOSAN recommends using automotive antifreeze suitable for gasoline engines having aluminum alloy The tendency of silicates and phosphates to precipitate parts.

  • Page 111: Fuel Specifications

    Maintenance Section Fuel Specifications General Fuel Information Use only fuel as recommended in this section. PREFERRED DISTILLATE FUEL FOR DISEL ENGINES Specifications Requirements* Aromatics (AST D1319) 35% Max. NOTICE Ash (ASTM D482) 0.02% Weight Max. Fill the fuel tank at the end of each day of operation Cetane Number 35 Min.
  • Page 112 Maintenance Section LP-Gas Specifications DOOSAN recommends infrared analysis (in conjunction with wear metal analysis) of used oil in determining the LP-Gas is “Liquefied Petroleum Gas”. The exact effectiveness of oil TBN and acid neutralization. composition of LP-Gas varies slightly between different parts of the country and different refineries.

  • Page 113: Lubricant Specifications

    Maintenance Section Lubricant Specifications Lubricant Information Hydraulic Oil (HYDO) Certain abbreviations follow Society of Automotive The following commercial classifications can be used in Engineers (SAE) J754 nomenclature and some the hydraulic system. classifications follow SAE J183 abbreviations. ISO 6743/4 The MIL specifications are U.S.A. Military Specifications. AFNOR NFE 48-603 DIN 51524 TEIL 2 H-LP...
  • Page 114 Maintenance Section Transmission Oil (TDTO) Drive Axle Oil NOTE: Failure to follow the recommendation will cause shortened life due to excessive gear wear. NOTICE Shoe Brake This oil is formulated for transmissions and drive Select oil that meets below specifications. trains only, and should not be used in engines.
  • Page 115 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 temperatures. Use NLGI No.1 or No.0 grade for extremely low temperature.

  • Page 116: 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 U.S. Compartment or System Liters or System Viscosities Min Max Min Max Gal. Engine Crankcase Engine -20 +40 -4 +104 w/Filter LP-Gas 10W30 Crankcase...
  • Page 117 Maintenance Section Every 250 Service Hours or Monthly Maintenance Intervals Air Intake System - Check, Clean ......136 Hydraulic Oil Level - Check ......... 139 Drive Axle Oil Level - Check........139 Mast, Carriage, Lift Chains, & Attachments - Check, NOTICE Lubricate.................
  • Page 118 Maintenance Section Every 1500 Service Hours or 9 Months Drive Axle Oil (Shoe Brake Only) - Check, Clean, Change................156 Inspect Ignition System (LP-Gas Engine Only)..156 Replace Spark Plugs (LP-Gas Engine Only).... 156 Replace LP Fuel Filter Element (LP-Gas Engine Only) ..................
  • Page 119 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Air Breather Change Air Cleaner Indicator Check Air Intake System Check, Clean Air Intake System Change Battery Terminal Clean, Inspect Belts(Diesel E/G Only) Check, Adjust Carburetor(LP-Gas E/G Only) Adjust, Clean Carriage Roller Extrusion Adjust, Check...

  • Page 120: 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 Engine Water Separator (Diesel Engine Only) Only) - Check, Adjust - Drain The water separator acts as a water trap to separate the water from the diesel fuel.

  • Page 121: Test Fuel System For Leaks (Lp Engine Only)

    Maintenance Section Test Fuel System for Leaks (LP Engine Only) 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 122: Priming The Fuel System (Diesel Engine Only)

    Maintenance Section Priming the Fuel System (Diesel Seat, Hood Latch & Support Cylinder Engine Only) - Check, Lubricate Bleeding the Fuel System After changing the fuel filter, or after having serviced any part of the fuel system, make sure that the air is bled from the system.

  • Page 123: Fuses, Bulbs & Circuit Breaker - Change, Reset

    Maintenance Section 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. NOTICE Always replace fuses with ones of the correct ampere rating.

