Doosan D20S-7 Operation & Maintenance Manual
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Doosan D20S-7 Operation & Maintenance Manual

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CHRIS MISTRETTA
May 28, 2025

what is the oil filter pn# and air filter pn# for a 2019 doosan g25p-7

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Summary of Contents for Doosan D20S-7

  • Page 2: Original Instruction

    FGA13, FGA14, FGA15, FGA16, FGA17 GCT Tier-3 G20P-7, G25P-7, G30P-7 G33P-7, G35C-7 FGA18, FGA19, FGA20, FGA21, FGA22 MMC 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. 1710...

  • Page 4: Table Of Contents

    Table of Contents Table of Contents Maintenance Section Information Section Inspection, Maintenance and Repair of Lift Truck Foreword ..............2 Forks ..............165 Tire Inflation Information ........169 Torque Specifications ........... 170 Safety Section Cooling System Specifications......172 Fuel Specifications ..........174 Important Safety Information ........

  • Page 5: Information Section

    Read, study and keep this manual with the lift truck. can still happen. The DOOSAN operator restraint system can minimize injuries. The DOOSAN Whenever a question arises regarding your lift truck,...

  • Page 6: Maintenance

    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 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

    Read and understand the Operation and Maintenance Manual. Additional manuals are available from DOOSAN Lift Truck dealers. This label also provides allowable lift truck capacity information.
  • Page 9 Safety Section Travel with load as low as possible and tilted back. General Warning to Operator If load interferes with visibility, travel with load trailing. On grade operations travel with load up grade. Watch out for pedestrians and obstructions. Check overhead clearances.
  • Page 10 Safety Section Pressure Warning No Standing On Fork Warning No Standing Under Fork 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: No Riders Warning

    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 12: Parking Brake

    Safety Section Parking Brake WARNING Correct adjustment is necessary to provide adequate braking. See the MAINTENANCE section for adjustment procedures. The lift truck may creep at engine idle and can cause damage, injury or death. Always apply the parking brake when leaving the lift truck. The parking brake is NOT automatically applied.

  • Page 13: 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 14: Operation Information

    DOOSAN spare parts waive any liability by DOOSAN. Operate the lift truck and controls only from the operator's station.
  • Page 15 Safety Section Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck equipped) and all other devices are working Always keep the lift truck under control. properly. Obey all traffic rules and warning signs. Check proper operation mast attachments.
  • 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 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 18: 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 19: Fire Extinguisher

    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 20: 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 21: Seat Adjustment

    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 overhead guard. It shows the proper use of the operator restraint system.

  • Page 22: Notice

    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 23 Safety Section WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 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.

  • Page 24: Avoiding Lift Truck Tipover

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipover Lift Truck Stability The stability of the lift truck is determined by the Counterbalanced lift truck design is based on the location of its CG; or, if the truck is loaded, the balance of two weights on opposite sides of a combined CG of the truck and load.

  • Page 25: Notice

    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 26: 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 27 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 28 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 29 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 30 Safety Section Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and Never overtake other vehicles.
  • Page 31 Safety Section An unloaded forklift may be easier to tip over than a Do not operate forklifts near flammable or 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 32: 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 33: General Section

    468, Injung-ro, Dong-gu, Incheon, Korea 22503 Authorized Representative, 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 36 A 9100 Sint-Niklaas BELGIUM herewith declare...

  • Page 34: Specifications

    General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN D20S-7 D25S-7 MODEL (D24NAP,TIER4) (D24NAP,TIER4) 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 35 General Section DOOSAN DOOSAN DOOSAN D30S-7 D33S-7 D35C-7 (D24NAP,TIER4) (D24NAP,TIER4) (D24NAP,TIER4) 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 36 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN G20N-7 G25N-7 MODEL (K25,TIER3) (K25,TIER3) 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 37 General Section DOOSAN DOOSAN DOOSAN G30N-7 G33N-7 G35NC-7 (K25,TIER3) (K25,TIER3) (K25,TIER3) 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 2595 2700 1197 1170 1197 2165 2165 2165 4490 4490...
  • Page 38 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN D20S-7 D25S-7 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 39 General Section DOOSAN DOOSAN DOOSAN D30S-7 D33S-7 D35C-7 (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 40 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN D20S-7 D25S-7 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 41 General Section DOOSAN DOOSAN DOOSAN D30S-7 D33S-7 D35C-7 (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 42 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN MODEL G20P-7 G25P-7 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 43 General Section DOOSAN DOOSAN DOOSAN G30P-7 G33P-7 G35C-7 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 44: Noise And Vibration

    Model Guaranteed Sound (m/s dB(A) dB(A) Mean Uncertainty TIER - 4 (D24NAP E/G) D20S-7, D25S-7, D30S-7, D33S-7, D35C-7 (W/O Cabin) TIER - III (GCT K25 E/G) G20N-7, G25N-7, G30N-7, G33N-7, G35NC-7 (W/O Cabin) TIER - III (4TNE98(94L) E/G) D20S-7, D25S-, D30S-7...

