Doosan D35C-5 FDA04 Operation & Maintenance Manual

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Operation &

Maintenance Manual

FORKLIFTS

D20S-5, D25S-5, D30S-5, D33S-5, D35C-5

FDA04, FDA05, FDA06, FDA07, FDA08 (Yanmar 3.3L/3.0L Tier-3)

G20E-5, G25E-5, G30E-5

FGA07, FGA08, FGA09 (HMC 2.4L Tier-3)

GC20E-5, GC25E-5, GC30E-5, GC33E-5

FGA0K, FGA0L, FGA0M, FGA0N (HMC 2.4L Tier-3)

G20P-5, G25P-5, G30P-5, G33P-5, G35C-5

FGA0A, FGA0B, FGA0C, FGA0D, FGA0E (MMC 2.4L Tier-3)

G20P-5 Plus, G25P-5 Plus,

G30P-5 Plus, G33P-5 Plus, G35C-5 Plus

FGB0H, FGB0J, FGB0K, FGB0L, FGB0M (GM 3.0L Tier-3)

GC20P-5, GC25P-5, GC30P-5, GC33P-5

FGA0P, FGA0R, FGA0S, FGA0T (MMC 2.4L Tier-3)

Original Instruction

SB2349E10

1703

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Page 1 SB2349E10 Operation & Maintenance Manual FORKLIFTS D20S-5, D25S-5, D30S-5, D33S-5, D35C-5 FDA04, FDA05, FDA06, FDA07, FDA08 (Yanmar 3.3L/3.0L Tier-3) G20E-5, G25E-5, G30E-5 FGA07, FGA08, FGA09 (HMC 2.4L Tier-3) GC20E-5, GC25E-5, GC30E-5, GC33E-5 FGA0K, FGA0L, FGA0M, FGA0N (HMC 2.4L Tier-3) G20P-5, G25P-5, G30P-5, G33P-5, G35C-5 FGA0A, FGA0B, FGA0C, FGA0D, FGA0E (MMC 2.4L Tier-3) G20P-5 Plus, G25P-5 Plus, G30P-5 Plus, G33P-5 Plus, G35C-5 Plus...
Page 3: Table Of Contents
Table of Contents Table of Contents Information Section Maintenance Section Foreword ..............2 Inspection, Maintenance and Repair of Lift Truck Forks ..............184 Tire Inflation Information ........188 Torque Specifications ........... 189 Safety Section Cooling System Specifications......191 Fuel Specifications ..........193 Important Safety Information ........
Page 4: Information Section
The DOOSAN operator restraint Read, study and keep this manual with the lift truck. system can minimize injuries. The DOOSAN...
Page 5 For example, at “Every 500 Service Hours or 3 Months”, also service those items listed under “Every 10 Service Hours or Daily”. Environment Management Note that DOOSAN CORPORATION INDUSTRIAL VEHICLE BG is ISO 14001 certified which is harmonized with 9001.
Page 6: Safety Section
The warnings in this publication and on the product are therefore not all inclusive. Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must be sure that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 7: Safety
Operation and Maintenance Manual. Additional manuals are available from Do not operate a lift truck if it is in need of DOOSAN Lift Truck dealers. maintenance, repair or appears to be unsafe in any way. Report all unsafe conditions immediately to...
Page 8 Safety Section 5. Travel with load as low as possible and tilted General Warning to Operator back. If load interferes with visibility, travel with load trailing. 6. On grade operations travel with load up grade. 7. Watch out for pedestrians and obstructions. Check overhead clearances.
Page 9 Safety Section Pressure Warning No Standing On Fork Warning No Standing Under Fork Warning WARNING Contents under pressure may be hot. Allow to WARNING cool before opening. Do not stand or ride on the forks. Do not stand or ride on a load or pallet on the forks. Do not stand or walk under the forks.
Page 10 Safety Section Overhead Guard Must Be In Place Moving Fan Warning Warning WARNING WARNING To avoid personal injury, stay clear of moving fan. Operation without this device in place may be hazardous. This guard conforms A.N.S.I.B56.1 and F.E.M.Section IV. This design has been tested with an impact of appropriate valve.
Page 11: Parking Brake
Safety Section Parking brake Pull the lever BACK to engage the parking brake. Push the lever FORWARD to release 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.
Page 12: General Hazard Information
Safety Section the overhead guard removed. 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.
Page 13: Operation Information
DOOSAN spare parts waive Operate the lift truck and controls only from the any liability by DOOSAN. operator's station.
Page 14 Safety Section Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck equipped) and all other devices are working properly. Always keep the lift truck under control. Check proper operation mast Obey all traffic rules and warning signs. attachments.
Page 15 Safety Section Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers.
Page 16: Maintenance Information
To avoid possible weakening of the Falling Objects The maximum air pressure must be below 205 kPa Protective Structure (FOPS), consult a DOOSAN (30 psi) for cleaning purposes. dealer before altering, by adding weight to, welding on, or cutting or drilling holes into the structure.
Page 17: Burn Prevention
Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant Coolant mixtures 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 18 Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your DOOSAN dealer for repair or replacement. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks.
Page 19: Operator Restraint System (If Equipped)
If a label is on a part misused equipment. that is replaced, make sure a new label is installed on the replaced part. See you DOOSAN forklift Stand behind the tread and use a self-attaching dealer for new labels.
Page 20 Safety Section If Optional Suspension Seat (weight adjusting type) Equipped Forward and Backward Adjustment The seat can be adjusted by pushing the lever on the right side of seat. The “Survive in tipover” warning is located on the Forward and Backward overhead guard.
Page 21 On visual inspection, fastenings must be intact, otherwise, contact the safety manager. WARNING Your DOOSAN truck comes equipped with a DOOSAN operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DOOSAN operator restraint system.
Page 22 Safety Section 3. In the event of a tipover, the seat and restraint system should be inspected for damage and replaced, if necessary. NOTE: Operator restraints shall be examined at the regular truck service intervals. It is recommended that they be replaced if any of the following conditions are found: •...
Page 23: Avoiding Lift Truck Tipover
Safety Section Avoiding Lift Truck Tipover Stability and Center of Gravity Lift Truck Stability The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the Counterbalanced lift truck design is based on the combined CG of the truck and load.
Page 24 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 tip to the side.
Page 25: Safety Rules
Safety Section Safety Rules Do not operate a lift truck unless you are in the operator’s seat. Keep hands and feet inside the operator’s compartment. Do not put any part of Only properly trained and authorized personnel the body outside of the operator’s compartment. should operate forklift trucks.
Page 26 Safety Section Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the Do not let other people ride on the truck. rated capacity shown on the capacity plate. Lift trucks are designed to carry loads, not people. Do not add extra counterweight to the truck.
Page 27 Safety Section Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward. load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards. cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
Page 28 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 29 Safety Section Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully lower the forks to the floor, put direction lever in Always keep a safe distance from other trucks and make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and Never overtake other vehicles.
Page 30 Safety Section An unloaded forklift may be easier to tip over than a Do not operate forklifts near flammable or combustible materials. loaded truck. avoid discoloration, deformation When traveling without a load, the risk of lateral combustion of materials (such as lumber, veneer overturn is greater.
Page 31: How To Survive In A Tipover
Safety Section How to Survive in a Tipover WARNING In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided. Brace your feet and keep them within the operator’s compartment.
Page 32: General Section
