Page 1 SB2356E0 SB2356E0 Operation & Operation & Maintenance Manual Maintenance Manual FORKLIFTS FORKLIFTS D50S-5, D60S-5, D70S-5 D50S-5, D60S-5, D70S-5 D80S-5, D90S-5 D80S-5, D90S-5 G50S-5, G60S-5, G70S-5 G50S-5, G60S-5, G70S-5 Original Instruction Original Instruction 1304 1304...
Page 2: Table Of Contents
Table of Contents Table of Contents Table of Contents Table of Contents Information Section Information Section Maintenan Maintenance ce Section Section Foreword ..............eword ..............2 2 Inspection, Maintenance and Repair of Lift Truck Inspection, Maintenance and Repair of Lift Truck ...
Page 3: Information Section
Your DOOSAN truck comes equipped with an Your DOOSAN truck comes equipped with an product design might have caused changes to your product design might have caused changes to your operator restraint system. Should it become operator restraint system.
Page 4 Environment Management The Operation Section is a reference for the new The Operation Section is a reference for the new Note Note that that DOOSAN DOOSAN INDUSTRIAL INDUSTRIAL VEHICLE VEHICLE operator and a refresher for operator and a refresher for the experienced one.
Page 5: Safety Section
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 available.
Page 6: Safety
Training Required To Operate or Service 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 Machinery Directive 98/37/EC and EMC directive Machinery Directive 98/37/EC and EMC directive 2004/108/EC.
Page 7 Safety Section Safety Section 10. Be sure operating surface can safely support Be sure operating surface can safely support General Warnings to Operator General Warnings to Operator machine. machine. 11. Operate machine and attachments only from Operate machine and attachments only from operator's position.
Page 8 Safety Section Safety Section Pressure Warning Pressure Warning No Standing On Forks Warning, No No Standing On Forks Warning, No Standing Under Forks Warning Standing Under Forks Warning WARNING WARNING WARNING WARNING Contents under pressure may be hot. Allow to Contents under pressure may be hot.
Page 9 Safety Section Safety Section Overhead Guard Must Be In Place Overhead Guard Must Be In Place Moving Fan Warning Moving Fan Warning Warning Warning WARNING WARNING WARNING WARNING To avoid personal injury, stay clear of moving To avoid personal injury, stay clear of moving fan.
Page 10 Safety Section Safety Section WARNING WARNING When leaving machine apply parking brake! When leaving machine apply parking brake! Parking brake is not automatically applied. Parking brake is not automatically applied. Alarm will sound if parking brake is not applied. Alarm will sound if parking brake is not applied.
Page 11: General Hazard Information
Safety Section Safety Section Do not raise loads any higher than necessary and Do not raise loads any higher than necessary and General Hazard Information General Hazard Information never raise a load higher than 1830 mm (72 in) with never raise a load higher than 1830 mm (72 in) with the overhead guard removed.
Page 12 Adjust the seat so that full brake pedal travel can be Adjust the seat so that full brake pedal travel can be please contact your DOOSAN dealer. We would like please contact your DOOSAN dealer. We would like obtained with the operator's back against the...
Page 13 Safety Section Safety Section Operate the lift truck and controls only from the Operate the lift truck and controls only from the Operating the Lift Truck Operating the Lift Truck operator's station. operator's station. Always keep the lift truck under control. Always keep the lift truck under control.
Page 14 Safety Section Safety Section some trailers, extra supports may be needed to some trailers, extra supports may be needed to prevent upending or corner dipping. prevent upending or corner dipping. Be certain dock plates are in good condition and Be certain dock plates are in good condition and properly placed and secured.
Page 15 To avoid possible weakening of the Falling Objects   incline. incline. Protective Structure (FOPS), consult a DOOSAN Protective Structure (FOPS), consult a DOOSAN dealer before altering, by adding weight to, welding dealer before altering, by adding weight to, welding Pressure Air Pressure Air on, or cutting or drilling holes into the structure.
Page 16 Safety Section Safety Section Burn Prevention Burn Prevention Fire or E Fire or Explosio xplosion Prevention n Prevention All fuels, most lubricants and some coolant mixtures All fuels, most lubricants and some coolant mixtures Coolant Coolant are flammable. are flammable. At operating temperature, the engine coolant is hot At operating temperature, the engine coolant is hot and under pressure.
Page 17 Leaks can cause fires. Contact nitrogen is still preferred for adjusting the pressure. nitrogen is still preferred for adjusting the pressure. your DOOSAN dealer for repair or replacement. your DOOSAN dealer for repair or replacement. Nitrogen mixes properly with air.
Page 18 See you DOOSAN Lift Truck dealer for new part. See you DOOSAN Lift Truck dealer for new Seat A...
Page 19 Safety Section Safety Section Weight ad Weight adjustment justment If Optional Suspension Seat Equipped If Optional Suspension Seat Equipped Pull the weight adjustment lever upwards and move Pull the weight adjustment lever upwards and move Forward and Backward Adjustment Forward and Backward Adjustment right or left side.
Page 20 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 become necessary to replace the seat for any 1.
Page 21 Safety Section Safety Section Release the Seat Belt Release the Seat Belt WARNING WARNING If you fasten the belt across your abdomen, the If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. belt may injure your abdomen in an accident.
Page 22 Safety Section Safety Section Stability and Center of Gravity Stability and Center of Gravity Avoiding Lift Truck Tipover Avoiding Lift Truck Tipover Lift Truck Stability Lift Truck Stability The stability of the lift truck is determined by the The stability of the lift truck is determined by the location of its CG;...
Page 23 If the CG moves outside of the line will tip forward. If the CG moves outside of the line 2. 2. DOOSAN assumes no responsibility for lift trucks DOOSAN assumes no responsibility for lift trucks on either side of the stability base, the lift truck will...
Page 24: Safety Rules
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 seat. Keep hands and feet inside the operator’s seat. Keep hands and feet inside the operator’s compartment.
Page 25 Safety Section Safety Section Do not overload. Always handle loads within the Do not overload. Always handle loads within the Do not raise anyone on the forks of your lift truck. Do not raise anyone on the forks of your lift truck. rated capacity shown on the capacity plate.
Page 26 Safety Section Safety Section Do not elevate the load with the mast til Do not elevate the load with the mast tilted forward. ted forward. Do not permit anyone to stand or walk under the Do not permit anyone to stand or walk under the Do not tilt the elevated loads forwards.
Page 27 Safety Section Safety Section Do not stack or turn on ramps. Do not stack or turn on ramps. 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 28 Safety Section Safety Section Park your lift truck in authorized areas only. Fully Park your lift truck in authorized areas only. Fully Do not operate your truck close to another truck. Do not operate your truck close to another truck. lower the forks to the floor, put direction lever in lower the forks to the floor, put direction lever in Always keep a safe distance from other trucks and...
Page 29 Safety Section Safety Section An unloaded forklift may be easier to tip over than a An unloaded forklift may be easier to tip over than a operate operate forklifts forklifts near near flammable flammable loaded truck. loaded truck. combustible materials. combustible materials.
Page 30: How To Survive In A Tipover (If Operator Restraint System Equipped)
Safety Section Safety Section How to Survive in a Tipover (If How to Survive in a Tipover (If Operator Restraint System Operator Restraint System Equipped) Equipped) 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: General Section
Safety Section Safety Section Lean away from the direction of fall. Lean away from the direction of fall. Lean forward. Lean forward. General Section General Section...