  • Page 45: Capacity Chart (Without Sideshifter Pneumatic)

    General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -42-...
  • Page 46 General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -43-...
  • Page 47 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -44-...
  • Page 48 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -45-...

  • Page 49: Capacity Chart (With Sideshifter Pneumatic)

    General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -46-...
  • Page 50 General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -47-...
  • Page 51 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -48-...
  • Page 52 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -49-...

  • Page 53: 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. 3.3 liter Diesel Engine (4TNE98 & 4TNE94L) Serial Number •_____________________________ Lift Truck Serial Number •_____________________________ 2.4 liter Spark-Ignition Engine Serial Number (G424P(E)) •_____________________________ 2.4 liter Diesel Engine (D24A) Serial Number...
  • Page 54 General Section Drive Axle Serial Number •_____________________________ Typical Example Side Shifter Serial Number (If Equipped) •_____________________________ -51-...
  • Page 55 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 56: 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 57: 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 58 Operation Section 1. Diesel Engine Water in Fuel Filter 6. Transmission Oil Temperature Indicator Light - Indicates when the Gauge - Shows transmission oil engine is running, there is water in the fuel temperature If the gauge pointer moves beyond the red band during filter exceeds 100cc.
  • Page 59 Operation Section 13. Mast interlock – Alarm warning lights when operator leaves the seat without applying parking brake and then, operation of mast is automatically interrupted. 14. Directional Turning Indicator Light 15. Brake oil level – Brake oil level Lamp indicates when the brake oil level is low.

  • Page 60: Engine Compartment

    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 located at cowl (G.D Series) and raising the hood and seat assembly (Note: Unlock latch before pulling-if key equipped) 1.
  • Page 61 Operation Section 3. Specifying a Maximum Measuring Scale Weight Scale Option (Load Cell This step is to specify the rated capacity of the Type) vehicle on which the load cell is installed. With this weight scale option, the operator can measure and limit the load's weight using a display Since the device does not weigh a load heavier than the set capacity (determins to be overloaded),...
  • Page 62 Operation Section 5. Inputting a Reference Load 7. Finishing Calibration This step is to input the weight of a reference load Once you have done all the steps above, a certain needed for weight setting. figure appears along with a blinking message If the weight of the reference load is 3,000 kg, input "C._End"...

  • Page 63: Location Of Controls

    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. 3. USB button: Select USB player. Radio mode: Plays frequencies with superior reception for 5 seconds each (press);...
  • Page 64 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 65 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 66: Getting Started

    Operation Section Getting started Setting the sound 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 67 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 68 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 69: Usb Player

    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 band.
  • Page 70 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 71 Operation Section Controlling the playback Change the playback mode 1. While playing, press the SCN button to begin the 1. While playing, turn the ▶▶│TRACK│◀◀ dial Intro scan playback. left/right to moves to the previous or next track. • When pressed shortly, scans the beginning •...
  • Page 72 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 73: Aux Player

    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 74: Seat Switch System (If Equipped)

    If seat or seat switch replacement becomes SYSTEM will automatically disengage necessary, be sure to use genuine DOOSAN transmission. The directional lever, however, will Corporation Industrial Vehicle lift truck parts. Lift trucks should never be operated without an remain in that forward or reverse location although operational SEAT SWITCH SYSTEM.

  • Page 75: Tilt Steering Column

    Operation Section Tilt Steering Column WARNING When closing the engine hood, be careful not to pinch your hand. Circuit Breaker Circuit Breaker -Protects main To adjust the steering column, push down the electrical circuits. To reset the circuit knob(1), and move the steering column to the breaker, push the button in.
  • Page 76 Operation Section WARNING TURN IGNITION KEY SWITCH OFF BEFORE CHANGING AS LPG MODE OR GAS MODE! (GCT K25 ENGINE ONLY) ECO Switch 1. STD MODE - If Multi Torque switch is located in the Off position, Max. RPM performance will be shown. 2.

