Doosan D60S-7 Operation & Maintenance Manual
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Doosan D60S-7 Operation & Maintenance Manual

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  • Page 2 FDB0U, FDB0V (D34NAP/D34P Tier-4) D80S-7, D90S-7 FDB0W, FDB0X (D34NAP/D34P Tier-4) G60S-7, G70S-7 FGB0P, FGB0Q (PSI 4.3L Tier-3) Original Instruction This document is the informational asset of Doosan Corporation. Thus, unauthorized access, revision, distribution and copying of this document are strictly prohibited. 1807...
  • Page 3 WARNING Do not start, operate or service this machine unless you have read and understood these instructions and received proper training. Unsafe or improper use of the machine may cause serious injury or death. Operators and maintenance personnel must read this manual and receive training before operating or maintaining the machine.

  • Page 4: Table Of Contents

    Table of Contents Table of Contents Information Section Maintenance Section Foreword ..............2 Inspection, Maintenance and Repair of Lift Truck Forks ............... 182 Tire Inflation Information ........186 Safety Section Torque Specifications ..........187 Cooling System Specifications ......189 Important Safety Information ........4 Specifications of Fuel and DEF/Ad-Blue ....

  • Page 5: Information Section

    Guards and covers might have WARNING been removed for illustrative purposes. Your DOOSAN truck comes equipped with an Continuing improvement and advancement of operator restraint system. Should it become product design might have caused changes to your lift truck which are not included in this publication.
  • Page 6 Operation Environment Management The Operation Section is a reference for the new Note that DOOSAN CPOPORATION INDUSTRIAL operator and a refresher for the experienced one. VEHICLE BG is ISO 14001 certified which is This section includes a discussion of gauges,...

  • Page 7: Safety Section

    The warnings in this publication and on the product are therefore not all inclusive. Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must be sure that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 8: Safety

    Since regulations vary from country to country outside of U.S.A., operate this lift truck in Warning accordance with local regulations. DOOSAN lift trucks are manufactured in accordance with the National Fire Protection Association (NFPA) No. 505 and the American National Standards Institute, Inc.
  • Page 9 Safety Section 10. Be sure operating surface can safely support General Warnings to Operator machine. 11. Operate machine and attachments only from operator's position. 12. Do not handle unstable or loosely stacked loads. 13. Use minimum tilt when picking up or depositing a load.
  • Page 10 Safety Section Pressure Warning No Standing On Forks Warning, No Standing Under Forks Warning WARNING WARNING Contents under pressure may be hot. Allow to cool before opening. Do not stand or ride on the forks. Do not stand or ride on a load or pallet on the forks. Do not stand or walk under the forks.
  • Page 11 Tool Warning Located on the Overhead Guard WARNING No Riders Warning 1. Do not use the tools provided by DOOSAN for other vehicles than DOOSAN's. WARNING 2. Check the tools for integrity before use. Do not use a defective tool.

  • Page 12: Parking Brake

    Safety Section Parking Brake Pushing forward the lever releases Mechanical Parking Brake (If Installed) the parking brake. Applying the parking brake puts the transmission in NEUTRAL. The parking brake must be applied when leaving the lift truck and when starting the engine. If the operator leaves the seat without applying the parking brake, an audible alarm will sound.

  • Page 13: General Hazard Information

    Safety Section General Hazard Information Always use load backrest extension when the carriage or attachment does not fully support the load. The load backrest extension is intended to prevent the load or any part of the load from falling backwards into the operator's station. When operating the lift truck, do not depend only on flashing lights or back-up alarms (if equipped) to warn pedestrians.

  • Page 14: Operation Information

    Make sure no one is standing and/or working on, and all other work concerning your forklift truck, underneath or close to the lift truck before operating please contact your DOOSAN dealer. We would like the lift truck. to draw your attention to the fact that any secondary...
  • Page 15 Safety Section Operate the lift truck and controls only from the Operating the Lift Truck operator's station. Always keep the lift truck under control. Make sure the lift truck horn, lights, backup alarm (if Obey all traffic rules and warning signs. equipped) and all other devices are working properly.
  • Page 16 Safety Section Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers.

  • Page 17: Maintenance Information

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

  • Page 18: Burn Prevention

    Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant mixtures Coolant are flammable. At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to Fuel leaked or spilled onto hot surfaces or electrical heaters or the engine contain hot water or steam.
  • Page 19 If the tires were originally inflated with air, tubes and hoses. Leaks can cause fires. Contact nitrogen is still preferred for adjusting the pressure. your DOOSAN dealer for repair or replacement. Nitrogen mixes properly with air. Check lines, tubes and hoses carefully. Do not use Nitrogen inflated tires reduce the potential of a tire your bare hand to check for leaks.
  • Page 20 Safety Section DOOSAN forklift is equipped with wheels from different manufacturers. Please re-use the original parts of the existing wheel, if there is no deformation of the wheel after checked. Mixing up new and old parts may cause incomplete assembly...

  • Page 21: Operator Restraint System (If Equipped)

    Operator Restraint System (If Equipped) Warning Signs and Labels Your DOOSAN lift truck has the following tip over warning decals. Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures.
  • Page 22 Safety Section Weight adjustment If Optional Suspension Seat Equipped Pull the weight adjustment lever upwards and move Forward and Backward Adjustment right or left side. The seat can be adjusted by pushing the lever on Adjust to driver’s weight in 7 steps (50 ~ 110 kg) the right side of seat.
  • Page 23 WARNING 1. Grip the plate (connector) of the belt and pull the Your DOOSAN truck comes equipped with a belt from the retractor. Then insert the plate into DOOSAN operator restraint system. Should it the slot of the buckle until a snap is heard. Pull become necessary to replace the seat for any on the belt to confirm it is latched.
  • Page 24 Safety Section Release the Seat Belt WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. Push the button of the buckle to release the belt. The belt will automatically retract when released. Hold the plate of the belt and allow the belt to slowly retract.

  • Page 25: Avoiding Lift Truck Tip Over

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tip over Lift Truck Stability The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the combined CG of the truck and load. The lift truck Counterbalanced lift truck design is based on the has moving parts and, therefore, has a CG that balance of two weights on opposite sides of a...
  • Page 26 CG moves forward of the front axle, the lift truck forklifts sold by DOOSAN shall not be removed, will tip forward. If the CG moves outside of the line altered or replaced without DOOSAN’s approval. on either side of the stability base, the lift truck will 2.

  • Page 27: Safety Rules

    Safety Section Safety Rules Do not operate a lift truck unless you are in the operator’s seat. Keep hands and feet inside the operator’s compartment. Do not put any part of the Only properly trained and authorized personnel body outside of the operator’s compartment. Never should operate forklift trucks.
  • Page 28 Safety Section Do not overload. Always handle loads within the Do not raise anyone on the forks of your lift truck. rated capacity shown on the capacity plate. Do not let other people ride on the truck. Lift trucks Do not add extra counterweight to the truck. An are designed to carry loads, not people.
  • Page 29 Safety Section Do not elevate the load with the mast tilted forward. Do not permit anyone to stand or walk under the Do not tilt the elevated loads forwards. load or lifting mechanism. The load can fall and This will cause the lift truck to tip over forward. cause injury or death to anyone standing below.
  • Page 30 Safety Section Do not stack or turn on ramps. Do not drive in forward direction when loads restrict Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
  • Page 31 Safety Section Park your lift truck in authorized areas only. Fully Do not operate your truck close to another truck. lower the forks to the floor, put direction lever in Always keep a safe distance from other trucks and NEUTRAL position, engage the parking brake, and make sure there is enough distance to stop safely.
  • Page 32 Safety Section An unloaded forklift may be easier to tip over than a operate forklifts near flammable loaded truck. combustible materials. When traveling without a load, the risk of lateral avoid discoloration, deformation overturn is greater. combustion of materials (such as lumber, veneer board, paper products and other similar items), always park at least 30 cm (12 inches) away from them.

  • Page 33: How To Survive In A Tip Over (If Operator Restraint System Equipped)

    Safety Section How to Survive in a Tip over (If Operator Restraint System Equipped) WARNING In the event of a tip over, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided.

  • Page 34: General Section

    Doosan Corporation Industrial Vehicle BG. 468, Injung-ro, Dong-gu, Incheon, Korea 22503 Authorized Representative and Compiler of Technical File According to 2006/42/EC Doosan Industrial Vehicle Europe N.V, Mr. Chankyo Chung Europark Noord 36 A 9100 Sint-Niklaas BELGIUM Herewith declare That the following equipment conforms to the appropriate requirements of the Directives...

  • Page 35: Specifications

    General Section Specifications CHARACTERISTICS 3 Speed (TIER-IV 80.9KW) Manufacturer DOOSAN DOOSAN MODEL D60S-7 D70S-7 Capacity at rated load center 7000 6000 Load center distance Power type electric, diesel, gasoline, LPG diesel diesel Operator type stand-on, rider-seated rider-seated rider-seated Tire type...
  • Page 36 General Section 3 Speed (TIER-IV 80.9KW) DOOSAN DOOSAN D80S-7 D90S-7 8000 9000 diesel diesel rider-seated rider-seated 3100 3100 70x180x1200 70x180x1200 410x2092 410x2092 43388 43388 4014 4040 2230 2230 2835 2835 4375 4375 2673(2771) 2673(2771) 1526 1526 3650 3680 4330 4355...
  • Page 37 General Section Specifications CHARACTERISTICS 3 Speed (TIER-IV 55KW) Manufacturer DOOSAN DOOSAN MODEL D60S-7 D70S-7 Capacity at rated load center 7000 6000 Load center distance Power type electric, diesel, gasoline, LPG diesel diesel Operator type stand-on, rider-seated rider-seated rider-seated Tire type...
  • Page 38 General Section Specifications CHARACTERISTICS 2 Speed (TIER-IV 55KW) Manufacturer DOOSAN DOOSAN MODEL D60S-7 D70S-7 Capacity at rated load center 7000 6000 Load center distance Power type electric, diesel, gasoline, LPG diesel diesel Operator type stand-on, rider-seated rider-seated rider-seated Tire type...
  • Page 39 General Section Specifications CHARACTERISTICS 2 Speed (TIER-3 PSI 4.3L) Manufacturer DOOSAN DOOSAN MODEL G60S-7 G70S-7 Capacity at rated load center 6000 7000 Load center distance Power type electric,diesel,gasoline,LPG Operator type stand-on, rider-seated rider-seated rider-seated Tire type c=cushion, p=pneumatic Wheels(x=driven) number, front/rear...
  • Page 40 General Section 2 Speed (Non Certi. PSI 4.3L) DOOSAN DOOSAN G60S-7 G70S-7 6000 7000 rider-seated rider-seated 3000 3000 60x180x1200 60x180x1200 410x2032 410x2032 15/10 15/10 3618 3697 2156 2156 2500 2500 4340 4340 2468 2468 1455 1455 3380 3430 3958 4000...