Page 32 Technical File According to 2006/42/EC and Keeper of Technical File According to 2000/14/EC Technical File According to 2000/14/EC Doosan Industrial Vehicle Europe N.V, Mr. Y.W. Chung Doosan Industrial Vehicle Europe N.V, Mr. Y.W. Chung Europark Noord 36 A 9100...
Page 33 CHARACTERISTICS CHARACTERISTICS 3 Speed, TIER- 3 Speed, TIER- Ⅱ Ⅱ Manufacturer Manufacturer DOOSAN DOOSAN DOOSAN DOOSAN MODEL MODEL D50S-5 D50S-5 D60S-5 D60S-5 Capacity Capacity at at rated rated load load center center 5000 5000 6000 6000 Load Load center...
Page 34 3 Speed, TIER- 3 Speed, TIER- Ⅱ Ⅱ DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D70S-5 D70S-5 D80S-5 D80S-5 D90S-5 D90S-5 7000 7000 8000 8000 9000 9000 diesel diesel diesel diesel diesel diesel rider-seated rider-seated rider-seated rider-seated rider-seated rider-seated...
Page 35 CHARACTERISTICS CHARACTERISTICS 3 Speed, TIER- 3 Speed, TIER- Ⅲ Ⅲ Manufacturer Manufacturer DOOSAN DOOSAN DOOSAN DOOSAN MODEL MODEL D50S-5 D50S-5 D60S-5 D60S-5 Capacity Capacity at at rated rated load load center center 5000 5000 6000 6000 Load Load center...
Page 36 3 Speed, TIER- 3 Speed, TIER- Ⅲ Ⅲ DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D70S-5 D70S-5 D80S-5 D80S-5 D90S-5 D90S-5 7000 7000 8000 8000 9000 9000 diesel diesel diesel diesel diesel diesel rider-seated rider-seated rider-seated rider-seated rider-seated rider-seated...
Page 37 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,diesel,gasoline,LPG electric,diesel,gasoline,LPG Operator Operator type type stand-on, stand-on, rider-seated rider-seated Tire Tire type type c=cushion, c=cushion, p=pneumatic...
Page 38 2 Speed, TIER- 2 Speed, TIER- Ⅱ Ⅱ DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D50S-5 D50S-5 D60S-5 D60S-5 D70S-5 D70S-5 5000 5000 6000 6000 7000 7000 diesel diesel diesel diesel diesel diesel rider-seated rider-seated rider-seated rider-seated rider-seated rider-seated...
Page 39 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,diesel,gasoline,LPG electric,diesel,gasoline,LPG Operator Operator type type stand-on, stand-on, rider-seated rider-seated Tire Tire type type c=cushion, c=cushion, p=pneumatic...
Page 40 2 Speed, TIER- 2 Speed, TIER- Ⅲ Ⅲ DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D50S-5 D50S-5 D60S-5 D60S-5 D70S-5 D70S-5 5000 5000 6000 6000 7000 7000 diesel diesel diesel diesel diesel diesel rider-seated rider-seated rider-seated rider-seated rider-seated rider-seated...
Page 41 Specifications Specifications CHARACTERISTICS CHARACTERISTICS TIER- TIER- Ⅱ Ⅱ Manufacturer Manufacturer DOOSAN DOOSAN DOOSAN DOOSAN MODEL MODEL G50S-5 G50S-5 G60S-5 G60S-5 Capacity Capacity at at rated rated load load center center 5000 5000 6000 6000 Load Load center center...
Page 42 TIER- TIER- TIER- TIER- Ⅱ Ⅱ Ⅲ Ⅲ DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN G70S-5 G70S-5 G50S-5 G50S-5 G60S-5 G60S-5 G70S-5 G70S-5 7000 7000 5000 5000 6000 6000 7000 7000 rider-seated rider-seated rider-seated rider-seated...
Page 43 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,diesel,gasoline,LPG electric,diesel,gasoline,LPG Operator Operator type type stand-on, stand-on, rider-seated rider-seated Tire Tire type type c=cushion, c=cushion, p=pneumatic...
Page 44 NON_CERTI NON_CERTI DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN G50S-5 G50S-5 G60S-5 G60S-5 G70S-5 G70S-5 5000 5000 6000 6000 7000 7000 rider-seated rider-seated rider-seated rider-seated rider-seated rider-seated 3000 3000 3000 3000 3000 3000 60x150x1200 60x150x1200 60x180x1200 60x180x1200 60x180x1200 60x180x1200 350x2032 350x2032...
Page 45 3 Speed, Interim TIER- 3 Speed, Interim TIER- CHARACTERISTICS CHARACTERISTICS Manufacturer Manufacturer DOOSAN DOOSAN DOOSAN DOOSAN MODEL MODEL D50S-5 D50S-5 D60S-5 D60S-5 Capacity Capacity at at rated rated load load center center 6000 6000 Load Load center center...
Page 46 3 Speed, Interim TIER- 3 Speed, Interim TIER- DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D70S-5 D70S-5 D80S-5 D80S-5 D90S-5 D90S-5 7000 7000 8000 8000 9000 9000 diesel diesel diesel diesel diesel diesel rider-seated rider-seated rider-seated rider-seated rider-seated rider-seated...
Page 47 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,diesel,gasoline,LPG electric,diesel,gasoline,LPG Operator Operator type type stand-on, stand-on, rider-seated rider-seated Tire Tire type type c=cushion, c=cushion, p=pneumatic...
Page 48 2 Speed, Interim TIER- 2 Speed, Interim TIER- DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN DOOSAN D50S-5 D50S-5 D60S-5 D60S-5 D70S-5 D70S-5 6000 6000 7000 7000 diesel diesel diesel diesel rider-seated rider-seated rider-seated rider-seated 3000 3000 3000 3000 60x180x1200 60x180x1200...
Page 49 12053 Drive-By Drive-By Lifting Mode Lifting Mode Directive Directive 2000/14/EC 2000/14/EC D50S-5, D60S-5 D50S-5, D60S-5 W/O Cabin W/O Cabin 83.7 83.7 85.8 85.8 81.3 81.3 78.3 78.3 ...
Page 50: Capacity Chart - - With
Capacity Chart - Without Side Shifter Capacity Chart - Without Side Shifter MODEL MODEL 5 5 - - S S 0 0 5 5 G G , , 5 5 - - S S 0 0 A.
Page 51 Capacity Chart - Without Side Shifter Capacity Chart - Without Side Shifter MODEL MODEL 5 5 - - 0 0 S S 8 8 D D A-FFT 4350~5400mm MAST A-FFT 4350~5400mm MAST B-FFT 5850mm MAST B-FFT 5850mm MAST ...
Page 52 Capacity Chart - With Side Shifter Capacity Chart - With Side Shifter MODEL MODEL 5 5 - - S S 0 0 5 5 G G 5 5 , , - - S S A. FFT 4550mm MAST A.
Page 53 Capacity Chart - With Side Shifter Capacity Chart - With Side Shifter MODEL MODEL 5 5 - - S S 0 0 8 8 D D A-FFT A-FFT 4350mm 4350mm MAST MAST A-STD A-STD 3100~3600m 3100~3600mm m MAST MAST B-FFT B-FFT...
Page 54 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 numbers spaces spaces provided provided below below photographs. photographs. Interim TIER-4 Diesel En Interim TIER-4 Diesel Engine Serial Number (V3800) gine Serial Number (V3800) .______________________________...