  • Page 124: Fuse Relay ( G643E Only)

    Maintenance Section Bulbs Bulbs are identified as follows: [ Diesel Engine ] 1. Bulb - head lamp halogen (24V - 55W) *2. Bulb - back up (24V - 10W) *3. Bulb - turn signal (24V - 25W) *4. Bulb - stop & tail (24V - 25/10W) [ LP Gas Engine ] 1.

  • Page 125: Tires And Wheels - Check, Inspect

    Maintenance Section Tires and Wheels - Check, Inspect Circuit Breaker WARNING Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious physical injury or death.

  • Page 126: Carriage Roller Extrusion - Check, Adjust

    Maintenance Section Carriage Roller Extrusion - Check, Adjust WARNING 1. Set the mast vertical. Deflate tire before removing wheel nuts from the 2. Lower the carriage completely. truck. 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 127: 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. Inspect Engine for Fluid Leaks Coolant Level - Check, Clean Check Coolant Level 1.

  • Page 128: Air Cleaner Indicator - Check

    Maintenance Section Typical Example LP-Gas Engine Truck 3. Start and run the engine to stabilize the coolant level in the filter neck. If low add coolant until it reaches the top of the filter neck. Install the radiator cap. 1. Observe the air cleaner service indicator. Observe coolant level in the expansion bottle.

  • Page 129: Walk - Around Inspection - Inspect

    Maintenance Section Walk - Around Inspection - Inspect For maximum service life of the lift truck, make a thorough walk-around inspection. Look around and under the truck for such items as loose or missing bolts, debris or dirt buildup, fuel, oil or coolant leaks and cut gouged tires.

  • Page 130: Mast Channels - Lubricate

    Maintenance Section Transmission Oil Level - Check 10. Inspect the forks. Visually inspect forks for cracks, especially in the WARNING heel section, around the mounting brackets, and all weld areas. Hot oil and components can cause personal injury. Inspect for broken or jagged fork tips, bent or Do not allow hot oil or components to contact skin.

  • Page 131: 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 & Filter (Diesel Engine Only) –...

  • Page 132: Transmission Oil, Oil Filter & Strainer - Clean, Change

    Maintenance Section Transmission Oil, Oil Filter & Strainer - Clean, 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, parking brake engaged, transmission in NEUTRAL and the engine stopped.
  • Page 133 Maintenance Section 9. Start the engine. 4. Remove and discard the oil filter. Wipe off the filter base. Make sure all of the old seal is removed. 10. With the service brake applied and engine at low idle, shift the transmission to forward and reverse to 5.

  • Page 134: Drive Axle Oil - Check, Clean, Change

    Maintenance Section Drive Axle Oil - Check, Clean, 3. Allow the oil to drain completely out. Discard the oil according to local regulations. Change 4. Clean and reinstall the drain plug. Park the lift truck on a level surface, parking brake applied, transmission in neutral.

  • Page 135: Parking Brake - Test, Adjust

    Maintenance Section Parking Brake - Test, Adjust NOTE: Be sure area around the lift truck is clear of personnel and obstructions. 1. Drive the lift truck with a capacity load, forward up a 15% incline [a slope that increases 1.5 meters in 10 meters (1.5 ft increase in 10 ft)].
  • Page 136 Maintenance Section To Adjust Park the lift truck level, with the forks lowered, transmission in NEUTRAL, the engine stopped and the wheels securely blocked. 1. Release the parking brake. 2. Turn the adjustment knob, clockwise to tighten the brake. 3. Test the parking brake adjustment. Repeat the adjustment procedure, if necessary.

  • Page 137: 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 3. Install new filter assembly in the hydraulic tank cover.

  • Page 138: 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. Air Intake System - Check, Clean Precleaner (If Equipped) Servicing Filter Element NOTICE NOTICE...
  • Page 139 Maintenance Section 6. Reset the air cleaner service indicator. 7. Install the air filter element. 8. Install the cover and tighten the cover latches. 9. 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 140 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 141: 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 Hot oil and components can cause personal injury. and under pressure. Do not allow hot oil or components to contact skin. Hot oil can cause burns.

