Doosan D20S-5 Operation & Maintenance Manual
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Doosan D20S-5 Operation & Maintenance Manual

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Operation &
Operation &
Maintenance Manual
Maintenance Manual
LIFT TRUCKS
LIFT TRUCKS
D20S-5, D25S-5, D30S-5, D33S-5, D35C-5
D20S-5, D25S-5, D30S-5, D33S-5, D35C-5
G20E-5, G25E-5, G30E-5
G20E-5, G25E-5, G30E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5
SB2349E02
SB2349E02
0712
0712

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  • Page 1 Operation & Operation & Maintenance Manual Maintenance Manual LIFT TRUCKS LIFT TRUCKS D20S-5, D25S-5, D30S-5, D33S-5, D35C-5 D20S-5, D25S-5, D30S-5, D33S-5, D35C-5 G20E-5, G25E-5, G30E-5 G20E-5, G25E-5, G30E-5 GC20E-5, GC25E-5, GC30E-5, GC33E-5 GC20E-5, GC25E-5, GC30E-5, GC33E-5 G20P-5, G25P-5, G30P-5, G33P-5, G35C-5...
  • Page 3     Table of Contents Table of Contents Table of Contents Table of Contents Information Section Information Section Maintenance Section Maintenance Section Fore Foreword word ..........................2 ....2 Inspection, Maintenance and Repair of Lift Truck Inspection, Maintenance and Repair of Lift Truck  ...
  • Page 4 Read, study and keep this manual with the lift truck. Read, study and keep this manual with the lift truck. can still happen. The DOOSAN operator restraint can still happen. The DOOSAN operator restraint system can minimize injuries. The DOOSAN system can minimize injuries.
  • Page 5 “Every 10 Service Hours or Daily”. Daily”. Environment Management Environment Management Note that DOOSAN INFRACORE is ISO 14001 Note that DOOSAN INFRACORE is ISO 14001 certified which is harmonized with ISO 9001. certified which is harmonized with ISO 9001. Periodic...
  • Page 6 These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DOOSAN dealers have the most current complete and most current information before starting any job. DOOSAN dealers have the most current information a information available.
  • Page 7 Traing Required To Operate or Service Traing Required To Operate or Service Warning Warning DOOSAN lift trucks are manufactured according to DOOSAN lift trucks are manufactured according to the regulations and standards laid down in EU the regulations and standards laid down in EU...
  • Page 8     Safety Section Safety Section 5. 5.     Travel with load as low as possible and tilted Travel with load as low as possible and tilted General Warning to Operator General Warning to Operator back. If load interferes with visibility, travel with back.
  • Page 9     Safety Section Safety Section Pressure Warning Pressure Warning No Standing On Fork Warning No Standing On Fork Warning No Standing Under Fork Warning No Standing Under Fork Warning WARNING WARNING Contents under pressure may be hot. Allow to Contents under pressure may be hot.
  • Page 10     Safety Section Safety Section     Moving Fan Warning Moving Fan Warning Overhead Guard Must Be In Place Overhead Guard Must Be In Place Warning Warning WARNING WARNING WARNING WARNING To avoid personal injury, stay clear of moving To avoid personal injury, stay clear of moving fan.
  • Page 11     Safety Section Safety Section Parking brake Parking brake Pull the lever BACK to engage the Pull the lever BACK to engage the parking brake. parking brake. Push the lever FORWARD to release Push the lever FORWARD to release the parking brake.

