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Doosan D40S-5 Operation & Maintenance Manual

Doosan D40S-5 Operation & Maintenance Manual

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SB2355E01

Operation &

Maintenance Manual

LIFT TRUCKS

D35S-5, D40S-5, D45S-5, D50C-5, D55C-5

G35S-5, G40S-5, G45S-5, G50C-5, G55C-5

D40SC-5, D45SC-5, D50SC-5, D55SC-5

G40SC-5, G45SC-5, G50SC-5, G55SC-5

0705

https://www.forkliftpdfmanuals.com/

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March 6, 2025

Где у Автопогрузчика DOOSAN D50SC-5 находиться серий номер

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Summary of Contents for Doosan D40S-5

Page 1 SB2355E01 Operation & Maintenance Manual LIFT TRUCKS D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 G35S-5, G40S-5, G45S-5, G50C-5, G55C-5 D40SC-5, D45SC-5, D50SC-5, D55SC-5 G40SC-5, G45SC-5, G50SC-5, G55SC-5 0705 https://www.forkliftpdfmanuals.com/...
Page 2 https://www.forkliftpdfmanuals.com/...
Page 3: Table Of Contents
Table of Contents Table of Contents Information Section Maintenance Section Inspection, Maintenance and Repair of Lift Truck Foreword ..............2 Forks ............... 123 Tire Inflation Information........127 Safety Section Torque Specifications ..........128 Cooling System Specifications......130 Important Safety Information ........4 Fuel Specifications..........
Page 4: Information Section
The DOOSAN operator restraint system can minimize Whenever a question arises regarding your lift truck, or injuries. The DOOSAN operator restraint system keeps this publication, please consult your DOOSAN dealer for the operator substantially within the confines of the the latest available information.
Page 5 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 is ISO 14001 certified which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by internal and external inspection entities.
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
Training Required to Operate or Service Please refer to the Directives 89/655/EC and 89/391/EC Warning and its amendments for the safe use of DOOSAN lift trucks. The most effective method of preventing serious injury or death to the lift truck operator or others is for the lift...
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
Make sure all hydraulic controls are in the HOLD wrong repairs or the use of other than original DOOSAN position. spare parts waive any liability by DOOSAN.
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
Do not mount any item such as fire extinguishers, first aid kits and lights by welding brackets to or drilling holes in any FOPS structure. See your DOOSAN dealer for Crushing or Cutting Prevention mounting guidelines. Support equipment and attachments properly when working beneath them.
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 DOOSAN dealer for repair or replacement. combustion. Also, nitrogen helps prevent oxidation and the resulting deterioration of rubber and corrosion of rim Check lines, tubes and hoses carefully. Do not use your components. bare hand to check for leaks. Use a board or cardboard to check for leaks.
Page 19: Operator Restraint System (If Equipped)
Operator Restraint System (If Equipped) Warning Signs and Labels Your DOOSAN lift truck has the following tipover warning decals. Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures.
Page 20 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 21 WARNING Your DOOSAN truck comes equipped with a 1. Grip the plate (connector) of the belt and pull the DOOSAN operator restraint system. Should it belt from the retractor. Then insert the plate into the become necessary to replace the seat for any slot of the buckle until a snap is heard.
Page 22 Safety Section WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 3. Be sure to fasten the belt across your hips, not across your abdomen. NOTE: The belt is designed to automatically adjust to your size and movement.
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 If the CG moves outside of the line on either side of the stability base, the lift truck will tip to the side. 1. Capacity/Nameplates originally attached to forklifts sold by DOOSAN shall not be WARNING removed, altered or replaced without DOOSAN's approval.
Page 25: 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 Only properly trained and authorized personnel should body outside of the operator’s compartment. Never operate forklift trucks.
Page 26 Safety Section Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the rated Do not let other people ride on the truck. capacity shown on the capacity plate. Lift trucks are designed to carry loads, not people. 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- https://www.forkliftpdfmanuals.com/...
Page 32: General Section
General Section Specifications CHARACTERISTICS Manufacture DOOSAN DOOSAN Model D35S-5 D40S-5 Capacity at rated load center 3500 4000 Load center distance Power type electric,diesel,gasoline,LP Diesel Diesel Operator type Stand-on, Driver-seated Driver-seated Driver-seated Tire type C=cushion, P=pneumatic Wheels(x=driven) number, front/rear x 2/2...
Page 33 7.00x12-12 7.00x12-14 7.00x12-14 2100 2100 2100 1153/1115 1153/1115 1153/1115 shoe/disc shoe/disc shoe/disc ratchet ratchet ratchet 24/75 24/75 24/75 DOOSAN /DB58S DOOSAN /DB58S DOOSAN /DB58S 92/2200 92/2200 92/2200 33/1600 33/1600 33/1600 4/6/5785 4/6/5785 4/6/5785 powershift powershift powershift 210/140 210/140 230/140 -31-...
Page 34 General Section Specifications CHARACTERISTICS Manufacture DOOSAN DOOSAN Model D40SC-5 D45SC-5 Capacity at rated load center 4000 4500 Load center distance Power type electric,diesel,gasoline,LP Diesel Diesel Operator type Stand-on, Driver-seated Driver-seated Driver-seated Tire type C=cushion, P=pneumatic Wheels(x=driven) number, front/rear x 2/2...
Page 35 3400 3500 6550 7050 10340/1210 11200/1350 2810/3740 2890/4160 300x15-18 300x15-18 7.50x16-12 7.50x16-12 7.00x12-12 7.00x12-14 2100 2100 1153/1115 1153/1115 shoe/disc shoe/disc ratchet ratchet 24/75 24/75 DOOSAN /DB58S DOOSAN /DB58S 92/2200 92/2200 33/1600 33/1600 4/6/5785 4/6/5785 powershift powershift 210/140 210/140 -33- https://www.forkliftpdfmanuals.com/...
Page 36 General Section Specifications CHARACTERISTICS Manufacture DOOSAN DOOSAN Model G35S-5 G40S-5 Capacity at rated load center 3500 4000 Load center distance Power type electric,diesel,gasoline,LP Operator type Stand-on, Driver-seated rider-seated rider-seated Tire type C=cushion, P=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS Lift with STD...
Page 37 General Section DOOSAN DOOSAN DOOSAN G45S-5 G50C-5 G55C-5 4500 5000 5500 rider-seated rider-seated Driver-seated x 2/2 3000 3050 3050 50x150x1200 60x150x1200 60x150x1200 8/10 8/10 8/10 3265 3300 3350 1451 1451 1451 2230 2380 2380 4420 4470 4470 2230 2230 2230...
Page 38 General Section Specifications CHARACTERISTICS Manufacture DOOSAN DOOSAN Model G40SC-5 G45SC-5 Capacity at rated load center 4000 4500 Load center distance Power type electric,diesel,gasoline,LP Operator type Stand-on, Driver-seated rider-seated rider-seated Tire type C=cushion, P=pneumatic Wheels(x=driven) number, front/rear DIMENSIONS Lift with STD...
Page 39 General Section DOOSAN DOOSAN G50SC-5 G55SC-5 5000 5500 rider-seated rider-seated 3000 3050 50x150x1200 60x150x1200 8/10 8/10 3265 3300 1451 1451 2230 2380 4420 4470 2230 2230 2865 2930 19.5/20.5 19.5/20.5 500/540 490/540 480/450 490/450 3400 3400 6550 7050 10340/1210 11200/1350...
Page 40: Noise And Vibration
General Section Noise and Vibration Noise Noise Level [Unit : dB(A)] Guaranteed Sound Sound Pressure Level at Sound Pressure Level at By- Model Power Level(L Operator’s ear(Leq) stander position (AS 3713) by new directive 2000/14/EC AS3713 prEN12053 Drive-By Lifting Mode D35/40/45S-5, D40/45/50/55SC-5, W/O Cabin...
Page 41: Capacity Chart
General Section Capacity Chart -39- https://www.forkliftpdfmanuals.com/...
Page 42 General Section Capacity Chart -40- https://www.forkliftpdfmanuals.com/...
Page 43: Capacity Chart (With Side Shifter)
General Section Capacity Chart (with Side Shifter) -41- https://www.forkliftpdfmanuals.com/...
Page 44 General Section Capacity Chart (with Side Shifter) -42- https://www.forkliftpdfmanuals.com/...
Page 45 General Section Capacity Chart -43- https://www.forkliftpdfmanuals.com/...
Page 46 General Section Capacity Chart -44- https://www.forkliftpdfmanuals.com/...
Page 47 General Section Capacity Chart (with Side Shifter) -45- https://www.forkliftpdfmanuals.com/...
Page 48 General Section Capacity Chart (with Side Shifter) -46- https://www.forkliftpdfmanuals.com/...
Page 49 General Section Capacity Chart -47- https://www.forkliftpdfmanuals.com/...
Page 50 General Section Capacity Chart (with Side Shifter) -48- https://www.forkliftpdfmanuals.com/...