468, Injung-ro, Dong-gu, Incheon, Korea Authorized Representative and Compiler of Technical File According to 2006/42/EC and Keeper of Technical File According to 2000/14/EC Doosan Industrial Vehicle Europe N.V. Mr. Chankyo Chung Europark-Noord 36A, 9100 Sint-Niklaas, Belgium herewith declare that the following equipment conforms with the appropriate requirements of the Directives...
Page 33: Specifications
General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN D20S-5 D25S-5 MODEL (YANMAR,TIER3,44kW) (YANMAR,TIER3,44kW) CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas diesel diesel OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven)
Page 34 General Section DOOSAN DOOSAN DOOSAN D30S-5 D33S-5 D35C-5 (YANMAR,TIER3,44kW) (YANMAR,TIER3,44kW) (YANMAR,TIER3,44kW) 3000 3250 3500 diesel diesel diesel rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197 1255 2165 2165...
Page 35 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN D20S-5 D25S-5 MODEL (YANMAR,TIER3, 35kW) (YANMAR,TIER3, 35kW) CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas diesel diesel OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic...
Page 36 General Section DOOSAN DOOSAN DOOSAN D30S-5 D33S-5 D35C-5 (YANMAR,TIER3, 35kW) (YANMAR,TIER3, 35kW) (YANMAR,TIER3, 35kW) 3000 3250 3500 diesel diesel diesel rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197...
Page 37 General Section Specifications CHARACTERISTICS MANUFACTURER MODEL CAPACITY at rated load center LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load LIFT WITH STD TWO-STAGE MAST free lift FORK CARRIAGE ISO class...
Page 38 General Section DOOSAN DOOSAN DOOSAN G20E-5 G25E-5 G30E-5 2000 2500 3000 LP/Gas LP/Gas LP/Gas rider-seated rider-seated rider-seated 3230 3230 3230 40x100x1050 40x100x1050 45x125x1050 275x1035 275x1035 286x1044 6/10 6/10 6/10 2530 2595 2700 1170 1170 1197 2175 2175 2165 4490 4490...
Page 39 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN MODEL G20P-5 G25P-5 CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS...
Page 40 General Section DOOSAN DOOSAN DOOSAN G30P-5 G33P-5 G35C-5 3000 3250 3500 rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197 1255 2165 2165 2165 4490 4490 4260 2183 2183...
Page 41 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN MODEL G20P-5 Plus G25P-5 Plus CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear...
Page 42 General Section DOOSAN DOOSAN DOOSAN G30P-5 Plus G33P-5 Plus G35C-5 Plus 3000 3250 3500 rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197 1255 2165 2165 2165 4490 4490...
Page 43 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN MODEL GC20E-5 CAPACITY at rated load center 2000 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load...
Page 44 General Section DOOSAN DOOSAN DOOSAN GC25E-5 GC30E-5 GC33E-5 2500 3000 3000(6500LBS) rider-seated rider-seated rider-seated 3230 3230 3230 40x100x1050 45x125x1050 45x125x1050 297x905 282x954 282x954 2268 2333 2368 1110 1110 1110 2130 2130 2130 4480 4480 4480 2150 2150 2150 1038 1038...
Page 45 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN MODEL GC20P-5 CAPACITY at rated load centre 2000 LOAD CENTRE distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated TYRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load...
Page 46 General Section DOOSAN DOOSAN DOOSAN GC25P-5 GC30P-5 GC33P-5 2500 3000 3000(6500LBS) rider-seated rider-seated rider-seated 3230 3230 3230 40x100x1050 45x125x1050 45x125x1050 297x905 282x954 282x954 2268 2333 2368 1110 1110 1110 2130 2130 2130 4480 4480 4480 2150 2150 2150 1038 1038...
Page 47: Noise And Vibration
General Section Noise and Vibration Sound Pressure Level at Whole-body Vibration Power level(L Operator’s ear (Leq.) Level By Noise Directive according to EN12053 according to EN13059 Model 2000/14/EC Guaranteed Sound (m/s dB(A) dB(A) Mean Uncertainty TIER - III (4TNE98 E/G) D20S-5, D25S-5, D30S-5, (W/O Cabin) TIER - III (4TNE98 E/G)
Page 48: Capacity Chart (Without Sideshifter Pneumatic)
General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -46-...
Page 49 General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -47-...
Page 50 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -48-...
Page 51 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -49-...
Page 52: Capacity Chart (With Sideshifter Pneumatic)
General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -50-...
Page 53 General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -51-...
Page 54 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -52-...
Page 55 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -53-...
Page 56: Capacity Chart (Without Sideshifter Cushion)
General Section Capacity Chart (Without Sideshifter cushion) NARROW TIRE MODEL STD, FFL -54-...
Page 57 General Section Capacity Chart (Without Sideshifter cushion) NARROW TIRE MODEL STD, FFL -55-...
Page 58 General Section Capacity Chart (Without Sideshifter cushion) WIDE TIRE MODEL STD, FFL -56-...
Page 59 General Section Capacity Chart (Without Sideshifter cushion) WIDE TIRE MODEL STD, FFL -57-...
Page 60: Capacity Chart (With Sideshifter Cushion)
General Section Capacity Chart (With Sideshifter cushion) NARROW TIRE MODEL STD, FFL -58-...
Page 61 General Section Capacity Chart (With Sideshifter cushion) NARROW TIRE MODEL STD, FFL -59-...
Page 62 General Section Capacity Chart (With Sideshifter cushion) WIDE TIRE MODEL STD, FFL -60-...
Page 63 General Section Capacity Chart (With Sideshifter cushion) WIDE TIRE MODEL STD, FFL -61-...
Page 64: 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. 2.4 liter Spark-Ignition Engine Serial Number (G424I(E)) •_____________________________ Lift Truck Serial Number •_____________________________ 3.3 liter Diesel Engine Serial Number •_____________________________ 3.3 liter Diesel Engine (4TNE98 &...
Page 65 General Section Drive Axle Serial Number 3.0 liter Spark-Ignition Engine Serial Number (G430FE) •_____________________________ •_____________________________ Typical Example Side Shifter Serial Number (If Equipped) •_____________________________ 2.4 liter Spark-Ignition Engine Serial Number (G424P(E)) •_____________________________ Power Shift Transmission Serial Number •_____________________________ -63-...
Page 66 General Section Attachment Abbreviations (Includes Special Forks) - Special Carriage-increased width, height or outreach - Shaft-type Sideshift Carriage - Hook-type Sideshift Carriage (ITA) - Counterweight - Special Forks - Swing Shift, Sideshift - Ram or Boom DBCBH - Double Cube Block Handler - Hydraulic Fork Positioner - Crane Arm or Crane Boom - Tire Handler...
Page 67: Operator's Warning And Identification Plate
General Section Operator's Warning and Identification Plate Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES. DO NOT exceed capacity as equipped load ratings. Operator's Warning Plate Identification, Lift Capacity and Attachment Plate Located on the right side of the operator's seat. Located on the cowl to the right side of the steering column.
Page 68: Operator's Station And Monitoring Systems
Operation Section Operator’s Station and Monitoring Systems Instrument Panel Your lift truck may not have the same indicator or warning lights as shown in the illustrations. Due to the various options available, typical instrument panels are shown. However, the symbols on the indicators and lights on your panel identify what those particular items are. Also, the symbol for each of the items is identified and an explanation of their function and location is described on the following pages.
Page 69 Operation Section 1. Engine Oil Pressure Indicator Light - temperature reaches approximately 110 °C on all (Except for G430FE) Indicates insufficient engines. engine oil pressure. The light will come on 7. Transmission Oil Temperature when the ignition switch is turned to the ON position.
Page 70 Operation Section 14. Front and Rear Floodlights Switch – The front floodlight is ON when push down switch to the first step. The front and rear floodlights are ON when push down switch to the second step. 15. Low Level Light of LP GAS – Indicates the low Level of LP GAS (LP or DUAL only) 16.