  • Page 41: Noise &Vibration

    Noise Level [Unit : dB(A)] Sound Pressure Level Guaranteed Sound Model at Operator's ear (Leq.) Power Level (L by new Directive prEN 12053 2000/14/EC OVHD D60S-7, D70S-7, D80S-7, D90S-7 (3 speed) With Cabin 79.7 D60S-7, D70S-7 OVHD (2 speed) OVHD 79.7...

  • Page 42: Capacity Chart - Without Side Shifter

    General Section Capacity Chart - Without Side Shifter MODEL A. FFT 4550mm MAST B. FFT 5000mm MAST C. FFT 5600mm MAST D. FFT 6050mm MAST A. FFT 4550mm MAST B. FFT 5000mm MAST C. FFT 5600mm MAST D. FFT 6050mm MAST...
  • Page 43 General Section Capacity Chart - Without Side Shifter MODEL A. FFT 4550mm MAST B. FFT 5000mm MAST C. FFT 5600mm MAST D. FFT 6050mm MAST A. FFT 4550mm MAST B. FFT 5000mm MAST C. FFT 5600mm MAST D. FFT 6050mm MAST...
  • Page 44 General Section Capacity Chart - Without Side Shifter MODEL A-FFT 4350~5400mm MAST B-FFT 5850mm MAST A-FFT 4350~5400mm MAST B-FFT 5850mm MAST...

  • Page 45: Capacity Chart - With Side Shifter

    General Section Capacity Chart - With Side Shifter MODEL A. FFT 4550mm MAST A. 3000 ~ 4000 mm (118 in - 158 in) B. FFT 5000mm MAST MAST C. FFT 5600mm MAST B. 4500 mm (177 in) MFH MAST D. FFT 6050mm MAST C.
  • Page 46 General Section Capacity Chart - With Side Shifter MODEL A. FFT 4550mm MAST A. 3000 ~ 4000 mm (118 in - 158 in) B. FFT 5000mm MAST MAST C. FFT 5600mm MAST B. 4500 mm (177 in) MFH MAST D. FFT 6050mm MAST C.
  • Page 47 General Section Capacity Chart - With Side Shifter MODEL MAST A-FFT 4350~5400mm MAST A-STD 3100~3600mm B-FFT 5850mm MAST B-STD 4100mm MAST C-STD 4600mm MAST D-STD 5100mm MAST E-STD 5600mm MAST A-FFT 4350~5400mm MAST B-FFT 5850mm MAST...

  • Page 48: Serial Number

    General Section Serial Number Serial Number Locations For quick reference, record your lift truck's serial numbers in the spaces provided below the photographs. D60/70/80/90S-7(3 speed) Typical Examp Lift Truck Serial Number .______________________________ D(G)50/60/70S-7 (2 spee Transmission Serial Number .______________________________ Typical Example Diesel Engine(G2 D34) G2 D34 Drive Axle Serial Number (OCDB type)

  • Page 49: Operator's Warning And Identification Plate

    General Section Operator's Warning and Identification Plate Familiarize yourself with the Operator’s WARNING Plate and IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES. DO NOT exceed Capacity as equipped load ratings. Identification, Lift Capacity and WARNING Attachment Plate The load capacity of lift truck should never be exceeded.
  • Page 50 General Section Below are abbreviations that may appear on the Attachment Abbreviations Identification, Lift Capacity and Attachment Plate (includes Special Forks) and their meanings. Special Carriage-increased width, Mast Abbreviations height or outreach Standard Mast STD - Shaft-type Side shift Carriage SSS - (single inner member, low free lift) Hook-type Side shift Carriage (ITA)

  • Page 51: Operator's Station And Monitoring Systems

    Operation Section Operator’s Station and Monitoring Systems Overhead Guard Cabin...
  • Page 52 Operation Section Horn Switch 17. Engine Coolant Temperature Gauge Steering Wheel 18. SCR Display (81kW Engine Only) Forward/Backward Control Lever 19. Hour Counter Instrument Panel 20. Warning Lamp Panel Parking Brake Lever. 21. Plug Lift Lever 22. Headlamp & Light Switch Tilt Lever 23.
  • Page 53 Operation Section 5. Hour Counter Instrument Panel Indicates the total number of 1. Engine Ignition Start Switch hours the engine and the lift truck have operated. The The key switch is a four position hour meter will operate when switch. Position the ignition switch is in the ACCESSORY ON.
  • Page 54 Operation Section 9. Light Switch Step Step Switch Light Clearance Lamp Tail Lamp License plate Lamp Instrument Lamp Head Lamp O: means “lights on” X: means “lights off” These lamps light up regardless of position of the ignition switch. 10. Hazard Lamp Switch (Optional) Push the button to active the hazard lamp.
  • Page 55 Operation Section Instrument Panel 1. Upper indicator light 7. Transmission neutral position light 2. Alternator indicator light 8. Seat belt warning light 3. Diesel engine start preheat indicator light 9. Seat leaving warning light 4. Water-in-fuel warning light 10. Engine warning light 5.
  • Page 56 Operation Section (4) Water-in-fuel Warning Light (Diesel) (10) Engine Check Lamp Indicates the fuel contains water. Open The Engine Control System has built-in the sensor under the fuel filter to remove fault diagnostics. Detected system faults the water. can be displayed by the Engine Check Lamp as Diagnostic Fault Codes (DFC) or flash codes, and viewed in detail with the (5) Front Floodlights...
  • Page 57 Operation Section SCR Display (Diesel 81kW Only) 1. Tachometer (RPM GAUGE) 10. DIRECTION (T/M STATUS) - Display engine RPM with 1/1000 unit. - Display Status for direction. “N” or “F” or “R” 2. MULTI TORQUE MODE for engine 11. SPEEDOMETER - Display mode of multi torque, for setting mode, - Display the current vehicle speed.
  • Page 58 Operation Section 1. DEF/Ad-Blue FAULT WARNING 4. High Exhaust System Temperature (HEST) - If the lamp is turned on, after-treatment - While Cleaning-DeSOx system should be checked. after-treatment, the temperature of exhaust - Refer page. 85 (Section “Detecting control gas will increase over 600℃. If this lamp on, operator should warn passengers around the failure) truck not to approach or touch exhaust system...
  • Page 59 Operation Section LCD Instrument Panel (Option) - (Diesel 55kW Only) Press MENU button for 2 seconds to light up the 1. Mode (Function) Configuration SET and ZERO at the top right screen. Then, - Engine RPM mode press MENU button for 3 times to blink the - Transmission information display mode current weight scale.
  • Page 60 Operation Section weight, press ENTER for 1 second to save the 4. Detail Description setting (SET and RLOAD blink for 3 seconds). b. Transmission 3) Error display A transmission display is to the right of the steering initial screen (engine &...
  • Page 61 Operation Section Audio System (AM/FM Tuner with USB/AUX Player) Location of controls LOUD MENU INFO 1. AM button: Select AM Radio mode. 8. SCN/AST button with│◀◀ TUNE/TRACK ▶▶│dial 2. FM button: Select FM Radio mode. Radio mode: Plays frequencies with superior 3.
  • Page 62 Operation Section Display window Wired remote controller 1. USB/AUX indicators: When the External Device is connected, indicator is lights up. 2. MP3/WMA indicators: When the Audio Stream is detected, indicator is lights up. 1. SCAN button: In Radio mode, tune up the frequency(press): find a station (press and hold).
  • Page 63 Operation Section Rear view/Connectors 1. Antenna jack: To plug the FM antenna cable. 2. I/0 connector: To plug the 1/0 cable. <ARA-5080WF: 18 Pin> <ARA-5081WF: 18 Pin> 1. Front R (+) 1. Tel Mute 2. Rear R (+) 2. Rear R (+) 3.
  • Page 64 Operation Section Setting the sound Getting started Turning the unit on/off MENU 1. Press MENU button repeatedly to select the Sound setting mode as below; • BAS (Bass): sets the bass sound level. (-5 ~ 1. Turn your car's ignition key to ACC or IGN (ON) position.
  • Page 65 Operation Section Setting the Loudness mode Radio Setting the region of radio reception LOUD 1. When the power is turned on, press and hold the buttons more 3 seconds at the same time as below; 1. Press the LOUD button to turn loudness mode •...
  • Page 66 Operation Section Tuning in a station Radio Saving radio stations manually You can save up to 6 preset channels each for FM 1, FM2, FMA, AM 1, AM2, and AMA. If change the stations while driving, use preset button to prevent accidents. 1.
  • Page 67 Operation Section Listening to a preset station USB player Before MP3 [WMA] USB playback This unit cannot play the following files; • MP3 files encoded with MP3i and MP3 PRO format. - MP3 files encoded in an inappropriate format. 1. Press AM or FM button repeatedly to select the - MP3 files encoded with Layer 1/2.
  • Page 68 Operation Section Playing a USB device INFO 4. Press the [4 INFO] button repeatedly to display information about the file being played. The information displayed includes the file name, playing time, ID3 Tag or folder name information saved with the song. If there is no information on the playing file, then the unit will display "NO INFO".
  • Page 69 Operation Section Controlling the playback Change the playback mode 1. While playing, turn the ▶▶│TRACK│◀◀ dial 1. While playing, press the SCN button to begin the left/right to moves to the previous or next track. Intro scan playback. • When pressed shortly, scans the beginning •...
  • Page 70 Operation Section Repeatedly connecting/disconnecting the USB in a About MP3/WMA short period of time may cause damage to the This unit can play MP3 (WMA) files with .mp3, .wma device. (Iower case letters) or .MP3 and .WMA (capital letters) file name extensions. When disconnecting the USB, an abnormal sound may occur occasionally.
  • Page 71 Operation Section AUX player Listening to auxiliary audio equipment By connecting an optional portable audio device to the AUX input jack (stereo mini jack) on the unit and then simply selecting the source, you can listen on 5. Set your usual listening volume by turn the your car speakers.
  • Page 72 Operation Section B. Air Conditioner Controller (Optional) 5. OPT button – no resultant action 1. OFF button - Stops all the functions and turns off power 6. WARM button - Pressing WARM button when power is off, or in 2. A/C button air conditioner mode or anti-fog mode will turn on - Pressing A/C button when power is off, or in the heater.
  • Page 73 Operation Section b. Operating Method Rear View Camera (optional) ▶ Color tone control a. Front display (basic operation menu) 1. Press MENU button for 0.5~1 second. 1. ‘POWER’ button 2. Select brightness, value of color, color tone and - Turns power on and off color depth using SELECT button.
  • Page 74 Operation Section ▶ Main MANU (SETUP MENU) setting method 2. TRIGGER DELAY - Call SETUP MENU window by pressing MENU button for 2 seconds. - OSD menu disappears if no entry for 5 seconds. Reset function Search menu Select image - When 2 trigger signals are active, each trigger source can be selected.
  • Page 75 Operation Section 4. SCALE MODE 5. ADVANCED MENU Search menu Select image Reset function Search menu Select image Reset function - DISPLAY ▪ FULL: images are displayed in a 16:9 ratio. Search menu Select image Reset function ▪ NORMAL: images are displayed in a 4:3 ratio. - UP/DOWN ▪...
  • Page 76 Operation Section 6. AUTO SCAN Search menu Select image Reset function - If AUTO SCAN is set to ON, images are displayed in the sequence of CAM1→CAM2. - The duration of an image display can be set to 0~20 seconds. ‘0’ setting eliminates the image. - Press the SELECT button to stop repeating images, and press it again to see the images repeatedly.
  • Page 77 Operation Section Weight Scale Optional (Hydraulic Pressure Sensing Type) iii) Rated Load Setting If weight scale option(Hydraulic Pressure Sensing Type) equipped, operator can measure and limit Press “MODE” 2 sec, ‘SET( )’ and ‘ZERO( )’ ⑤ ⑥ load with display. Press “MODE” to convert display light will on.
  • Page 78 Operation Section Weight Scale Optional (Load Cell Type) With this weight scale option, the operator can 3. Specifying a Maximum Measuring Scale measure and limit the load's weight using a display This step is to specify the rated capacity of the vehicle on which the load cell is installed.
  • Page 79 Operation Section 6. Reference Load Lift Put a reference load that weighs as much as the set value on the attachment (e.g. forks). You should align the centers of gravity of the attachment and of the reference load. Raise the mast approx. 300 mm from the ground vertically.