Page 55 D50/60/70S-5(2 speed), G50/60/70S-5 D50/60/70S-5(2 speed), G50/60/70S-5 D50/60/70/80/90S-5(3 speed) D50/60/70/80/90S-5(3 speed) Transmission Serial Number Transmission Serial Number .______________________________ .______________________________ DRIVE AXLE Serial Number (OCDB type) DRIVE AXLE Serial Number (OCDB type) .______________________________ .______________________________ D50/60/70S-5(2 speed), G50/60/70S-5 D50/60/70S-5(2 speed), G50/60/70S-5 Transmission Serial Number Transmission Serial Number .______________________________ .______________________________...
Page 56 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 ATTACHMENT PLATES. DO NOT exceed Capacity as equipped l ATTACHMENT PLATES. DO NOT exceed Capacity as equipped load ratings. oad ratings.
Page 57: Operation Section
Identification, Lift Capacity and Attachment Plate Identification, Lift Capacity and Attachment Plate (includes Special Forks) (includes Special Forks) and their meanings. and their meanings. Mast Abbreviations Mast Abbreviations SC- Special Special Carriage-increased Carriage-increased width, width, height or outreach height or outreach STD - STD - Standard Mast...
Page 58 1. 1. Horn Switch Horn Switch 2. 2. Steering Handwheel Steering Handwheel 3. 3. Turn Signal Lever Turn Signal Lever 4. 4. Instrument Panel Instrument Panel 5. 5. Parking Brake Lever Parking Brake Lever 6. 6. Lift Lever Lift Lever 7.
Page 59 5. Hour Counter 5. Hour Counter Instrument Panel Instrument Panel 1. Engine Ignition Start Switch 1. Engine Ignition Start Switch Indicates the total number of Indicates the total number of hours the engine and the lift hours the engine and the lift The key switch is a four position The key switch is a four position truck have operated.
Page 60 9. Light Switch 9. Light Switch st st Switch Switch Light Light Clearance Clearance Lamp Lamp Tail Tail Lamp Lamp License License plate plate Lamp Lamp Instrument Instrument Lamp Lamp Head Head Lamp Lamp O : means “lights on” O : means “lights on”...
Page 61 - Kubota V3800 ( Interim Tier - Kubota V3800 ( Interim Tier Operation Section Operation Section 1. 1. Upper Upper Indicator Indicator Light Light 12. Transmission Transmission Neutral Neutral Position Position Light Light...
Page 62 2. 2. Air Air Cleaner Cleaner Indicator Indicator Light Light 13. Engine Engine Malfunction Malfunction Indicator Indicator Light Light 3. 3. Alternator Alternator Indicator Indicator Light Light 14. Directional Directional Turning Turning Indicator Indicator Lights Lights 4. 4. Diesel Diesel Engine Engine Start Start Preheat Preheat Indicator...
Page 63 Engine control systems are equipped with Engine control systems are equipped with Blinking of the light indicates the quantity Blinking of the light indicates the quantity built-in fault diagnostics. Detected system built-in fault diagnostics. Detected system of PM loaded on DPF is required of of PM loaded on DPF is required of faults can be displayed by the Malfunction faults can be displayed by the Malfunction...
Page 64 This This switch switch used used performing performing Typical Example Typical Example operation relevant to DPF regeneration. If operation relevant to DPF regeneration. If The tilting angle of the steering wheel is adjustable The tilting angle of the steering wheel is adjustable the light of the same logo of the top the light of the same logo of the top within a range of 15 degrees to suit individual...
Page 65 Capacity Capacity Engine Engine Start Start Alternator, Alternator, ECU, ECU, Fuel, Fuel, Iso3691 Iso3691 Valve Valve T/M Solenoid Solenoid Valve Valve Control Control Sys. Sys. Cabin Cabin Relay Relay Coil, Coil, Aircon Aircon Relay Relay Coil Coil Gague Gague Panel, Panel, Strobe Strobe Light Light...
Page 66 Engine Engine Start Start ECU(Engine Control Unit) Main Relay Coil, ECU(Engine Control Unit) Main Relay Coil, Iso3691 Valve, Alternator Iso3691 Valve, Alternator T/M Solenoid Solenoid Valve Valve Control Control Sys. Sys. Cabin Cabin Relay Relay Coil, Coil, Aircon Aircon Relay Relay Coil Coil Gague...
Page 67: Seat Switch System
Typical Example Diesel Engine Truck Typical Example Diesel Engine Truck Circuit Breaker protects the main electrical circuit. It Circuit Breaker protects the main electrical circuit. It is located in the engine compartment on the left is located in the engine compartment on the left side.
Page 68: Lift Truck Controls
If seat or seat switch replacement becomes remain in that forward or reverse location although remain in that forward or reverse location although necessary, be sure to use genuine DOOSAN necessary, be sure to use genuine DOOSAN internally the transmission will have shifted into internally the transmission will have shifted into Infracore lift truck parts.
Page 69 machine is parked, "LOCK" the direction control machine is parked, "LOCK" the direction control Direction Control Lever Direction Control Lever lever in "NEUTRAL" to prevent accidental lever in "NEUTRAL" to prevent accidental machine movement. machine movement. Transmission Display (3 Speed Transmission Display (3 Speed Only) Only)
Page 70 This switch changes over the modes of the inching This switch changes over the modes of the inching Automatic speed range: Automatic speed range: control pedal, inching and no-inching. control pedal, inching and no-inching. . FORWARD: 3 speeds. . FORWARD: 3 speeds. .
Page 71 Typical Example Typical Example Typical Example Typical Example Push DOWN on the brake pedal to slow or Push DOWN on the brake pedal to slow or stop the lift truck. stop the lift truck. Inching Control Pedal - Pushing down on Inching Control Pedal - Pushing down on the inching pedal, modulates the hydraulic the inching pedal, modulates the hydraulic...
Page 72: Refueling
NOTICE NOTICE Do not engage the parking brake while the lift truck Do not engage the parking brake while the lift truck is moving unless an emergency exists. The use of is moving unless an emergency exists. The use of the parking brake as a service foot brake in regular the parking brake as a service foot brake in regular operation will cause severe damage to the parking...
Page 73 WARNING WARNING Explosive Explosive fumes fumes present present during during refueling. refueling. Do not smoke in refueling areas. Lift truck Do not smoke in refueling areas. Lift truck should be refueled only at designated safe should be refueled only at designated safe locations.
Page 74 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 shield, long sleeves and gauntlet gloves.
Page 75 9. 9. Check to be sure that the LP warning plate is in Check to be sure that the LP warning plate is in position on the lift truck, and is legible. position on the lift truck, and is legible. 10.
Page 76 Walk Around Inspection Walk Around Inspection loose or missing mounting bolts. loose or missing mounting bolts. 8. 8. Inspect the hydraulic system for leaks, worn Inspect the hydraulic system for leaks, worn Make a thorough walk-around inspection before Make a thorough walk-around inspection before hoses or damaged lines.
Page 77 ⅣInterim) Typical Typical Example Example Diesel Diesel Engine(Tier- Engine(Tier-ⅣInterim) Typical Typical Example Example Diesel Diesel Engine Engine Typical Typical Example Example LP Engine Engine 10. Inspect the engine compartment for oil, coolant Inspect the engine compartment for oil, coolant and fuel leaks.
Page 78 Always adjust the operator s seat before starting Always adjust the operator s seat before starting the lift truck engine. the lift truck engine. Seat adjustment must be done at the beginning Seat adjustment must be done at the beginning of each shift a of each shift and when operators change.
Page 79 NOTE: NOTE: The engine will not start unless the The engine will not start unless the to START position, without waiting for the to START position, without waiting for the transmission directional control lever is in transmission directional control lever is in preheat light to go OFF.