Page 71 Operation Section Electrical Disconnect Switch (If Engine Compartment Equipped) 1. The engine compartment is accessible by pulling the latch (GC Series), or pushing down the lever 1. ON - Connects the battery for electrical located at cowl (G.D Series) and raising the hood power to all electrical circuits.
Page 72 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 73 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 3.
Page 74 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-5081WF: 18 Pin> <ARA-5080WF: 18 Pin> 1. Tel Mute 1. Front R (+) 2. Rear R (+) 2. Rear R (+) 3.
Page 75 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 76 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 on/off.
Page 77 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 78 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 1. Press AM or FM button repeatedly to select the format.
Page 79 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 80 Operation Section Controlling the playback Change the playback mode 1. While playing, press the SCN button to begin 1. While playing, turn the ▶▶│TRACK│◀◀ the Intro scan playback. dial left/right to moves to the previous or next track. • When pressed shortly, scans the beginning parts of device files.
Page 81 Operation Section About MP3/WMA device. This unit play (WMA) files When disconnecting the USB, an abnormal sound with .mp3, .wma (Iower case letters) or .MP3 may occur occasionally. and .WMA (capital letters) file name extensions. Abruptly disconnecting the external USB device This unit can display ID3 Tag (Version 1.0, 1.1, 2.2, while the USB is operating may cause the device 2.3 or 2.4) information for MP3 files.
Page 82 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 5. Set your usual listening volume by turn the listen on your car speakers.
Page 83: Seat Switch System (If Equipped)
If seat or seat switch replacement becomes transmission. The directional lever, however, will necessary, be sure to use genuine DOOSAN remain in that forward or reverse location although CORPORATION INDUSTRIAL VEHICLE lift truck internally the transmission will have shifted into parts.
Page 84 Operation Section Tilt Steering Column WARNING When closing the engine hood, be careful not to pinch your hand. Circuit Breaker To adjust the steering column, push down the knob(1), and move the steering column to the desired position, then release the knob(1). Circuit Breaker - Protects the main Fuel Selector Switch (G424I(E) electrical circuits.
Page 85: Lift Truck Controls
Operation Section Lift Truck Controls Direction Control Lever Service Brake Pedal 1. Forward - Push the lever forward for FORWARD direction travel. Push DOWN on the brake pedal to slow 2. Neutral - Move the lever to center or stop the lift truck. position for NEUTRAL.
Page 86 Operation Section Parking Brake Lever Tilt Control 1. Mast Tilt Forward - Push the lever FORWARD smoothly to tilt the mast Pull the lever BACK to engage the parking forward. brake. 2. Mast Hold - When the lever is released it will return to the HOLD or center position.
Page 87: Refueling
Operation Section Refueling Gasoline or Diesel Engine Equipped WARNING Explosive fumes be present during refueling. Do not smoke in refueling areas. Lift truck should be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors. Stop the engine and get off the lift truck during 1.
Page 88 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 2.
Page 89 Operation Section NOTICE If the location pin (dowel) is missing or broken, be sure the pin is replaced. 11. Position the replacement tank so that the locating pin (dowel) is in place. WARNING The LP tank must not extend past the 6.
Page 90: Before Starting The Engine
Operation Section Before Starting the Engine Walk - Around Inspection Make a thorough walk - around inspection before mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or coolant leaks. Check condition of tires, mast, carriage, forks or attachments.
Page 91 Operation Section 12. Measure the engine crankcase oil level with the 14. Observe the fuel level gauge after starting the dip stick. Maintain the oil level between the truck. Add fuel if necessary. MAX. and MIN., (or FULL and ADD) notches on the dip stick.
Page 92: Starting The Engine
Operation Section Starting the Engine Prestart Conditions Gasoline Engine NOTE: The engine will not start unless the transmission directional control lever is in NOTICE the NEUTRAL position. Do not leave the key in ON position when engine is not running. Do not engage the starter more than 10 seconds at any one time.
Page 93 Operation Section LP Engine Diesel Engine Starting a Cold Diesel Engine WARNING 1. Turn the key to the ON position. The start pre LP fuel is flammable and can cause personal heat light will come ON. The preheat light will injury.
Page 94 POSITIVE(+) to POSITIVE(+) and NEGATIVE( - ) to NEGATIVE( - ). Attach ground cable last, remove first. All lift trucks equipped with DOOSAN built internal combustion engines are NEGATIVE( - ) ground. -92-...
Page 95: Dual Fuel System
Operation Section Dual Fuel System Changing From Gasoline to LP – 4. Open the fuel valve, on the LP tank, by slowly turning the valve counterclockwise. 5. Turn the ignition switch key to the OFF position NOTE: The Underwriter’s Laboratory (U.L.) and then to the START position to start the requires that the gasoline tank must be at...
Page 96 Operation Section 3. Move lever (1) from the LPG (3) POSITION to the OFF (2) position. Allow the engine to run until the fuel in the line runs out and engine stops. 4. Move lever (1) from the LPG (3) position to the GAS (4) position.
Page 97 Operation Section The diesel engine water in fuel filter indicator After Starting the Engine light(4), will not come ON with the engine running, unless water in fuel filter exceeds Observe all indicator lights and gauges frequently 100cc. Stop the engine immediately and drain during operation, to make sure all systems are the water if the light comes ON.
Page 98: Lift Truck Operation
Operation Section Lift Truck Operation Power Shift Transmission/ Drive WARNING axle A lift truck with the engine running but without an operator can move slowly (creep) if the 1. Start the engine. See topic “Starting the transmission is engaged. Engine”. This could result in personal injury.
Page 99 Operation Section Inching 7. To change the lift truck direction of travel, release the accelerator pedal. NOTE: The purpose of the inching pedal is to 8. Push down on the service brake pedal to provide precise lift truck inching control at reduce the lift truck speed as necessary.
Page 100 Operation Section Electronic Controlled Spark-Ignition Engines G424IE Engine EMS (Engine management system) of G424IE (SECM) uses two heated exhaust gas oxygen engine is a closed loop system utilizing a 3-way sensors (HEGO) in the exhaust system to monitor catalytic muffler to reduce the emission level in the exhaust gas content.
Page 101 Operation Section G424I Engine EMS (Engine management system) of G424I engine is an open loop LP system and/or closed loop gasoline system. 3-way catalytic muffler is not used for this system. LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM. Manifold pressure from the TMAP, rpm from the crank position sensor and throttle position is used by the SECM to calculate load.
Page 102 Operation Section Basic Troubleshooting(LP) The MI-07 systems are equipped with built-in fault basic checks that should be made before referring diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
Page 103 Operation Section Problem Probable Cause Corrective Action LPG Vapor from liquid outlet Fuel container almost empty Fill fuel container  Do not exceed 80% of liquid capacity  Reset excess flow valve Close liquid valve  Excess flow valve closed Wait for a “click”...
Page 104 Operation Section Problem Probable Cause Corrective Action LPG Vapor from liquid outlet Fuel container almost empty Fill fuel container  Do not exceed 80% of liquid capacity  Reset excess flow valve Close liquid valve  Excess flow valve closed Wait for a “click”...
Page 105 Operation Section Problem Probable Cause Corrective Action Repair/replace as required See Maintenance Clogged fuel filter  Section, LP Fuel Filter replacement Check connection Faulty vapor connection between Verify no holes in hose  the pressure regulator/converter Clamps must be tight Will Not ...