  • Page 80: Seat Switch System

    The directional lever, however, will 4. If seat or seat switch replacement becomes remain in that forward or reverse location although necessary, be sure to use genuine DOOSAN internally the transmission will have shifted into Industrial Vehicle lift truck parts. Lift trucks neutral.
  • Page 81 Operation Section Steering Wheel Column Tilt Angle Electrical Disconnect Switch Adjustment (If Equipped) 1. ON - Connects the battery for electrical power to Typical Example all electrical circuits. The steering wheel column tilt angle is adjustable within 15 degrees to fit for the operator position. The 2.
  • Page 82 Operation Section Fuse Locations 1. D60/70/80/90S-7 (3 SPEED) Fuses protect the electrical system from damage caused by overloaded circuits. Change a fuse if the element separates. If the element of a new fuse separates, have the circuit checked and repaired. Rated Rated Description...
  • Page 83 Operation Section 2. D60/70/80/90S-7 (2 SPEED) Rated Description Rated Capacity Description Capacity START RELAY CIGAR LIGHTER, WIPER TIMER OSS CONTROLLER(IGN) ECU KEY POWER, FUEL HEATER PARKING BRAKE CONTROLLER RELAY LCD DISPLAY, TCU F/R LEVER ISO 3691 VALVE, TCU AUTO HAZARD SWITCH, CABIN RELAY NEUTRAL, PARKING GAUGE LAMP, ENGINE CHECK CAMERA OPTION (ACC)
  • Page 84 Operation Section 3. G60/70S-7 (2 speed, Overhead Guard) Rated Description Rated Capacity Description Capacity VIC CONN (START) OSS CONTROLLER (IGN) VIC CONN (IGN) AS CONTROLLER POWER FWD RELAY F/R LEVEL CREEP SPEED RELAY HAZARD LAMP ISO SOL V/V GAUGE LAMP CAMERA ENGINE CHECK LAMP OPTION (ACC)
  • Page 85 Operation Section 4. G60/70S-7 (2 Speed, Cabin) Rated Rated Description Description Capacity Capacity VIC CONN (START) CIGAR LIGHTER WIPER TIMER OSS CONTROLLER (IGN) VIC CONN (IGN) AS CONTROLLER POWER F/R LEVEL FWD RELAY CREEP SPEED RELAY HAZARD LAMP ISO SOL V/V CABIN RELAY CAMERA GAUGE LAMP...
  • Page 86 Operation Section Circuit Breaker Seat Seat Adjustment NOTE: Seat arrangements may vary. Basic operation will be similar. Seat adjustment should be checked at the beginning of each shift and when operators change. Lock the seat into position before operating, to prevent an unexpected seat change.

  • Page 87: Lift Truck Controls

    Operation Section Lift Truck Controls WARNING Direction Control Lever “LOCK” the direction control lever. Whenever machine is parked, "LOCK" the direction control lever in "NEUTRAL" to prevent accidental machine movement. Transmission Display(3 Speed Only) A transmission display is to the right of the steering wheel on the dash.
  • Page 88 Operation Section Automatic Transmission Switch Inching Switch(3 Speed Only) (3 Speed Only) This switch changes over the modes of the inching control pedal, inching and no-inching. Automatic speed range: . FORWARD: 3 speeds. . REVERSE: 3 speeds. 1. In the "1" position, “NO INCHING” mode is selected.
  • Page 89 Operation Section IDLE Select Switch (Diesel Only) Emergency Engine Stop Switch (Optional) This switch controls engine idle speed. This switch stops the engine under an emergency condition. 1. When this switch is at "1" position, the engine idle rpm is increased from 875 (basic speed) to 1.
  • Page 90 Operation Section Multi Torque Switch (Diesel Only) SCR Cleaning - DeSOx Switch (81kW, Diesel Engine Only) <Overhead Guard> <Overhead Guard> <Cabin> <Cabin> This switch changes truck operation mode. This switch initiates regular regeneration process of the post-treatment device. 1) A pop-up on the SCR Display warns the operator to perform SCR Cleaning.
  • Page 91 Operation Section 3) The switch returns to the normal position of "2" after pressed by the operator to position "1". However, it does not return when pressed to position "3" and the operator shall return the switch from position "3". 4) Setting this switch to position "3"...
  • Page 92 Operation Section Transmission Inching Control Service Foot Brake Pedal Pedal Typical Example Typical Example Push DOWN on the brake pedal to slow or stop the lift truck. Inching Control Pedal - Pushing down on the inching pedal, modulates the hydraulic pressure to the clutch packs, permitting RELEASE the brake pedal to allow the lift disc slippage.
  • Page 93 Operation Section Mechanical Parking Brake (If Installed) Emergency Lowering Device WARNING If the carriage fails to descend when the lift lever is pushed forward, it can be lowers using the emergency lowering valve in the control box. Do not stay beneath or near the carriage when using the emergency lowering valve, otherwise, you may get severely injured.
  • Page 94 Operation Section Safety Function WARNING Once the operator leaves the seat for three seconds with the parking brake released, the parking brake After pressing the parking brake switch, hold gets engaged by itself to keep the vehicle from down the brake pedal to keep the vehicle moving.
  • Page 95 Operation Section Lift Control The forks can be raised or lowered by pulling backwards or pushing forwards on this lever. The lift speed is controlled by tilt angle of the lever and accelerator pedal effort. The lowering speed can be controlled by tilt angle of the lever.

  • Page 96: Fuel Replenishment

    Operation Section Fuel Replenishment 1. Park the lift truck only at a designated safe Diesel Engine location. Place the transmission in Neutral. Lower the forks on the ground. Apply the parking brake. Stop the engine. WARNING Explosive fumes present during refueling.
  • Page 97 Operation Section Changing LP Tanks WARNING Only trained, authorized personnel should fill or exchange LP tanks. Personnel engaged in filling of LP containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves. Do not refuel or store LP powered lift trucks near any underground entrance, elevator shafts or any other place where LP could collect in a pocket causing a potentially dangerous condition.
  • Page 98 Operation Section WARNING LP tank must extend past counterweight. 9. Check to be sure that the LP warning plate is in position on the lift truck, and is legible. 10. Check to be sure the replacement tank is of the correct type.
  • Page 99 Operation Section DEF/Ad-Blue Replenishment (81kW Diesel Engine Only) NOTICE Do not allow the lift truck to become low on DEF(Ad-Blue) or completely run out of /DEF (Ad-Blue). Sediment or other impurities in the DEF(Ad-Blue) Tank could be drawn into the after treatment.