  • Page 12: All Maintenance And Repair, Except Every

        Safety Section Safety Section Always use the overhead guard. The overhead Always use the overhead guard. The overhead General Hazard Information General Hazard Information guard is intended to protect the lift truck operator guard is intended to protect the lift truck operator from overhead obstructions and from falling from overhead obstructions and from falling objects.
  • Page 13 DOOSAN spare parts waive of other than original DOOSAN spare parts waive any liability by any liability by DOOSAN DOOSAN.
  • Page 14     Safety Section Safety Section Make sure the lift truck h Make sure the lift truck horn, lights, backup alarm (if orn, lights, backup alarm (if Operating the Lift Truck Operating the Lift Truck equipped) and all other devices are working equipped) and all other devices are working properly.
  • Page 15     Safety Section Safety Section     Loading or Unloading Trucks/Trailers Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be are not designed or intended for that purpose.
  • Page 16 To avoid possible weakening of the Falling Objects The maximum air pressure must be below 205 kPa The maximum air pressure must be below 205 kPa Protective Structure (FOPS), consult a DOOSAN Protective Structure (FOPS), consult a DOOSAN (30 psi) for (30 psi) for cleaning purposes.
  • Page 17     Safety Section Safety Section Burn Prevention Burn Prevention Fire or Explosion Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant All fuels, most lubricants and some coolant Coolant Coolant mixtures are flammable. mixtures are flammable. At operating temperature, the engine coolant is hot At operating temperature, the engine coolant is hot and under pressure.
  • Page 18 Leaks can cause fires. Contact tubes and hoses. Leaks can cause fires. Contact your DOOSAN dealer for repair your DOOSAN dealer for repair or replacement. or replacement. Check lines, tubes and hoses carefully. Do not use Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks.
  • Page 19 See you DOOSAN Lift Truck on the replaced part. See you DOOSAN Lift Truck Stand behind the tread and use a self-attaching Stand behind the tread and use a self-attaching dealer for new labels.
  • Page 20     Safety Section Safety Section     If Optional Suspension Seat (weight If Optional Suspension Seat (weight adjusting type) Equipped adjusting type) Equipped Forward and Backward Adjustment Forward and Backward Adjustment The seat can be adjusted by pushing the lever on The seat can be adjusted by pushing the lever on the right side of seat.
  • Page 21 WARNING WARNING Your DOOSAN truck comes equipped with a Your DOOSAN truck comes equipped with a DOOSAN operator restraint system. Should it DOOSAN operator restraint system. Should it become necessary to replace the seat for any...
  • Page 22     Safety Section Safety Section     WARNING WARNING If you fasten the belt across your abdomen, the If you fasten the belt across your abdomen, the belt may injure your a belt may injure your abdomen in an accident. bdomen in an accident.
  • Page 23     Safety Section Safety Section Avoiding Lift Truck Tipover Avoiding Lift Truck Tipover Stability and Center of Gravity Stability and Center of Gravity Lift Truck Stability Lift Truck Stability The stability of the lift truck is determined by the stability of the lift truck is determined by the Counterbalanced lift truck design is based on the Counterbalanced lift truck design is based on the...
  • Page 24 2. 2. DOOSAN assumes no responsibility for lift trucks DOOSAN assumes no responsibility for lift trucks placed in service without a valid DOOSAN placed in service without a valid DOOSAN Nameplate.
  • Page 25     Safety Section Safety Section Safety Rules Safety Rules Do not operate a lift truck unless you are in the Do not operate a lift truck unless you are in the operator’s s operator’s seat. eat. Keep hands Keep hands and feet and feet inside the inside the operator’s...
  • Page 26     Safety Section Safety Section     Do not raise anyone on the forks o Do not raise anyone on the forks of your lift truck. f your lift truck. Do not overload. Always handle loads within the Do not overload. Always handle loads within the Do not let other people ride on the Do not let other people ride on the truck.
  • Page 27     Safety Section Safety Section     Do not permit anyone to stand or walk under the Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted for Do not elevate the load with the mast tilted forward. ward.
  • Page 28     Safety Section Safety Section     Do not stack or turn on r Do not stack or turn on ramps. amps. Do not drive in forward direction when loads restrict Do not drive in forward direction when loads restrict Do not attempt to pick-up or deposit a load unless Do not attempt to pick-up or deposit a load unless your visibility.
  • Page 29     Safety Section Safety Section     Do not operate your truck close to another truck. Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully Park your lift truck in authorized areas only. Fully Always keep a safe distance from other trucks and Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in...
  • Page 30     Safety Section Safety Section How to Survive in a Tipover How to Survive in a Tipover WARNING WARNING In the event of a tipover, the risk of serious In the event of a tipover, the risk of serious injury or death will be reduced if the operator is injury or death will be reduced if the operator is using the operator restraint system and follows...
  • Page 31     Safety Section Safety Section     Lean away from the direction of fall. Lean away from the direction of fall. Lean forward. Lean forward. -29- -29-...
  • Page 32     General Section General Section Specifications Specifications CHARACTERISTICS CHARACTERISTICS MANUFACTURER MANUFACTURER DOOSAN DOOSAN DOOSAN DOOSAN D20S-5 D20S-5 D25S-5 D25S-5 MODEL MODEL (YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2) CAPACITY CAPACITY at at rated rated load load center center 2000 2000 2500 2500...
  • Page 33     General Section General Section     DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D30S-5 D30S-5 D33S-5 D33S-5 D35C-5 D35C-5 (YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2) 3000 3000 3250 3250 3500 3500 diesel diesel diesel diesel diesel diesel rider-seated rider-seated...
  • Page 34     General Section General Section Specifications Specifications CHARACTERISTICS CHARACTERISTICS MANUFACTURER MANUFACTURER DOOSAN DOOSAN DOOSAN DOOSAN D20S-5 D20S-5 D25S-5 D25S-5 MODEL MODEL (YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3) CAPACITY CAPACITY at at rated rated load load center center 2000 2000 2500 2500...
  • Page 35     General Section General Section     DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D30S-5 D30S-5 D33S-5 D33S-5 D35C-5 D35C-5 (YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3) 3000 3000 3250 3250 3500 3500 diesel diesel diesel diesel diesel diesel rider-seated rider-seated...
  • Page 36     General Section General Section Specifications Specifications CHARACTERISTICS CHARACTERISTICS MANUFACTURER MANUFACTURER MODEL MODEL CAPACITY CAPACITY at at rated rated load load center center LOAD LOAD CENTER CENTER distance distance POWER POWER TYPE TYPE electric, electric, diesel, diesel, gas, gas, LPG-gas LPG-gas OPERATOR OPERATOR TYPE...
  • Page 37     General Section General Section     DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN G20E-5 G20E-5 G25E-5 G25E-5 G30E-5 G30E-5 2000 2000 2500 2500 3000 3000 rider-sea rider-sea ted rider-s rider-s eated eated rider-seate rider-seated d 3230 3230 3230 3230...
  • Page 38     General Section General Section Specifications Specifications CHARACTERISTICS CHARACTERISTICS MANUFACTURER MANUFACTURER DOOSAN DOOSAN DOOSAN DOOSAN MODEL MODEL G20P-5 G20P-5 G25P-5 G25P-5 CAPACITY CAPACITY at at rated rated load load center center 2000 2000 2500 2500 LOAD LOAD CENTER CENTER...
  • Page 39     General Section General Section     DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN G30P-5 G30P-5 G33P-5 G33P-5 G35C-5 G35C-5 3000 3000 3250 3250 3500 3500 lp lp lp lp lp lp rider-seated rider-seated rider-seated rider-seated rider-seated rider-seated 3230 3230...
  • Page 40     General Section General Section Specifications Specifications CHARACTERISTICS CHARACTERISTICS MANUFACTURER MANUFACTURER DOOSAN DOOSAN MODEL MODEL GC20E-5 GC20E-5 CAPACITY CAPACITY at at rated rated load load center center 2000 2000 LOAD LOAD CENTER CENTER distance distance POWER POWER TYPE TYPE...
  • Page 41     General Section General Section     DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN GC25E-5 GC25E-5 GC30E-5 GC30E-5 GC33E-5 GC33E-5 2500 2500 3000 3000 3000(6500LBS 3000(6500LBS ) ) rider-s rider-seated eated rider-sea rider-sea ted rider-seat rider-seated 3230 3230 3230 3230...
  • Page 42     General Section General Section Specifications Specifications CHARACTERISTICS CHARACTERISTICS MANUFACTURER MANUFACTURER DOOSAN DOOSAN MODEL MODEL GC20P-5 GC20P-5 CAPACITY CAPACITY at at rated rated load load center center 2000 2000 LOAD LOAD CENTER CENTER distance distance POWER POWER TYPE TYPE...
  • Page 43     General Section General Section     DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN GC25P-5 GC25P-5 GC30P-5 GC30P-5 GC33P-5 GC33P-5 2500 2500 3000 3000 3000(6500LBS 3000(6500LBS) ) rider-seat rider-seated rider-seated rider-seated rider-seated rider-seated 3230 3230 3230 3230 3230 3230 II II...
  • Page 44 Mean Mean Uncertainty Uncertainty TIER - II (4TNV98 E/G) TIER - II (4TNV98 E/G) D20S-5,D25S-5,D30S-5, D20S-5,D25S-5,D30S-5, D33S-5, D35C-5 D33S-5, D35C-5 (W/O Cabin) (W/O Cabin)    TIER - III (4TNE98 E/G) TIER - III (4TNE98 E/G) D20S-5,D25S-5,D30S-5, D20S-5,D25S-5,D30S-5,...