Page 106 Operation Section Problem Probable Cause Corrective Action Repair/replace Fuel Lock-off Fuel Lock-off malfunction See Engine Service Manual  Check connection Faulty vapor connection between Verify no holes in hose  the pressure regulator/converter Clamps must be tight  and the mixer Look for kinked, pinched and/or ...
Page 107 Operation Section Problem Probable Cause Corrective Action Incorrect Idle speed control See Advanced Diagnostics & See Engine Service Manual Rough Idle Incorrect timing or spark control Engine Mechanical See Engine Service Manual Incorrect Idle speed control See Advanced Diagnostics & See Engine Service Manual Throttle sticking High Idle Speed...
Page 108 Operation Section Problem Probable Cause Corrective Action Check mixer Air/Fuel Mixer malfunction See Engine Service Manual  Check air filter Air filter clogged Clean/replace as required  Check system vacuum hoses from Vacuum leak regulator to FTV and mixer Repair/replace as necessary ...
Page 109 Operation Section Basic Troubleshooting (Gasoline) Problem Probable Cause Corrective Action Fill fuel container The tank should be at least ¼ full to  Fuel tank empty properly prime the fuel pump. Fuel select switch is not on GAS  Repair/replace as required Clogged fuel filter See Maintenance section Primary and ...
Page 110 Operation Section Problem Probable Cause Corrective Action Fuel Pump Cavitations The tank should be at least ¼ full to  Fuel tank almost empty properly prime the fuel pump Fuel select switch is not on GAS  Repair/replace as required Clogged fuel filter See Maintenance section, Primary and ...
Page 111 Operation Section Problem Probable Cause Corrective Action Check electrical connection Electric Fuel Pump malfunction Check Relay and fuse Turn key ON and  (GAS) verify pump is operating See Engine Service Manual  Test pressure regulator operation Pressure regulator malfunction See Engine Service Manual ...
Page 112 Operation Section Problem Probable Cause Corrective Action Throttle butterfly valve not opening or sticking Will Not Foot Pedal signal incorrect or Accelerate/Hesita See Advanced Diagnostics intermittent tion During Acceleration or Incorrect air/fuel or ignition control Engine Stalls (Gas) Engine Mechanical See Engine Service Manual Verify LPG cylinder is full and valve is open.
Page 113 Operation Section Problem Probable Cause Corrective Action Incorrect Idle speed control See Advanced Diagnostics & Engine Service Manual Incorrect timing or spark control Rough Idle (Gas) Engine Mechanical See Engine Service Manual Incorrect Idle speed control See Advanced Diagnostics & Engine Service Manual High Idle Speed Throttle sticking...
Page 114 Operation Section Problem Probable Cause Corrective Action Verify LPG cylinder is full and valve is open. If the problem does not exist in LPG mode proceed with the corrective action steps below. Isolate the gasoline system by If the problem also exists in LPG mode then running the lift truck on LPG the root cause is most likely to be something other than the fuel system...
Page 115 Operation Section Advanced Diagnostics Displaying Fault Codes (DFC) from SECM Memory MI-07 systems are equipped with built-in fault diagnostics. Detected system faults To enter code display mode you must turn OFF the displayed by the Malfunction Indicator Lamp (MIL) ignition key. Now turn ON the key but do not start as Diagnostic Fault Codes (DFC) or flash codes, the engine.
Page 116 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK NONE None, used as end of the fault list Signifies the end of one pass NONE identification through the fault list (1) TurnOnMil Check INJ1 wiring for an open circuit Inj1Open...
Page 117 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check coolant system for radiator blockage, proper coolant level and for ECTOverTempFault leaks in the system. Engine coolant temperature is (1) TurnOnMil Possible ECT short to GND, check ECT high.
Page 118 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TPS1RangeLow Check throttle connector connection and TPS1 sensor for an open circuit or short to TPS1 sensor voltage out of (1) TurnOnMil range low, normally set if the (22)
Page 119 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TPS2AdaptHiMin Learned WOT end of TPS2 None sensor range lower than expected TPS1AdaptLoMax Learned closed throttle end None of TPS1 sensor range higher than expected TPS2AdaptLoMax Learned closed throttle end of...
Page 120 Operation Section Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 (signal) MAPRangeLow TMAP Pin 1 to SECM Pin B1 (sensor GND) Manifold Absolute Pressure TMAP Pin 3 to SECM Pin B24 (XDRP +5 sensor input is low, normally Vdc) (1) TurnOnMil...
Page 121 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check TMAP connector and MAP signal wiring for a shorted circuit MAPTimeRangeHigh TMAP Pin 4 to SECM Pin B18 (signal) Manifold Absolute Pressure TMAP Pin 1 to SECM Pin B1 (sensor GND) Sensor Input is High, normally TMAP Pin 3 to SECM Pin B24 (XDRP +5 Vdc)
Page 122 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check TMAP connector and IAT signal wiring IATRangeHigh for a shorted circuit TMAP Pin 2 to SECM Pin B12 (signal) Intake Air Temperature TMAP Pin 1 to SECM Pin B1 (sensor GND) Sensor Input is High normally set if the IAT temperature...
Page 123 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A6 (EST4) to OEM ignition EST4_Open system. See application manual. Verify GND on ignition module EST4 output open, possibly TurnOnMil...
Page 124 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK EST2_Short EST2 output shorted high or low, EST2 signal shorted to None ground or power or defective spark module EST3_Short EST3 output shorted high or low, EST3 signal shorted to None ground or power or defective...
Page 125 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK EST7_Short EST7 output shorted high or low, EST7 signal shorted to None ground or power or defective spark module EST8_Short EST8 output shorted high or None low, EST8 signal shorted to ground or power or defective...
Page 126 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check ETC driver wiring for a shorted circuit SECM Pin A17 to ETC + Pin 1 HbridgeFault_ETC SECM Pin A18 to ETC - Pin 4 Electronic Throttle Control •...
Page 127 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 XDRP +5 Vdc to TMAP Pin 1 XDRG GND Verify transducer power at the (1) TurnOnMil SECM with a multimeter...
Page 128 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION FIRST PROBABLE FAULT FAULT ACTION * CHECK APP2RangeLow APP2 sensor voltage out of range Check foot pedal connector • low, normally set if the APP2 signal TurnOnMil Check APP2 signal at SECM PIN (65) has shorted to ground, circuit has opened or sensor has failed...
Page 129 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check FTV1 for an open wire or FTV connector (1) TurnOnMil being disconnected LSDFault_Dither1 (2) Disable FTV1 Pin 1 (signal) to SECM Pin A1 Dither Valve 1 Fault, signal GasO2 Ctrl FTV1 Pin 2 (power) to SECM (DRVP) Pin A23...
Page 130 Operation Section LSDFault_MIL Malfunction Indicator Lamp Fault, signal has opened or None None shorted to ground or power or defective MIL lamp (1) TurnOnMil (2) Disable GasFuelAdaptRangeLo Check for vacuum leaks. GasO2 Ctrl Check fuel trim valves, e.g. leaking valve or In LPG mode, system had to (3) Disable (72)
Page 131 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK (1) TurnOnMil GasFuelAdaptRangeHi (2) Disable Check dual dither valves, e.g. plugged valve or In LPG mode, system had GasO2 Ctrl hose. (73) to adapt lean more than (3) Disable...
Page 132 Operation Section Correct other faults that may contribute to 752 (e.g. faults pertaining to dither valves, Pre-Cat GasPostO2FailedLean (1) TurnOnMil O2, Post Cat O2 sensor) (2) DisableGasPost Check for vacuum leaks Pre-catalyst O2 sensor indicates extended lean O2Ctrl Check for leaks in exhaust, catalytic converter, operation on LPG (Certified Units Only) HEGO sensors;...