  • Page 100: Before Starting The Engine

    Operation Section Before Starting the Engine 6. Inspect the tires and wheels for cuts, gouges, Walk-Around Inspection foreign objects, inflation pressure and loose or missing bolts. Make a thorough walk-around inspection before mounting the lift truck or starting the engine. Look 7.
  • Page 101 Operation Section Typical Example Diesel Engine Typical Example 14. Observe the fuel level gauge after starting the truck. Add fuel if necessary WARNING Personal injury may occur from accidents caused by improper seat adjustment. Always adjust the operator's seat before starting the lift truck engine.

  • Page 102: Starting The Engine

    Operation Section Starting the Engine Diesel Engine Prestart Conditions NOTE: The engine will not start unless the Starting Diesel Engine at cold transmission directional control lever is in 1. Turn the ignition key to the ON position. The the NEUTRAL position. start preheat light will come ON.
  • Page 103 NEGATIVE(-). Release it when the engine starts. Attach ground cable last, remove first. All lift trucks equipped with DOOSAN built internal 3. If the engine does not start, Do not press on the combustion engines are NEGATIVE(-) ground. accelerator pedal. Turn the starter switch to OFF position, the repeat step 2 and depress the accelerator pedal slightly during cranking.
  • Page 104 Operation Section 10. Connect one end of the negative (-) jumper Use of Jumper Cables cable to the other terminal (negative) of the When auxiliary start receptacles are not available, boost battery. use the following procedure. 11. Make final connection of negative (-) cable to the 1.