Page 51 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE MODEL STD, FFL DOUBLE TIRE DOUBLE TIRE STD, FFL -49- https://www.forkliftpdfmanuals.com/...
Page 52 General Section Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD, FFL DOUBLE TIRE DOUBLE TIRE STD, FFL -50- https://www.forkliftpdfmanuals.com/...
Page 53 General Section Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD, FFL DOUBLE TIRE DOUBLE TIRE STD, FFL -51- https://www.forkliftpdfmanuals.com/...
Page 54 General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE MODEL STD, FFL DOUBLE TIRE DOUBLE TIRE STD, FFL -52- https://www.forkliftpdfmanuals.com/...
Page 55: 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(G643E) •______________________________ Lift Truck Serial Number •______________________________ Transmission Serial Number •______________________________ 5.8 liter Diesel Engine(TIER II )Serial Number •______________________________ 4.3 liter GM Vortec Engine Serial Number(G643)
Page 56 General Section DRIVE AXLE Serial Number •______________________________ Side Shifter Serial Number(If Equipped) •______________________________ -54- https://www.forkliftpdfmanuals.com/...
Page 57: 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 58 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 59: 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 60 Operation Section 1. Engine Oil Pressure Indicator Light - Chack the cooling system for a malfunction. Both tenth Indicates insufficient engine oil pressure. The & ninth will flash out of phase when the coolant light will come on when the ignition switch is temperature reaches approximately 106℃(223℉) on all turned to the ON position.
Page 61 Operation Section Engine Compartment 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. Do not continue to operate the lift truck if the light is ON during operation.
Page 62 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 63: Seat Switch System (If Equipped)
The directional lever, however, will 4. If seat or seat switch replacement becomes remain in that forward or reverse location although necessary, be sure to use genuine DOOSAN internally the transmission will have shifted into Infracore lift truck parts. Lift trucks should never neutral.
Page 64: Lift Truck Controls
Operation Section Lift Truck Controls Direction Control Lever Transmission Inching Control Pedal Inching Control Pedal - Pushing down on the 1. Forward - Push the lever forward for inching pedal, modulates the hydraulic pressure FORWARD direction travel. to the clutch packs, permitting disc slippage. 2.
Page 65 Operation Section Service Brake Pedal Parking Brake Lever Push DOWN on the brake pedal to slow or stop Pull the lever BACK to engage the parking brake. the lift truck. Push the lever FORWARD to release the RELEASE the brake pedal to allow the lift truck parking brake.
Page 66 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 67: 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 68 Operation Section Changing LP Tanks WARNING Only trained, authorized personnel should fill or exchange LP tanks. Personnel engaged in filling of LP containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves. Do not refuel or store LP powered lift trucks near any underground entrance, elevator shafts or any other place where LP could collect in a pocket 2.
Page 69 Operation Section WARNING tank must extend past 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 70: Before Starting The Engine
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 71 Operation Section Typical Example LP 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 tanks in Refueling Section.
Page 72: Starting The Engine
Operation Section Starting the Engine Prestart Conditions Diesel Engine Starting a Cold Diesel Engine NOTE: The engine will start unless 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 73 : POSITIVE(+) to POSITIVE(+) and NEGATIVE(-) to 4. Allow the engine to warm up slowly. NEGATIVE(-). Attach ground cable last, remove first. All lift trucks equipped with DOOSAN built internal combustion engines are NEGATIVE(-) ground. -71- https://www.forkliftpdfmanuals.com/...
Page 74: 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 75 Operation Section Electronic Controlled Spark-Ignition Engines G643E Engine EMS (Engine management system) of G643E engine is control module (SECM) uses two heated exhaust gas a closed loop system utilizing a catalytic muffler to oxygen sensors (HEGO) in the exhaust system to reduce the emission level in the exhaust gas.
Page 76 Operation Section G643 Electronic Controlled LP Engines (If Equipped) General Description Engine speed is monitored by the SECM through a ambient temperature, fuel variations, ignition variable reluctance (VR) sensor. Intake manifold air component wear, clogged air filter, and other temperature and absolute pressure is monitored operating variables are compensated.
Page 77 Operation Section Basic Troubleshooting Below are basic checks that should be made before referring to the Advanced Diagnostics section, if engine The EMS 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 78 Operation Section Problem Probable Cause Corrective Action No VR Sensor Signal Verify the VR signal is present Engine Cranking but Will Not Start See Advanced Diagnostics 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...
Page 79 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Will Not Run 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 80 Operation Section Problem Probable Cause Corrective Action Clogged fuel filter Repair/replace as required Will Not Accelerate/Hesitation See Maintenance Section, LP Fuel Filter During Acceleration 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 collapsed...
Page 81 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 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 82 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 83 Operation Section Problem Probable Cause Corrective Action Air/Fuel Mixer malfunction Check mixer Excessive Fuel Consumption/LPG See Engine Service Manual Exhaust Smell 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 Test pressure regulator operation...
Page 84 Operation Section Mixer Idle Screw / Power Valve Adjust. (G643 Engine Only) • Forklift have Unstable Idle RPM, You can adjust idle screw. Idle Screw turn to rich side (turn in screw) • Forklift have Poor High Speed Performance, you can adjust power valve, power valve turn to rich side.
Page 85 Operation Section Reading Diagnostic Fault Codes Advanced Diagnostics (G643 Only) All MI-04 fault codes are two digit codes. When the fault MI-04 systems are equipped with built-in fault codes are retrieved (displayed) the MIL will flash for diagnostics. Detected system faults can be displayed by each digit with a short pause (0.5 seconds) between the Malfunction Indicator Lamp (MIL) as Diagnostic digits and a long pause (1.2 seconds) between fault...
Page 86 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 87 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 88 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check ETCSticking Engine Shutdown Check for debris or obstructions inside the throttle body Throttle plate sticking inside the throttle body or the ETC driver Check throttle-plate shaft for bearing signal is open wear...
Page 89 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check MapSensorInputHigh Disable Throttle Check TMAP connector and MAP signal wiring for a shorted circuit TMAP sensor failure or shorted circuit IATSensorInputLow Stored Fault Code Check TMAP connector and IAT signal wiring for a shorted circuit TMAP sensor failure or shorted...
Page 90 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check BatterySensorInputLow Stored Fault Code Check battery voltage Battery voltage measured below (MIL Only) Perform maintenance check electrical connections to the battery +8.0 VDC and chassis ground Check battery...
Page 91 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check XDRPSensorInputHigh Engine Shutdown Measure transducer power at the 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 92 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Pedal2SensorInputLo MIN power Limit Check foot pedal connector APP2 sensor failure or shorted circuit Pedal2SensorInputHi MIN power Limit Check foot pedal connector APP2 signal disconnected, open circuit or sensor malfunction (Expected faults...
Page 93 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check AFRTrimValveLowerDC Stored Fault Code Engine measured Air/Fuel ratio at the O2 sensor is excessively lean. FTV duty cycle at lower (lean) limit (MIL, Disable Adaptive learns) If LP fuel in LP tank is not enough, this (G643E only)