  • Page 45     General Section General Section Capacity Chart (Without Sideshifter Pneumatic) Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE SINGLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    0    0    2...
  • Page 46     General Section General Section Capacity Chart (Without Sideshifter Pneumatic) Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE SINGLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    3    3    3...
  • Page 47     General Section General Section Capacity Chart (Without Sideshifter Pneumatic) Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE DOUBLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    0    0    2...
  • Page 48 -45- -45-     General Section General Section Capacity Chart (Without Sideshifter Pneumatic) Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE DOUBLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    3...
  • Page 49 -46- -46-     General Section General Section Capacity Chart (With Sideshifter Pneumatic) Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE SINGLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    0...
  • Page 50 -47- -47-     General Section General Section Capacity Chart (With Sideshifter Pneumatic) Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE SINGLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    3...
  • Page 51 -48- -48-     General Section General Section Capacity Chart (With Sideshifter Pneumatic) Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE DOUBLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    0...
  • Page 52 -49- -49-     General Section General Section Capacity Chart (With Sideshifter Pneumatic) Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE DOUBLE TIRE     MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P    P    3...
  • Page 53 -50- -50-     General Section General Section Capacity Chart (Without Sideshifter cushion) Capacity Chart (Without Sideshifter cushion) NARROW TIRE NARROW TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 54 -51- -51-     General Section General Section Capacity Chart (Without Sideshifter cushion) Capacity Chart (Without Sideshifter cushion) NARROW TIRE NARROW TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 55 -52- -52-     General Section General Section Capacity Chart (Without Sideshifter cushion) Capacity Chart (Without Sideshifter cushion) WIDE TIRE WIDE TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 56 -53- -53-     General Section General Section Capacity Chart (Without Sideshifter cushion) Capacity Chart (Without Sideshifter cushion) WIDE TIRE WIDE TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 57 -54- -54-     General Section General Section Capacity Chart (With Sideshifter cushion) Capacity Chart (With Sideshifter cushion) NARROW TIRE NARROW TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 58 -55- -55-     General Section General Section Capacity Chart (With Sideshifter cushion) Capacity Chart (With Sideshifter cushion) NARROW TIRE NARROW TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 59 -56- -56-     General Section General Section Capacity Chart (With Sideshifter cushion) Capacity Chart (With Sideshifter cushion) WIDE TIRE WIDE TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 60 -57- -57-     General Section General Section Capacity Chart (With Sideshifter cushion) Capacity Chart (With Sideshifter cushion) WIDE TIRE WIDE TIRE         MODEL MODEL STD, FFL STD, FFL                5    5   -   -    P...
  • Page 61 -58- -58-     General Section General Section Serial Number Serial Number Serial Number Locations Serial Number Locations For quick reference, record your lift truck's serial For quick reference, record your lift truck's serial numbers in the spaces provided below the numbers in the spaces provided below the photographs.
  • Page 62 -59- -59-     General Section General Section     Power Shift Transmission Serial Number Power Shift Transmission Serial Number •_____________________________ •_____________________________ Drive Axle Serial Number Drive Axle Serial Number •_____________________________ •_____________________________ Typical Example Typical Example Side Shifter Serial Number (If Equipped) Side Shifter Serial Number (If Equipped) •_____________________________ •_____________________________...
  • Page 63 -60- -60-     General Section General Section Attachment Abbreviations (Includes Attachment Abbreviations (Includes Special Forks) Special Forks) -Special Carriage-increased width, -Special Carriage-increased width, height or outreach height or outreach -Shaft-type Sideshift Carriage -Shaft-type Sideshift Carriage -Hook-type Sideshift Carriage (ITA) -Hook-type Sideshift Carriage (ITA) -Counterweight -Counterweight...
  • Page 64 -61- -61-     General Section General Section Operator's Warning and Identification Plate Operator's Warning and Identification Plate Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT CAPACITY and Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT CAPACITY and ATTACH ATTACHMENT PLATES.
  • Page 65 -62- -62-     Operation Section Operation Section Operator’s Station and Monitoring Systems Operator’s Station and Monitoring Systems Instrument Panel Instrument Panel Your lift truck may not have the same indicator or warning lights as shown in the illustrations. 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.
  • Page 66 -63- -63-     Operation Section Operation Section 1. 1.    Engine Oil Pressure Indicator Light - Engine Oil Pressure Indicator Light - 7. Transmission Oil Temperature Gauge 7. Transmission Oil Temperature Gauge Indicates insufficient engine oil pressure. Indicates insufficient engine oil pressure. - -  Indicates transmission oil temperature.
  • Page 67 -64- -64-     Operation Section Operation Section 15. Low Level Light of LP GAS – 15. Low Level Light of LP GAS – Indicates Indicates the low Level of LP GAS (LP or the low Level of LP GAS (LP or DUAL only) DUAL only) 16.
  • Page 68 -65- -65-     Operation Section Operation Section Electrical Disconnect Switch (If Electrical Disconnect Switch (If Engine Compartment Engine Compartment Equipped) Equipped) 1. 1. The engine compartment is accessible by pulling The engine compartment is accessible by pulling the latch (GC Series), or pushing down the lever the latch (GC Series), or pushing down the lever 1.
  • Page 69 DOOSAN necessary, be sure to use genuine DOOSAN transmission. The directional lever, however, will transmission. The directional lever, however, will Infracore lift truck parts. Lift trucks should never be Infracore lift truck parts.
  • Page 70 -67- -67-     Operation Section Operation Section Tilt Steering Column Tilt Steering Column   WARNING   WARNING When closing the engine hood, be careful not to When closing the engine hood, be careful not to pinch your hand. pinch your hand. Circuit Breaker Circuit Breaker To adjust the steering column, push down the...
  • Page 71 -68- -68-     Operation Section Operation Section Lift Truck Controls Lift Truck Controls Direction Control Lever Direction Control Lever Service Brake Pedal Service Brake Pedal Push Push DOWN on the brake pedal to slow DOWN on the brake pedal to slow 1.
  • Page 72 -69- -69-     Operation Section Operation Section Parking Brake Lever Parking Brake Lever Tilt Control Tilt Control Pull the lever BACK to engage the parking Pull the lever BACK to engage the parking brake. brake. 1. 1. Mast Tilt Forward - Push the lever Mast Tilt Forward - Push the lever FORWARD smoot FORWARD smoothly to tilt...
  • Page 73 -70- -70-     Operation Section Operation Section Refueling Refueling Gasoline or Diesel Engine Gasoline or Diesel Engine Equipped Equipped WARNING WARNING Explosive Explosive fumes fumes present present during during refueling. refueling. Do not smoke in re Do not smoke in refueling areas. fueling areas.
  • Page 74 -71- -71-     Operation Section Operation Section Changing LP Tanks Changing LP Tanks WARNING WARNING Only trained, authorized personnel should fill or Only trained, authorized personnel should fill or exchange LP tanks. exchange LP tanks. Personnel engaged in filling of LP containers Personnel engaged in filling of LP containers should wear protective clothing such as face should wear protective clothing such as face...
  • Page 75 -72- -72-     Operation Section Operation Section     NOTICE NOTICE If the location pin (dowel) is missing or broken, be If the location pin (dowel) is missing or broken, be sure the pin is replaced. sure the pin is replaced. 11.
  • Page 76 -73- -73-     Operation Section Operation Section Before Starting the Engine Before Starting the Engine Walk - Around Inspection Walk - Around Inspection Make a thorough walk - around inspection before Make a thorough walk - around inspection before mounting the lift truck or starting the engine.
  • Page 77 -74- -74-     Operation Section Operation Section     11.     Measure the engine crankcase oil level with the 13.     Observe the fuel level gauge after starting the Measure the engine crankcase oil level with the Observe the fuel level gauge after starting the dip stick.
  • Page 78 -75- -75-     Operation Section Operation Section Starting the Engine Starting the Engine Prestart Conditions Prestart Conditions Gasoline Engine Gasoline Engine NOTE: NOTE:     The engine will not start unless the The engine will not start unless the transmission directional control lever is in transmission directional control lever is in NOTICE...