Page 80 NEGATIVE(-). NEGATIVE(-). Attach ground cable last, remove first. Attach ground cable last, remove first. All lift trucks equipped with DOOSAN built internal All lift trucks equipped with DOOSAN built internal combustion engines are NEGATIVE(-) gro combustion engines are NEGATIVE(-) ground.
Page 81: After Starting The Engine
stalled truck frame (not battery negative post) stalled truck frame (not battery negative post) truck to crank. Procedure applies even i truck to crank. Procedure applies even if lift truck f lift truck away from battery, fuel or hydraulic lines, or away from battery, fuel or hydraulic lines, or does not have diagnostic connector.
Page 82 oil temperature is reached, the Electronics oil temperature is reached, the Electronics remains in Neutral, and the symbol of the remains in Neutral, and the symbol of the WARNING WARNING cold start phase will be indicated on the cold start phase will be indicated on the Transmission Display.
Page 83 EMS (Engine management system) of G643E EMS (Engine management system) of G643E uses two heated exhaust gas oxygen sensors uses two heated exhaust gas oxygen sensors engine is a closed loop system utilizing a catalytic engine is a closed loop system utilizing a catalytic (HEGO) in the exhaust system to monitor exhaust (HEGO) in the exhaust system to monitor exhaust muffler to reduce the emission level in the exhaust...
Page 84 LP Fuel Fuel Line Line Key switch Key switch Fault Fault Light Light Fuel Fuel Lock Lock Fuel Fuel Filter Filter Main Main PWR Foot Foot Pedal Pedal Relay Relay ...
Page 85 section. section. Items such Items such as as fuel fuel level, level, plugged plugged fuel lines, fuel lines, exactly the same way as with a gasoline engine. exactly the same way as with a gasoline engine. clogged fuel filters and malfunctioning pressure clogged fuel filters and malfunctioning pressure Consider all parts of the ignition and mechanical Consider all parts of the ignition and mechanical...
Page 86 Difficult to Start Difficult to Start Fuel Fuel container container almost almost empty empty LPG Vapor Vapor from from liquid liquid outlet outlet Fill fuel container Fill fuel container   Do not exceed 80% of liquid Do not exceed 80% of liquid ...
Page 87 capacity capacity Excess Excess flow flow valve valve closed closed Reset Reset excess excess flow flow valve valve Close liquid valve Close liquid valve   Wait for a “click” sound Wait for a “click” sound   ...
Page 88 Acceleration Acceleration Faulty vapor connection between Faulty vapor connection between Check connection Check connection the pressure regulator/converter the pressure regulator/converter Verify no holes in hose Verify no holes in hose   and the mixer and the mixer Clamps must be tight Clamps must be tight ...
Page 89 the pressure regulator/converter the pressure regulator/converter Verify no holes in hose Verify no holes in hose   and the mixer and the mixer Clamps must be tight Clamps must be tight   Look for kinked, pinched and/or Look for kinked, pinched and/or ...
Page 90 High Idle Speed High Idle Speed See Advanced Diagnostics & See Engine See Advanced Diagnostics & See Engine Incorrect Idle speed control Incorrect Idle speed control Service Manual Service Manual Throttle sticking Throttle sticking Foot pedal sticking or incorrect Foot pedal sticking or incorrect Check pedal return spring travel for binding Check pedal return spring travel for binding pedal signal...
Page 91 Clean/replace as required Clean/replace as required   Check system vacuum hoses from regulator Check system vacuum hoses from regulator Vacuum leak Vacuum leak to FTV and mixer to FTV and mixer Repair/replace as necessary Repair/replace as necessary ...
Page 92 screw) screw) • • Forklift have Poor High Speed Performance, you Forklift have Poor High Speed Performance, you can adjust power valve, power valve turn to rich can adjust power valve, power valve turn to rich side. Power valve marked “R” and “L”. “R” is rich side.
Page 93 The MI 04 systems are equipped with built in fault The MI 04 systems are equipped with built in fault beginning of the code list. beginning of the code list. diagnostics. diagnostics. Detected Detected system system faults faults displayed by the Malfunction Indicator Lamp (MIL) displayed by the Malfunction Indicator Lamp (MIL) EXAMPLE: EXAMPLE: ...
Page 94 it to the floor and then fully releasing the pedal it to the floor and then fully releasing the pedal (pedal maneuver). You must fully cycle the foot (pedal maneuver). You must fully cycle the foot pedal three ( pedal three (3 3 ) times within five ( ) times within five (5 5 ) seconds to ) seconds to enable the display codes feature of the SECM.
Page 95 through the fault list through the fault list ECTSensorInputLow ECTSensorInputLow Stored Fault Code Stored Fault Code Check ECT sensor connector and Check ECT sensor connector and wiring for a short to GND wiring for a short to GND Coolant sensor failure or shorted Coolant sensor failure or shorted (MIL Only) (MIL Only)
Page 96 signal is open signal is open bearing wear bearing wear Check the ETC driver wiri Check the ETC driver wiring for ng for   an open circuit an open circuit PredictedTPSDifference PredictedTPSDifference Engine Engine Shutdown Shutdown Check Check for for manifold manifold leaks...
Page 97 IATSensorInputLow IATSensorInputLow Stored Fault Code Stored Fault Code Check TMAP connector and IAT Check TMAP connector and IAT signal wiring for a shorted circuit signal wiring for a shorted circuit TMAP sensor failure or shorted TMAP sensor failure or shorted (MIL Only) (MIL Only) circuit...
Page 98 Check battery voltage during Check battery voltage during   starting and with the engine starting and with the engine running running verify verify charging charging system and alternator function system and alternator function Measure battery power at the Measure battery power at the ...
Page 99 SECM with a multimeter SECM with a multimeter Verify transducer power at ETC with Verify transducer power at ETC with a multimeter a multimeter Verify transducer power to the foot Verify transducer power to the foot pedal with a multimeter pedal with a multimeter Usually associated with additional Usually associated with additional...
Page 100 Pedal2SensorInputHi Pedal2SensorInputHi MIN power power Limit Limit Check Check foot foot pedal pedal connector connector APP2 signal disconnected, open APP2 signal disconnected, open circuit or sensor malfunction circuit or sensor malfunction (Expected (Expected faults faults when when connector is unplugged connector is unplugged CODES: 61 &...
Page 101 is frozen, this fault code can be set, is frozen, this fault code can be set, too. It is not system trouble. too. It is not system trouble. Check for intake m Check for intake manifold leaks anifold leaks ...
Page 102 trouble. trouble. Check the FTV for proper operation Check the FTV for proper operation Check FTV Hose Connections Check FTV Hose Connections   OxygenSensorInputHigh OxygenSensorInputHigh Stored Fault Code Stored Fault Code Check if O2 sensor is shorted to Check if O2 sensor is shorted to +5VDC or Battery.
Page 103 end of the code list. end of the code list. and viewed in detail with the use of the Service Tool and viewed in detail with the use of the Service Tool software. When the ignition key is turned on, the MIL software.
Page 104 Check ECT sensor connector and Check ECT sensor connector and wiring for a short to GND wiring for a short to GND ECTRangeLow ECTRangeLow SECM (Signal) Pin B15 To ECT Pin 3 SECM (Signal) Pin B15 To ECT Pin 3 Coolant Sensor failure or Coolant Sensor failure or TurnOnMil...