Page 133 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 772 (1) TurnOnMil (e.g. faults pertaining to FTVs, Pre-Cat O2, GasPostO2FailedRich (2) DisableGasPost Post Cat O2 sensor) Pre-catalyst O2 sensor O2Ctrl Look for leaks in exhaust, catalytic converter,...
Page 134 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 852 (e.g. faults pertaining to Injectors, MAP, IAT, LiqPostO2FailedLean (1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor) Pre-catalyst O2 sensor (2) DisableLiqPost Look for leaks in exhaust, catalytic converter,...
Page 135 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TransOilTemp (1) TurnOnMil Refer to drivetrain manufacturer’s Excessive transmission oil (2) DelayedEngine transmission service procedures. temperature Shutdown ServiceFault1 Perform service procedure related to None Service Interval 1 Service Interval 1 has been...
Page 136 Operation Section Electronic Controlled Spark-Ignition Engines G430FE / G424P(E) 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 137 Operation Section EMS schematic of G430FE / G424P(E) LP engine -135-...
Page 138 Operation Section EMS schematic of G424P(E) Gasoline engine -136-...
Page 139 Operation Section Basic Troubleshooting(LP/DF) The G430FE / G424P(E) 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 140 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 141 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 • Check all system fuses engine fuse holder. Refer to Engine Controls Schematics. ECM Checks •...
Page 142 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. • Improper valve timing. Engine Mechanical • Low compression. Checks •...
Page 143 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 144 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 145 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 146 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 147 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 148 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 149 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 150 Operation Section ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action Check the engine for: • Broken motor mounts. • Improper valve timing. • Low compression. Engine Mechanical • Improper valve clearance. Check • Worn rocker arms. • Broken or weak valve springs. •...
Page 151 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 152 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 153 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 154 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 position DTC 268: Injector 3 coil shorted 520800 error DTC 16: Crank and/or cam could not...
Page 155 Operation Section DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 172: Adaptive-learn gasoline bank1 DTC 326: Knock1 excessive or 520200 erratic signal DTC 174: Adaptive-learn gasoline bank2 DTC 327: Knock1 sensor open or 520201 high not present DTC 175: Adaptive-learn gasoline bank2 DTC 331: Knock2 excessive or...
Page 156 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 1175: MegaJector voltage DTC 601: Microprocessor failure - FLASH 520260 supply low DTC 1176: MegaJector internal DTC 604: Microprocessor failure - RAM 520260...
Page 157 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 158 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 159 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 160 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 161 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 162 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 163 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 164 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 165 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 166 Operation Section DTC 8906: UEGO return voltage shorted DTC 1514: AUX analog Pull-Up 2 3056 520217 high low voltage 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...
Page 167 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 168: Mono-Ped Control System (Option)
Operation Section Mono-Ped Control System (Option) Forward-Push the left side (2) of the pedal for FORWARD direction travel. Neutral-The lift truck should not move when the Mono-Ped pedal is released.. Reverse-Push the right side (1) of the pedal for REVERSE direction travel. The MONO-PED pedal controls the speed and direction of the lift truck.
Page 169: Auto Shift Controller Asc-100 (If Equipped)
Operation Section Auto Shift Controller ASC-100 (If Equipped) Product Description Adjustments The Autoshift controller is an electrical control system, specially designed for use on forklift trucks (Direction Inhibit Point) with internal combustion engines. Its primary purpose is to prevent the operator from NOTCH Vehicle Speed driving the truck outside of the design parameters,...
Page 170 Operation Section Diagnostics Features Operation ASC-100 has an internal indicator on the right side This system can basically operate in 2 pre-selected of the controller for displaying the selected gear modes. and the abnormal condition. Automatic mode (Direction Inhibit mode): ...
Page 171 Operation Section Manual Mode (Fail-Safe mode) The system still allows movement of the vehicle in case of controller breakdown by selecting the manual mode with the Fail-Safe mode Switch in the controller. WARNING In the manual mode, direction inhibition function can not be operated normally. The sudden reversal of a loaded lift truck traveling forward can cause the load to fall or the lift truck to tip.
Page 172: Finger Tip (Option)
Operation Section Finger Tip (Option) Tilt Control knob Function of Knobs If finger tip control option is equipped, the hall-effect type electric knobs replace conventional control valve levers. Lift Control knob Tilt Forward - Push the knob forward smoothly to tilt the lift forks forward. Hold - Release the tilt knob.
Page 173 Operation Section Sideshift Attachment Control Warning Lamp Sideshift Left - Push the knob forward The state of the finger tip system can be checked smoothly to shift the carriage to the left. by the external warning lamp blinking.. Sideshift Hold - Release the sideshift Blinking Lamp State attachment knob.
Page 174 Operation Section Auto Tilt Leveling Switch [Aux2] Optional Selector Switch for SAFETY Operating a Rotating Cramp Attachment In case of auto tilt leveling, push this button. Pushing button makes auto tilt leveling function on and off alternately. When the function is on, the mast stops at a vertical position while tilting forward and backward.
Page 175 Operation Section Adjustment of Armrest Up and Down Adjustment To move the armrest down, turn the knob(2) By using 2 knobs, adjust the position of the armrest counterclockwise to give the operator the best comfortable position of arm. knob #1 - Forward and backward adjustment knob #2 - Up and down adjustment.
Page 176: Operating Techniques
Operation Section Operating Techniques Inching into Loads Lifting the Load 1. Lift the load carefully and tilt the mast back a short distance. Typical Example 1. Move the lift truck slowly FORWARD into Typical Example position and engage the load. The lift truck should be square with load, forks spaced 2.
Page 177 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 Examp 1. Travel with the load uphill on upgrades and downgrades.
Page 178 Operation Section Turning Typical Examp 1. When turning sharp corners, keep close to the 3. Deposit the load and BACK away carefully to inside corner. Begin the turn when the inside disengage the forks. drive wheel meets the corner. Typical Example 2.
Page 179 Operation Section Lifting Drums or Round Objects Operating in hot weather Keep the following points in mind when you operate the lift truck in hot weather. 1. Check the radiator. Clogging can cause overheating. Clean them out regularly with a blast of compressed air, also, check for leakage of water.
Page 180: Parking The Lift Truck
Operation Section Parking the Lift Truck 5. Turn the key in the ignition switch to the OFF position and remove the key. NOTE: Park the lift truck level with the fork lowered and the mast tilted forward until the fork touches the floor.