  • Page 105: After Starting The Engine

    Operation Section NOTE: At an oil temperature in the shifting circuit After Starting the Engine lower than -12°C, the transmission must be warmed-up for some minutes. This must be Observe all indicator lights and gauges frequently carried out in Neutral with an increased during operation, to make sure all systems are engine speed (about 1500 rpm).
  • Page 106 Operation Section Diesel Engine Engine and After-treatment System Introduction The D34 engine which is a high-power engine in compliance with the EPA/CARB TIER-4 (EURO STAGE Ⅳ) Engine Emissions Standard is provided with various systems. The D34 engine is equipped with a turbo charger intercooler system that compresses and cools air and feeds it to the intake manifold.
  • Page 107 Operation Section Detecting Control Failure As shown in the table below, the ECU / DCU performs self diagnosis. If a fault/failure is detected, engine check lamp lights up and failure code (DTC) is indicated by the number of flashes of the engine check lamp. To check failure code(DTC) refer page.48 #6 Engine Check Lamp(RED) section.
  • Page 108 Operation Section Engine Limphome Description LAMP STOP in Mode 5minutes P0190 Rail Pressure Sensor Gradient Fault FLASH P0193 Rail Pressure Sensor High Fault FLASH P0192 Rail Pressure Sensor Low Fault FLASH P0087 Rail Pressure Build-up Fault P0191 Rail Pressure Sensor Drift Fault FLASH P0002 Rail Pressure Control Fault (IMV only)
  • Page 109 Operation Section Engine Limphome Description LAMP STOP in Mode 5minutes P0261 Harness Resistance Low Fault (Cylinder #1) Injector Minimum Drive Pulse Drift Fault (Cylinder P029B P0202 Injector Open Fault (Cylinder #2) P02EF Injector Short Fault (Cylinder #2) P0265 Harness Resistance High Fault (Cylinder #2) P0264 Harness Resistance Low Fault (Cylinder #2) Injector Minimum Drive Pulse Drift Fault (Cylinder...
  • Page 110 Operation Section Engine Limphome Description LAMP STOP in Mode 5minutes P0545 Turbo In Temperature Sensor Low Fault P2081 Turbo In Temperature Sensor Noise Fault P0685 Main Relay Stuck Fault P068A Main Relay Drop Fault P062D Injector Bank 1 SCB Fault FLASH P062D Injector Bank 1 SCG Fault...
  • Page 111 Operation Section Engine Limphome Description LAMP STOP in Mode 5minutes P0381 Glow plug lamp fault P0711 Transmission oil temperature is out of range P2135 Pedal position sensor 1,2 voltage correlation P060D Pedal position performance out of range P0120 Pedal position sensor 1 fault P0220 Pedal position sensor 2 fault P2544...
  • Page 112 Operation Section Engine Limphome Description LAMP STOP in Mode 5minutes P2BB6 SCR Inducement Fault - Repeat offense P2BC1 SCR Inducement Fault - UREA(DEF) tank warning SCR Inducement Fault - UREA(DEF) tank level very P2BC2 low (warning escalation) P2BC3 SCR Inducement Fault SCR Inducement Fault - UREA(DEF) tank level P2BC4 empty...
  • Page 113 Operation Section DCU Fault List An inducement is set to limit engine power and speed when the SCR system fails to regularly reduce nitrogen oxides. This is for the operator to stop work and take a measure. Description Inducement P2530 Key Position Error P0071 Environment Temperature Too High...
  • Page 114 Operation Section Description Inducement P23F0 Inlet Nox Delay (O2 Signal High) U1223 Inlet NOx Sensor SAE J1939 Error (Power Signal) P23E1 Inlet Nox Delay (O2 Signal Low) U1219 Inlet NOx Sensor SAE J1939 Error (Temperature) P23EE Inlet NOx sensor Wire monitoring P23EF Outlet NOx sensor Wire monitoring P23D1...
  • Page 115 Operation Section Description Inducement P2396 Outlet NOx Sensor SRC Max P2398 Outlet NOx Sensor SRC Min U1225 Outlet NOx Sensor SAE J1939 Error (Nox Signal) P239F Nox Undershoot Error (Sensor 2) U1235 Outlet NOx Sensor SAE J1939 Error (O2 Signal) P2047 Dosing Valve Short Circuit to Battery Tampering...
  • Page 116 Operation Section Description Inducement P204C DEF Pump Pressure Min Tampering P204F DEF Pump Pressure Signal Error P23BB DEF Pump Pressure Too High P23BA DEF Pump Pressure Too Low P204E Defective Pressure Reduction P204D DEF Pump Pressure Max Tampering P204C DEF Pump Pressure Min Tampering P204B Monitoring of Pressure Build-up...
  • Page 117 Operation Section Description Inducement P0427 SCR Inlet Temperature Sensor Signal Low Tampering P24F6 SCR Inlet Temperature Plausibility Max P24F5 SCR Inlet Temperature Plausibility Min P24F4 SCR Inlet Temperature Static Plausibility P0426 SCR Inlet Temperature Error Interruption of Dosing P042B SCR Outlet Temperature Error Interruption of Dosing P042B SCR Outlet Temperature Error...
  • Page 118 Operation Section Description Inducement P2080 DOC Inlet Temperature Sensor Signal Error P2080 DOC Inlet Temperature Sensor Signal Error U1024 CAN communications faulty: DOC Inlet NOx sensor U1025 CAN communications faulty: DOC Inlet NOx sensor U1026 CAN communications faulty: DOC Inlet NOx sensor U1027 CAN communications faulty: DOC Inlet NOx sensor U1028...
  • Page 119 Operation Section Description Inducement P06EA Inlet NOx Sensor Self-Diagnosis U1904 Timeout of NOxSensGlbReqTx (NOX sensor) U1646 Timeout of DM1ECU BAM (ECU) U1660 Timeout of DM1ECU Packet (ECU) U1444 Timeout of EEC1 (ECU) U111A Timeout of AT1I1 (Inlet Nox sensor) U116D Timeout of AT1O1 (Outlet Nox sensor) U1300 Variant Dataset Error...
  • Page 120 Operation Section Description Inducement P160D DCU Reset 1 P160E DCU Reset 2 P160C DCU Reset 0 P160D DCU Reset 1 P160E DCU Reset 2 P160F Peripheral Monitoring Error P1602 Sensor Supply Error P1220 DEF Temperature Plausibility High P1221 DEF Temperature Plausibility Low P1223 DEF Temperature Too High P1224...
  • Page 121 Operation Section Description Inducement P1511 DEF Quality Sensor Fail P1531 DEF Quality Signal Error P1560 DEF Quality Too High P1630 DCU EEP Read Error P1631 DCU EEP Write Error P16C0 DCU Reset 0 P16C1 DCU Monitoring Error (query-/response-communication) P16C2 DCU Reset 1 P16C3 DCU Monitoring Error (SPI communication) P16C4...
  • Page 122 Operation Section Description Inducement U0025 SAE J1939 Error (Inlet Nox sensor) U0026 SAE J1939 Error (Inlet Nox sensor) U0027 SAE J1939 Error (Inlet Nox sensor) U0028 SAE J1939 Error (Inlet Nox sensor) U0029 SAE J1939 Error (Inlet Nox sensor) U002A SAE J1939 Error (Inlet Nox sensor) U002B SAE J1939 Error (outlet Nox sensor)
  • Page 123 Operation Section Description Inducement U0401 UDS CAN ID Error U040F DEF Pump Motor Communication Fail (Supply Module) Tampering U0444 Timeout of EEC1 (ECU) U0646 Timeout of DM1ECU BAM (ECU) U0660 Timeout of DM1ECU Packet (ECU) U0661 Timeout of DM1ECUSPN1 (ECU) U0800 Timeout of A1DOC (DOC Inlet Temperature Sensor) U0904...
  • Page 124 LCD Display Engine Torque Buzzer RPM Limit Method Message on the Display Check Lamp Reduction Warning Stage Normal ENGINE MALFUNCTION CALL DOOSAN Reduced Reduced Continuous Level1 SERVICE AGENT Engine Power Reduced! ENGINE MALFUNCTION CALL DOOSAN Blinking Limp home Limp home Continuous...
  • Page 125 Operation Section DEF/Ad-Blue Level inducement for USA / Europe There are several DEF/Ad-Blue level points at which the DEF level indicator lamp changes and the display shows a message to warn the shortage of DEF/Ad-Blue. The lower the point, the more the system limits the engine power and speed in order to prevent nitrogen oxide emissions from exceeding the acceptable level due to a lack of DEF/Ad-Blue.
  • Page 126 Operation Section DEF/Ad-Blue Level Inducement for Europe Inducement Strategy Engine DEF Level Torque Check Buzzer Condition Repeat Indicator Indicator Reduction Limit Lamp Inducement Offence Stage volume (within 40hrs) 25 ~ 100 Green ON Normal 10 ~ 25 Green ON Level1 At starting Yellow 5~10...
  • Page 127 Operation Section DEF/Ad-Blue Quality Failure for USA / Europe If you use a poor quality DEF/Ad-Blue type, engine power will decrease in order to prevent the SCR system from functional degradation and damage. Continued use of poor quality DEF/Ad-Blue may result in high replacement cost due to damage caused to the SCR system.
  • Page 128 Operation Section DEF/Ad-Blue Quality Failure for Europe Inducement Strategy Engine DEF Level Torque Check Buzzer Repeat Indicator Indicator Reduction Limit Lamp Inducement Offence Condition Stage (within 40hrs) Green ON Normal ≥ 90% Poor DEF quality Green ON Level1 counter value detected At starting severe...
  • Page 129 Offence Stage (within 40hrs) Normal SCR SYSTEM MALFUNCTION Tampering At starting & Every 20min Level1 CALL DOOSAN SERVICE AGENT was detected Engine Power Reduced in 30min SCR SYSTEM MALFUNCTION 0.5~2.5hrs Immediately At starting & Every 20min Level2 CALL DOOSAN SERVICE AGENT...
  • Page 130 Condition Offence Stage (within 40hrs) Normal SCR SYSTEM MALFUNCTION Tampering At starting & Every 20min Level1 CALL DOOSAN SERVICE AGENT was detected ≥ 95% of Engine Power will be Reduced counter value for SCR SYSTEM MALFUNCTION severe 36~100hrs Every 10min...
  • Page 131 Condition Offence Stage (within 40hrs) Normal SCR SYSTEM MALFUNCTION Impeded EGR At starting & Every 20min Level1 CALL DOOSAN SERVICE AGENT detected ≥ 95% of Engine Power will be Reduced counter value for SCR SYSTEM MALFUNCTION severe 36~100hrs Every 10min...
  • Page 132 Condition Offence Stage (within 40hrs) Normal Dosing SCR SYSTEM MALFUNCTION Interruption At starting & Every 20min Level1 CALL DOOSAN SERVICE AGENT ≥ 90% of detected Engine Power will be Reduced counter value for SCR SYSTEM MALFUNCTION severe 10~20hrs Every 10min...
  • Page 133 Operation Section Electronic Controlled Spark-Ignition Engines PSI 4.3L LP Engine The primary components of the fuel system are the fuel supply, direct electronic pressure regulator (DEPR), fuel mixer, electronic throttle control (ETC) device, 2-Stage convertor, engine control module (ECM), and a catalytic converter.
  • Page 134 Operation Section EMS schematic of PSI 4.3L LP engine...
  • Page 135 Operation Section Basic Troubleshooting(LP) The PSI 4.3L fuel systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) and are covered in the Advanced Diagnostics section. Items such as fuel level, plugged fuel lines, clogged fuel filters and malfunctioning pressure regulators may not set a fault code by the Engine Control Module (ECM).
  • Page 136 Operation Section INTERMITTENT Checks Action DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code (DTC). Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables Preliminary Checks with this condition may result in the replacement of good parts.
  • Page 137 Operation Section NO START Checks Action DEFINITION: The engine cranks OK but does not start. Preliminary Checks None Use the DST to: • Check for proper communication with both the ECM ECM Checks • Check all system fuses engine fuse holder. Refer to Engine Controls Schematics. •...
  • Page 138 Operation Section NO START Checks Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel system. Check for the following: • Vacuum leaks. Engine Mechanical • Improper valve timing. Checks • Low compression. •...
  • Page 139 Operation Section HARD START Checks Action DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. Preliminary Checks Make sure the vehicle’s operator is using the correct starting procedure. •...
  • Page 140 Operation Section HARD START Checks Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system. Check for the following: • Vacuum leaks • Improper valve timing Engine Mechanical • Low compression Checks •...
  • Page 141 Operation Section CUTS OUT, MISSES Checks Action DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
  • Page 142 Operation Section HESITATION, SAG, STUMBLE Checks Action DEFINITION: The engine has a momentary lack of response when putting it under load. The condition can occur at any engine speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks None •...
  • Page 143 Operation Section BACKFIRE Checks Action DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Checks None Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire.
  • Page 144 Operation Section LACK OF POWER, SLUGGISHNESS, OR SPONGINESS Checks Action DEFINITION: The engine delivers less than expected power. • Refer to the LPG Fuel system OBD System Check. • Compare the customer’s vehicle with a similar unit to verify customer has an actual problem.
  • Page 145 Operation Section ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action DEFINITION: The engine runs unevenly at idle. If severe enough, the engine may shake. Preliminary Checks None. Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance: • Check for silicone contamination from fuel or improperly used sealant. If contaminated, the sensor may have a white powdery coating result in a high but false signal voltage (rich exhaust indication).
  • Page 146 Operation Section ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action Check the engine for: • Broken motor mounts. • Improper valve timing. Engine Mechanical • Low compression. Check • Improper valve clearance. • Worn rocker arms. • Broken or weak valve springs. •...
  • Page 147 Operation Section Advanced Diagnostics The Fuel system has built-in diagnostics for system trouble shooting. The system has a dash mounted malfunction indicator lamp (MIL) that provides indications of engine or fuel system related problem. Most engine control system related problems that affect emissions or driveability of the vehicle will set a (DTC) diagnostic trouble code and illuminate the MIL.
  • Page 148 Operation Section Blink Code Function Although the DST is considered a required tool to access the DTC codes, codes may be retrieved without a laptop computer using the blink code function. To enable this function follow the steps below: • Jump pins 1 and 4 at the DLC connector (see illustration below) •...
  • Page 149 Operation Section Malfunction Indicator Lamp (MIL) Operation How does my MIL work? The emissions control system utilizes a MIL to warn the operator or technician of a possible issue with the engine or emissions control system. The system will keep the MIL illuminated for the entire key cycle in which the trouble code was set.
  • Page 150 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (1 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 11: Intake cam / distributor DTC 268: Injector 3 coil shorted 520800 position error DTC 16: Crank and/or cam could not DTC 270: Injector 4 open or short to...
  • Page 151 Operation Section DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 172: Adaptive-learn gasoline DTC 326: Knock1 excessive or 520200 bank1 low erratic signal DTC 174: Adaptive-learn gasoline DTC 327: Knock1 sensor open or 520201 bank2 high not present DTC 175: Adaptive-learn gasoline DTC 331: Knock2 excessive or...
  • Page 152 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (2 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 601: Microprocessor failure - DTC 1175: MegaJector voltage 520260 FLASH supply low DTC 1176: MegaJector internal DTC 604: Microprocessor failure - RAM 520260...
  • Page 153 Operation Section DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 1122: FPP1/2 do not match each DTC 1422: ERWT2 voltage low 520250 other or IVS (redundancy lo) DTC 1423: ERWT1 higher than DTC 1131: WGP voltage high 1192 expected stage 1 DTC 1424: ERWT2 higher than...
  • Page 154 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (3 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 1546: AUX analog Pull-Up/Down 520221 DTC 1662: PWM6 short to power 3 low voltage DTC 1547: AUX analog Pull-Up/Down DTC 1663: PWM7 open / ground short 4 high voltage...
  • Page 155 Operation Section DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 1628: J1939 CAN address / DTC 2303: Spark coil 2 primary open or 1269 engine-number conflict short to ground DTC 1629: J1939 TSC1 message DTC 2304: Spark coil 2 primary shorted 1269 receipt loss DTC 1630: J1939 ETC message...
  • Page 156 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (4 of 4) DTC Set 2 Description SPN-2 FMI-2 DTC 2618: Tach output ground short DTC 2619: Tach output short to power DTC 8901: UEGO microprocessor internal fault 3221 DTC 8902: UEGO heater supply high voltage 3222...
  • Page 157 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (1 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 1561: AUX analog Pull-Down 2 DTC 107: MAP voltage low high voltage DTC 1561: AUX analog Pull-Down 3 DTC 108: MAP pressure high high voltage DTC 1561: AUX analog Pull-Down 2...
  • Page 158 Operation Section DTC 1426: ERWT2 higher than DTC 2123: FPP1 voltage low expected stage 2 DTC 1651: J1939 ETC message DTC 1420: ERWT2 voltage high receipt loss while in DTC 2126: FPP1-2 higher than DTC 1422: ERWT2 voltage low expected DTC 2121: FPP1-2 lower than DTC 1424: ERWT2 higher than expected...
  • Page 159 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (2 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 16: Crank and/or cam could not DTC 1661: PWM6 open / ground synchronize du short DTC 1629: J1939 TSC1 message DTC 1664: PWM7 short to power...
  • Page 160 Operation Section DTC 2312: Spark coil 5 primary open DTC 286: Injector 9 coil shorted 1272 or short to ground DTC 288: Injector 10 open or short to DTC 2313: Spark coil 5 primary 1272 ground shorted DTC 2315: Spark coil 6 primary open DTC 289: Injector 10 coil shorted 1273 or short to ground...
  • Page 161 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (3 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 304: Cylinder 4 emissions/catalyst DTC 175: Adaptive-learn gasoline 1326 520201 damaging m bank2 low DTC 1315: Cylinder 5 misfire detected 1327 DTC 1161: Adaptive-learn LPG high...
  • Page 162 Operation Section DTC 8907: UEGO return voltage shorted DTC 1517: AUX analog Pull-Up 3 3056 520218 high voltage DTC 1518: AUX analog Pull-Up 3 DTC 8910: UEGO sense cell voltage high 3217 520218 low voltage 1541: analog DTC 8911: UEGO sense cell voltage low 3217 520219 Pull-Up/Down 1 high voltage...
  • Page 163 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (4 of 4) DTC Set 2 Description SPN-2 FMI-2 DTC 188: Gaseous fuel temperature sender high voltage 520240 DTC 187: Gaseous fuel temperature sender low voltage 520240 DTC 331: Knock2 excessive or erratic signal 520241 DTC 332: Knock2 sensor open or not present 520241...
  • Page 164 Operation Section Lift Truck Operation Power Shift Transmission / Drive WARNING Axle 1. Start the engine. See item "Starting the Engine" A lift truck with the engine running but without an operator can move slowly (creep) if the transmission is left engaged. This could result in personal injury.
  • Page 165 Operation Section Inching WARNING NOTE: The purpose of the inching pedal is to Watch the road carefully for any obstacle when provide precise lift truck inching control at driving the truck. Do not go fast over bumps, pot very slow travel speed and high engine rpm. holes or other rough grounds, otherwise the This is used for fast hydraulic lift during load engine might go OFF by a severe impact.