Page 105 normally due to noise on the normally due to noise on the SECM (Sensor GND) Pin B1 to Crank SECM (Sensor GND) Pin B1 to Crank signal or an intermittent signal or an intermittent sensor Pin 2 sensor Pin 2 connection on the crankshaft connection on the crankshaft Switched 12V to Crank sensor Pin 1...
Page 106 Learned closed throttle end Learned closed throttle end None None resistance from: resistance from: of TPS2 sensor range lower of TPS2 sensor range lower TPS Pin 2 (GND) to Pin 5 (TPS2 TPS Pin 2 (GND) to Pin 5 (TPS2 than expected than expected SIGNAL) (1.3K...
Page 107 Manifold Absolute Pressure Manifold Absolute Pressure (sensor GND) (sensor GND) sensor input is low, normally sensor input is low, normally TMAP Pin 3 to SECM Pin B24 TMAP Pin 3 to SECM Pin B24 set if the TMAP pressure set if the TMAP pressure (XDRP +5 Vdc) (XDRP +5 Vdc) None...
Page 108 pressure signal wire has pressure signal wire has (sensor GND) (sensor GND) become shorted to power, become shorted to power, TMAP Pin 3 to SECM Pin TMAP Pin 3 to SECM Pin B24 shorted to the IAT signal, the shorted to the IAT signal, the (1) TurnOnMil (1) TurnOnMil (XDRP +5 Vdc)
Page 109 EST1 output open, possibly EST1 output open, possibly Verify GND on ignition module Pin A Verify GND on ignition module Pin A TurnOnMil TurnOnMil open EST1 signal or open EST1 signal or (of both connectors) (of both connectors) defective spark module defective spark module Verify +12 Vdc on ignition module Pin Verify +12 Vdc on ignition module Pin...
Page 110 perform a safety test of the perform a safety test of the throttle return spring throttle return spring following engine shutdown. If following engine shutdown. If (1) TurnOnMil (1) TurnOnMil this spring has become weak this spring has become weak Perform throttle spring test by cycling Perform throttle spring test by cycling (2) EngineShutdown...
Page 111 and charging system and charging system SysVoltRangeHigh SysVoltRangeHigh Check battery and wiring for Check battery and wiring for TurnOnMil TurnOnMil (54) (54) System voltage too high System voltage too high overheating and damage overheating and damage Measure battery power at SECM with a Measure battery power at SECM with a multimeter (with key on) multimeter (with key on)
Page 112 a steep grade a steep grade Usually associated with additional ETC Usually associated with additional ETC SoftOverspeed SoftOverspeed faults faults (1) TurnOnMil (1) TurnOnMil Engine speed has exceeded Engine speed has exceeded (2) SoftRevLimit (2) SoftRevLimit Check for ETC Sticking or other ETC Check for ETC Sticking or other ETC the first level (1 of 3) of the first level (1 of 3) of...
Page 113 APP2AdaptHiMin APP2AdaptHiMin Learned full pedal end of Learned full pedal end of None None APP2 sensor range lower APP2 sensor range lower than expected than expected APP1AdaptLoMax APP1AdaptLoMax Learned idle end o Learned idle end of APP1 f APP1 None None sensor range higher than sensor range higher than...
Page 114 crank disable relay crank disable relay Check fuel lock off valve for an open Check fuel lock off valve for an open wire or connector being disconnected wire or connector being disconnected LSDFault_LockOff LSDFault_LockOff or signal shorted to GND or signal shorted to GND Fuel lock off Valve Fault, Fuel lock off Valve Fault, Lockoff Pin B (signal) to SECM...
Page 115 O2 Pin 1 (HEATER PWR) to Post O2 Pin 1 (HEATER PWR) to Post O2 Heater Relay. Relay pin 87. This relay Heater Relay. Relay pin 87. This relay turns on only after engine has been turns on only after engine has been running for some time and SECM has running for some time and SECM has GasPostO2NotActive...
Page 116 operation on LPG operation on LPG Check all sensor connections (see Check all sensor connections (see fault fault 742 corrective actions). 742 corrective actions). Reserved Reserved Check if O2 sensor installed before the Check if O2 sensor installed before the O2RangeLow O2RangeLow catalyst is shorted to GND or sensor...
Page 117 ground or the sensor has ground or the sensor has SECM (system GND) Pin A16, B17 SECM (system GND) Pin A16, B17 failed. failed. FuelTempRangeHigh FuelTempRangeHigh Check if fuel temp sensor connector is Check if fuel temp sensor connector is Fuel Temperature Sensor Fuel Temperature Sensor disconnected or for an open FTS circuit...
Page 118 parking brake before dismounting from the lift parking brake before dismounting from the lift truck. truck. 6. 6. RELEASE the service foot brake. RELEASE the service foot brake. 7. 7. PUSH DOWN on the accelerator pedal to obtain PUSH DOWN on the accelerator pedal to obtain the desired travel speed.
Page 119 Typical Example Typical Example 1. 1. To inch (creep) in either direction, slowly push To inch (creep) in either direction, slowly push down on the inching pedal. This will start to down on the inching pedal. This will start to apply the service foot brakes and allow the apply the service foot brakes and allow the Typical Example...
Page 120 e.g. selecting the reverse gear when travelling in e.g. selecting the reverse gear when travelling in excess of 5 km/h (3.11 mph) in a forward direction, excess of 5 km/h (3.11 mph) in a forward direction, and vice versa. and vice versa. The Autoshift controller is mounted on a convenient The Autoshift controller is mounted on a convenient position away from excessive heat sources and...
Page 121 maximum of 6.0km/h(3.75mph) travel speed. maximum of 6.0km/h(3.75mph) travel speed. SW2(FWD RVS SHIFT) SW2(FWD RVS SHIFT) Direction lnhibit Point Direction lnhibit Point ASC-204/202 has internal indicator on the right side ASC-204/202 has internal indicator on the right side of the controller for displaying the selected gear and of the controller for displaying the selected gear and Notch Notch...
Page 122 This test is used to verify operation of direction This test is used to verify operation of direction controller, manual mode(Fail-Safe Mode) is controller, manual mode(Fail-Safe Mode) is control lever. control lever. selected as a default for direction inhibit selected as a default for direction inhibit while automatic mode is selected as a while automatic mode is selected as a default for two-speed auto shift control.
Page 123 In the manual mode, direction inhibition function In the manual mode, direction inhibition function 8. 8. The direction of travel will change automatically The direction of travel will change automatically can not be operated normally. The sudden can not be operated normally. The sudden when the vehicle speed is reduced as much as when the vehicle speed is reduced as much as reversal of a loaded lift truck traveling forward...
Page 124 Typical Example of ASC-204 Typical Example of ASC-204 NOTE: NOTE: In ASC-204 ASC-204 factory-setting factory-setting controller, controller, automatic automatic mode mode selected selected both both direction inhibit and two-speed auto shift direction inhibit and two-speed auto shift control as a default on the PCB(Printed control as a default on the PCB(Printed Circuit Board).In ASC-202 factory-setting...
Page 125 Typical Example Typical Example Typical Example Typical Example 1. 1. Move the lift truck slowly FORWARD into Move the lift truck slowly FORWARD into 2. 2. Tilt the mast further back to cradle the loa Tilt the mast further back to cradle the load d position and engage the load.
Page 126 Typical Example Typical Example 1. 1. Move the lift truck into the unloading position. Move the lift truck into the unloading position. Typical Example Typical Example 1. 1. Carry the load as low as possible but maintain Carry the load as low as possible but maintain clearance.