Page 94 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check O2SensorSwitching Stored Fault Code Note : If LP fuel in LP tank is not 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 95 Operation Section Advanced Diagnostics(G643E Only) Reading Diagnostic Fault Codes All MI-07 fault codes are three-digit codes. When the fault MI-07 systems are equipped with built-in fault diagnostics. codes are retrieved (displayed) the MIL will flash for each Detected system faults can be displayed by the Malfunction digit with a short pause (0.5 seconds) between digits and a Indicator Lamp (MIL) as Diagnostic Fault Codes (DFC) or long pause (1.2 seconds) between fault codes.
Page 96 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK NONE None, used as end of the fault list Signifies the end of one pass NONE identification through the fault list Check ECT sensor connector and wiring for a short to GND ECTRangeLow...
Page 97 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION* FIRST CHECK CrankSyncFault Check Crankshaft sensor connections Loss of synchronization on SECM (SIGNAL) Pin B5 to Crank the crankshaft sensor, sensor Pin 3 None normally due to noise on the SECM (Sensor GND) Pin B1 to Crank...
Page 98 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check the throttle connector and pins for corrosion. To check the TPS disconnect the TPS2AdaptLoMin throttle connector and measure the Learned closed throttle end None resistance from:...
Page 99 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 (signal) MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1 Manifold Absolute Pressure (sensor GND)
Page 100 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK MAPRangeHigh Check TMAP connector and MAP Manifold Absolute Pressure signal wiring for a shorted circuit Sensor Input is High, TMAP Pin 4 to SECM Pin B18 (signal) normally set if the TMAP TMAP Pin 1 to SECM Pin B1 pressure signal wire has...
Page 101 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A9 (EST1) to OEM ignition EST1_Open system. See application note. EST1 output open, possibly Verify GND on ignition module Pin A TurnOnMil...
Page 102 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK ETCSpringTest Electronic Throttle Control Spring Return Test has failed. The SECM will perform a safety test of the throttle return spring following engine shutdown.
Page 103 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check battery and charging system voltage Check battery voltage during starting and with the engine running Check voltage regulator, alternator, and charging system SysVoltRangeHigh Check battery and wiring for...
Page 104 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Usually associated with additional ETC MediumOverspeed faults (1) TurnOnMil Engine speed has exceeded Check for ETC Sticking or other ETC (2) MediumRevLimit the second level (2 of 3) of faults...
Page 105 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK APP1AdaptHiMin Learned full pedal end of None APP1 sensor range lower than expected APP2AdaptHiMin Learned full pedal end of None APP2 sensor range lower than expected APP1AdaptLoMax...
Page 106 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK LSDFault_CrankDisable Crank Disable Fault, signal has opened or shorted to None ground or power or defective crank disable relay Check fuel lock off valve for an open wire or connector being disconnected LSDFault_LockOff or signal shorted to GND...
Page 107 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check that Post-catalyst O2 sensor connections are OK. O2 (signal) Pin 3 to SECM Pin B19 O2 Pin 2 (HEATER GND) to SECM (DRVG GNG) Pins A16, B17 O2 Pin 1 (HEATER PWR) to Post O2 Heater Relay.
Page 108 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Correct other faults that may contribute to 772 (e.g. faults pertaining to FTVs, GasPostO2FailedRich (1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor) Pre-catalyst O2 sensor (2) DisableGas Look for leaks in exhaust, catalytic...
Page 109 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK FuelTempRangeLow Check fuel temp sensor connector and Fuel Temperature Sensor wiring for a short to GND Input is Low normally set if SECM (signal) Pin B14 to FTS Pin 1 the fuel temperature sensor TurnOnMil...
Page 110: 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 111 Operation Section Inching 7. To change the lift truck direction of travel, release the accelerator pedal. NOTE: The purpose of the inching pedal is to provide 8. Push down on the service brake pedal to reduce the precise lift truck inching control at very slow lift truck speed as necessary.
Page 112: Mono-Ped Control System (Option)
Operation Section Steering Knob (If Equipped) Mono-Ped Control System There is a steering knob available for inclusion with (Option) new truck deliveries. This option is solely intended for slow travel situations when two handed steering is not possible due to hydraulic operations. Forward-Push the left side (2) of the pedal for FORWARD direction travel.
Page 113: 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 114 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 115 Operation Section Manual Mode (Fail-Safe mode) WARNING In case that the controller is broken down or you don’t want to use the functions of the Auto Shift Controller, When you want to change the travel direction, you you can select Manual Mode. In Manual Mode, you can must press down on the service brake pedal to operate your lift truck in the same manner as any lift reduce the travel speed.
Page 116: 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 117 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 118 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 119 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 120: 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 121: 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 122: 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 123: Transportation Hints
Check the state and local laws governing weight, width and length of a load. NOTICE Contact your DOOSAN Lift Truck dealer for shipping Remove ice, snow or other slippery material from the instructions for your lift truck. shipping vehicle and the loading dock.
Page 124: Towing Information
Personal injury or death could result when towing a conditions. disabled lift truck incorrectly. Consult your DOOSAN Lift Tuck dealer for towing a Block the lift truck wheels to prevent movement disabled lift truck. before releasing the brakes. The lift truck can roll free if it is not blocked.
Page 125: 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 126 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 127 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 128 Maintenance Section 12 Months Inspection Consult the fork manufacturer for further information as may be applicable to the specific Forks should be inspected, at a minimum, every 12 fork involved. months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six Testing is not required for repairs to the months.
Page 129: 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 130: 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 NOTICE measurement.
Page 131 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 132: Cooling System Specifications
Cooling system problems can arise without a important as the quality of fuel and lubricating oil. thermostat. NOTICE DOOSAN recommends that the coolant mixture contain 50% commercially available automotive antifreeze, and 50% water. The coolant mix with concentration of antifreeze smaller than 30% does not provide sufficient corrosion protection.
Page 133 DOOSAN recommends that the coolant mix contain 50% commercially available automotive antifreeze, or DOOSAN prefers the use of distilled water or deionized equivalent and acceptable water to maintain and water to reduce the potential and severity of chemical adequate water pump cavitation temperature for insolubility.
Page 134: Fuel Specifications
Fuel sulfur is chemically changed Fuel Types during combustion to form both sulfurous and sulfuric DOOSAN Diesel Engines have the ability to burn a wide acid. These acids chemically attack metal surfaces and variety of fuels. These fuels are divided into two general cause corrosive wear.
Page 135 LP varies slightly between different parts of the country and different refineries. HD5 is recommended for DOOSAN forklift trucks. Remember LP 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 136: Lubricant Specifications
Drain the fluid, retighten all or excessive wear. hydraulic suction line clamps, purge and refill the system. Consult your DOOSAN Lift Truck dealer for purging instructions. Consult the EMA Lubricating Oils Data Book for a listing of oil brands.