  • Page 79 -76- -76-     Operation Section Operation Section LP Engine LP Engine Diesel Engine Diesel Engine Starting a Cold Diesel Engine Starting a Cold Diesel Engine WARNING WARNING 1. 1.     Turn the key to the ON position. The start pre Turn the key to the ON position.
  • Page 80 NEGATIVE( - ). Attach ground cable last, remove first. All lift trucks Attach ground cable last, remove first. All lift trucks equipped with DOOSAN built internal combustion equipped with DOOSAN built internal combustion engines are NEGATIVE( - ) ground.
  • Page 81 -78- -78-     Operation Section Operation Section Dual Fuel System Dual Fuel System Changing From Gasoline to LP – Changing From Gasoline to LP – 4. 4. Open the fuel valve, on the LP tank, by slowly Open the fuel valve, on the LP tank, by slowly turning the turning the valve counterclockwis valve counterclockwise.
  • Page 82 -79- -79-     Operation Section Operation Section     3. 3.     Move lever (1) from the LPG (3) POSITION to Move lever (1) from the LPG (3) POSITION to the OFF (2) position. Allow the engine to run the OFF (2) position.
  • Page 83 -80- -80-     Operation Section Operation Section 4. 4.     The diesel engine water in fuel filter indicator The diesel engine water in fuel filter indicator After Starting the Engine After Starting the Engine light(4), will not come ON with the engine light(4), will not come ON with the engine Observe all indicator lights and gauges frequently Observe all indicator lights and gauges frequently...
  • Page 84 -81- -81-     Operation Section Operation Section Lift Truck Operation Lift Truck Operation Power Shift Transmission/ Drive Power Shift Transmission/ Drive WARNING WARNING axle axle A lift truck with the engine running but without A lift truck with the engine running but without an operator can move slowly (creep) if the an operator can move slowly (creep) if the 1.
  • Page 85 -82- -82-     Operation Section Operation Section     Inching Inching 7. 7.     To change the lift truck direction of travel, To change the lift truck direction of travel, release the accelerator pedal. release the accelerator pedal. NOTE: NOTE:  ...
  • Page 86 -83- -83-     Operation Section Operation Section Electroni Electronic c Controlled Spark-Ignition Engines Controlled Spark-Ignition Engines G420FE Engine and G424FE Engine G420FE Engine and G424FE Engine EMS (Engine management system) of G420FE EMS (Engine management system) of G420FE engine control module (SECM) uses two heated engine control module (SECM) uses two heated engine and G424FE engine is a closed loop system engine and G424FE engine is a closed loop system...
  • Page 87 -84- -84-     Operation Section Operation Section G420F Engine and G424F Engine G420F Engine and G424F Engine EMS (Engine management system) of G420F engine and G424F engine is an open loop LP system and/or EMS (Engine management system) of G420F engine and G424F engine is an open loop LP system and/or closed loop gasoline system.
  • Page 88 -85- -85-     Operation Section Operation Section Basic Troubleshooting(LP) Basic Troubleshooting(LP)     The MI-07 systems are equipped with built-in fault The MI-07 systems are equipped with built-in fault basic checks that should be made before referring basic checks that should be made before referring diagnostics.
  • Page 89 -86- -86-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Fuel Fuel container container almost almost empty empty LPG Vapor Vapor from from liquid liquid outlet outlet Difficult to Start Difficult to Start Fill fuel container Fill fuel container  ...
  • Page 90 -87- -87-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Fuel Fuel container container almost almost empty empty LPG Vapor Vapor from from liquid liquid outlet outlet Will Not Run Will Not Run Fill fuel container Fill fuel container  ...
  • Page 91 -88- -88-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Clogged Clogged fuel fuel filter filter Repair/replace Repair/replace as as required required Will Not Will Not See Maintenance See Maintenance     ...
  • Page 92 -89- -89-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Fuel Fuel Lock-off Lock-off malfunction malfunction Repair/replace Repair/replace Fuel Fuel Lock-off Lock-off Engine Stalls Engine Stalls See Engine Service Manual See Engine Service Manual  ...
  • Page 93 -90- -90-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Incorrect Idle speed control Incorrect Idle speed control    See Advanced Diagnostics & See Engine See Advanced Diagnostics & See Engine Rough Idle Rough Idle Service Manual Service Manual...
  • Page 94 -91- -91-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Air/Fuel Air/Fuel Mixer Mixer malfunction malfunction Check Check mixer mixer Excessive Excessive Fuel Fuel See Engine Service Manual See Engine Service Manual  ...
  • Page 95 -92- -92-     Operation Section Operation Section Basic Troubleshooting (Gasoline) Basic Troubleshooting (Gasoline) Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Fuel Fuel tank tank empty empty Fill Fill fuel fuel container container Engine Cranking Engine Cranking The tank should be at least ¼...
  • Page 96 -93- -93-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Fuel Fuel tank tank almost almost empty empty Fuel Fuel Pump Pump Cavitations Cavitations Difficult to Start Difficult to Start The tank should be at least ¼ full to The tank should be at least ¼...
  • Page 97 -94- -94-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Electric Fuel Pump malfunction Electric Fuel Pump malfunction Check electrical connection Check electrical connection Will Not Run Will Not Run (GAS) (GAS) Check Relay and fuse Turn key ON Check Relay and fuse Turn key ON ...
  • Page 98 -95- -95-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Throttle butterfly valve not opening Throttle butterfly valve not opening See Advanced Diagnostics See Advanced Diagnostics Will Not Will Not or sticking or sticking Accelerate/Hesita Accelerate/Hesita...
  • Page 99 -96- -96-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Incorrect Idle speed control Incorrect Idle speed control    Advanced Advanced Diagnostics Diagnostics & & Engine Engine Rough Idle (Gas) Rough Idle (Gas) Service Manual Service Manual Incorrect timing or spark control...
  • Page 100 -97- -97-     Operation Section Operation Section Problem Problem Probable Probable Cause Cause Corrective Corrective Action Action Isolate the gasoline system by Isolate the gasoline system by Verify LPG cylinder is full and valve is open. Verify LPG cylinder is full and valve is open. Poor High Speed Poor High Speed running the lift truck on LPG...
  • Page 101 -98- -98-     Operation Section Operation Section Advanced Diagnostics Advanced Diagnostics Displaying Fault Codes (DFC) from Displaying Fault Codes (DFC) from SECM Memory SECM Memory MI-07 systems are equipped with built-in fault MI-07 systems are equipped with built-in fault diagnostics.
  • Page 102 -99- -99-     Operation Section Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CORRECT CORRECTIVE IVE ACTION ACTION FIRST FIRST CHECK CHECK NONE...
  • Page 103 -100- -100-     Operation Section Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CORRECT CORRECTIVE IVE ACTION ACTION FIRST FIRST CHECK CHECK...
  • Page 104 -101- -101-     Operation Section Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. DFC C PROBA OBABL BLE E FA FAULT FAUL ULT T AC ACT T ION ION * * CORR RREC...
  • Page 105 -102- -102-     Operation Section Operation Section Table Table 2. 2. Diagnostic Diagnostic Fault Fault Codes (Fla Codes (Flash C sh Codes) odes) cont’d. cont’d. PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CORRECTIVE CORRECTIVE ACTION ACTION FIRST FIRST CHECK CHECK TPS2AdaptHiMin...
  • Page 106 -103- -103-     Operation Section Operation Section Table Table 2. 2. Diagnostic Diagnostic Fault Fault Codes (Fla Codes (Flash C sh Codes) odes) cont’d. cont’d. DFC C PROBA OBABL BLE E FA FAULT FAULT ULT AC ACTI TION ON * * CORR RREC ECTI TIVE...
  • Page 107 -104- -104-     Operation Section Operation Section Table Table 2. 2. Diagnostic Diagnostic Fault Fault Codes (Fla Codes (Flash C sh Codes) odes) cont’d. cont’d. DFC C PROBA OBABL BLE E FA FAULT FAULT ULT AC ACTI TION ON * * CORR RREC ECTI TIVE...
  • Page 108 -105- -105-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC C P P ROB ROBAB ABL L E E FA FAUL ULT T FAUL ULT T AC ACT T ION ION * * CORR...
  • Page 109 -106- -106-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CORRECTIVE CORRECTIVE ACTION ACTION FIRST FIRST CHECK CHECK EST2_Short EST2_Short...
  • Page 110 -107- -107-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CORRECTIVE CORRECTIVE ACTION ACTION FIRST FIRST CHECK CHECK EST7_Short EST7_Short...
  • Page 111 -108- -108-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CORRECTIVE CORRECTIVE ACTION ACTION FIRST FIRST CHECK CHECK Check ETC driver wiring for a shorted circuit Check ETC driver wiring for a shorted circuit...
  • Page 112 -109- -109-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CORRECTIVE CORRECTIVE ACTION ACTION FIRST FIRST CHECK CHECK Measure transducer power at the Measure transducer power at the...
  • Page 113 -110- -110-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION FIRST CORRECTIVE ACTION FIRST PROBABLE PROBABLE FAULT FAULT FAULT FAULT ACTION ACTION * * CHECK CHECK APP2RangeLow...
  • Page 114 -111- -111-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. D D F F C C P P RO ROBA BABL BLE E F F AU AULT FAUL ULT T A A CT...
  • Page 115 ( ) Fault actions shown are default values specified by the OEM. ( ) Fault actions shown are default values specified by the OEM. -112- -112-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2.