Page 127 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 128: Parking The Lift Truck
tension tension 3. 3. Even if the engine overheats and the coolant Even if the engine overheats and the coolant boils over, let the engine idle for a while with boils over, let the engine idle for a while with 1.
Page 129 and remove the key. and remove the key. Typical Example Typical Example Park the lift truck level, with the forks lowered and Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the the mast tilted forward until the fork tips touch the floor.
Page 130 possible. Position the load evenly on both forks. possible. Position the load evenly on both forks. Typical Example of Shaft type Fork Typical Example of Shaft type Fork Typical Example of Hook-on type Fork Typical Example of Hook-on type Fork 1.
Page 131 2. 2. While cleaning the truck, check general condition While cleaning the truck, check general condition of the truck. Especially check the truck body for of the truck. Especially check the truck body for To Operate the Lift Truck After a To Operate the Lift Truck After a dents or damage and tires for wear or nails or dents or damage and tires for wear or nails or...
Page 132: Plate
Block the wheels and secure lift truck with tiedowns. Operation Section Operation Section Consult your DOOSAN Lift Truck dealer for towing a Consult your DOOSAN Lift Truck dealer for towing a Towing Information Towing Information disabled lift truck.
Page 133: Inspection, Maintenance And Repair Of Lift Truck
These towing instructions are for moving a disabled These towing instructions are for moving a disabled lift truck a short distance, at low speed, no faster lift truck a short distance, at low speed, no faster Typical Example Typical Example than 2 km/h (1.2 mph), to a convenient location for than 2 km/h (1.2 mph), to a convenient location for 1.
Page 134 Register 1910.178 Powered Industrial Truck, and Register 1910.178 Powered Industrial Truck, and A fork failure during use can cause damage to the A fork failure during use can cause damage to the ANSI/ASME Safety Standard(s) B56.1, B56.5 or ANSI/ASME Safety Standard(s) B56.1, B56.5 or equipment and the load.
Page 135 tip. tip. Overloading Overloading Bent or Twisted Forks Bent or Twisted Forks Extreme overloading can cause permanent bending Extreme overloading can cause permanent bending Forks can be bent out of shape by extreme Forks can be bent out of shape by extreme or immediate failure of the forks.
Page 136 4," in the "2000 Service Hours or Yearly" in 4," in the "2000 Service Hours or Yearly" in "Maintenance Intervals" "Maintenance Intervals" Establish a daily and 12 month inspection routine by Establish a daily and 12 month inspection routine by 3.
Page 137: Tire Inflation Information
Most repairs or modifications should be done Most repairs or modifications should be done only by the original manufacturer of the forks or only by the original manufacturer of the forks or an expert knowledgeable of the materials, an expert knowledgeable of the materials, design, welding and heat treatment process.
Page 138: Torque Specifications
Proper inflation equipment, and training in using Proper inflation equipment, and training in using equipment, equipment, necessary necessary avoid avoid The operating inflation pressure is based on the The operating inflation pressure is based on the overinflation. A tire blowout or rim failure can overinflation.
Page 139 Standard Nut and Bolt Torque Standard Nut and Bolt Torque Thread Size Thread Size Torques for Standard Hose Torques for Standard Hose Inch Inch Clamps - Worm Drive Band Type Clamps - Worm Drive Band Type N N • • m m lb lb •...
Page 140: Cooling System Specifications
170 ± ± 30 125 ± ± 22 The material strength identification is usually shown The material strength identification is usually shown 260 ± ± 40 190 ± ± 30 on the bolt head by numbers (8.8, 10.9, etc). The on the bolt head by numbers (8.8, 10.9, etc).
Page 141 NOTICE NOTICE DOOSAN recommends that the coolant mixture DOOSAN recommends that the coolant mixture contain a minimum of 30% antifreeze or equivalent. contain a minimum of 30% antifreeze or equivalent. Never add coolant to an overheated engine, engine Never add coolant to an overheated engine, engine damage can result.
Page 142 DOOSAN prefers the use of distilled water or DOOSAN prefers the use of distilled water or dissolved solids and undissolved chemical inhibitors dissolved solids and undissolved chemical inhibitors...
Page 143: Specifications
Doosan approves the use of bio-diesel fuels that do Doosan approves the use of bio-diesel fuels that do not exceed a blend of 5% (by volume) of FAME with...
Page 144 DOOSAN DOOSAN forklift forklift trucks. trucks. requirements. requirements. Remember LP is heavier than air and will sink to the Remember LP is heavier than air and will sink to the lowest spot possible.
Page 145 Multi-grade oils oils blended blended shortened engine life due to carbon deposits or shortened engine life due to carbon deposits or DOOSAN DOOSAN transmissions. transmissions. excessive wear. excessive wear. Multi-grade oils which use high molecular Multi-grade oils which use high molecular...
Page 146 Use MPGM for heavily loaded bearings and joints where an extreme pressure grease will maximize where an extreme pressure grease will maximize the life of DOOSAN equipment. This NLGI No. 2 the life of DOOSAN equipment. This NLGI No. 2 grade is suitable for most temperatures.
Page 147 temperature [ up to 175 C (350 F) ] is required. temperature [ up to 175 C (350 F) ] is required. This grease offers excellent mechanical stability, This grease offers excellent mechanical stability, high resistance to oxidation, good rust protection high resistance to oxidation, good rust protection and excellent breakaway torque.
Page 148 Chains Chains 5W30 5W30 e w/Filter e w/Filter Tier- Ⅳ Ⅳ Tier- API SJ API SJ 13.5 13.5 13.5 13.5 Interim Interim Engine Engine (V3800) (V3800) Crankcase Crankcase Tier- Ⅱ Ⅱ (Diesel) (Diesel) ...
Page 149 Hydraulic Hydraulic Return Return Filter Filter – – Change..Change.......... 171 .. 171 NOTICE NOTICE Careless disposal of waste oil can harm the Careless disposal of waste oil can harm the Every 250 Service Hours or Every 250 Service Hours or Monthl Monthly y environment and can be dangerous to persons.
Page 150 Change ..............187 Change ..............187 Transmission O Transmission Oil (2 il (2 Speed Only) Speed Only) – Ch – Change . ange ....187 Lift Lift Chains Chains - - Test, Test, Check, Check, Adjust ..
Page 151: Adjust Adjust
Air Intake Intake System System Check, Check, Clean Clean Battery Battery Terminal Terminal Clean, Clean, Inspect Inspect Belts Belts (Diesel (Diesel E/G E/G Only) Only) Check, Check, Adjust Adjust Brake Brake Oil Oil (OCDB) (OCDB) Check Check Carburetor Carburetor (LP (LP - - Gas Gas Engine Engine Only)
Page 152: When Required
Inspect Inspect Vacuum Vacuum Lines Lines Fittings Fittings (G643(E) Engine only) (G643(E) Engine only) Inspection Inspection Engine Engine for for Fluid Fluid Leaks Leaks Lift Lift Chains Chains - - Test, Test, Check, Check, Adjust Adjust LP Regulator/Converter Inspection (LP LP Regulator/Converter Inspection (LP Engine Only) Engine Only)
Page 153 heads are disassembled. heads are disassembled. When severe noise comes from valve train. When severe noise comes from valve train.   When the engine is not normally operated even When the engine is not normally operated even ...
Page 154 Typical Typical Example Example <DB58S> <DB58S> Obtain a leak check squirt bottle or pump spray Obtain a leak check squirt bottle or pump spray   bottle. bottle. Fill the bottle with an approved leak check Fill the bottle with an approved leak check ...