Page 137 Select oil that meets below specifications. API GL-5 MIL-L-2105 C, D NOTE: MuIti-grade oils are not blended by DOOSAN Gear Oil offers maximum protection against the scoring for use in transmissions. Multi-grade oils which and pitting of gear teeth and rolling element bearings.
Page 138 Maintenance Section Lubricating Grease (MPGM) Brake Fluid 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 139: 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 10W30 Crankcase...
Page 140: Maintenance Intervals
Maintenance Section First 250 Service Hours or a Month Maintenance Intervals Hydraulic Return Filter - Change ......159 Every 250 Service Hours or Monthly NOTICE Air Intake System - Check, Clean......160 All maintenance and repair, except Every 10 Service Brake Oil Level - Check.........
Page 141 Maintenance Section Every 1500 Service Hours or 9 Months Drive Axle Oil (Shoe Brake Only) - Check, Clean, Change..............180 Inspect Ignition System (LP Engine Only) ....180 Replace Spark Plugs (LP Engine Only)....180 Replace LP Fuel Filter Element (LP Engine Only) .................181 Fuel Filter (LP Engine Only) ........181 Disassembly.............181...
Page 142 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Air Breather Change Air Cleaner Indicator Check Air Intake System Change Air Intake System Check, Clean Battery Terminal Clean, Inspect Belts (Diesel Engine Only) Check, Adjust Brake Oil Level Check Carriage Roller Extrusion Check, Adjust...
Page 143: Adjust
Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Hydraulic Oil Level Check Hydraulic Return Filter Change 159, 176 Inching & Brake Control shaft Lubricate Inspect Battery System Inspect Electrical System (LP Engine only) Inspect Engine for Fluid Leaks Inspect for Intake Leaks (LP Engine Only) Inspect Ignition System (LP Engine Only) Inspect Vacuum Lines and Fittings (LP...
Page 144: 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 145 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 146: 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 147: Fuses, Bulbs & Circuit Breaker - Change, Reset
Maintenance Section Fuses, Bulbs & Circuit Breaker - Diesel 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 148: Fuse & Relay (Lp Engine Only)
Maintenance Section Bulbs Circuit Breaker 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 149: Tires And Wheels - Check, Inspect
Maintenance Section Tires and Wheels - Check, Inspect WARNING WARNING Deflate tire before removing wheel nuts from the Servicing and changing tires and rims can be truck. dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while Check all components carefully and replace any servicing tires and rims, the assemblies could burst...
Page 150: Carriage Roller Extrusion - Check, Adjust
Maintenance Section Carriage Roller Extrusion - Check, Adjust 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 151: 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 152: Air Cleaner Indicator - Check
Maintenance Section Typical Example LP Engine Truck 3. Start and run the engine to stabilize the coolant level in the filter neck. If low add coolant until it reaches 1. Observe the air cleaner service indicator. the top of the filter neck. Install the radiator cap. Observe coolant level in the expansion bottle.
Page 153: 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 154: Mast Channels - Lubricate
Maintenance Section Mast Channels – Lubricate Transmission Oil Level - Check 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 155: 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 156: 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 157 Maintenance Section 12. Remove the dipstick/ filter cap. 13. Maintain the oil level between the Min and Max marks on the dipstick/filter cap. When the oil temperature is 40°C approximately, the cold side mark on the dipstick is applicable. When the oil temperature is 80°C approximately, the hot side mark on the dipstick is applicable.
Page 158: Drive Axle Oil - Check, Clean, Change
Maintenance Section Drive Axle Oil - Check, Clean, 6. Add sufficient fresh oil through the fill opening until it reaches the bottom of the oil level plug opening ③. Change See the section, “Lubricant Specification – Drive Park the lift truck on a level surface, parking brake Axle Oil”...
Page 159: Parking Brake - Test, Adjust
Maintenance Section Parking Brake - Test, Adjust Parking Brake Testing WARNING To prevent personal injury, the operator MUST be ready to use the service brake if the parking brake NOTICE is not adjusted correctly and the lift truck starts to OSHA requires the parking brake to hold the lift move.
Page 160 Maintenance Section 6. Remove the pin (3) and the cotter pin (4). Tighten the nut (6) to compress the spring (7) further and pull downward and turn the clevis (5) until the pin (3) fits into the brake lever when the lever (1) is held against the stop pin (2).
Page 161: 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 162: Every 250 Service Hours Or Monthly
Maintenance Section Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Servicing Filter Element Air Intake System - Check, Clean Precleaner (If Equipped) NOTICE Never service precleaner with the engine running.
Page 163: Brake Oil Level - Check
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 164 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 165: 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 166: 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 167: 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 168: Battery Terminal - Clean, Inspect
Maintenance Section Battery Terminal - Clean, Inspect Engine Oil & Filter – Change TIER II Diesel Engine(DB58S) WARNING See topic, “Engine Oil & Filter (Diesel Engine Only) - Change” in “First 50-100 Service Hours”. Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels.
Page 169: 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 170: 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 171: Tilt Cylinders - Check, Adjust, Lubricate
Maintenance Section Cylinder Rod Extension Tilt Cylinders - Check, Adjust, Lubricate NOTE: The following description is for forward tilt. For Chassis Pivot Eyebolts 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 172: 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 173: 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 Hot oil and components can cause personal injury. Circulation Pump Belt (OCDB & LP Do not allow hot oil or components to contact skin.
Page 174: Inching & Brake Control Shaft - Lubricate
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 175: 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 176: 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. Fuel Filters - Change Air Intake System - Change Diesel Engine Changing Primary Element See topic, “Air Intake System - Check, Clean”...
Page 177: Fuel Lines & Fittings - Check
Maintenance Section Inspect Coolant Hoses (LP Engines Only) Fuel Lines & Fittings - Check 1. Visually inspect coolant hoses and clamps. Visually inspect fuel lines and fittings for physical Remember to check the two coolant lines that damage. Replace as required. connect to the pressure regulator/converter.
Page 178: Hydraulic Return Filter - Change
Maintenance Section Hydraulic Return Filter - Change Lift Chains - Test, Check, Adjust Lift Chain Wear Test See topic “Hydraulic Return Filter - Change” in “First 250 Service Hours or a Month”. Inspect the part of the chain that is normally operated over the cross head roller.
Page 179 Maintenance Section Check for Equal Tension Typical example Lift the carriage and the mast high enough for getting tension on lift chains. Check the chains, and make sure the tension is the same. Lift chains are required to check for equal tension about every 1,000 service hours or 6 months.
Page 180 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 181: Universal Joint - Inspect
Maintenance Section Universal Joint - 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. -179- https://www.forkliftpdfmanuals.com/...
Page 182: Every 1500 Service Hours Or 9 Months
Maintenance Section Every 1500 Service Hours or 9 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Drive Axle Oil (Shoe Brake Only) - Replace Spark Plugs (LP Engine Check, Clean, Change Only)
Page 183: Replace Lp Fuel Filter Element (Lp Engine Only)
Maintenance Section Replace LP Fuel Filter Element (LP Fuel Filter (LP Engine Only) 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. Close the fuel shutoff valve on the LP-Fuel tank. Run the engine until the fuel in the system runs out and the engine stops.
Page 184: Testing Fuel Lock-Off Operation (Lp Engine Only)