  • Page 77: Lift Truck Controls

    Operation Section Lift Truck Controls Direction Control Lever Service Brake Pedal Push DOWN on the brake pedal to slow or stop the lift truck. 1. Forward - Push the lever forward for FORWARD direction travel. RELEASE the brake pedal to allow the lift truck to move.

  • Page 78: Parking Brake Lever

    Operation Section Parking Brake Lever Tilt Control 1. Mast Tilt Forward - Push the lever Pull the lever BACK to engage the parking FORWARD smoothly to tilt the mast brake. forward. 2. Mast Hold - When the lever is released Push the lever FORWARD to release the it will return to the HOLD or center position.

  • Page 79: 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 refueling.
  • Page 80 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...
  • Page 81 Operation Section NOTICE If the location pin (dowel) is missing or broken, be sure the pin is replaced. Position the replacement tank so that the locating pin (dowel) is in place. WARNING The LP tank must not extend past the Check to be sure that the LP warning plate is in counterweight position on the lift truck, and is legible.

  • Page 82: Before Starting The Engine

    Operation Section Before Starting the Engine Walk - Around Inspection Inspect the overhead guard for damage and loose Make a thorough walk - around inspection before or missing mounting bolts. mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or Inspect the hydraulic system for leaks, worn hoses coolant leaks.
  • Page 83 Operation Section Measure the engine crankcase oil level with the dip stick. Maintain the oil level between the MAX. and Observe the fuel level gauge after starting the truck. MIN., (or FULL and ADD) notches on the dip stick. Add fuel if necessary. WARNING Personal injury may occur from accidents caused by improper seat adjustment.

  • Page 84: 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 85: Diesel Engine

    Operation Section LP Engine Diesel Engine Starting a Cold Diesel Engine WARNING Turn the key to the ON position. The start pre heat LP fuel is flammable and can cause personal light will come ON. The preheat light will stay ON injury.
  • Page 86 POSITIVE(+) to POSITIVE(+) and NEGATIVE( - ) the battery, and well clear of fuel system to NEGATIVE( - ). components. Attach ground cable last, remove first. All lift trucks equipped with DOOSAN built internal combustion engines are NEGATIVE( - ) ground. -83-...

  • Page 87: Dual Fuel System

    Operation Section Dual Fuel System Changing From Gasoline to LP – 4. Open the fuel valve, on the LP tank, by slowly NOTE: The Underwriter’s Laboratory (U.L.) turning the valve counterclockwise. requires that the gasoline tank must be at least one - quarter full when operating on 5.
  • Page 88 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 89: After Starting The Engine

    Operation Section After Starting the Engine Observe all indicator lights and gauges frequently during operation, to make sure all systems are working properly. The entire indicator lights will come ON with the ignition switch in the ON position before the engine is started. Diesel and LPG/GAS (12V) Observe the hour meter (8) to make sure it is operating properly.

  • Page 90: 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 Start the engine. See topic “Starting the Engine”. transmission is engaged. This could result in personal injury. Always place the transmission control lever in the NEUTRAL (center) position and apply the parking brake before dismounting the lift truck.
  • Page 91 Operation Section Inching To change the lift truck direction of travel, release the accelerator pedal. NOTE: The purpose of the inching pedal is to provide precise lift truck inching control at Push down on the service brake pedal to reduce very slow travel speed and high engine the lift truck speed as necessary.
  • Page 92 Operation Section D24A Diesel Engine Introduction The D24A engine which is a high-power engine in compliance with the TIER4 Engine Emissions Standard is provided with various systems. The D24A engine is equipped with a turbo-charger intercooler system that compresses and cools air and feed it to the intake manifold. Here, AMF sensor and temperature/pressure sensors detect the air condition and transmit the data to the ECU which controls fuel injection rate according to the engine load, speed and air quantity.
  • Page 93 Key Off & Pressure Check sensors and harness Sensor Key off Batteries Close the EGR valve Check battery condition Check battery connection Key off Crank & Cam Check the sensors and Idle rpm rises Sensor harness *Call Doosan A/S Team -90-...
  • Page 94 Conditions for Restoration Classification Others Check Lamp Reduction Atmospheric Key off Pressure Check/Replace ECU Sensor *Call Doosan A/S Team Turbine Inlet Key Off Temperature Close the EGR valve Check sensors and harness Sensor Key off Flash Engine stops after 20...