Page 155 Check the operation of the seat adjuster rod. Make Check the operation of the seat adjuster rod. Make sure that the seat slides freely on its track. Lightly oil sure that the seat slides freely on its track. Lightly oil ...
Page 156 Remove the front cover of fuse box. The fuses are Remove the front cover of fuse box. The fuses are Located on top of engine Located on top of engine located under the cover. located under the cover. Circuit Breaker Circuit Breaker Fuse - Fuse - Protects an electrical circuit from...
Page 157: Radiator Cap - Clean, Change
3. 3. Bulb turn signal(Front, 12V 23/8W) Bulb turn signal(Front, 12V 23/8W) 4. 4. Bulb-turn signal(Rear, 12V-23W) Bulb-turn signal(Rear, 12V-23W) 5. 5. Bulb-stop & tail(12V, 23/8W) Bulb-stop & tail(12V, 23/8W) 6. 6. Bulb-back up(12V-10W) Bulb-back up(12V-10W) Tires and Wheels - Inspect, Check Tires and Wheels - Inspect, Check...
Page 158: Brake Oil (Ocdb) - Check
radiator. radiator. The use of compressed air is preferred. The use of compressed air is preferred. The radiator cap is located on the left side of the lift The radiator cap is located on the left side of the lift truck.
Page 159: Daily
The brake reservoir is located on the left side of the The brake reservoir is located on the left side of the steering column. steering column. 1. 1. Remove the filter cap. Remove the filter cap. 2. 2. Maintain the brake fluid level to the fluid level Maintain the brake fluid level to the fluid level mark on the brake system reservoir.
Page 160: Engine Oil Level - Check
Remove the filter cap slowly to relieve pressure. Remove the filter cap slowly to relieve pressure. Engine Oil Level - Check Engine Oil Level - Check Cooling system conditioner contains alkali. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent Avoid contact with the skin and eyes to prevent personal injury.
Page 161 Typical Typical Example Example Diesel Diesel Engine Engine Truck Truck 3. 3. Start and run the engine to stabilize the coolant Start and run the engine to stabilize the coolant level in the filter neck. If low, add coolant until it level in the filter neck.
Page 162: Mast Channels - Lubricate
Inspect Engine for Inspect Engine for Exhaust Leaks Exhaust Leaks Typical Example Typical Example 1. 1. Start the engine and allow it to reach operating Start the engine and allow it to reach operating 5. 5. Inspect the operator's compartment for loose Inspect the operator's compartment for loose temperatures. ...
Page 163: Transmission Oil Level - Check
channels where the rollers ride. This will prevent channels where the rollers ride. This will prevent metal peel until the rollers set a pattern. metal peel until the rollers set a pattern. LP Engine LP Engine 8. 8. Inspect engine compartment for oil, coolant and Inspect engine compartment for oil, coolant and fuel leaks.
Page 164 7. 7. Install the oil dipstick again and tighten it Install the oil dipstick again and tighten it 3. 3. With the service brake applied and the engine at With the service brake applied and the engine at clockwise.
Page 165 the lift truck with the forks lowered, parking the lift truck with the forks lowered, parking brake applied, transmission in neutral and the brake applied, transmission in neutral and the Typical Typical Example Example Diesel Diesel Engine Engine Truck Truck (D439 (D439E) E) engine stopped.
Page 166 Typical Typical Example Example Diesel Diesel Engine Engine Truck Truck (D439E) (D439E) Typical Typical Example Example D50/60/70/8 D50/60/70/80/90S-5 0/90S-5 (3 (3 Speed Speed) ) 10. Fill the crankcase. See "Refill Capacities". Fill the crankcase. See "Refill Capacities". 11. Start the engine and allow the oil to fill the filter Start the engine and allow the oil to fill the filter and passages.
Page 167 3. 3. Install the drain plug. Install the drain plug. D50/60/70/80/90S-5 (3 Speed) D50/60/70/80/90S-5 (3 Speed) : Every 1,000 Service Hours or 6 Months. : Every 1,000 Service Hours or 6 Months. ZF 3WG116 ZF 3WG116 D50/60/70S-5 (2 Speed), G50/60/70S-5 D50/60/70S-5 (2 Speed), G50/60/70S-5 : Every 500 Service Hours or 3 Months.
Page 168 9. 9. Start the engine. Start the engine. 10. With the service brake applied and engine at low With the service brake applied and engine at low idle, shift the transmission to forward and idle, shift the transmission to forward and reverse to fill the clutches.
Page 169 through the drive axle housing level/fill plug through the drive axle housing level/fill plug 1. 1. Remove three drain plugs of the drive axle Remove three drain plugs of the drive axle opening until it reaches the bottom of the hole. opening until it reaches the bottom of the hole.
Page 170 NEUTRAL. NEUTRAL. applying the service brakes. applying the service brakes. 8. 8. Maintain the oil level between lower mark and Maintain the oil level between lower mark and upper mark on the dip stick/filter cap. upper mark on the dip stick/filter cap. 9.
Page 171: First 250 Service Hours Or A Month
Typical Example Typical Example 1. 1. Release the parking brake Release the parking brake 2. 2. Turn the adjustment knob, clockwise to tighten Turn the adjustment knob, clockwise to tighten the brake. the brake. 3. 3. Test the parking brake adjustment. Repeat the Test the parking brake adjustment.
Page 172 base. Install bolts and tighten 20 to 30 N•m (15 base. Install bolts and tighten 20 to 30 N•m (15 to 20 lb•ft). to 20 lb•ft). 10. Start the engine and operate the hydraulic Start the engine and operate the hydraulic controls, and the steering system, through a few controls, and the steering system, through a few cycles to fill the lines.
Page 173 Typical Typical Example Example Diesel Diesel Engine Engine Truck Truck Typical Example Typical Example 1. 1. Check the precleaner bowl for dirt build-up. If the Check the precleaner bowl for dirt build-up. If the dirt is up to the line, remove the precleaner bowl dirt is up to the line, remove the precleaner bowl and empty it.
Page 174: Clean
Typical Example Typical Example 2. 2. Replace the nut or clamp(1). Replace the nut or clamp(1). 3. 3. Remove the element to separate it from its base Remove the element to separate it from its base and remove it from the air cleaner housin and remove it from the air cleaner housing.
Page 175: Check
them. them. Detergent Detergent Inspect filter elements after cleaning. Do not use a Inspect filter elements after cleaning. Do not use a filter with damaged pleats, gaskets or seals. filter with damaged pleats, gaskets or seals. 1. 1. Wash the element in warm water and mild ...
Page 176: Hydraulic Oil Level - Check
contact skin. contact skin. 13. Stop the engine and measure the oil level. Stop the engine and measure the oil level. Maintain the oil level to the FULL mark on the Maintain the oil level to the FULL mark on the dip stick.
Page 177: Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate
the engine stopped. the engine stopped. wood to hold the carriage in the raised position. wood to hold the carriage in the raised position. 2. 2. Raise the hood and seat assembly. Make sure Raise the hood and seat assembly. Make sure 3.
Page 178: Lubricate
2. 2. Maintain the oil level between lower mark and Maintain the oil level between lower mark and upper mark on the dip stick/filter cap. upper mark on the dip stick/filter cap. 3. 3. Install the dip stick/filter cap. Install the dip stick/filter cap.
Page 179: Inspect
2. 2. Lubricate the steering link bearings, total of four Lubricate the steering link bearings, total of four fittings. Two on the right side and two on the left fittings. Two on the right side and two on the left side side 3.