Maintenance Section Testing Fuel Lock-off Operation (LP 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 185: 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 4. Remove the castle nut and washer. 5.
Page 186: Cooling System - Clean, Change
Maintenance Section Cooling System - Clean, Change 4. Close radiator drain valve and install block drain plug. Fill the cooling system with 1 kg (2 lb) sodium bisulphate per 40 liters (10 gallons) of water. Most WARNING commercial cooling system cleaners can be used. 5.
Page 187: Fork - Inspect
3 percent of blade length (L). Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer for further information. 2. Check the angle between the upper face of the blade and the front face of the shank.
Page 188 Maintenance Section 8. Check fork markings (N) for legibility. Renew 5. Check the fork blade (J) and shank (H) for wear with markings as required to retain legibility. special attention to the heel (G). The fork should be withdrawn from service if the thickness is reduced to 9.
Page 189: 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 Inspect Battery System 1.
Page 190: Checking The Tmap Sensor (Lp Engine Only)
Maintenance Section Checking the TMAP Sensor (LP Replace Oxygen Sensor (G643E Engine Only) Engine Only) 1. Verify that the TMAP sensor (2) is mounted tightly into the manifold adapter (3), with no leakage. 2. If the TMAP is found to be loose, remove the TMAP retaining screw and the TMAP sensor from the manifold adapter.
Page 191: Index
Index Section Changing Primary Element ........174 Index Changing Secondary Element ......174 Chassis Pivot Eyebolts .......... 169 Check Coolant Level..........149 Check for Equal Tension ........177 Check Inflation and Damage......... 147 12 Months Inspection ..........126 Checking Element..........162 Checking Service Indicator........
Page 192 Index Section Engine Valve Lash (Diesel Engine Only) - Check, Hydraulic Oil Level - Check ........163 Adjust...............142 Hydraulic Return Filter - Change ....159,177 Environment Management.........3 Environment Protection..........123 Every 10 Service Hours or Daily ......149 Every 1000 Service Hours or 6 Months ....174 Identification, Lift Capacity and Attachment Plate ...
Page 193 Index Section LP Specifications ............133 LPG (12V) ..............72 Lubricant Information..........134 Parking Brake - Test, Adjust......157,172 Lubricant Specifications .........134 Parking Brake Adjusting ........157 Lubricant Viscosities and Refill Capacities...137 Parking Brake Lever ..........63 Lubricant Viscosities..........137 Parking Brake Testing ........... 157 Lubricating Grease (MPGM)........136 Parking brake .............
Page 194 Index Section Test Fuel System for Leaks (LP Engine Only) ..143 Walk-Around Inspection........... 68 Testing Fuel Lock-off Operation (LP Engine Only) Walk - Around Inspection - Inspect....... 151 .................182 Warning Signs and Labels........5,17 TIER II Diesel Engine (DB58S) Only ....172 Water-280 kPa (40 psi) Maximum Pressure ..
Page 195 SB2357E00 Operation & Maintenance Manual LIFT TRUCKS GC35S-5, GC40S-5, GC45S-5 GC50C-5, GC55C-5 0706 https://www.forkliftpdfmanuals.com/...
Page 196 https://www.forkliftpdfmanuals.com/...
Page 197 Table of Contents Table of Contents Information Section Maintenance Section Foreword ..............2 Inspection, Maintenance and Repair of Lift Truck Forks ................. 93 Tire Inflation Information.......... 97 Safety Section Torque Specifications ..........98 Cooling System Specifications......100 Important Safety Information ........4 Fuel Specifications..........
Page 198: Information Section
The DOOSAN operator restraint system can minimize Whenever a question arises regarding your lift truck, or injuries. The DOOSAN operator restraint system keeps this publication, please consult your DOOSAN dealer for the operator substantially within the confines of the the latest available information.
Page 199 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 is ISO 14001 certified which is harmonized with ISO 9001. Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by internal and external inspection entities.
Page 200: 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 201: Safety
Training Required to Operate or Service Please refer to the Directives 89/655/EC and 89/391/EC Warning and its amendments for the safe use of DOOSAN lift trucks. The most effective method of preventing serious injury or death to the lift truck operator or others is for the lift...
Page 202 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 203 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 204 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 205 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 206: 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 207: Operation Information
Make sure all hydraulic controls are in the HOLD wrong repairs or the use of other than original DOOSAN position. spare parts waive any liability by DOOSAN.
Page 208 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 209 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 210: Maintenance Information
Do not mount any item such as fire extinguishers, first aid kits and lights by welding brackets to or drilling holes in any FOPS structure. See your DOOSAN dealer for Crushing or Cutting Prevention mounting guidelines. Support equipment and attachments properly when working beneath them.
Page 211 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 212 DOOSAN dealer for repair or replacement. combustion. Also, nitrogen helps prevent oxidation and the resulting deterioration of rubber and corrosion of rim Check lines, tubes and hoses carefully. Do not use your components. bare hand to check for leaks. Use a board or cardboard to check for leaks.
Page 213: Operator Restraint System (If Equipped)
Operator Restraint System (If Equipped) Warning Signs and Labels Your DOOSAN lift truck has the following tipover warning decals. Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures.
Page 214: If Optional Suspension Seat (Weight Adjusting Type) Equipped
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 215 WARNING Your DOOSAN truck comes equipped with a 1. Grip the plate (connector) of the belt and pull the DOOSAN operator restraint system. Should it belt from the retractor. Then insert the plate into the become necessary to replace the seat for any slot of the buckle until a snap is heard.
Page 216 Safety Section WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 3. Be sure to fasten the belt across your hips, not across your abdomen. NOTE: The belt is designed to automatically adjust to your size and movement.
Page 217: 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 218 If the CG moves outside of the line on either side of the stability base, the lift truck will tip to the side. 1. Capacity/Nameplates originally attached to forklifts sold by DOOSAN shall not be WARNING removed, altered or replaced without DOOSAN's approval.
Page 219: 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 Only properly trained and authorized personnel should body outside of the operator’s compartment. Never operate forklift trucks.
Page 220 Safety Section Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the rated Do not let other people ride on the truck. capacity shown on the capacity plate. Lift trucks are designed to carry loads, not people. Do not add extra counterweight to the truck.
Page 221 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 222 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 223 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 224: 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 225 Safety Section Lean away from the direction of fall. Lean forward. -29- https://www.forkliftpdfmanuals.com/...
Page 226: General Section
General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN MODEL GC35S-5 GC40S-5 CAPACITY at rated load center 3500 4000 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS...
Page 227 General Section DOOSAN DOOSAN DOOSAN GC45S-5 GC50C-5 GC55C-5 4500 5000 5500 rider-seated rider-seated rider-seated 3000 2750 2750 50x150x1220 50x150x1220 50x150x1220 2882 2947 2988 1420 1420 1420 2195 2195 2195 4315 4065 4065 2155 2155 2155 1080 1080 1080 2530 2580...
Page 228: Noise And Vibration
General Section Noise and Vibration Noise Noise Level [Unit : dB(A)] Guaranteed Sound Sound Pressure Level at Sound Pressure Level at By- Model Power Level(L Operator’s ear(Leq) stander position (AS 3713) by new directive 2000/14/EC AS3713 prEN12053 Drive-By Lifting Mode GC35/40/45S-5, GC50/55C-5 81.5...
Page 229: Capacity Chart
General Section Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD, FFL -33- https://www.forkliftpdfmanuals.com/...
Page 230: Capacity Chart (With Side Shifter)