  • Page 166: Auto Shift Controller Asc-209 (If Equipped)

    Operation Section Auto Shift Controller ASC-208 (If Equipped) Product Description Adjustments The Autoshift controller is an electrical control system, specially designed for use on forklift trucks with internal combustion engines. Its primary purpose is to prevent the operator from operating the truck outside of the design parameters, e.g.
  • Page 167 Operation Section Diagnostics Features NOTICE The transmission of your lift truck may be reversed under full power up to a travel of 6.0 km/h (3.73 mph). But the Inhibit Speed of Auto Shift is set by the factory at 4~5 km/h (2.5~3.2 mph) because reversing the transmission at lower travel speeds prolongs the lift of the transmission, axle shafts and tires.
  • Page 168 Operation Section • Display for Troubleshooting Operation This system can be basically operated in two Display Description Remark preselected modes, automatic mode and manual Automatic operation mode. High speed s/w input Lever input test Automatic mode Forward s/w input Lever input test Direction Inhibit Reverse s/w input Lever input test...
  • Page 169 Operation Section 8. The direction of travel will change automatically Manual Mode (Fail-Safe mode) when the vehicle speed is reduced as much as In case that the controller is broken down or you the pre-selected speed in the controller. don't want to use the functions of the Auto Shift Controller, you can select Manual Mode.

  • Page 170: Operating Techniques

    Operation Section Lifting the Load Operating Techniques 1. Lift the load carefully and tilt the mast back a Inching into Loads short distance. Typical Example Typical Example 1. Move the lift truck slowly FORWARD into 2. Tilt the mast further back to cradle the load position and engage the load.
  • Page 171 Operation Section Traveling with the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. Typical Example 1. Move the lift truck into the unloading position. Typical Example 1. Carry the load as low as possible but maintain clearance.
  • Page 172 Operation Section Turning Typical Example 3. Deposit the load and BACK away carefully to 1. When turning sharp corners, keep close to the disengage the forks. inside corner. Begin the turn when the inside drive wheel meets the corner. Typical Example 4.
  • Page 173 Operation Section Lifting Drums or Round Objects Operating in Hot Weather Keep the following points in mind when you operate the lift truck in hot weather. 1. Check the radiator. Clogging can cause the overheating. Clean them out regularly with a blast of compressed air.
  • Page 174 Operation Section Safety instructions for attachments when transporting suspended load WARNING Swinging/wide loads and a reduced residual capacity can result in accidents. Adapt the travel speed to the load, less than walking pace. Secure swinging loads for example with lifting slings.

  • Page 175: Parking The Lift Truck

    Operation Section Parking the Lift Truck Typical Example 4. Lower the forks to the ground. WARNING Blocking the wheels will prevent unexpected lift truck movement, which could cause personal injury. Typical Example Park the lift truck level, with the forks lowered and 5.

  • Page 176: Lift Fork Adjustment

    Operation Section Lift Fork Adjustment WARNING WARNING When adjusting the fork spread, be careful not to Make sure the forks are locked before carrying a pinch your hand between forks and the carriage load. slot. If the fork/locking pin is not fully engaged, the fork could become unintentionally disengaged.

  • Page 177: Storage Information

    Operation Section Storage Information Cover components such as the breather and air Before Storage cleaner which may be caught with humidity. Before storing your lift truck, clean and inspect as The machine should be operated at least once per the following procedures. a week.

  • Page 178: Method And Caution For Cabin Tilting (Optional)

    Operation Section Cabin Tilting (power type) Method and Caution for Cabin Tilting (Optional) WARNING Make sure that there is sufficient space before Cabin Tilting tilting the cabin. Cabin Tilting Limit Switch Do not remove the switch on the left tilting cylinder. The switch protects the front glazing during cabin WARNING tilting.
  • Page 179 Operation Section 2. To adjust cabin tilting position in manual tilting Cabin Tilting (manual) operation, change the direction with the Manual 1. For manual cabin tilting, open the cover under the Override Position shown below. left step equipped with power-pack. Support the power-pack with a lever and move the lever up - NORMAL POSITION: keep pressing the button, and down.

  • Page 180: Transportation Hints

    Remove ice, snow or other slippery material from width, and length of a load. the shipping vehicle and the loading dock. Contact your DOOSAN Lift Truck dealer for shipping instructions for your lift truck. Typical Example Always block the trailer or the rail car wheels before loading the lift truck.
  • Page 181 Operation Section Lifting a Forklift Using a Crane WARNING 1. If lifting rope/cable breaks, serious injury/damage would occur. 2. The lifting wire rope and stay must be long enough to avoid contact with the forklift. Short rope/stay can damage the vehicle. If it's too long, it may cause interference.
  • Page 182 Operation Section How to Fix Forklift to a Carrier 1. The rope/chain must have sufficient length for fixing. 2. Park the vehicle on a level ground. 3. Set the mast vertically. Lower the fork or attachment to the lowest position. 4.

  • Page 183: Towing Information

    9. Remove the wheel blocks. Tow the lift truck inclines or poor surface conditions. Consult your DOOSAN Lift Truck dealer for towing a slowly. Do not tow any faster than 2 km/h (1.2 disabled lift truck.
  • Page 184 Operation Section Electronic Parking Brake (If Installed) NOTICE In the case of the electronic parking brake, it always stays engaged when the ignition is off, regardless of where the parking switch is positioned. Before towing the vehicle, therefore, you should release the parking brake by force to prevent WARNING excessive wear and damage on the park brake...

  • Page 185: Maintenance Section

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for Users also refer International inspection, maintenance and repair of lift truck forks. Organization For Standardization-ISO Technical It also provides general information on the design Report 5057-Inspection and Repair of Fork Arms and application of forks and the common cause of Standard...
  • Page 186 Maintenance Section Causes of Fork Failure Wear  Forks are constantly subjected to abrasion as Improper Modification or Repair they slide on floors and loads. The thickness of Fork failure can occur as a result of a field the fork blade is gradually reduced to the point modification involving welding, flame cutting or other where it may not be capable of handling the similar processes which affect the heat treatment...
  • Page 187 Maintenance Section Fork Inspection First Installation 1. Inspect forks to ensure they are the correct size for the truck on which they will be used. Make sure they are the correct length and type for the loads to be handled. If the forks have been previously used, perform the "12 Month Inspection".
  • Page 188 Maintenance Section With the fork restrained in the same manner as 12 Months Inspection its mounting on the lift truck, apply the test load twice, gradually and without shock. Maintain the Forks should be inspected, at a minimum, every 12 months.

  • Page 189: Tire Inflation Information

    Maintenance Section Tire Shipping Pressure Tire Inflation Information The tire inflation pressures shown in the following Tires Inflation chart are cold inflation shipping pressures. WARNING Shipping Ply Rating Or Size Pressure Strength Index Personal injury or death could result when tires are inflated incorrectly.

  • Page 190: Torque Specifications

    Maintenance Section Torques for Standard Bolts, Nuts Torque Specifications and Taper lock Studs Metric Hardware - This lift truck is almost totally metric design. Specifications are given in metric and U.S. Customary measurement. NOTICE Metric hardware must be replaced with metric The following charts give general torques for bolts, hardware.
  • Page 191 Maintenance Section Torques for Taper lock Studs Torques for Metric Fasteners Thread Size Standard Taper lock Stud Torque Inch N·m lb·ft NOTICE 8 ± 3 6 ± 2 Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or 5/16 17 ±...

  • Page 192: Cooling System Specifications

    Cooling system problems can arise without lubricating oil. a thermostat. NOTICE DOOSAN recommends that the coolant mixture contain a minimum of 30% antifreeze or equivalent. Never add coolant to an overheated engine, engine damage can result. Allow the engine to cool first.
  • Page 193 DOOSAN recommends that the coolant mix contain 50% commercially available automotive antifreeze, DOOSAN prefers the use of distilled water or or equivalent and acceptable water to maintain an de-ionized water to reduce the potential and severity adequate water pump cavitation temperature for of chemical insolubility.