  • Page 95: Electronic Controlled Spark-Ignition Engines (Gct K25 Engine)

    Operation Section Electronic Controlled Spark-Ignition Engines (GCT K25 Engine) Adopts Electronic Concentrated engine Control System (ECCS). Fuel injection control, ignition timing control, idle speed control, and electronically controlled governor control etc. are all performed by a single control unit. Adopts electric throttle control actuator system to control electronically controlled governor. Adopts Hall IC type crankshaft position sensor (POS) and camshaft position sensor (PHASE).
  • Page 96 Operation Section ECCS schematic of GCT K25 LP engine -93-...
  • Page 97 Operation Section ECCS schematic of GCT K25 Dual Fuel engine -94-...
  • Page 98 Operation Section Basic Troubleshooting(LP/DF) Trouble Diagnosis flow chart There are many different malfunction symptoms. So there is no perfect trouble diagnosis technique applicable to all malfunctions. Experience is also important to achieving an accurate trouble diagnosis. Nonetheless, an accurate trouble diagnosis can be performed by applying similar procedures, regardless of the malfunction symptom.
  • Page 99 Operation Section Diagnosis Chart by Symptom (Cont'd) Symptoms Poor idle Poor driving control Engine stall Other Description/notable characteristics of the symptom Sensor malfunction ⊕: Highly possible ◆: Possible Vehicle • Duration of fuel cut becomes OPEN/ ◆ ◆ ◆ ◆ speed SHORT shorter or fuel may SHORT...
  • Page 100 Operation Section Symptoms Poor idle Poor driving control Engine stall Other Description/notable characteristics of the symptom Sensor malfunction ⊕: Highly possible ◆: Possible Sensor ground (coolant temperatur OPEN/ • The same as the open circuit ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆...
  • Page 101 Operation Section Diagnosis Chart by Symptom (Cont'd) Relationships Between Malfunctioning symptoms and actuator circuits The table below shows the possible symptoms caused by the malfunction of each actuator circuit. Symptoms Poor idle Poor driving control Engine stall Other Description/notable characteristics of the symptom Actuator malfunction ⊕: Highly possible...
  • Page 102 Operation Section Symptoms Poor idle Poor driving control Engine stall Other Description/notable characteristics of the symptom Actuator malfunction ⊕: Highly possible ◆: Possible OPEN ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ Power supply Momentarily circuit •...
  • Page 103 Operation Section Diagnosis Chart by Symptom (Cont'd) Symptoms Poor idle Poor driving control Engine stall Other Description/notable characteristics of the symptom Actuator malfunction ⊕: Highly possible ◆: Possible ECM relay ◆ ⊕ ⊕ ⊕ ⊕ OPEN ⊕ circuit Throttle OPEN/ ◆...
  • Page 104 Operation Section Symptoms Poor idle Poor driving control Engine stall Other Description/notable characteristics of the symptom Actuator malfunction ⊕: Highly possible ◆: Possible Malfunction indicator OPEN lamp Improper ◆ ◆ ◆ ◆ ◆ ◆ ◆ OPEN TAS learning -101-...
  • Page 105 Operation Section Diagnosis Chart by Symptom (Cont'd) Relationships Between Malfunctioning symptoms and the engine main body/auxiliary component The table below shows the possible symptoms caused by the malfunction of engine main body system. It will be helpful in malfunction trouble diagnosis. (The table lists general symptoms and some may not be applicable.) Symptoms Poor idle...
  • Page 106 Operation Section Symptoms Poor idle Poor driving control Engine stall Other Description/notable characteristics of the symptom ⊕: Highly possible ◆: Possible ▽: Not very possible • Symptom depends on Clogged LPG clogging status. This tends to ◆ ▽ ◆ ▽ ◆ ◆ ◆ ◆ ◆ ▽...
  • Page 107 Operation Section Self-Diagnosis Function (without Service Tool) Diagnostic test mode II (self-diagnostic results) starting procedure 1. Turn ignition switch ON with accelerator pedal released. 2. After 3 seconds, fully depress accelerator pedal and then release it. Quickly repeat this cycle 5 times within 5 seconds (end in released position).