General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE MODEL STD, FFL -34- https://www.forkliftpdfmanuals.com/...
Page 231: Capacity Chart
General Section Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD, FFL -35- https://www.forkliftpdfmanuals.com/...
Page 232: Capacity Chart (With Side Shifter)
General Section Capacity Chart (with Side Shifter) SINGLE TIRE SINGLE TIRE MODEL STD, FFL -36- https://www.forkliftpdfmanuals.com/...
Page 233: 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. DRIVE AXLE Serial Number •______________________________ Lift Truck Serial Number •______________________________ Side Shifter Serial Number(If Equipped) •______________________________ 4.3 liter GM Vortec Engine Serial Number(G643E) •______________________________ Transmission Serial Number •______________________________...
Page 234: 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 235 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 236: 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 237 Operation Section 1. Engine Oil Pressure Indicator Light - Chack the cooling system for a malfunction. Both tenth Indicates insufficient engine oil pressure. The & ninth will flash out of phase when the coolant light will come on when the ignition switch is temperature reaches approximately 106℃(223℉) on all turned to the ON position.
Page 238 Operation Section Engine Compartment 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. Do not continue to operate the lift truck if the light is ON during operation.
Page 239 Operation Section Circuit Breaker Electrical Disconnect Switch (If Equipped) Typical Example LP Engine Truck 1. ON-Connects the battery for electrical power to all Circuit Breaker - Protects the main electrical circuits. To reset the circuit breaker, push the electrical circuits. button in.
Page 240: Seat Switch System (If Equipped)
The directional lever, however, will 4. If seat or seat switch replacement becomes remain in that forward or reverse location although necessary, be sure to use genuine DOOSAN internally the transmission will have shifted into Infracore lift truck parts. Lift trucks should never neutral.
Page 241: Lift Truck Controls
Operation Section Lift Truck Controls Direction Control Lever Transmission Inching Control Pedal Inching Control Pedal - Pushing down on the 1. Forward - Push the lever forward for inching pedal, modulates the hydraulic pressure FORWARD direction travel. to the clutch packs, permitting disc slippage. 2.
Page 242 Operation Section Service Brake Pedal Parking Brake Lever Push DOWN on the brake pedal to slow or stop Pull the lever BACK to engage the parking brake. the lift truck. Push the lever FORWARD to release the RELEASE the brake pedal to allow the lift truck parking brake.
Page 243 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 244: Refueling
Operation Section Refueling Changing LP Tanks WARNING Only trained, authorized personnel should fill or exchange LP tanks. Personnel engaged in filling of LP containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves. Do not refuel or store LP powered lift trucks near any underground entrance, elevator shafts or any other place where LP could collect in a pocket 2.
Page 245 Operation Section WARNING tank must extend past 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 246: Before Starting The Engine
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 247 Operation Section 13. In case of LPG truck, if needed, change LPG Fuel Tank as the procedure of changing LP tanks in Refueling Section. WARNING Personal injury may occur from accidents caused by improper seat adjustment. Always adjust the operator's seat before starting the lift truck engine. Seat adjustment must be done at the beginning of each shift and when operators change.
Page 248: Starting The Engine
Operation Section Starting the Engine Prestart Conditions LP Engine NOTE: The engine will start unless WARNING transmission directional control lever is in the NEUTRAL position. LP fuel is flammable and can cause personal injury. Inspect LP fuel lines and fitting for leaks. Inspect tank for secure mounting.
Page 249 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. -53- https://www.forkliftpdfmanuals.com/...
Page 250: After Starting The Engine
Operation Section After Starting the Engine Observe all indicator lights and gauges frequently during operation, to make sure all systems are working properly. All of the indicator lights will come ON with the ignition switch in the ON position before the engine is started.
Page 251 Operation Section Electronic Controlled Spark-Ignition Engines G643E Engine EMS (Engine management system) of G643E engine is control module (SECM) uses two heated exhaust gas a closed loop system utilizing a catalytic muffler to oxygen sensors (HEGO) in the exhaust system to reduce the emission level in the exhaust gas.
Page 252 Operation Section Basic Troubleshooting Below are basic checks that should be made before referring to the Advanced Diagnostics section, if engine The EMS 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 253 Operation Section Problem Probable Cause Corrective Action No VR Sensor Signal Verify the VR signal is present Engine Cranking but Will Not Start See Advanced Diagnostics 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...
Page 254 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Will Not Run 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 255 Operation Section Problem Probable Cause Corrective Action Clogged fuel filter Repair/replace as required Will Not Accelerate/Hesitation See Maintenance Section, LP Fuel Filter During Acceleration 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 collapsed...
Page 256 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 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 257 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 258 Operation Section Problem Probable Cause Corrective Action Air/Fuel Mixer malfunction Check mixer Excessive Fuel Consumption/LPG See Engine Service Manual Exhaust Smell 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 Test pressure regulator operation...
Page 259 Operation Section Advanced Diagnostics(G643E Only) Reading Diagnostic Fault Codes All MI-07 fault codes are three-digit codes. When the fault MI-07 systems are equipped with built-in fault diagnostics. codes are retrieved (displayed) the MIL will flash for each Detected system faults can be displayed by the Malfunction digit with a short pause (0.5 seconds) between digits and a Indicator Lamp (MIL) as Diagnostic Fault Codes (DFC) or long pause (1.2 seconds) between fault codes.
Page 260 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK NONE None, used as end of the fault list Signifies the end of one pass NONE identification through the fault list Check ECT sensor connector and wiring for a short to GND ECTRangeLow...
Page 261 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION* FIRST CHECK CrankSyncFault Check Crankshaft sensor connections Loss of synchronization on SECM (SIGNAL) Pin B5 to Crank the crankshaft sensor, sensor Pin 3 None normally due to noise on the SECM (Sensor GND) Pin B1 to Crank...
Page 262 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check the throttle connector and pins for corrosion. To check the TPS disconnect the TPS2AdaptLoMin throttle connector and measure the Learned closed throttle end None resistance from:...
Page 263 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 (signal) MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1 Manifold Absolute Pressure (sensor GND)
Page 264 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK MAPRangeHigh Check TMAP connector and MAP Manifold Absolute Pressure signal wiring for a shorted circuit Sensor Input is High, TMAP Pin 4 to SECM Pin B18 (signal) normally set if the TMAP TMAP Pin 1 to SECM Pin B1 pressure signal wire has...
Page 265 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A9 (EST1) to OEM ignition EST1_Open system. See application note. EST1 output open, possibly Verify GND on ignition module Pin A TurnOnMil...
Page 266 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK ETCSpringTest Electronic Throttle Control Spring Return Test has failed. The SECM will perform a safety test of the throttle return spring following engine shutdown.
Page 267 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check battery and charging system voltage Check battery voltage during starting and with the engine running Check voltage regulator, alternator, and charging system SysVoltRangeHigh Check battery and wiring for...
Page 268 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Usually associated with additional ETC MediumOverspeed faults (1) TurnOnMil Engine speed has exceeded Check for ETC Sticking or other ETC (2) MediumRevLimit the second level (2 of 3) of faults...