Page 181: Lift Fork Adjustment
Operation Section Lift Fork Adjustment WARNING When adjusting the fork spread, be careful not to pinch your hand between forks and the carriage slot. Hook-on type Fork 1. Move up the hook pin to the free position. 2. Raise the hook pin in each fork to side the fork on the carriage bar.
Page 182: Storage Information
Operation Section Storage Information Before Storage To Operate the Lift Truck after a Long Time Storage Before storing your lift truck, clean and inspect as the following procedures. Remove covers and antirust from each of the  components and exposed parts. Wipe away grease, oil, etc.
Page 183: Transportation Hints
Check the state and local laws governing weight, width and length of a load. Contact your DOOSAN Lift Truck dealer for shipping instructions for your lift truck. Always block the trailer or the rail car wheels before loading the lift truck.
Page 184 Operation Section Lifting a Forklift using a Crane How to Fix Forklift to a Carrier 1. The rope/chain must have sufficient length for fixing. WARNING 2. Park the vehicle on a level ground. 1. If lifting rope breaks, serious injury/damage may occur.
Page 185: Towing Information
Operation Section Towing Information Consult your DOOSAN Lift Tuck dealer for towing a WARNING disabled lift truck. Personal injury or death could result when towing a disabled lift truck incorrectly. Block the lift truck wheels to prevent movement before releasing the brakes. The lift truck can roll free if it is not blocked.
Page 186: Maintenance Section
Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for Some countries have standards or regulations which apply specifically to the inspection and repair inspection, maintenance and repair of lift truck forks. It also provides general information on the design of forks.
Page 187 Maintenance Section Repetitive Overloading  Causes of Fork Failure Repetitive cycling of loads which exceeds the Improper Modification or Repair fatigue strength of the material can lead to fatigue failure. The overload could be caused by loads in Fork failure can occur as a result of a field excess of the rated fork capacity and by use of the modification involving welding, flame cutting or forks tips as pry bars.
Page 188 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 189 Maintenance Section Check the fork arm before and after the second 12 Months Inspection application of the test load. It shall not show any permanent deformation. Forks should be inspected, at a minimum, every 12 months. If the truck is being used in a multi-shift or Consult fork manufacturer...
Page 190: Tire Inflation Information
Maintenance Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures. Shipping Pressure Ply Rating or Size Strength Index 6.5X10 7.0X15 28X9-15 Standard tire, ply rating and inflation pressures. The operating inflation pressure is based on the weight of a ready - to - work machine without attachments, at rated payload, and in average...
Page 191: Torque Specifications
Maintenance Section Torque Specifications Metric Hardware Torque for Standard Bolts, Nuts, and Taperlock Studs Most of the nuts, bolts, studs, and threaded holes in your lift truck are metric. In this manual we provide specifications in both metric and U.S. customary measurement.
Page 192 Maintenance Section Torque for Metric Fasteners Torques for Taperlock Studs Thread Size Standard Taperlock Stud Torque NOTICE Inch N·m lb·ft Be very careful never to mix metric with U.S. 8 ± 3 6 ± 2 customary (standard) fasteners. Mismatched or 5/16 17 ±...
Page 193: Cooling System Specifications
NOTICE DOOSAN recommends that the coolant mixture contain 50% commercially available automotive antifreeze, and 50% water. The coolant mix with concentration of antifreeze smaller than 30% does not provide sufficient corrosion protection.
Page 194 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 and deionized water to reduce the potential and severity adequate water pump cavitation temperature for of chemical insolubility.
Page 195: Fuel Specifications
For electronically controlled engines, it is  Doosan approves the use of bio-diesel fuels that do mandatory to use fuel that does not contain not exceed a blend of 5% (by volume) of FAME 0.1 % or more sulfur content.
Page 196 LP varies slightly between different Precautions and concerns regarding the use of parts of the country and different refineries. HD5 or bio- fuels: HD10 is recommended for DOOSAN forklift trucks. Composition of HD5 1. Free methanol in FAME may result in corrosion Propane (C 90.0 %...
Page 197: Lubricant Information
Drain the fluid, retighten all hydraulic suction line clamps, purge and refill the system. Diesel Engine : API CH4, ACEA E5  Consult your DOOSAN Lift Truck dealer for purging instructions. NOTICE Failure to follow the oil recommendations can cause...
Page 198 Use heavy duty hydraulic brake fluid certified by oil Shortened engine life will result. supplier to meet the latest version of following classifications. NOTE: Multi-grade oils blended DOOSAN for use in transmissions. • ISO 6743/4 Multi-grade oils which use high molecular • AFNOR NFE 48-603 weight polymers viscosity index •...
Page 199: Lubricant Viscosities And Refill Capacities
Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities LUBRICANT VISCOSITIES REFILL CAPACITIES - (APPROXIMATE) FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment or System Liters U.S Gal. Compartment °C °F or System Viscosities Engine Crankcase w/Filter G424I & G424IE 2.4 liter G424I(E) 1.56 G424P &...
Page 200: Maintenance Intervals
Maintenance Section Maintenance Intervals Drive Axle Oil Level – Check ....... 214 Hydraulic Oil Level – Check ......... 215 NOTICE Never exceed the Maintenance Intervals specified in the manual. Defects and/or damage to the First 50 - 100 Service Hours or a Week important functional components may be resulted Engine Oil &...
Page 201 Maintenance Section Every 1000 Service Hours or 6 Months Inspect Intake Leaks (G424I(E) /G430FE/G424P(E) Engine Only) ....... 255 Replace PCV Valve and breather element - Hydraulic Return Filter, Breather & Strainer - Check, Change (LP, Gasoline and Dual Fuel Engines) Change ..............
Page 202 Maintenance Section Quick Reference to Maintenance Schedule EVERY ITEMS SERVICES PAGE Air Cleaner Indicator Check Air Intake System Change Air Intake System Check, Clean Battery Terminal Clean, Inspect Belts Check, Adjust Brake Oil Level Check Carriage Roller Extrusion Adjust Checking the TMAP Sensor (G424I(E)/G430FE/G424P(E) Engine Only) Coolant Level Check...
Page 203 Maintenance Section Quick Reference to Maintenance Schedule EVERY ITEMS SERVICES PAGE Check, Clean, Hydraulic Oil Change Hydraulic Oil Level Check Check, Hydraulic Return Filter, Breather & Strainer Change Inching & Braking Control Shaft Lubricate Inspect Battery System Inspect Coolant Hoses (LP, Dual Fuel Engine Only) Inspect Electrical System (G424I(E)/G430FE/G424P(E) Engine Only)
Page 204 Maintenance Section Quick Reference to Maintenance Schedule EVERY ITEMS SERVICES PAGE Replace Oxygen Sensor (G424I(E)/G430FE/G424P(E) Engine Only) Replace PCV Valve and breather element (LP, Change Gasoline and Dual Fuel Engines) Replace Spark Plugs (G424I(E) Engine Only) Replace Spark Plugs (G430FE/G424P(E) Engine Only) Check, Seat, Hood Latch &...
Page 205: 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. Fuel Tank Filter Cap and Screen (If Seat, Hood Latch & Support Equipped) - Clean Cylinder - Check, Lubricate Park the lift truck with the forks lowered, parking...
Page 206: Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset
Maintenance Section Fuses, Bulbs, Circuit Breaker & Relay - 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 207: Battery Terminal - Clean, Inspect
Maintenance Section Battery Terminal - Clean, Inspect Circuit Breaker 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 with batteries.
Page 208: Priming The Fuel System(Diesel Engine Only)