  • Page 116 (*) Fault actions shown are default values specified by the OEM. (*) Fault actions shown are default values specified by the OEM. -113- -113-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE PROBABLE FAULT FAULT...
  • Page 117 (*) Fault actions shown are default values specified by the OEM. (*) Fault actions shown are default values specified by the OEM. -114- -114-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE PROBABLE FAULT FAULT...
  • Page 118 ( ) Fault actions shown are default values specified by the OEM. ( ) Fault actions shown are default values specified by the OEM. -115- -115-     Operation Section Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. Table 2.
  • Page 119 -116- -116-     Operation Section Operation Section Mono-Ped Control System (Option) Mono-Ped Control System (Option) Forward- Forward-Push the left side (2) of the pedal Push the left side (2) of the pedal for FORWARD direction travel. for FORWARD direction travel. Neutral- Neutral-The lift truck should not move when The lift truck should not move when...
  • Page 120 -117- -117-     Operation Section Operation Section Auto Shift Controller ASC-100 (If Equipped) Auto Shift Controller ASC-100 (If Equipped) Product Description Product Description Adjustments Adjustments The Autoshift controller is an electrical control The Autoshift controller is an electrical control system, specially designed for use on forklift trucks system, specially designed for use on forklift trucks (Direction Inhibit Point)
  • Page 121 -118- -118-     Operation Section Operation Section Diagnostics Features Diagnostics Features Operation Operation ASC-100 has an internal indicator on the right side ASC-100 has an internal indicator on the right side This system can basically operate in 2 pre-selected This system can basically operate in 2 pre-selected of the controller for displaying the selected gear of the controller for displaying the selected gear...
  • Page 122 -119- -119-     Operation Section Operation Section Manual Mode (Fail-Safe mode) Manual Mode (Fail-Safe mode) The system still allows movement of the vehicle in The system still allows movement of the vehicle in case of controller breakdown by selecting the case of controller breakdown by selecting the manual mode with the Fail-Safe mode Switch in the manual mode with the Fail-Safe mode Switch in the...
  • Page 123 -120- -120-     Operation Section Operation Section Operating Techniques Operating Techniques Inching into Loads Inching into Loads Lifting the Load Lifting the Load 1. 1.     Lift the load carefully and tilt the mast back a Lift the load carefully and tilt the mast back a short distance.
  • Page 124 -121- -121-     Operation Section Operation Section Traveling With the Load Traveling With the Load Unloading Unloading NOTICE NOTICE Travel with the load as low as possible, while still Travel with the load as low as possible, while still maintaining ground clearance.
  • Page 125 -122- -122-     Operation Section Operation Section     Turning Turning Typical Example Typical Example 3. 3.     Deposit the load and BACK away carefully to Deposit the load and BACK away carefully to 1. 1.     When turning sharp corners, keep close to the When turning sharp corners, keep close to the disengage the forks.
  • Page 126 -123- -123-     Operation Section Operation Section Lifting Drums or Round Objects Lifting Drums or Round Objects Operating in hot weather Operating in hot weather Keep the following points in mind when you operate Keep the following points in mind when you operate the lift truck in hot weather.
  • Page 127 -124- -124-     Operation Section Operation Section Parking the Lift Truck Parking the Lift Truck 5. 5. Turn the key in the ignition switch to the OFF Turn the key in the ignition switch to the OFF position and remove the key. position and remove the key.
  • Page 128 -125- -125-     Operation Section Operation Section Lift Fork Adjustment Lift Fork Adjustment WARNING WARNING When adjusting the fork spread, be careful not When adjusting the fork spread, be careful not to pinch your hand between forks and the to pinch your hand between forks and the carriage slot.
  • Page 129 -126- -126-     Operation Section Operation Section Storage Information Storage Information Before Storage Before Storage To Operate the Lift Truck after a To Operate the Lift Truck after a Long Time Storage Long Time Storage Before storing your lift truck, clean and inspect as Before storing your lift truck, clean and inspect as the following the following procedures.
  • Page 130 Check the state and local laws governing weight, width and length of a load. width and length of a load. Contact your DOOSAN Lift Truck dealer for Contact your DOOSAN Lift Truck dealer for shipping instructions for your lift truck.
  • Page 131 -128-     Operation Section Operation Section Towing Information Towing Information Consult your DOOSAN Lift Tuck dealer for towing a Consult your DOOSAN Lift Tuck dealer for towing a WARNING WARNING disabled lift truck. disabled lift truck. Personal injury or death could result when Personal injury or death could result when towing a disabled lift truck incorrectly.
  • Page 132 inclines or poor su inclines or poor surface conditions. rface conditions. -129- -129-     Maintenance Section Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for The following section gives practical guidelines for Some countries have standards or regulations Some countries have standards or regulations...
  • Page 133 -130- -130-     Maintenance Section Maintenance Section Repetitive O Repetitive Overloadi verloading Causes of Fork Failure Causes of Fork Failure       Repetitive cycling of loads which exceeds the Repetitive cycling of loads which exceeds the Improper Modification or Repair Improper Modification or Repair fatigue strength of the material can lead to fatigue fatigue strength of the material can lead to fatigue...
  • Page 134 -131- -131-     Maintenance Section Maintenance Section Fork Inspection Fork Inspection First Installation First Installation 1. 1.     Inspect forks to ensure they are the correct size Inspect forks to ensure they are the correct size for the truck on which they will be used. Make for the truck on which they will be used.
  • Page 135 -132- -132-     Maintenance Section Maintenance Section With the fork restrained in the same manner as With the fork restrained in the same manner as 12 Months Inspection 12 Months Inspection its mounting on the lift truck, apply the test load its mounting on the lift truck, apply the test load Forks should be inspected, at a minimum, every 12 Forks should be inspected, at a minimum, every 12...
  • Page 136 -133- -133-     Maintenance Section Maintenance Section Tire Inflation Information Tire Inflation Information Tire Inflation Tire Inflation Tire Shipping Pressure Tire Shipping Pressure The tire inflation pressures shown in the following The tire inflation pressures shown in the following chart are cold chart are cold inflation shipping pressures.
  • Page 137 -134- -134-     Maintenance Section Maintenance Section Torque Specifications Torque Specifications Metric Hardware Metric Hardware Torque for Standard Bolts, Nuts, Torque for Standard Bolts, Nuts, and Taperlock Studs and Taperlock Studs Most of the nu Most of the nuts, bolts, studs, and threaded holes in ts, bolts, studs, and threaded holes in your lift truck are metric.
  • Page 138 -135- -135-     Maintenance Section Maintenance Section Torque for Metric Fasteners Torque for Metric Fasteners Torques for Taperlock Studs Torques for Taperlock Studs Thread Size Thread Size Standard Taperlock Stud Torque Standard Taperlock Stud Torque NOTICE NOTICE Inch Inch  ...
  • Page 139 NOTICE NOTICE DOOSAN recommends that the coolant mixture DOOSAN recommends that the coolant mixture contain 50% commercially available automotive contain 50% commercially available automotive antifreeze, and 50% water. antifreeze, and 50% water.
  • Page 140 50% commercially available automotive antifreeze, 50% commercially available automotive antifreeze, DOOSAN prefers the use of distilled water or DOOSAN prefers the use of distilled water or or equivalent and acceptable water to maintain and or equivalent and acceptable water to maintain and...
  • Page 141 Fuel Types *As delivered to fuel system     *As delivered to fuel system DOOSAN Diesel Engines have the ability to burn a DOOSAN Diesel Engines have the ability to burn a wide variety of fuels. These fuels are divided into wide variety of fuels.
  • Page 142 LP varies slightly between different parts of the country and different refineries. HD5 or parts of the country and different refineries. HD5 or HD10 is recommended for DOOSAN forklift trucks. HD10 is recommended for DOOSAN forklift trucks. Composition of HD5 Composition of HD5  ...
  • Page 143 Consult your DOOSAN Lift Truck dealer for purging Consult your DOOSAN Lift Truck dealer for purging excessive wear.
  • Page 144 NOTE: NOTE:     Multi-grade Multi-grade oils oils blended blended DOOSAN for use in transmissions. DOOSAN for use in transmissions. • • ISO ISO 6743/4 6743/4 Multi-grade oils which use high molecular Multi-grade oils which use high molecular • • AFNOR...
  • Page 145 -142- -142-     Maintenance Section Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities and Refill Capacities Lubricant Viscosities Lubricant Viscosities Refill Capacities Refill Capacities LUBRICANT VISCOSITIES LUBRICANT VISCOSITIES REFILL CAPACITIES - (APPROXIMATE) REFILL CAPACITIES - (APPROXIMATE) FOR AMBIENT (OUTSIDE) TEMPERATURES     FOR AMBIENT (OUTSIDE) TEMPERATURES Gal.