Page 180: Belts (Diesel E/G On E/G Only) - Ly) - Check, Adjust
Typical Example Typical Example 1. 1. Install steer wheel. Put two nuts opposite each Install steer wheel. Put two nuts opposite each other (180°). Tighten bolt. other (180°). Tighten bolt. 2. 2. Inspect tightness of wheel nuts in a sequence Inspect tightness of wheel nuts in a sequence opposite each other 610 ~ 680 N.m (370~450 opposite each other 610 ~ 680 N.m (370~450...
Page 181: Lubricate
NOTICE NOTICE Tier- Ⅱ Ⅱ ) ) Typical Typical Example Example D50/60/70/80 D50/60/70/80/90S-5(3 /90S-5(3 Speed, Speed, Tier- Failure to loosen the alternator mounting bolt(2) will Failure to loosen the alternator mounting bolt(2) will cause excessive stress and break the alternator cause excessive stress and break the alternator mounting ear.
Page 182: Parking Brake - Test, Adjust
Typical Example Typical Example 1. 1. Lubricate two fittings for the pivot eyebolts, one Lubricate two fittings for the pivot eyebolts, one on each tilt cylinder. on each tilt cylinder. 2. 2. Check for damaged crosshead rollers, guards Check for damaged crosshead rollers, guards and retainer rings.
Page 183: Overhead Guard - Inspect
2. 2. Check and replace all defective gauges. Check and replace all defective gauges. 2. 2. Look for leaks at the power steering hose and Look for leaks at the power steering hose and tube connections . tube connections .
Page 184 the engine is running. the engine is running. Inspect Electrical System (G643E Inspect Electrical System (G643E If abnormally soft lines are detected, replace as If abnormally soft lines are detected, replace as   necessary. necessary. Engine only) Engine only) Check for loose, dirty or damaged connectors Check for loose, dirty or damaged connectors...
Page 185 your specific engine, see the " Service Man your specific engine, see the " Service Manual ". ual ". 5. 5. Turn the new fuel filter cartridge assembly until Turn the new fuel filter cartridge assembly until the filter gasket is fitted against the sealing face. the filter gasket is fitted against the sealing face.
Page 186 Inspect Coolant Hoses (LP Inspect Coolant Hoses (LP Inspect Mixer Assembly (LP Inspect Mixer Assembly (LP Engines Only) Engines Only) Engine Only) Engine Only) Refer to the LP mixer section of the engine service Refer to the LP mixer section of the engine service Visually inspect coolant hoses and clamps.
Page 187 9. 9. Install the breather. Install the breather. 1. 1. Remove the hydraulic tank drain plug located on Remove the hydraulic tank drain plug located on the bottom of the frame. Allow the oil to drain in the bottom of the frame.
Page 188 Only for D50/60/70S-5 (2 Speed), Only for D50/60/70S-5 (2 Speed), G50/60/70S-5 G50/60/70S-5 See topic, "Transmission Oil & Oil Filter - Change See topic, "Transmission Oil & Oil Filter - Change" in " in "First 50-100 Service Hours or a Week". "First 50-100 Service Hours or a Week".
Page 189 carriage height. carriage height. WARNING WARNING 1. 1. Fully lower the carriage and tilt mast forward or Fully lower the carriage and tilt mast forward or Personal injury can be caused by sudden Personal injury can be caused by sudden lift the carriage and put blocks under the carriage lift the carriage and put blocks under the carriage movement of the mast and carriage.
Page 190 Extrusion" in "When Required" for proper Extrusion" in "When Required" for proper carriage height. carriage height. inner mast height. inner mast height. 1. 1. Fully lower the carriage and tilt mast forward or Fully lower the carriage and tilt mast forward or 1.
Page 191 5. 5. Apply anti-seize compound to the spark plug Apply anti-seize compound to the spark plug 3. 3. Test secondary cables with an Ohmmeter. If Test secondary cables with an Ohmmeter. If threads and install. threads and install. maximum resistance is higher than 25 kOhms, maximum resistance is higher than 25 kOhms, G643(E) Engine : 30 N•m (22 lb•ft)
Page 192 Point Point 8. 8. Re-assemble the filter assembly aligning the Re-assemble the filter assembly aligning the scribe lines on the top and bottom covers. scribe lines on the top and bottom covers. 9. 9. Install the cover retaining screws, tightening the ...
Page 193 (1) LP fuel lock-off, (1) LP fuel lock-off, (2) LP regulator/converter (2) LP regulator/converter Maintenance Section Maintenance Section Every 2000 Service Hours or Yearly Every 2000 Service Hours or Yearly 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 or maintenance procedures.
Page 194 if necessary. if necessary. 5. 5. Remove the inner bearing. Clean and lubricate Remove the inner bearing. Clean and lubricate the steering knuckle. Reassemble both the inner the steering knuckle. Reassemble both the inner and outer bearing cones. and outer bearing cones.
Page 195 5. 5. Start and run the engine for 30 minutes. Start and run the engine for 30 minutes. 6. 6. Stop the engine and drain the cleaning solution. Stop the engine and drain the cleaning solution. 7.
Page 196 Replace one or both forks when the difference in fork tip height exceeds the maximum allowable fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift difference. Contact your local DOOSAN Lift Truck Dealer for further information.
Page 197 parallel with the floor. Place two straight parallel with the floor. Place two straight bars that are the same width as the bars that are the same width as the carriage, across the forks as shown. carriage, across the forks as shown. b.
Page 198 (1) Adapter-Throttle body (1) Adapter-Throttle body (2) TMAP sensor, (2) TMAP sensor, (3) Adapter-Manifold, (3) Adapter-Manifold, (4) Throttle body (4) Throttle body Maintenance Section Maintenance Section Inspect for Intake Leaks (L Inspect for Intake Leaks (LP P Replace Oxygen Sensor (G6 Replace Oxygen Sensor (G643E Engine Only) Engine Only)
Page 199 Muffler Ass’y Muffler Ass’y When indicated by MIL, replace oxygen sensors on When indicated by MIL, replace oxygen sensors on the exhaust tube and muffler assembly. the exhaust tube and muffler assembly. 1. 1. Stop engine and wait until the exhaust pipe and Stop engine and wait until the exhaust pipe and exhaust pipe is cooled.
Page 200 <DPF, interim Tier-4> <DPF, interim Tier-4> Use recommended engine oil to reduce the amount Use recommended engine oil to reduce the amount of generated ash (CJ-4 Grade in US / ACEA-E9 in of generated ash (CJ-4 Grade in US / ACEA-E9 in EU).
Page 201: Service Service Hours Hours Or Or Monthly
Cooling System - Clean, Change ......194 Cooling System - Clean, Change ......194 Attachment Abbreviations (includes Special Forks) Attachment Abbreviations (includes Special Forks) ..............................56 ...... 56 Cooling System Specifications ......140 Cooling System Specifications ......
Page 202 First 250 First 250 Service H Service Hours or ours or a M a Month ..onth ........171 Index Index............................200 ..200 Inspect Inspect Battery Battery Syste System m ..........
Page 203 Parking Brake Lever..........71 Parking Brake Lever..........71 Mainten Maintenance ance and and Repai Repair r ................136 Parki Parking Brak ng Brake e .......................... 8 8 Maintenance Information.......... 14 Maintenance Information..........
Page 204 Table Table of Con of Contents ............tents ............1 1 Walk-Around Walk-Around Inspection Inspection - - Inspect ..Inspect ........... 161 ... 161 Test Fuel Test Fuel System for Leaks System for Leaks (LP Engine (LP Engine Only) ...

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