  • Page 108: Diagnostic Trouble Code (Dtc) Table

    Operation Section Diagnostic Trouble Code (DTC) Table Engine Name warning Malfunction return condition Diagnosis outline Trip lamp When the engine is running and the mass air flow sensor output voltage has P0102 been 0.5V or less (open or shorted) for a Mass air flow Detect disconnection predetermined period.
  • Page 109 Operation Section Diagnostic Trouble Code (DTC) Table (Cont'd) Engine Name warning Malfunction return condition Diagnosis outline Trip lamp Accelerator pedal position sensor 1 output voltage has been approx. 0.15V P2122 or less (open) for a predetermined period. Accelerator pedal position sensor 1 output voltage has been approx.
  • Page 110 Operation Section Engine Name warning Malfunction return condition Diagnosis outline Trip lamp •At start-up, no camshaft position sensor (PHASE) signal has been detected for more than a predetermined period. •The camshaft position sensor (PHASE) Camshaft signal is not detected for a position predetermined time during engine Detect abnormal cam...
  • Page 111 Operation Section Diagnostic Trouble Code (DTC) Table (Cont'd) Engine Name warning Malfunction return condition Diagnosis outline Trip lamp Detect abnormal condition in CPU or an CPU system or circuits in ECM have a P0605 engine control module malfunction. circuit and make MIL go on.
  • Page 112 Operation Section Engine Name warning Malfunction return condition Diagnosis outline Trip lamp • LPG fuel pressure sensor circuit is Detect abnormally open. higher fuel pressure by • LPG fuel pressure in fuel piping from vaporizer P1249 LPG fuel pressure LPG Vapo to injector has been malfunction sensor and make MIL excessively increased for a...
  • Page 113 Operation Section Diagnostic Trouble Code (DTC) Table (Cont'd) Engine Name warning Malfunction return condition Diagnosis outline Trip lamp After engine warmed with gasoline fuel, when oxygen sensor signal is Air-fuel ratio does not P1814 sticked and does not reverse at a cross stoichiometry for GAS air-fuel condition of A/F ratio is excessively lean...
  • Page 114 Operation Section Diesel Engine Overview Electronic control system components cannot be The electronic engine control system features individually repaired. The repair of a failed include the following. component requires the replacement of the entire assembly. • Overview of engine speed control Droop control / Low idle speed control / Auto deceleration / High idle speed drop / Black Electronic Control System...
  • Page 115 When the rack position vs. *For replacement, the speed control is active). the rack actuator output contact Doosan rises above the rated value. maintenance shop. When the rack position vs. the rack actuator output drops below the rated value.
  • Page 116 When the rack actuator output Engine stops. fuel injection pump. failure drops below the rated value *For replacement, contact Doosan When the engine is suddenly maintenance shop. accelerated even with the minimum rack actuator output When the engine stalls while the rack position sensor is disabled Key off.
  • Page 117 Operation Section Table 14-14 List of faults to be detected No. of Operation Status Corrective Action/ Item Fault Detection Conditions Lamp When Faults Occur Recovery Conditions Blinking Retain it until faults are Main relay The main relay is OFF, but the The engine operates corrected.
  • Page 118 ECU failure Flash ROM EEPROM Engine stops. repeated failures. [ROM error] checksum error. *For replacement, contact Doosan maintenance shop. Key off. Read / write failure. Replace the ECU in case of ECU failure The engine operates repeated failures. [EEPROM error] normally.
  • Page 119 Operation Section Electronic Controlled Spark-Ignition Engines 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. The system operates on a slightly positive fuel pressure. Primary fuel pressure can be measured at the LD 2-Stage convertor.
  • Page 120 Operation Section EMS schematic of G424P(E) LP engine -117-...
  • Page 121 Operation Section EMS schematic of G424P(E) Gasoline engine -118-...
  • Page 122 Operation Section Basic Troubleshooting(LP/DF) The 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 123 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 124 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 125 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 126 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 127 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 128 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 129 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 130 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 131 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 132 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 133 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 134: Advanced Diagnostics

    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 135 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 136 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 137 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 138 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 139 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 140 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 141 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 142 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 143 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 144 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 145 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 146 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 147 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 148 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 149 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 150 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 151: Electronic Controlled Transmission (Ect; If Installed)

    Operation Section Electronic Controlled Transmission (ECT; if installed) Electronic Controlled Transmission (ECT) is an electronic control system designed for the forklift trucks driven by diesel engines. The main functions of the ECT are to improve the pressure of heavy inching pedal and reduce shock at forward/reverse gear shift.
  • Page 152 Forward/Reverse Turn key off and Failure the controller is 30 always on gear shift impossible replace the controller. Volt or above. *Call Doosan A/S Controller Temperature in the Remain Center to replace the Forward/Reverse Failure controller is -40°C always on...
  • Page 153 Operation Section If a fault is detected, the controller flashes the ECT function fault warning lamp to notify the operator of the problem. The ECT function fault warning lamp is lit for one second at the power on of the controller. This is to inform the operator of the normal power supply of the controller.