  • Page 146: Table Of Contents

    -143- -143-     Maintenance Section Maintenance Section Maintenance Intervals Maintenance Intervals First 250 Service Hours or a Month First 250 Service Hours or a Month Hydraulic Return Filter – Hydraulic Return Filter – Change Change ..........
  • Page 147 188     Universal Universal Joint Joint – – Inspect Inspect ................188 Parking Brake Parking Brake - Test, - Test, Adjust Adjust ..............164 ...188     Air Intake Intake System - System - Change...
  • Page 148 -145- -145-     Maintenance Section Maintenance Section FIRST FIRST Quick Reference to Maintenance Schedule Quick Reference to Maintenance Schedule EVERY EVERY           s   s   s   s    k    k   s   s   s   s    h    h    h    h   e   e    l   y...
  • Page 149 I I n n s s p p e e c c t t F F o o o o t t P P e e d d a a l l O O p p e e r r a a t t i i o o n n ( ( G G 4 4 2 2 0 0 F F ( ( E E ) ) / / G G 4 4 2 2 4 4 F F ( ( E E ) ) O O n n l l y y ) ) 1 1 5 5 7 7 Inspect pect for...

  • Page 150: When Required

    -147- -147-     Maintenance Section Maintenance Section When Required When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation before performing any operation or maintenance procedures.

  • Page 151: Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset

    3. 3.     Lightly oil the hood latch mechanism and the Lightly oil the hood latch mechanism and the rod for the hood support cylinder. rod for the hood support cylinder. -148- -148-     Maintenance Section Maintenance Section Fuses, Bulbs, Circuit Breaker &...

  • Page 152: Priming The F Priming The Fuel System(Di Uel System(Diesel Engine O Esel Engine Only) Nly)

    Check the fuses. Use a flashlight, if necessary. Check the fuses. Use a flashlight, if necessary. -149- -149-     Maintenance Section Maintenance Section Circuit Breaker Circuit Breaker Priming the Fuel System(Diesel Priming the Fuel System(Diesel Engine Only) Engine Only) 4TNV98 Diesel Engine Only 4TNV98 Diesel Engine Only The fuel system needs to be primed under certain...
  • Page 153 seconds or until the fuel coming out of the air seconds or until the fuel coming out of the air bleed port is free o bleed port is free of bubbles. f bubbles. 4. 4.     Tighten the air bleed port. Tighten the air bleed port.

  • Page 154: Water Seperator (Diesel Engine Only) - Check, Drain

    -151- -151-     Maintenance Section Maintenance Section Water Seperator (Diesel Engine Water Seperator (Diesel Engine WARNING WARNING Only) - Check, Drain Only) - Check, Drain If the fuel filter/water separator is positioned If the fuel filter/water separator is positioned higher than the fuel level in the fuel tank, water higher than the fuel level in the fuel tank, water 4TNV98 Diesel Engine Only...
  • Page 155 -152- -152-     Maintenance Section Maintenance Section Test Fuel System for Leaks(LP and Dual Fuel Test Fuel System for Leaks(LP and Dual Fuel 4TNE98 Diesel Engine Only 4TNE98 Diesel Engine Only Engines Only) Engines Only) NEVER NEVER wait wait until until scheduled...

  • Page 156: Tires And Wheels (D, G-Series) - Inspect, Check

    -153- -153-     Maintenance Section Maintenance Section Tires and Wheels (D, G-Series) - Tires and Wheels (D, G-Series) - Carriage Roller Extrusion – Adjust Carriage Roller Extrusion – Adjust Inspect, Check Inspect, Check 1. 1.     Set the mast vertical. Set the mast vertical.

  • Page 157: Every 10 Service Hours Or Daily

    Do not, under an Do not, under any circumstances, y circumstances, attempt to rework, attempt to rework, weld, heat or b weld, heat or braze any rim components. raze any rim components. -154- -154-     Maintenance Section Maintenance Section Every 10 Service Hours or Daily Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual,...
  • Page 158 -155- -155-     Maintenance Section Maintenance Section 3. 3.     Start and run the engine to stabilize the coolant Start and run the engine to stabilize the coolant Coolant Level – Check Coolant Level – Check level in the filter neck. If low, add coolant until it level in the filter neck.

  • Page 159: Inspect Foot Pedal Operation (G420F(E)/G424F(E) Only) )

    -156- -156-     Maintenance Section Maintenance Section Air Cleaner Indicator-Check Air Cleaner Indicator-Check Walk-Around Inspection - Inspect Walk-Around Inspection - Inspect For maximum service life of the lift truck, make a For maximum service life of the lift truck, make a Checking Service Indicator Checking Service Indicator thorough walk-around inspection.

  • Page 160: Lubricate

    -157- -157-     Maintenance Section Maintenance Section     Mast Channels – Lubricate Mast Channels – Lubricate 8. 8.     Inspect the cooling system for leaks, worn Inspect the cooling system for leaks, worn hoses and debris buildup. hoses and debris buildup.

  • Page 161: Check

    -158- -158-     Maintenance Section Maintenance Section Transmission Oil Level – Check Transmission Oil Level – Check Parking Brake - Inspect Parking Brake - Inspect Inspection from Operator's Seat, Engine Inspection from Operator's Seat, Engine WARNING WARNING Hot oil and components can cause personal Hot oil and components can cause personal injury.
  • Page 162 -159- -159-     Maintenance Section Maintenance Section PARKING BRAKE PARKING BRAKE NOTE: NOTE:     The parking brake is required to be The parking brake is required to be adjusted to hold the lift truck with capacity adjusted to hold the lift truck with capacity load on a 15% grade.

  • Page 163: First 50 - 100 Service Hours Or A Week

    -160- -160-     Maintenance Section Maintenance Section First 50 - 100 Service Hours or a Week 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, You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation before performing any operation or maintenance procedures.
  • Page 164 4. 4.     Add new engine oil to Add new engine oil to the engine as specified in the engine as specified in Adding Engine Oil on page 4-14. Adding Engine Oil on page 4-14. Fig ure 5- ure 5-1 1  ...
  • Page 165 engine life. engine life. Engine oil and filter element must be changed after Engine oil and filter element must be changed after the first 50 hours. the first 50 hours. -162- -162-     Maintenance Section Maintenance Section     12.