  • Page 142: Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate

    Maintenance Section Mast, Carriage, Lift Chains, & Attachments - Check, 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 143: Carriage Side Rollers - Lubricate

    Maintenance Section Steering Mechanism - Check, Lubricate 7. In case of Full Free Lift Mast, Extend the primary cylinder to full length and then check the clearance and over lapped dimension between carriage stopper bolt or block (1) and Inner mast stopper 1.

  • Page 144: Battery Terminal - Clean, Inspect

    Maintenance Section Battery Terminal - Clean, Inspect Engine Oil & Filter – Change TIER I Diesel Engine(DB58) WARNING See topic, “Engine Oil & Filter (Diesel Engine Only) - Change” in “First 50-100 Service Hours”. Batteries give off flammable fumes that can explode. LP-Gas Engine Crankcase Do not smoke when observing the battery electrolyte levels.

  • Page 145: Wheel Bolts And Nuts - Inspect

    Maintenance Section Wheel Bolts and Nuts - Inspect 8. Install the new filter element. When the gasket contacts the base, tighten it 3/4 of a turn more. Do Inspect Tightness not overtighten. 9. Raise the lift truck, remove the blocking and lower the lift truck.

  • Page 146: 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 Engine Only) - Check, Adjust 1.

  • Page 147: Tilt Cylinders - Check, Adjust, Lubricate

    Maintenance Section Cylinder Rod Extension Tilt Cylinders - Check, Adjust, Lubricate Chassis Pivot Eyebolts 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 148: Crosshead Rollers - Inspect

    Maintenance Section Crosshead Rollers - Inspect 1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make sure the chain is tracking over the rollers properly. 2. Lubricate 2 side thrust roller fittings, one on each side of the mast.

  • Page 149: Parking Brake - Test, Adjust

    Maintenance Section Parking Brake - Test, Adjust Drive Axle Oil & Strainer (OCDB Only) - Check, Clean, Change See topic, “Parking Brake - Test, Adjust” in “First 50-100 Service Hours.” WARNING Circulation Pump Belt (OCDB & LP- Gas Engine Only) - Check, Adjust Hot oil and components can cause personal injury.

  • Page 150: Engine Oil & Filter - Change

    Maintenance Section Horn & Lights (If Equipped) – Check 6. Remove the dip stick/filter cap. Fill the drive axle housing with oil. See “Lubricant Specification - Drive 1. Press horn button, to determine if horn is Axle Oil” and “Refill Capacity”. operational.

  • Page 151: Fuel Trim Valve(Ftv) Inspection (G643E Engine Only)

    Maintenance Section Fuel Trim Valve(FTV) Inspection Overhead Guard – Inspect (G643E Engine only) 1. Visually inspect the Fuel trim valve(3) for abrasions or cracking. Replace as necessary. 2. To ensure the valve is not leaking a blow-by test can be performed. 3.

  • Page 152: 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. Carburetor (LP - Gas Engine Only) - Fuel Filters - Change Adjust, Clean Diesel Engine...

  • Page 153: Air Intake System - Change

    Maintenance Section Air Intake System - Change Inspect Coolant Hoses (LP Engines Only) Changing Primary Element 1. Visually inspect coolant hoses and clamps. See topic, “Air Intake System - Check, Clean” in “Every Remember to check the two coolant lines that 250 Service Hours or Monthly”.

  • Page 154: Fuel Lines & Fittings - Check

    Maintenance Section Fuel Lines & Fittings - Check Hydraulic Return Filter - Change Visually inspect fuel lines and fittings for physical See topic “Hydraulic Return Filter - Change” in “First 250 damage. Replace as required. Service Hours or a Month”. Inspect Mixer Assembly (G643E Air Breather - Change Engine Only)

  • Page 155: Lift Chains - Test, Check, Adjust

    Maintenance Section Check for Equal Tension Lift Chains - Test, Check, Adjust 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 wears.
  • Page 156 Maintenance Section Carriage Chain Adjustment Mast Chain Adjustment - FF,FFT Mast Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts(1),(2). NOTE: See the previous section, “Carriage Roller Extrusion”...