  • Page 154: 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. NOTCH Vehicle Speed Its primary purpose is to prevent the operator from 3.3 km/h ( 2.05 mph ) driving the truck outside of the design parameters, 3.6 km/h ( 2.24 mph )
  • Page 155 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): Selected as factory-setting.
  • Page 156 Operation Section Manual Mode (Fail-Safe mode) Ground Speed Control The system still allows movement of the vehicle in The following describes how to perform ground case of controller breakdown by selecting the speed control using the instrument panel: manual mode with the Fail-Safe mode Switch in the This method is available in vehicles configured with controller.
  • Page 157 Operation Section Switch at notch 0 Switch at notch 2 Ground speed not limited Ground speed limited to 10km/h Switch at notch 1 Switch at notch 3 Ground speed limited to 8 km/h Ground speed limited to 15km/h *Notches 4 and 5 are not used. -154-...

  • Page 158: Operating Techniques

    Operation Section Operating Techniques Inching into Loads Lifting the Load 1. Lift the load carefully and tilt the mast back a short distance. Typical Example 1. Move the lift truck slowly FORWARD into position and engage the load. The lift truck Typical Example should be square with load, forks spaced evenly between pallet stringers and as far apart...
  • Page 159 Operation Section Traveling With the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. Typical Example 1. Move the lift truck into the unloading position. Typical Example 1. Travel with the load uphill on upgrades and downgrades.
  • Page 160 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 2.

  • Page 161: Operating In Hot Weather

    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 162: 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. 6. Actuate each loading lever several times to remove the residual pressure in the respective cylinders and hoses. If Parking Brake Alarm Equipped NOTE: Park the lift truck level with the fork lowered and the mast tilted forward until the fork...

  • Page 163: 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 164: 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. •...

  • Page 165: 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 166 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 167: 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 168: 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 inspection, maintenance and repair of lift truck forks. which apply specifically to the inspection and repair It also provides general information on the design of forks.

  • Page 169: Bent Or Twisted Forks

    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 170: Fork Inspection

    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 171: Maintenance And Repair

    Maintenance Section 12 Months Inspection Consult the fork manufacturer for further Forks should be inspected, at a minimum, every 12 information as may be applicable to the specific months. If the truck is being used in a multi-shift or fork involved. heavy duty operation, they should be checked every six months.

  • Page 172: 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 173: 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 174 Maintenance Section Torques for Taperlock Studs Torque for Metric Fasteners 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 175: Cooling System Specifications

    Cooling system problems can arise without lubricating oil. a thermostat. NOTICE DOOSAN recommends that the coolant mixture contain 50% commercially available automotive antifreeze, and 50% water. The coolant mix with concentration of antifreeze smaller than 30% does not provide sufficient corrosion protection.

  • Page 176: Coolant Water

    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 177: Fuel Specifications

    EN590:96 additives may cause poor engine performance. IS0 8217 DMX International BS 2869-A1 or A2 United Kingdom • Consult your Doosan representative for more JIS K2204 Grade No. 2 Japan information. KSM-2610 Korea • The ash content must not exceed 0.01% by...

  • Page 178: Gasoline Specifications

    It is recommended to use gasoline fuel that has octane number RON89(AKI87), to prevent knocking Doosan approves the use of bio-diesel fuels that do trouble. not exceed a blend of 5% (by volume) of FAME with 95% (by volume) of approved mineral oil derived diesel fuel.

  • Page 179: Lubricant Information

    Water or air in the system will cause about it. pump failure. Drain the fluid, retighten all hydraulic suction line clamps, purge and refill the system. Consult your DOOSAN Lift Truck dealer for purging • Diesel Engine: API CJ4, ACEA E9 or higher instructions. NOTICE...