  • Page 166: Change

    -163- -163-     Maintenance Section Maintenance Section Drive Axle Oil - Change Drive Axle Oil - Change Parking Brake - Test, Adjust Parking Brake - Test, Adjust Park the lift truck on a level surface. Apply the Park the lift truck on a level surface. Apply the Parking Brake Testing Parking Brake Testing parking brake.
  • Page 167 -164- -164-     Maintenance Section Maintenance Section   WARNING   WARNING To prevent personal injury, the operator MUST To prevent personal injury, the operator MUST be ready to use the service brake if the parking be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck brake is not adjusted correctly and the lift truck starts to move.
  • Page 168 further and pull downward and turn the clevis further and pull downward and turn the clevis (5) until the pin (3) (5) until the pin (3) fits into the brake lever when fits into the brake lever when the lever (1) is held against the stop pin (2). the lever (1) is held against the stop pin (2).

  • Page 169: Every 250 Service Hours Or Monthly

    -166- -166-     Maintenance Section Maintenance Section Every 250 Service Hours or Monthly Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation before performing any operation or maintenance procedures.
  • Page 170 service indicator stays locked in the visible position service indicator stays locked in the visible position or 6 months section or 6 months section with the engine stopped. with the engine stopped. 10.     Stop the engine and close the hood and seat Stop the engine and close the hood and seat assembly.

  • Page 171: Brake Oil Level - Brake Oil Level - Che Check

    -168- -168-     Maintenance Section Maintenance Section Checking Element Checking Element Hydraulic Oil Level – Check Hydraulic Oil Level – Check WARNING WARNING At operating temperature, the hydraulic tank is At operating temperature, the hydraulic tank is hot and under pressure. hot and under pressure.

  • Page 172: Check

    -169- -169-     Maintenance Section Maintenance Section 5. 5.     Raise and lower the carriage a few times to Raise and lower the carriage a few times to Drive Axle Oil Level - Check Drive Axle Oil Level - Check allow lubricant to enter into the chain links.

  • Page 173: Battery Terminal - Clean, Battery Terminal - Clean, Inspect Inspect

    -170- -170-     Maintenance Section Maintenance Section Battery Terminal - Clean, Inspect Battery Terminal - Clean, Inspect Engine Oil & Filter (LP & Gasoline Engine Oil & Filter (LP & Gasoline Engine Only) - Change Engine Only) - Change WARNING WARNING Gasoline, LP Engine Crankcase...
  • Page 174 mounting base. Make sure the entire old gasket mounting base. Make sure the entire old gasket is removed. is removed. -171- -171-     Maintenance Section Maintenance Section 7. 7.     Before installing a new filter element, apply a Before installing a new filter element, apply a PCV Valve System - Inspect, PCV Valve System - Inspect,...

  • Page 175: Wheel Bolts Wheel Bolts & Nuts & Nuts - In - Inspect Spect

    -172- -172-     Maintenance Section Maintenance Section Wheel Bolts & Nuts - Inspect Wheel Bolts & Nuts - Inspect Inspect Tightness (GC - Series) Inspect Tightness (GC - Series) Drive Wheels Drive Wheels Inspect Tightness (D, G - Series) Inspect Tightness (D, G - Series) Steer Wheels Steer Wheels...

  • Page 176: Governor Lever And Engine Speed Control

    -173- -173-     Maintenance Section Maintenance Section Governor Lever and Engine Speed Governor Lever and Engine Speed WARNING WARNING Control (Diesel Engine Only) - Control (Diesel Engine Only) - NEVER attempt to adjust the low or high idle NEVER attempt to adjust the low or high idle Check ,Adjust Check ,Adjust speed limit screw.
  • Page 177 loosen the throttle cable lock nut loosen the throttle cable lock nut (Figure 5-11, (Figure 5-11, (4)) (4)) and adjust the cable so the governor lever  and adjust the cable so the governor lever makes proper contact with the high / low idle makes proper contact with the high / low idle speed limit screw speed limit screw...

  • Page 178: Every 500 Service Hours Or 3 Months

    Fig ure 5- ure 5-12     -175- -175-     Maintenance Section Maintenance Section Every 500 Service Hours or 3 Months Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation before performing any operation or maintenance procedures.

  • Page 179: Crosshead Rollers - Crosshead Rollers - Inspect Inspect

    -176- -176-     Maintenance Section Maintenance Section Mast Pivot Eyes-Lubricate Mast Pivot Eyes-Lubricate Typical Example Typical Example 3. 3.     To adjust the cylinder rod extension, move the To adjust the cylinder rod extension, move the Typical Example Typical Example spacer to the rear and loosen the pinch bolt on spacer to the rear and loosen the pinch bolt on...

  • Page 180: Transmission Oil Filter - Transmission Oil Filter - Change Change

    -177- -177-     Maintenance Section Maintenance Section Transmission Oil Filter – Change Transmission Oil Filter – Change Overhead Guard – Inspect Overhead Guard – Inspect WARNING WARNING Hot oil and components can cause personal Hot oil and components can cause personal injury.

  • Page 181: Drive Axle Oil & Strainer - Change, Clean Drive Axle Oil & Strainer - Change, Clean

    10.     Check for oil leaks at the fil Check for oil leaks at the filters. ters. 11.     Stop the engine. Install the floor mat and floor Stop the engine. Install the floor mat and floor plate. plate.

  • Page 182: Steer Suspension - Steer Suspension - Inspect Inspect

    -179- -179-     Maintenance Section Maintenance Section Steer Suspension – Inspect Steer Suspension – Inspect Inching & Braking Control Shaft - Inching & Braking Control Shaft - Lubricate Lubricate     1. 1.     Inspect the suspension mounting bolts. Tighten Inspect the suspension mounting bolts.

  • Page 183: Inspect Vacuum Lines And Fittings (G420F(E)/G424F (G420F(E)/G424F(E) (E) Engine Engine Only) Only)

    -180- -180-     Maintenance Section Maintenance Section Inspect Vacuum Lines and Inspect Vacuum Lines and Fittin Fittings Inspect Electrical System Inspect Electrical System (G420F(E)/G (G420F(E)/G424F(E) Engine 424F(E) Engine Only) Only) (G420F(E)/G (G420F(E)/G424F(E) Engine 424F(E) Engine Only) Only) 1. 1.     Visually inspect vacuum lines and fittings for Visually inspect vacuum lines and fittings for 1.

  • Page 184: Fuel Filter (Diesel Engi Fuel Filter (Diesel Engine Only) - Change Ne Only) - Change

    -181- -181-     Maintenance Section Maintenance Section Fuel Filter (Diesel Engine Only) - Fuel Filter (Diesel Engine Only) - 4TNE98 Diesel Engine Only 4TNE98 Diesel Engine Only Change Change Replace the fuel filter at specified intervals to Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the prevent contaminants from adversely affecting the 4TNV98 Diesel Engine Only...

  • Page 185: Engine Oil & Filter (Diesel Engine Only) - Change

    -182- -182-     Maintenance Section Maintenance Section     17.     Install the new fuel filter Install the new fuel filter (Figure 5-14, (2)) (Figure 5-14, (2))    by turning it to the right turning it to the right (Figure 5-14, (4)) (Figure 5-14, (4)) ...

  • Page 186: Water Separator (4Tnv98 Diesel Engine Only) - Clean

    16.     Clean the fuel filter mounting surface Clean the fuel filter mounting surface (Figure (Figure 5-15, (10)) 5-15, (10)) and apply a small amount of diesel  and apply a small amount of diesel fuel to the gasket of the fuel to the gasket of the new filter.