Page 269 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK APP1AdaptHiMin Learned full pedal end of None APP1 sensor range lower than expected APP2AdaptHiMin Learned full pedal end of None APP2 sensor range lower than expected APP1AdaptLoMax...
Page 270 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK LSDFault_CrankDisable Crank Disable Fault, signal has opened or shorted to None ground or power or defective crank disable relay Check fuel lock off valve for an open wire or connector being disconnected LSDFault_LockOff or signal shorted to GND...
Page 271 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check that Post-catalyst O2 sensor connections are OK. O2 (signal) Pin 3 to SECM Pin B19 O2 Pin 2 (HEATER GND) to SECM (DRVG GNG) Pins A16, B17 O2 Pin 1 (HEATER PWR) to Post O2 Heater Relay.
Page 272 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Correct other faults that may contribute to 772 (e.g. faults pertaining to FTVs, GasPostO2FailedRich (1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor) Pre-catalyst O2 sensor (2) DisableGas Look for leaks in exhaust, catalytic...
Page 273 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK FuelTempRangeLow Check fuel temp sensor connector and Fuel Temperature Sensor wiring for a short to GND Input is Low normally set if SECM (signal) Pin B14 to FTS Pin 1 the fuel temperature sensor TurnOnMil...
Page 274: 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 275 Operation Section Inching 7. To change the lift truck direction of travel, release the accelerator pedal. NOTE: The purpose of the inching pedal is to provide 8. Push down on the service brake pedal to reduce the precise lift truck inching control at very slow lift truck speed as necessary.
Page 276: Mono-Ped Control System (Option)
Operation Section Steering Knob (If Equipped) Mono-Ped Control System There is a steering knob available for inclusion with (Option) new truck deliveries. This option is solely intended for slow travel situations when two handed steering is not possible due to hydraulic operations. Forward-Push the left side (2) of the pedal for FORWARD direction travel.
Page 277: 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 278 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 279 Operation Section Manual Mode (Fail-Safe mode) WARNING In case that the controller is broken down or you don’t want to use the functions of the Auto Shift Controller, When you want to change the travel direction, you you can select Manual Mode. In Manual Mode, you can must press down on the service brake pedal to operate your lift truck in the same manner as any lift reduce the travel speed.
Page 280: 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 281 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 282 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 283 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 284: 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 285: 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 286: 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 287: Transportation Hints
Check the state and local laws governing weight, width and length of a load. NOTICE Contact your DOOSAN Lift Truck dealer for shipping Remove ice, snow or other slippery material from the instructions for your lift truck. shipping vehicle and the loading dock.
Page 288: Towing Information
Personal injury or death could result when towing a conditions. disabled lift truck incorrectly. Consult your DOOSAN Lift Tuck dealer for towing a Block the lift truck wheels to prevent movement disabled lift truck. before releasing the brakes. The lift truck can roll free if it is not blocked.
Page 289: 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 290 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 291 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 292 Maintenance Section 12 Months Inspection Consult the fork manufacturer for further information as may be applicable to the specific Forks should be inspected, at a minimum, every 12 fork involved. months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six Testing is not required for repairs to the months.
Page 293: 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 294: 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 NOTICE measurement.
Page 295 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 296: Cooling System Specifications
Cooling system problems can arise without a important as the quality of fuel and lubricating oil. thermostat. NOTICE DOOSAN recommends that the coolant mixture contain 50% commercially available automotive antifreeze, and 50% water. The coolant mix with concentration of antifreeze smaller than 30% does not provide sufficient corrosion protection.
Page 297 DOOSAN recommends that the coolant mix contain 50% commercially available automotive antifreeze, or DOOSAN prefers the use of distilled water or deionized equivalent and acceptable water to maintain and water to reduce the potential and severity of chemical adequate water pump cavitation temperature for insolubility.
Page 298: Fuel Specifications
LP varies slightly between different parts of the country and different refineries. HD5 is recommended for DOOSAN forklift trucks. Remember LP 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 299: Lubricant Specifications
Water or air in the system will cause pump failure. Drain the fluid, retighten all hydraulic suction line clamps, purge and refill the system. Consult your DOOSAN Lift Truck dealer for Consult the EMA Lubricating Oils Data Book for a listing purging instructions.
Page 300 This oil is formulated for transmissions and drive trains only, and should not be used in engines. Shortened engine life will result. NOTE: MuIti-grade oils are not blended by DOOSAN for use in transmissions. Multi-grade oils which use high molecular weight polymers as viscosity...
Page 301: 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 10W30 Crankcase...
Page 302: Maintenance Intervals
Maintenance Section First 250 Service Hours or a Month Maintenance Intervals Hydraulic Return Filter - Change ......124 Every 250 Service Hours or Monthly NOTICE Air Intake System - Check, Clean......125 All maintenance and repair, except Every 10 Service Hydraulic Oil Level - Check ........
Page 303 Maintenance Section Every 1500 Service Hours or 9 Months Drive Axle Oil (Shoe Brake Only) - Check, Clean, Change..............142 Inspect Ignition System (LP Engine Only) ....142 Replace Spark Plugs (LP Engine Only)....142 Replace LP Fuel Filter Element (LP Engine Only) .................143 Fuel Filter (LP Engine Only) ........143 Disassembly.............143...
Page 304 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Air Breather Change Air Cleaner Indicator Check Air Intake System Change Air Intake System Check, Clean Battery Terminal Clean, Inspect Brake Oil Level Check Carriage Roller Extrusion Check, Adjust Carriage Side Rollers Lubricate Carriage Side Rollers Thrust (If...
Page 305 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Inspect Battery System Inspect Electrical System (LP Engine only) Inspect Engine for Fluid Leaks Inspect for Intake Leaks (LP Engine Only) Inspect Ignition System (LP Engine Only) Inspect Vacuum Lines and Fittings (LP Engine only) Test, Check, Lift Chains...
Page 306: 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. Test Fuel System for Leaks (LP Seat, Hood Latch & Support Cylinder Engine Only) - Check, Lubricate Check...
Page 307: 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 308: Fuse & Relay (Lp Engine Only)
Maintenance Section Bulbs Circuit Breaker Bulbs are identified as follows: [ LP Gas Engine ] 1. Bulb - head lamp halogen (12V - 35W) *2. Bulb - back up (12V - 8W) *3. Bulb - turn signal (12V - 23W) *4.
Page 309: Tires And Wheels - Check, Inspect
Maintenance Section Tires and Wheels - Check, Inspect WARNING WARNING Deflate tire before removing wheel nuts from the Servicing and changing tires and rims can be truck. dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while Check all components carefully and replace any servicing tires and rims, the assemblies could burst...
Page 310: Carriage Roller Extrusion - Check, Adjust
Maintenance Section Carriage Roller Extrusion - Check, Adjust 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 311: 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 312: Air Cleaner Indicator - Check
Maintenance Section Air Cleaner Indicator - Check Checking Service Indicator 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. Observe coolant level in the expansion bottle.
Page 313: 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 314: Mast Channels - Lubricate