  • Page 194: Specifications Of Fuel And Def/Ad-Blue

    Maintenance Section Specifications of Fuel and DEF/Ad-Blue DO NOT USE Fuels that have sulfer content General Fuel Information  greater than 0.0015 % (15 ppm). Use only fuel as recommended in this section. Diesel fuels specified to EN 590 or ASTM D975 ...
  • Page 195 Doosan approves the use of bio-diesel fuels that do not exceed a blend of 5% (by volume) of FAME with General DEF/Ad-Blue Information 95% (by volume) of approved mineral oil derived diesel fuel.
  • Page 196 Maintenance Section Storage Between 4°C/40°F and 26°C/80°F is recommended CAUTION to maintain shelf life. • Make sure to wear personal protective equipment Above -10°C/12° F is recommended to avoid observe precautions when handling freezing, which starts at -11°C/11° F. DEF/Ad-Blue. Below 30°C/86°...
  • Page 197 LP varies slightly between different parts of the country and different refineries. HD5 is recommended DOOSAN forklift trucks. Remember LP is heavier than air and will sink to the lowest spot possible. Avoid areas near floor drains or lubrication pits where escaped fuel may collect.

  • Page 198: Lubricant Specifications

    Shortened engine life will result. NOTICE NOTE: Multi-grade oils blended Failure to follow the oil recommendations can cause DOOSAN transmissions. shortened engine life due to carbon deposits or Multi-grade oils which use high molecular excessive wear. Especially for D34 Tier4 Final weight...
  • Page 199 Use MPGM for heavily loaded bearings and joints where an extreme pressure grease will maximize • Oil Cooled Disc Brake (OCDB) the life of DOOSAN equipment. This NLGI No. 2 grade is suitable for most temperatures. Select oil that meets below specifications.

  • Page 200: Lubricant Viscosities And Refill Capacities

    Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities LUBRICANT VISCOSITIES D5/6/7 D8//9 G5/6/7 Refill Capacities FOR AMBIENT (OUTSIDE) TEMPERATURES (Approximate) °C °F 3speed 3speed 2speed Compartment Viscosities Min Max Min Max or System Compartment SAE 5W30 Liters or System SAE10W30 Engine...

  • Page 201: Maintenance Intervals

    Maintenance Section Mast Channels - Lubricate........220 Maintenance Intervals DEF/Ad-Blue Fluid Level - Check ......220 Hydraulic Oil Level - Check ........220 Transmission Oil Level - Check ......221 Drive Axle Oil Level - Check........221 NOTICE Never exceed the Maintenance Intervals specified in the manual.
  • Page 202 Maintenance Section Every 1500 Service Hours or 9 Months Transmission Oil & Oil Filter – Change (3 Speed, ZF 3WG94) ..............243 Inspect Ignition System (LP Engine Only) .... 243 Replace Spark Plugs (LP Engine Only) ....243 Replace LP Fuel Filter Element (LP Engine Only) .................
  • Page 203 Maintenance Section Quick Reference to Maintenance Schedule EVERY FIRST ITEMS SERVICES PAGE Air Cleaner Indicator Check Air Intake System Change Air Intake System Check, Clean Clean, Battery Terminal Inspect Belts (Diesel E/G Only) Check, Adjust Carburetor (LP-Gas Engine Only) Adjust, Clean Carriage Roller Extrusion Adjust Checking the TMAP Sensor (LP Engine Only)
  • Page 204 Maintenance Section Quick Reference to Maintenance Schedule EVERY FIRST ITEMS SERVICES PAGE Inspect Throttle Assembly (LP Engine Only) Inspect Vacuum Lines and Fittings (LP Engine only) Inspecting Engine Fuel Supply System Inspection Engine for Fluid Leaks Test, Check, Lift Chains Adjust LP Regulator/Converter Inspection (LP Engine Only)
  • Page 205 Maintenance Section Quick Reference to Maintenance Schedule EVERY FIRST ITEMS SERVICES PAGE Transmission Oil & Oil Filter Change Change (3 Transmission Oil & Oil Filter Speed, ZF 3WG94) Transmission Oil (2 Speed Only) Change Transmission Oil Level Check Inspect, Universal Joint Lubricate Walk-Around Inspection Inspect...

  • Page 206: When Required

    Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Valve Lash Inspecting Engine Fuel Supply (Diesel E/G Only) - Check, Adjust System WARNING NOTICE...

  • Page 207: Notice

    Maintenance Section Getting Rid of Foreign Substances from Priming the Fuel System Fuel Supply System (Diesel Engine Only) Once foreign substances are detected in the fuel, Bleeding the Fuel System the pressure sensor warning function is activated. With this warning triggered, all or either of the After changing the fuel filter, or after having serviced following measures are taken depending on the any part of the fuel system, make sure that the air is...

  • Page 208: Test Fuel System For Leaks (Lp Engine Only)

    Maintenance Section Test Fuel System for Leaks Fuel Tank Filter Cap & Screen - (LP Engine Only) Clean Park the lift truck with the forks lowered, parking brake applied, transmission in neutral and the engine stopped. Obtain a leak check squirt bottle or pump spray ...

  • Page 209: Seat - Check, Lubricate

    Maintenance Section Seat - Check, Lubricate Battery Terminal - Clean, Inspect WARNING Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear protective glasses when working Typical Example with batteries.

  • Page 210: Scr Cleaning - Desox (Diesel)

    Maintenance Section SCR Cleaning – DeSOx (Diesel) SCR Cleaning - DeSOx Display Pop-up In order that the SCR system may maintain its exhaust cleaning efficiency at a proper level, it should be periodically initialized—“SCR cleaning.” NOTICE Keep monitoring the vehicle condition via the SCREEN display.
  • Page 211 Maintenance Section Setting this switch to position "3" prohibits automatic 5. After holding down the switch at the “3” position SCR Cleaning in an environment subject to dust, for three seconds, check that SCR cleaning has explosion or regulated noise level. At position "3", a started.
  • Page 212 Maintenance Section Information - correlation between Symbol and message (Display) As shown in the table below, for your information, we provide Information about correlation between Symbol and message (Display) State SYMBOL Lamp Message on the Display Recommend SCR Cleaning in 10hr Need Engine Warm up Request Service SCR Should Do SCR Cleaning in 5hr...

  • Page 213: Fuses, Bulbs & Circuit Breaker - Change, Reset

    Maintenance Section Fuses, Bulbs & Circuit Breaker - Change, Reset Fuses NOTE: If a fuse filament separates, use only the same type and size fuses for replacement. If the filament in a new fuse separates. Have the circuits and instruments checked. NOTICE Always replace fuses with ones of the correct ampere rating.

  • Page 214: Tires And Wheels - Inspect, Check

    Maintenance Section Circuit Breaker Tires and Wheels - Inspect, Check 1. Operation the pilot box. WARNING Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. Deflate tire before removing wheel nuts from the truck.
  • Page 215 Maintenance Section Check Inflation and Damage Inspect tires for wear, cuts, gouges and foreign objects. Look for bent rims and correct seating of locking ring. Check tires for proper inflation. See "Tire Inflation Pressures". To inflate tires always use a clip-on chuck with a minimum 60 cm (24 inches) length of hose to an inline valve and gauge.

  • Page 216: Radiator Cap - Clean, Change

    Maintenance Section Clean Outside of Radiator Core Radiator Cap - Clean, Change Clean Pressure Cap WARNING Pressure air can cause personal injury. WARNING When using pressure air for cleaning, wear a protective face shield, protective clothing and Hot oil and components can cause personal protective shoes.

  • Page 217: Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate

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

  • Page 218: Steering Mechanism (Link Bearing) - Check, Lubricate

    Maintenance Section Steering Mechanism (Link Bearing) - Check, Lubricate Typical Example 1. Lubricate the steering link bearings, total of four fittings. Two on the right side and two on the left side 2. Check for any worn or loose components of the steering mechanism.

  • Page 219: Every 10 Service Hours Or Daily

    Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspection Engine for Fluid Leaks Coolant Level - Check 1.

  • Page 220: Air Cleaner Indicator - Check

    Maintenance Section Air Cleaner Indicator - Check Service Indicator Typical Example 3. Start and run the engine to stabilize the coolant level in the filter neck. If low, add coolant until it reaches the top of the filter neck. Install the radiator cap.

  • Page 221: Thermostat Valve (Optional) - Check

    Maintenance Section Failure detected by a defective Thermostat Valve (optional) - thermostat valve part: Check 1) Fault occurred with the internal thermostat Thermostat Valve Function closed: in the initial operation, the transmission oil gauge exceeds red line and B7 error code A thermostat valve is provided in the transmission oil appears on the transmission display.

  • Page 222: Inspect Engine For Exhaust Leaks

    Maintenance Section Inspect Engine for Exhaust Leaks 1. Start the engine and allow it to reach operating temperatures. 2. Perform visual inspection of exhaust system. Repair any/all leaks found. Walk-Around Inspection - Inspect For maximum service life of the lift truck, make a thorough walk-around inspection.

  • Page 223: Mast Channels - Lubricate

    Maintenance Section Mast Channels - Lubricate Hydraulic Oil Level - Check WARNING At operating temperature, the hydraulic tank is hot and under pressure. Hot oil can cause burns. Remove the filter cap only when the engine is stopped, and the cap is cool enough to touch with your bare hand.

  • Page 224: Transmission Oil Level - Check

    Maintenance Section 5. Loosen dipstick counter-clockwise, Transmission Oil Level - Check remove and clear it. Insert the oil dipstick slowly into the oil level tube until contact is obtained, and pull the dipstick out again. WARNING 6. When the oil temperature is around 40°C, the Hot oil and components can cause personal marking on the oil dipstick must be lying above injury.

  • Page 225: First 50-100 Service Hours Or A Week

    Maintenance Section First 50-100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Oil & Oil Filter - Change The percentage of sulfur in the fuel will affect the engine oil recommendations.

  • Page 226: Transmission Oil & Oil Filter - Change

    Maintenance Section Transmission Oil & Oil Filter - 13. Stop the engine and measure the oil level. The Change oil level should be close as possible to upper point of the oil dip stick. WARNING 14. Close side cover. Hot oil and components can cause personal injury.
  • Page 227 Maintenance Section ZF 3WG94 Typical Example D60/70/80/90S-7 (3 Speed) 4. Rotate the oil filter counter clockwise to remove Typical Example D(G)60/70S-7 (2 Speed) 8. Remove the dip stick/filter cap. Fill • Replacement Interval of Transmission Oil Filter compartment with oil. See "Refill Capacities". Install the dip stick/filter cap.