  • Page 187: Every 1000 Service Hours Or 6 Months

    5. 5.     Carefully hold the cup to prevent fuel from Carefully hold the cup to prevent fuel from spilling. If you spill any fuel, clean up the spill spilling. If you spill any fuel, clean up the spill completely.

  • Page 188: Adjust

    -185- -185-     Maintenance Section Maintenance Section Transmission Oil, Oil Filter & Transmission Oil, Oil Filter & Check for Equal Tension Check for Equal Tension Strainer - Check, Clean, Change Strainer - Check, Clean, Change See topic, “Transmission Oil, Oil Filter & Strainer- See topic, “Transmission Oil, Oil Filter &...
  • Page 189 -186- -186-     Maintenance Section Maintenance Section Carriage Chain Adjustment Carriage Chain Adjustment Mast Chain Adjustment - FF, FFT Mast Mast Chain Adjustment - FF, FFT Mast Make sure that carriage height is correct. If correct, Make sure that carriage height is correct. If correct, adjust the chain for equal tension.
  • Page 190 completed. completed. -187- -187-     Maintenance Section Maintenance Section Universal Joint – Inspect Universal Joint – Inspect Air Intake System - Change Air Intake System - Change Changing Primary Element Changing Primary Element See topic, “Air Intake System - Check, Clean” in See topic, “Air Intake System - Check, Clean”...

  • Page 191: Inspect Inspect Coolant Coolant Hoses Hoses (Lp, (Lp, Dual Dual Fuel Fuel Engine Only) Engine Only)

    -188- -188-     Maintenance Section Maintenance Section Inspect Coolant Hoses Inspect Coolant Hoses Fuel Lines & Fittings - Check Fuel Lines & Fittings - Check (LP, Dual Fuel Engine Only) (LP, Dual Fuel Engine Only) Visually inspect fuel lines and fittings for physical Visually inspect fuel lines and fittings for physical damage.

  • Page 192: Engine Valve Lash (Diesel Engine Only) - Check, Adjust

    -189- -189-     Maintenance Section Maintenance Section Engine Valve Lash (Diesel Engine Engine Valve Lash (Diesel Engine Only) - Check, Adjust Only) - Check, Adjust NOTICE NOTICE The valve clearances are to be adjusted at the The valve clearances are to be adjusted at the times of the fol times of the following situations.

  • Page 193: Every 1500 Service Hours Or 9 Months

    -190- -190-     Maintenance Section Maintenance Section Every 1500 Service Hours or 9 Months Every 1500 Service Hours or 9 Months Inspect Ignition System (LP, Inspect Ignition System (LP, Replace Spark Plugs (G424F(E) Replace Spark Plugs (G424F(E) Gasoline & Dual Fuel Engines Gasoline &...

  • Page 194: Replace Lp Fuel Filter Element

    -191- -191-     Maintenance Section Maintenance Section 3. 3.     Check bottom cover O-ring seal (6) for damage. Check bottom cover O-ring seal (6) for damage. Replace LP Fuel Filter Element Replace LP Fuel Filter Element Replace if necessary. Replace if necessary.

  • Page 195: Clean, Test Clean, Test

    (1) LP fuel lock off (1) LP fuel lock off 2. 2.     Replace the filter element (7). Replace the filter element (7). (2) Regulator/Conv Regulator/Converter erter (3) Fuel Trim valve (FTV) (3) Fuel Trim valve (FTV) -192- -192-  ...

  • Page 196: Every 2000 Service Hours Or Yearly

    To inspect the diaphragm and spring To inspect the diaphragm and spring (Figure5-19, (Figure5-19, (3)) (3)): : 1. 1.     Remove the bolts retaining the diaphragm Remove the bolts retaining the diaphragm cover cover (Figure5-19, (4)) (Figure5-19, (4)). . -193- -193-  ...
  • Page 197 -194- -194-     Maintenance Section Maintenance Section 3. 3.     Straighten the lock washer Straighten the lock washer tangs. tangs. 8. 8.     Install the outer wheel bearing and the out Install the outer wheel bearing and the out washer.

  • Page 198: Drive Wheel Bearing

    Torque for wheel bolts (1) is 270 ± 25 N•m (200 ± 20 lb•ft). 20 lb•ft). Consult your DOOSAN lift truck dealer for the Consult your DOOSAN lift truck dealer for the proper wheel bearing reassembling procedure. proper wheel bearing reassembling procedure.
  • Page 199 Apply Loctite No.242 to threads of spindle bolts Apply Loctite No.242 to threads of spindle bolts (5).Torque for spindle bolts is 115 ± 14 N•m (85 ± (5).Torque for spindle bolts is 115 ± 14 N•m (85 ± 10 lb•ft). 10 lb•ft).
  • Page 200 4TNE98 3.3L Diesel Engine 4TNE98 3.3L Diesel Engine -197- -197-     Maintenance Section Maintenance Section     NOTICE NOTICE Hold the drain port when the radiator drain valve is Hold the drain port when the radiator drain valve is turned because the tank and the drain port are turned because the tank and the drain port are separated.

  • Page 201: Forks - Inspect

    Contact Contact your your local local DOOSAN DOOSAN Lift Lift Truck Truck Dealer Dealer further further 2. 2.     Check the angle between the upper face of the Check the angle between the upper face of the information.
  • Page 202 exceeds 93 degrees or deviates by more than 3 exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees from an original angle other than 90 degrees, as may be found in some special degrees, as may be found in some special application forks.

  • Page 203: Every 2500 Service Hours Or 15 Months

    prevented from sliding off the end of the carriage by prevented from sliding off the end of the carriage by stop blocks. These stop blocks are at both ends of stop blocks. These stop blocks are at both ends of the carriage and in the path of the bottom fork hook.

  • Page 204: Replace Oxygen Sensor (G420F(E)/G424F(E)

    -201- -201-     Maintenance Section Maintenance Section 4. 4.     Assemble new oxygen sensor Assemble new oxygen sensor Replace Oxygen Sensor Replace Oxygen Sensor Tightening torque : 45 N•m (32 Tightening torque : 45 N•m (32.5 lb•ft) .5 lb•ft) (G420F(E)/G424F(E) Engine Only) (G420F(E)/G424F(E) Engine Only) 5.

  • Page 205: Checking The Tmap Sensor (G420F(E)/G424F(E)

    2. 2.     Disconnect the electrical connector of oxygen Disconnect the electrical connector of oxygen (1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug (1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug sensor sensor 3.

  • Page 206: Every 3000 Service Hours Or 18 Months

    -203- -203-     Maintenance Section Maintenance Section Every 3000 Service Hours or 18 Months Every 3000 Service Hours or 18 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation before performing any operation or maintenance procedures.
  • Page 207 -204- -204-     Index Section Index Section Index Index Changing Changing Primary Primary Element Element ..............188 .188     Changing Changing Secondary Secondary Element Element ............188 .188    ...
  • Page 208 Change Change ..........................171 ..171     Causes of Causes of Fork F Fork Failu ailure re.................. 131     Center Center of of Gravity Gravity (CG) (CG) ..................21 Engine Oil (DEO and EO)........141 Engine Oil (DEO and EO)........141  ...
  • Page 209 General General Fuel Fuel Information Information ................139     General General Hazard Info Hazard Information rmation ..............10     General Warning to General Warning to Operator Operator ......
  • Page 210 Opera Operating ting in in hot hot weather. weather................124 Servi Service ce Brake Brake Pedal Pedal ..............69 ......69         Opera Operating ting Technique Techniques.......... s.......... 121     Servicing Filter Element........167 Servicing Filter Element........167  ...

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