Maintenance Section Priming the Fuel System(Diesel Engine Only) 4TNE98 & 4TNE94L Diesel Engine Only The fuel system needs to be primed under certain conditions. Before starting the engine for the first time.  After running out of fuel and fuel has been added ...
Page 209: Water Separator (Diesel Engine Only) - Check, Drain
Maintenance Section Test Fuel System for Leaks(LP and Dual Fuel Water Separator (Diesel Engine Engines Only) Only) - Check, Drain 4TNE98 & 4TNE94L Diesel Engine Only NEVER wait until scheduled periodic maintenance if the fuel filter indicator comes on. The fuel filter / water separator contains a sensor to detect the amount of water and contaminants.
Page 210: Tires And Wheels (D, G-Series) - Inspect, Check
Maintenance Section Tires and Wheels (D, G-Series) - Carriage Roller Extrusion – Adjust Inspect, Check 1. Set the mast vertical. WARNING 2. Lower the carriage completely. Servicing and changing tires and rims can be dangerous and should be done only by trained 3.
Page 211: Every 10 Service Hours Or Daily
Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspect Engine for Fluid Leaks Gasoline and LP Engines 1.
Page 212: Coolant Level - Check
Maintenance Section 3. Start and run the engine to stabilize the coolant Coolant Level – Check level in the filter neck. If low, add coolant until it reaches the top of the filter neck. Install the WARNING radiator cap. Observe coolant level in the expansion bottle.
Page 213: Air Cleaner Indicator - Check
Maintenance Section Air Cleaner Indicator - Check Walk- Around Inspection - Inspect For maximum service life of the lift truck, make a Checking Service Indicator thorough walk-around inspection. Look around and under the truck for such items as loose or missing bolts, debris or dirt buildup, fuel, oil or coolant leaks and cut or gouged tires.
Page 214: Mast Channels - Lubricate
Maintenance Section Mast Channels – Lubricate 8. Inspect the cooling system for leaks, worn hoses and debris buildup. The channels on the roller-type mast require a 9. Inspect engine compartment for oil, coolant and break-in period. Apply a light film of lubricant on the fuel leaks.
Page 215: Transmission Oil Level - Check
Maintenance Section Transmission Oil Level – Check Parking Brake - Inspect Inspection from Operator's Seat, Engine WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Start and operate the lift truck until the engine reaches normal operating temperature.
Page 216: Brake Oil Level - Check
Maintenance Section Brake Oil Level - Check Parking Brake NOTE: The parking brake is required to be adjusted to hold the lift truck with capacity load on a 15% grade. If there is a 15% grade in your workplace, engage a capacity load and drive over to the grade.
Page 217: Hydraulic Oil Level - Check
Maintenance Section 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 218: 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. 6. Remove the oil drain plug (Figure 5-2, (1)) from Engine Oil &...
Page 219: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
Maintenance Section Transmission Oil, Oil Filter & WARNING Strainer - Check, Clean, Change NEVER overfill the engine with engine oil. ALWAYS keep the oil level between the upper WARNING and lower lines on the oil cap/dipstick. Hot oil and components can cause personal injury.
Page 220 Maintenance Section 12. Maintain the oil level between the Min and Max marks on the dip stick/filter cap. When the oil temperature is 40°C approximately, the cold side mark on the dipstick is applicable. When the oil temperature is 80°C approximately, the hot side mark on the dipstick is applicable.
Page 221: Drive Axle Oil - Change
Maintenance Section Drive Axle Oil - Change Parking Brake - Test, Adjust Park the lift truck on a level surface. Apply the Parking Brake Testing parking brake. Place the directional control lever in NEUTRAL and stop the engine. NOTICE OSHA requires the parking brake to hold the lift truck, with capacity load, on a 15% grade.
Page 222 Maintenance Section WARNING 5. Make sure the brake lever (1) is held against stop pin (2). If the brake lever (1) is held against To prevent personal injury, the operator MUST the stop pin (2), go to step 7. If the brake lever be ready to use the service brake if the parking (1) is NOT held against the stop pin (2), go to brake is not adjusted correctly and the lift truck...
Page 223: Every 250 Service Hours Or Monthly
Maintain the oil level to the FULL mark on the dip stick. 14. Close hood and seat assembly NOTICE Engine Oil Service hours can be extended to 5 00 hours by using Doosan supplied specific oil. Please consult Doosan dealer about it. -221-...
Page 224: 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. 1. To service the air cleaner, raise the hood and Air Intake System - Check, Clean seat assembly.
Page 225 Maintenance Section Air-205 kPa (30 psi) Maximum Pressure Cleaning Primary Filter Elements 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 226: Belts - Check, Adjust
Maintenance Section Checking Element Belts - Check, Adjust 1. Insert a light inside the clean dry element and Typical Example examine it. Discard the element if tears, rips or damage are found. 1. Check the condition and adjustment of the belt. Correct adjustment allows 10 mm (3/8 inch) 2.
Page 227: Mast Hinge Pin - Lubricate
Maintenance Section Mast Hinge Pin – Lubricate Mast Pivot Eyes - Lubricate Typical Example Typical Example 1. Lower the forks and tilt the mast forward. 1. Lubricate two fittings for the mast pivot eyes, 2. Lubricate the two fittings for the mast hinge pins, one on each side of the pin.
Page 228: Crosshead Rollers - Inspect
Maintenance Section 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. Inspect for loose bolts and nuts on the carriage. Remove any debris from the carriage and mast.
Page 229: Transmission Oil Filter - Change
Maintenance Section Transmission Oil Filter – Change Parking Brake - Test, Adjust See topic, “Parking Brake - Test, Adjust” in “First WARNING 50-100 Service Hours or a Week”. Hot oil and components can cause personal injury. Do not allow hot oil or components to Inching &...
Page 230: Drive Axle Oil & Strainer - Change, Clean
Maintenance Section Drive Axle Oil & Strainer - Change, Clean 7. Install the dip stick/filter cap. Park the lift truck level, with the forks lowered, Overhead Guard – Inspect parking brake engaged, transmission in NEUTRAL and engine stopped. 1. Remove drain plug. Allow the oil to drain into a suitable container.
Page 231: Steer Suspension - Inspect
Maintenance Section Steer Suspension – Inspect Steering Mechanism - Check, Lubricate 1. Inspect the suspension mounting bolts. Tighten suspension mounting bolts, if necessary, to 240 1. Lubricate the steer axle king pins, total of four ± 30 N·m (180 ± 20 lb·ft). fittings.
Page 232: Wheel Bolts & Nuts - Inspect
Maintenance Section Wheel Bolts & Nuts – Inspect Inspect Tightness (GC - Series) Drive Wheels Inspect Tightness (D, G - Series) Steer Wheels Typical Example 1. Inspect tightness of wheel bolts in a sequence opposite each other to 245 N·m (180 lb·ft). Typical Example 1.
Page 233: Inspect Vacuum Lines And Fittings (G424I(E) Engine Only)
Maintenance Section Inspect Vacuum Lines and Fittings Inspect Electrical System (G424I(E) (G424I(E) Engine Only) /G430FE/G424P(E) Engine Only) 1. Visually inspect vacuum lines and fittings for 1. Check for loose, dirty or damaged connectors physical damage such as bittleness, cracks and and wires on the harness including: Fuel kinks.
Page 234: Engine Oil & Filter (Diesel Engine Only) - Change
Maintenance Section Engine Oil & Filter (Diesel Engine Only) - Change See topic, “Engine Oil & Filter (Diesel Engine Only) - Change” in “First 50-100 Service Hours or a Week”. Fuel Filter (Diesel Engine Only) - Change 4TNE98 & 4TNE94L Diesel Engine Only Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow.
Page 235: Pcv Valve System - Inspect, Clean
Maintenance Section 17. Install the new fuel filter (Figure 5-14, (2)) by PCV Valve System - Inspect, Clean turning it to the right (Figure 5-14, (4)) until it contacts the mounting surface. Tighten one G424I(E) LP and Duel Fuel Engines additional turn.
Page 236: Governor Lever And Engine Speed Control (Diesel Engine Only) - Check, Adjust