Maintenance Section Mast Channels – Lubricate Transmission Oil Level - Check 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 315: 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. Transmission Oil, Oil Filter & Strainer - Clean, Change WARNING Hot oil and components can cause personal injury.
Page 316 Maintenance Section 7. Open the access door in the floor plate. 8. Remove the dipstick/filter cap. Fill the transmis-sion with oil. See “Refill Capacities” Install the dipstick/ filter cap. 9. Start the engine. 10. With the service brake applied and engine at low idle, shift the transmission to forward and reverse to fill the clutches.
Page 317: Drive Axle Oil - Check, Clean, Change
Maintenance Section Oil Cooled Disc Brake (OCDB) Type Drive Axle Oil - Check, Clean, Change Park the lift truck on a level surface, parking brake applied, transmission in neutral. WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1.
Page 318: Parking Brake - Test, Adjust
Maintenance Section Parking Brake - Test, Adjust Parking Brake Testing WARNING To prevent personal injury, the operator MUST be ready to use the service brake if the parking brake NOTICE is not adjusted correctly and the lift truck starts to OSHA requires the parking brake to hold the lift move.
Page 319 Maintenance Section 6. Remove the pin (3) and the cotter pin (4). Tighten the nut (6) to compress the spring (7) further and pull downward and turn the clevis (5) until the pin (3) fits into the brake lever when the lever (1) is held against the stop pin (2).
Page 320: 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 321: 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 Servicing Filter Element NOTICE Never service precleaner with the engine running.
Page 322 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 323: 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 324: Mast, Carriage, Lift Chains, & Attachments - Check, Lubricate
Maintenance Section Oil Cooled Disc Brake (OCDB) Type 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 325: 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 326: Battery Terminal - Clean, Inspect
Maintenance Section Battery Terminal - Clean, Inspect Engine Oil & Filter – Change LP Engine Crankcase WARNING 1. Operate lift truck a few minutes to warm oil. Park the lift truck with the forks lowered, parking brake Batteries give off flammable fumes that can explode. applied, transmission in neutral and the engine stopped.
Page 327: 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 328: 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. Mast Hinge Pins – Lubricate Tilt Cylinders - Check, Adjust, Lubricate Chassis Pivot Eyebolts Typical Example...
Page 329: Crosshead Rollers - Inspect
Maintenance Section Cylinder Rod Extension Crosshead Rollers - Inspect 1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make sure NOTE: The following description is for forward tilt. For the chain is tracking over the rollers properly. cylinder rod back tilt, the collar should be stationary by the tilt eye.
Page 330: Carriage Sideshifter (If Equipped) - Lubricate
Maintenance Section Parking Brake - Test, Adjust See topic, “Parking Brake - Test, Adjust” in “First 50-100 Service Hours.” Circulation Pump Belt (OCDB & LP Engine Only. If Eguipped) - Check, Adjust 1. Raise the hood and seat assembly. 2. Lubricate 2 side thrust roller fittings, one on each side of the mast.
Page 331: Drive Axle Oil & Strainer (Ocdb Only) - Check, Clean, Change
Maintenance Section Drive Axle Oil & Strainer (OCDB Only) - Check, 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 on a level surface. Apply the parking brake.
Page 332: Horn & Lights (If Equipped) - Check
Maintenance Section Horn & Lights (If Equipped) – Check Fuel Trim Valve(FTV) Inspection (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.
Page 333: Overhead Guard - Inspect
Maintenance Section Overhead Guard – Inspect 1. Check tightness of overhead guard mounting bolts at 95 N•m (70 lb•ft). 2. Check overhead guard for bent or cracked sections. Have repairs made if needed. Steer Suspension - Inspect 1. Inspect the suspension mounting bolts. Tighten suspension mounting bolts, if necessary, to 240+30 N•m (180+20 lb•ft).
Page 334: 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. Inspect Coolant Hoses (LP Engines Only) Air Intake System - Change 1.
Page 335: Fuel Lines & Fittings - Check
Maintenance Section Fuel Lines & Fittings - Check Lift Chains - Test, Check, Adjust Lift Chain Wear Test Visually inspect fuel lines and fittings for physical damage. Replace as required. Inspect the part of the chain that is normally operated over the cross head roller.
Page 336 Maintenance Section Check for Equal Tension Carriage Chain Adjustment 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 337: Universal Joint - Inspect
Maintenance Section Universal Joint - Inspect Mast Chain Adjustment - FF, FFT Mast Typical example for FF mast 1. Inspect for loose retaining bolts. Check for worn or damaged bearings. Typical example for FFT mast 2. Have worn or damaged bearings replaced. Tighten the bolts if necessary.
Page 338: Every 1500 Service Hours Or 9 Months
Maintenance Section Every 1500 Service Hours or 9 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Drive Axle Oil (Shoe Brake Only) - Replace Spark Plugs (LP Engine Check, Clean, Change Only)
Page 339: Replace Lp Fuel Filter Element (Lp Engine Only)
Maintenance Section Replace LP Fuel Filter Element (LP Fuel Filter (LP Engine Only) 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. Close the fuel shutoff valve on the LP-Fuel tank. Run the engine until the fuel in the system runs out and the engine stops.
Page 340: Testing Fuel Lock-Off Operation (Lp Engine Only)
Maintenance Section Testing Fuel Lock-off Operation (LP 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 341: 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 4. Remove the castle nut and washer. 5.
Page 342: Cooling System - Clean, Change
Maintenance Section Cooling System - Clean, Change 4. Close radiator drain valve and install block drain plug. Fill the cooling system with 1 kg (2 lb) sodium bisulphate per 40 liters (10 gallons) of water. Most WARNING commercial cooling system cleaners can be used. 5.
Page 343: Fork - Inspect
3 percent of blade length (L). Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer for further information. 2. Check the angle between the upper face of the blade and the front face of the shank.
Page 344 Maintenance Section 8. Check fork markings (N) for legibility. Renew 5. Check the fork blade (J) and shank (H) for wear with markings as required to retain legibility. special attention to the heel (G). The fork should be withdrawn from service if the thickness is reduced to 9.
Page 345: 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 Inspect Battery System 1.
Page 346: Checking The Tmap Sensor (Lp Engine Only)
Maintenance Section Checking the TMAP Sensor (LP Replace Oxygen Sensor (G643E Engine Only) Engine Only) 1. Verify that the TMAP sensor (2) is mounted tightly into the manifold adapter (3), with no leakage. 2. If the TMAP is found to be loose, remove the TMAP retaining screw and the TMAP sensor from the manifold adapter.
Page 347: Index
Index Section Index Check Inflation and Damage......... 113 Checking Element..........126 Checking Service Indicator........116 12 Months Inspection ..........96 Checking the TMAP Sensor (LP Engine Only) ..150 Circuit Breaker..........43, 112 Circulation Pump Belt (OCDB & LP Engine Only. If Eguipped) - Check, Adjust........
Page 348 Index Section Inspect Coolant Hoses (LP Engines Only)... 138 Inspect Electrical System (LP Engine only) ..136 Inspect Engine for Exhaust Leaks ......116 Falling Objects Protective Structure(FOPS)...14 Inspect Engine for Fluid Leaks......115 Fatigue ..............94 Inspect for Intake Leaks (LP Engine Only)... 150 Features ..............81 Inspect Ignition System (LP Engine Only)....
Page 349 Index Section Mast Channels – Lubricate ........118 Mast Hinge Pins – Lubricate........132 Mast Pivot Eyes............132 Refill Capacities............105 Mast, Carriage, Lift Chains, & Attachments - Check, Refueling..............48 Lubricate..............128 Replace LP Fuel Filter Element (LP Engine Only) Metric Hardware ............98 .................
Page 350 Index Section Torques for Bolts and Nuts With Standard Threads ...................98 Torques for Taperlock Studs ........99 Towing Information...........92 Training Required to Operate or Service Warning...5 Transmission Inching Control Pedal .......45 Transmission Oil (TDTO) ........104 Transmission Oil Level - Check......118 Transmission Oil, Oil Filter & Strainer - Clean, Change............

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