  • Page 228: Drive Axle Oil - Change

    Maintenance Section Drive Axle Oil - Change Park the lift truck on a level surface, parking brake applied, transmission in neutral. WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 6.

  • Page 229: Parking Brake - Test, Adjust

    Maintenance Section To Adjust Parking Brake - Test, Adjust Park the lift truck level, with the forks lowered, WARNING transmission in NEUTRAL, the engine stopped and the wheels securely blocked. To prevent personal injury, the operator must be ready to use the service brake if the parking Mechanical Parking Brake (If Installed) brake is not adjusted correctly and the lift truck starts to move.
  • Page 230 Maintenance Section Electronic Parking Brake (If Installed) 1. Park the vehicle with the parking brake drum's rubber cap positioned at 6 o'clock and then turn off the ignition. 6. Remove the 6-o’clock-positioned rubber cap from the parking brake drum. 7. Screw up the adjuster as far as possible. 8.
  • Page 231 Close hood and seat assembly. NOTICE Engine Oil Service hours can be extended to 500 hours by using Doosan supplied specific oil. Please consult Doosan dealer about it. Remove the crankcase drain plug and allow oil to drain. Clean and install drain plug.

  • Page 232: Every 500 Service Hours Or 3 Months

    Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Belts (Diesel E/G Only) - Check, Mast Hinge Pins - Lubricate Adjust Typical Example 1.

  • Page 233: Tilt Cylinders - Check, Adjust, Lubricate

    Maintenance Section Tilt Cylinders - Check, Adjust, Crosshead Rollers - Inspect Lubricate 1. Operate the mast through a lift cycle. Watch the chains move over the crosshead rollers. Make Chassis Pivot Eyebolts sure the chain is tracking over the rollers properly.

  • Page 234: Horn And Lights(If Equipped) - Check

    Maintenance Section Horn and Lights(If Equipped) - Steer Suspension - Inspect Check 1. Inspect the suspension mounting bolts. Tighten Typical Example suspension each four mounting bolts (total eight bolts), if necessary, to 240±40N m (177±29 · 1. Press horn button, to determine if horn is ft).

  • Page 235: Engine Oil & Filter (Diesel Engine Only) - Change

    Maintenance Section Engine Oil & Filter Fuel Trim Valve (FTV) Inspection (Diesel Engine Only) - Change (LP Engine only) Diesel Engine Crankcase Visually inspect the Fuel trim valve(3) for  abrasions or cracking. Replace as necessary. See topic, "Engine Oil & Filter (Diesel E/G Only) - To ensure the valve is not leaking a blow-by test Change"...

  • Page 236: Fuel Filter - Check, Clean, Change

    Maintenance Section Fuel Filter - Check, Clean, Change Wheel Bolts & Nuts - Inspect Diesel Engine Inspect Tightness Park lift truck with the forks lowered, parking brake applied, transmission in neutral, engine stopped and Steer Wheels cool. 1. Open left door of hood. WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

  • Page 237: Steering Mechanism - Check, Lubricate

    Maintenance Section Steering Mechanism - Check, Air Intake System - Check, Clean Lubricate Precleaner or rain cap (when Equipped) NOTICE Never service pre-cleaner with the engine running. Typical Example 1. Lubricate the steer axle kingpins, total of four fittings. Two on the right side and two on the left side.
  • Page 238 Maintenance Section Servicing Filter Element Diesel Engine Truck (Dual Element) NOTICE Never service filter with the engine running. Typical Example 2. Replace the nut and clamp. 3. Remove the element to separate it from its base and remove it from the air cleaner housing. 4.
  • Page 239 Maintenance Section Cleaning Primary Filter Elements Water-280 kPa (40 psi) Maximum Pressure WARNING Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

  • Page 240: Every 1000 Service Hours Or 6 Months

    Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Air Intake System - Change Carburetor (LP - Gas Engine Only) - Adjust, Clean Changing Primary Element See topic, “Air Intake System - Check, Clean”...

  • Page 241: Inspect Coolant Hoses (Lp Engines Only)

    NOTE: For pressure testing and internal inspection of the pressure regulator/converter, contact to the Doosan service. Fuel Lines & Fittings – Check Visually inspect fuel lines and fittings for physical damage. Replace as required.

  • Page 242: Hydraulic Oil, Return Filter, Strainer & Breather - Check, Clean, Change

    Maintenance Section Hydraulic Oil, Return Filter, Strainer & Breather - Check, Clean, Change WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Park the lift truck level with the forks lowered, 6.

  • Page 243: Lift Chains - Test, Check, Adjust

    Maintenance Section 18. Install the filter housing with filter to the housing Lift Chains - Test, Check, Adjust base. Install bolts and tighten 20 to 30 N m (15 · to 20 lb ft). · Lift Chain Wear Test Inspect the part of the chain that is normally 19.
  • Page 244 Maintenance Section Check for Equal Tension Carriage Chain Adjustment - STD Mast Typical example Typical example for carriage chain of STD mast Lift the carriage and the mast high enough for Make sure that carriage height is correct. If correct, getting tension on lift chains.

  • Page 245: Transmission Oil (2 Speed Only) - Change

    Maintenance Section Carriage Chain Adjustment - FFT Mast Chain Adjustment - FFT Typical example for carriage chain of FFT mast Typical example for FFT mast Make sure that carriage height is correct. If correct, Make sure that mast height is correct. If correct, adjust chain for equal tension.

  • Page 246: Every 1500 Service Hours Or 9 Months

    Maintenance Section Every 1500 Service Hours or 9 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Transmission Oil & Oil Filter – Replace Spark Plugs Change (3 Speed, ZF 3WG94) (LP Engine Only) See topic, "Transmission Oil &...

  • Page 247: Replace Lp Fuel Filter Element (Lp Engine Only)

    Maintenance Section Fuel Filter - Disassembly Replace LP Fuel Filter Element (LP Engine Only) Park the lift truck in an authorized refueling area with the forks lowered, parking brake applied and the transmission in Neutral. 1. Close the fuel shutoff valve on the LP-Fuel tank. Run the engine until the fuel in the system runs out and the engine stops.

  • Page 248: Testing Fuel Lock-Off Operation (Lp Engine Only)

    Maintenance Section Testing Fuel Lock-off Operation (LP Engine Only) Start engine.  Locate the electrical connector for the fuel lock  Disconnect the electrical connector.  The engine should run out of fuel and stop  within a short period of time. Turn the ignition key switch off and re-connect ...

  • Page 249: Every 2000 Service Hours Or Yearly

    Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Steer Wheel Bearings - Reassemble Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL and the engine stopped.

  • Page 250: Cooling System - Clean, Change

    Maintenance Section Cooling System - Clean, Change WARNING At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand.

  • Page 251: Fork - Inspect

    (L). Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer for further information. 2. Check the angle between the upper face of the blade and the front face of the shank.
  • Page 252 Maintenance Section Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage. 5.

  • Page 253: Every 2500 Service Hours Or 15 Months

    Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspect Battery System Checking the TMAP Sensor (LP Engine Only) Clean battery outer surfaces with a mixture of ...

  • Page 254: Inspect For Intake Leaks (Lp Engine Only)

    Maintenance Section Inspect for Intake Leaks Replace Oxygen Sensor (LP Engine Only) (LP Engine Only) 1. Visually inspect the intake manifold, throttle assembly (4), and manifold adapters (3), for looseness and leaks. Repair as necessary. Replace PCV Valve and breather element - Change (LP Engine Only) 1.

  • Page 255: Every 3000 Service Hours Or 36 Months

    Maintenance Section Every 3000 Service Hours or 36 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. DEF/Ad-Blue Supply module filter replacement (D34P Engine Only) 1.

  • Page 256: Environment Protection Section

    Environment Protection Section Environment Protection When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil, fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items are disconnected or removed. After servicing, dispose of those materials in an authorized place and container.

  • Page 257: Index

    Index Section Cabin Tilting ............175 Index Capacity Chart - With Side Shifter ....42,43,44 Capacity Chart - Without Side Shifter ... 39,40,41 Carburetor (LP - Gas Engine Only) - Adjust, Clean ................. 237 Carriage Chain Adjustment - FFT ......242 Carriage Chain Adjustment - STD Mast ....
  • Page 258 Index Section Display for Troubleshooting ........165 Fuel Replenishment ..........93 Draining Water from Fuel Filter ......204 Fuel Tank Filter Cap & Screen - Clean ....205 Drive Axle Oil - Change .......... 225 Fuel Trim Valve (FTV) Inspection (LP Engine only) Drive Axle Oil (OCDB) - Change ......
  • Page 259 Index Section Inspect Coolant Hoses (LP Engines Only) ... 238 Inspect Electrical System (LP Engine only) ..232 Inspect Engine for Exhaust Leaks ......219 Machine Lifting and Tie down Information.... 177 Inspect for Intake Leaks (LP Engine Only) ... 251 Maintenance and Repair........
  • Page 260 Index Section Specifications of Fuel and DEF/Ad-Blue ....191 Specifications ........... 32,34,35,36 Stability and Center of Gravity......... 22 Parking Brake - Test, Adjust ......226,230 Starting From a 12/24 Volt External Source ..100 Parking Brake Lever ..........90 Starting the Engine ........... 99 Parking Brake .............
  • Page 261 Index Section Transmission Oil (TDTO) ........195 Transmission Oil Level - Check ......221 Transportation Hints ..........177 Traveling with the Load .......... 168 Turning ..............169 Universal Joint - Inspect, Lubricate ....... 231 Unloading ..............168 Vibration (weighted overall value) ......38 Walk-Around Inspection - Inspect ......

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