Maintenance Section Governor Lever and Engine Speed Control (Diesel Engine Only) - Check, Adjust Checking and adjusting the governor lever: 4TNE98 & 4TNE94L Diesel Engine Only governor lever engine speed 1. Check that the governor lever (Figure 5-12, (1)) control(accelerator lever, pedal, etc.) makes uniform contact with the low idle (Figure...
Page 237: 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. Hydraulic Return Filter, Breather & Strainer - Check, Change WARNING Hot oil and components can cause personal injury.
Page 238: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
Maintenance Section Transmission Oil, Oil Filter & Check for Equal Tension Strainer - Check, Clean, Change See topic, “Transmission Oil, Oil Filter & Strainer- Check, Clean, Change” in “First 50 - 100 Service Hours” Lift Chains - Test, Check, Adjust Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller.
Page 239 Maintenance Section Carriage Chain Adjustment Mast Chain Adjustment - FF, FFT Mast Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts (1), (2). NOTE: See the previous section, “Carriage Roller Extrusion”...
Page 240: Universal Joint - Inspect
Maintenance Section Universal Joint – Inspect Air Intake System - Change Changing Primary Element See topic, “Air Intake System - Check, Clean” in “Every 500 Service Hours or Monthly” Changing Secondary Element 1. Remove the primary air cleaner element. See topic “Servicing Filter Element.”...
Page 241: Inspect Coolant Hoses (Lp, Dual Fuel Engine Only)
G424I(E) Engine 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: Inspect Mixer Assembly (G424I(E) /G430Fe/G424P(E) Engine Only)
Maintenance Section Inspect Mixer Assembly (G424I(E) Engine Valve Lash (Diesel Engine /G430FE/G424P(E) Engine Only) Only) - Check, Adjust Refer to the LP mixer section of the engine service manual for procedures. NOTICE The valve clearances are to be adjusted at the Inspect Throttle Assembly times of the following situations.
Page 243: Every 1500 Service Hours Or 9 Months
Maintenance Section Every 1500 Service Hours or 9 Months Inspect Ignition System (LP, G424P(E) Engine Gasoline & Dual Fuel Engines Only) 1. Disconnect Battery Cables. 2. Remove and inspect the spark plugs. Replace as required. 3. Test secondary cables with an Ohmmeter. If the maximum resistance is higher than 25 kOhms, repair and/or replace.
Page 244: Replace Lp Fuel Filter Element (Lp, Dual Fuel Engine Only)
Maintenance Section 3. Check bottom cover O-ring seal (6) for damage. Replace LP Fuel Filter Element (LP, Replace if necessary. Dual Fuel Engine Only) 4. Re-assemble the filter assembly aligning the scribe lines on the top and bottom covers. Park the lift truck in an authorized refueling area with the forks lowered, parking brake applied and 5.
Page 245: Fuel Injectors (Diesel Engine Only) - Inspect, Clean, Test
Maintenance Section Fuel Injectors (Diesel Engine Only) – Inspect, Clean, Test WARNING HIGH-PRESSURE HAZARD! Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury.
Page 246: 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 Engine Valve Lash (Diesel Engine Steer Wheel Bearings - Only) –...
Page 247 Maintenance Section 3. Straighten the lock washer tangs. 8. Install the outer wheel bearing and the out washer. Install a new lock washer and fit the locknut. 4. Remove the locknut, lock washer and flat washer. Typical Example Remove the outer wheel bearing. 9.
Page 248: Drive Wheel Bearing (Power Shaft And Drive Wheel) - Apply Grease And Reassemble
Maintenance Section 2. Loosen the adapter assembly bolts(1) and Drive Wheel Bearing (Power Shaft remove the disk brake adapter(2). and Drive Wheel) – Apply Grease and Reassemble Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL and the engine stopped.
Page 249 Loosen the nut completely and tighten nut again to Consult your DOOSAN lift truck dealer for the 50 ±5 N·m (37 ± 4 lb·ft). Bend the lock washer tang proper wheel bearing reassembling procedure.
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 filler cap is cool enough to touch with your bare hand.
Page 251 Maintenance Section 3. Open the radiator drain valve. Allow the coolant NOTICE to drain into a suitable container. Drain the recovery bottle. Inject the coolant additionally into below specific port of G424I(E) engine besides the radiator if needs more coolant while clean & change the cooling system.
Page 252: Forks - Inspect
Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer further information. 2. Check the angle between the upper face of the blade and the front face of the shank. The fork...
Page 253 Maintenance Section of the stop blocks in some cases. Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage.
Page 254: Every 2500 Service Hours Or 15 Months
Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Oil - Check, Clean, Inspect Battery System Change 1.
Page 255: Replace Oxygen Sensor (G424I(E) /G430Fe/G424P(E) Engine Only)
Maintenance Section Replace Oxygen Sensor (G424I(E) /G430FE/G424P(E) Engine Only) G424P(E) Engine G424I(E) Engine G430FE Engine When indicated by MIL, replace oxygen seasor on the exhaust manifold and oxygen sensor on muffler assembly. 1. Stop engine and wait until the exhaust pipe and exhaust pipe is cooled.
Page 256: Replace Spark Plugs (G424I(E) Engine Only)
Maintenance Section Replace Spark Plugs (G424I(E) Engine Only) 1. Disconnect Battery Cables. 2. Remove the ignition wiring harness. 3. Remove the ignition coil assy. 4. Remove spark plugs. 5. Gap the new spark plugs to the proper specifications. G424I(E) Engine: 0.8 ~ 0.9 mm 6.
Page 257: Checking The Tmap Sensor (G424I(E) /G430Fe/G424P(E) Engine Only)
Maintenance Section Checking the TMAP Sensor Replace PCV Valve and breather (G424I(E) /G430FE/G424P(E) element - Change (LP, Gasoline Engine Only) and Dual Fuel Engines) G424I(E) Engine 1. Verify that the TMAP sensor (F) is mounted tightly into the manifold adapter (E), with no leakage.
Page 258: Every 8000 Service Hours Or 48 Months
Maintenance Section Every 8000 Service Hours or 48 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. Timing Belt (G424P(E) LP, Dual Fuel Engine Only) - Change See the “Service manual”...
Page 259: 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.
Page 260: Index
Index Section Index Capacity Chart (With Sideshifter cushion) ..............58,59,60,61 Capacity Chart (With Sideshifter Pneumatic) ..............50,51,52,53 [Aux2] Optional Selector Switch for SAFETY Capacity Chart (Without Sideshifter cushion) Operating a Rotating Cramp Attachment.... 172 ..............54,55,56,57 12 Months Inspection ........... 187 Capacity Chart (Without Sideshifter Pneumatic) 4TNE98 &...
Page 261 Index Section Drive Axle Oil Level – Check ....... 214 Fuel Selector Switch (G424I(E) /G424P(E) Dual Drive Axle Oil ............195 Fuel Only) ..............82 Drive Wheel Bearing (Power Shaft and Drive Wheel) Fuel Specifications ..........193 – Apply Grease and Reassemble......246 Fuel Tank Filter Cap and Screen (If Equipped) - Dual Fuel System ............93 Clean ..............
Page 262 Index Section If Optional Suspension Seat (weight adjusting type) Location of controls ..........70 Equipped ..............18 Long Time Storage..........180 If Parking Brake Alarm Equipped ......178 LP Engine ..............91 Important Safety Information ........4 LP Regulator/Converter Inspection (LP, Dual Fuel Improper Modification or Repair ......
Page 263 Index Section Overhead Guard Must Be In Place Warning ... 8 Starting a Cold Diesel Engine ........ 91 Overloading ............185 Starting a Warm Diesel Engine ......91 Starting From a 12 Volt External Source ....92 Starting the Engine..........90 Starting the Lift truck ..........
Page 264 Index Section Universal Joint – Inspect ........238 Unloading .............. 175 Up and Down Adjustment ........173 USB player ...............76 Walk- Around Inspection - Inspect ...... 211 Walk - Around Inspection ........88 Warning Lamp ............171 Warning Signs and Labels ........5,17 Water Separator (Diesel Engine Only) - Check, Drain ..............

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