  • Page 157: Universal Joint (Diesel Engine Only) - Inspect

    Maintenance Section Universal Joint (Diesel Engine Only) - Inspect 1. Inspect for loose retaining bolts. Check for worn or damaged bearings. 2. Have worn or damaged bearings replaced. Tighten the bolts if necessary. -155-...

  • Page 158: 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-Gas Engine Check, Clean, Change Only)

  • Page 159: Replace Lp Fuel Filter Element (Lp-Gas Engine Only)

    Maintenance Section Replace LP Fuel Filter Element (LP- Fuel Filter (LP - Gas Engine Only) Gas Engine Only) Disassembly Park the lift truck in an authorized refueling area with the forks lowered, parking brake applied and the transmission in Neutral. 1.

  • Page 160: Testing Fuel Lock-Off Operation (Lp-Gas Engine Only)

    Maintenance Section Testing Fuel Lock-off Operation (LP- Gas Engine Only) 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. 5.

  • Page 161: 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 162 Maintenance Section Typical Example 9. Tighten the locknut to 135 N•m (100 lb•ft), while turning wheel hub to seat the bearing. 10. Loosen the locknut. Retorque it to 50 ± 5 N•m (37 ± 4 lb•ft). Bend the lockwasher tang to secure locknut. 11.

  • Page 163: 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 164: Fork - Inspect

    Maintenance Section Fork – Inspect 3. Check the straightness of the upper face of blade (D) and the front face of shank (E) with a straight Forks should be inspected, at a minimum, every 12 edge. months. If the truck is being used in a multi-shift or The fork should be withdrawn from service if the heavy duty operation, they should be checked every six deviation from straightness exceeds 0.5 percent of...
  • Page 165 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.

  • Page 166: 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 - Check, Clean, Change WARNING Hot oil and components can cause personal injury.

  • Page 167: Inspect Battery System

    Maintenance Section Inspect Battery System Inspect for Intake Leaks (G643E Engine Only) 1. Clean battery outer surfaces with a mixture of baking soda and water. 1. Visually inspect the intake manifold, throttle assembly (11), and manifold adapters (6), for 2. Inspect battery outer surfaces for damage and looseness and leaks.

  • Page 168: Every 4500 Service Hours Or Two Years

    Maintenance Section Every 4500 Service Hours or two Years Replace Oxygen Sensor (G643E Engine Only) 1. Stop engine and wait until the exhaust pipe and exhaust pipe is cooled. 2. Disconnect the electrical connector of oxygen sensor 3. Remove oxygen sensor 4.

  • Page 169: Index

    Index Section Index Check for Equal Tension .........153 Check Inflation and Damage ......123 12 Months Inspection........103 Checking Element .........138 Checking Service Indicator.......126 Checking the TMAP Sensor (G643E Engine Only) ...165 Circuit Breaker..........55 Accelerator Pedal ...........58 Circulation Pump Belt (OCDB & LP-Gas Engine Only) - Adjustments ..........88 Check, Adjust ..........147 Advanced Diagnostics........76...
  • Page 170 Index Section Adjust............118 Hydraulic Oil (HYDO)........111 Environment Management ........3 Hydraulic Oil Level - Check......139 Environment Protection........100 Hydraulic Return Filter - Change ....135,152 Every 10 Service Hours or Daily......125 Identification, Lift Capacity and Attachment Plate ... 49 Every 1000 Service Hours or 6 Months ....
  • Page 171 Index Section LPG/GAS (12V) ..........67 LP-Gas Engine ..........66 Parking brake..........9 LP-Gas Engine Crankcase ......142 Parking Brake - Test, Adjust ...... 133,147 LP-Gas Specifications ........110 Parking Brake Lever ........58 Lubricant Information ........111 Parking the Lift Truck ........95 Lubricant Specifications........
  • Page 172 Index Section Wheel Bolts and Nuts - Inspect......143 When Required ........115,118 Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Will Not Run Continuously......... 71 ........78,79,80,81,82,83,84,85 Table of Contents ..........1 Test Fuel System for Leaks (LP Engine Only) ..119 Testing Fuel Lock-off Operation (LP-Gas Engine Only) ...............

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