  • Page 180: Brake Fluid

    Shortened engine life will result. Use heavy duty hydraulic brake fluid certified by oil NOTE: Multi-grade oils blended supplier to meet the latest version of following DOOSAN for use in transmissions. classifications. Multi-grade oils which use high molecular weight polymers viscosity index •...

  • Page 181: 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 Engine Crankcase w/Filter 2.27 or System Viscosities Max Min Max D24A Diesel SAE 5W30 Engine Crankcase w/Filter...

  • Page 182: Maintenance Intervals

    Maintenance Section Mast Channels – Lubricate ........195 Maintenance Intervals Brake Oil Level - Check ........195 Transmission Oil Level – Check ......196 Parking Brake - Inspect ........196 Hydraulic Oil Level – Check ......... 197 NOTICE Never exceed the Maintenance Intervals specified in the manual.
  • Page 183 Maintenance Section Every 1000 Service Hours or 6 Months Replace PCV Valve and breather element - Change (LP, Gasoline and Dual Fuel Engines) ................237 Hydraulic Return Filter, Breather & Strainer - Check, Change ..............220 Transmission Oil, Oil Filter & Strainer - Check, Every 8000 Service Hours or 48 Months Clean, Change ............
  • Page 184 Maintenance Section Quick Reference to Maintenance Schedule FIRST 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 (G424P(E) Engine Only) Coolant Level...
  • Page 185 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Inspect Engine for Exhaust Leaks Inspect Engine for Fluid Leaks Inspect Foot Pedal Operation Inspect for Intake Leaks (G424P(E) Engine Only) Inspect Ignition System (LP, Dual Fuel Engine Only) Inspect Mixer Assembly (GCT K25 / G424P(E) Engine Only)
  • Page 186 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Tires and Wheels Inspect, Check Transmission Oil Filter Change Transmission Oil Level Check Check, Clean, Transmission Oil, Oil Filter & Strainer 201,221 Change Universal Joint Inspect Walk-Around Inspection Inspect Water Separator (Diesel Engine Only) Check, Drain...

  • Page 187: 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 188: 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 189 Maintenance Section Relays are identified as follows: Circuit Breaker 1. FWD 2. C/SPEED 3. LP FUEL 4. LAMP 5. REV 6. NEUTRAL 7. FUEL PUMP 8. STARTER 9. MAIN 10. ETC Raise the hood and seat assembly. Make sure the support cylinder securely holds the hood open.

  • Page 190: Battery Terminal - Clean, Inspect

    Maintenance Section 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 with batteries.

  • Page 191: Priming The Fuel System

    Maintenance Section Priming the Fuel System Water Separator (Diesel Engine Only) - Check, Drain D24A Diesel Engine Only D24A Diesel Engine Only In any one of the following cases, the fuel system 1. If the engine check lamp indicates any fault requires priming.

  • Page 192: 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 193: Test Fuel System For Leaks(Lp And Dual Fuel Engines Only)

    Maintenance Section Test Fuel System for Leaks(LP and LP Regulator (LP and Dual Fuel Dual Fuel Engines Only) Engine Only) - Tar Drain GCT K25 Engine Only 1. Start and warm up the engine using LPG. 2. Close tank cock, and then consume LPG in fuel line.

  • Page 194: Tires And Wheels - Inspect, Check

    Maintenance Section Tires and Wheels - Inspect, Check Carriage Roller Extrusion – Adjust 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 195: 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 Drive Axle Oil Level - Check 1.

  • Page 196: Coolant Level - Check

    Maintenance Section 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 radiator WARNING cap. Observe coolant level in the expansion bottle. If necessary, add coolant to bring the coolant to the At operating temperature, the engine coolant is appropriate line on the expansion bottle.

  • Page 197: 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 198: Mast Channels - Lubricate

    Maintenance Section Mast Channels – Lubricate The channels on the roller-type mast require a break-in period. Apply a light film of lubricant on the Inspect the cooling system for leaks, worn hoses channels where the rollers ride. This will prevent and debris buildup.

  • Page 199: 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. Start and operate the lift truck until the engine reaches normal operating temperature.

  • Page 200: Hydraulic Oil Level - Check

    Maintenance Section Parking Brake Hydraulic Oil Level – Check WARNING NOTE: The parking brake is required to be adjusted to hold the lift truck with capacity At operating temperature, the hydraulic tank is load on a 15% grade. hot and under pressure. If there is a 15% grade in your workplace, engage a capacity load and drive over to Hot oil can cause burns.

  • Page 201: 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. Replenishing Engine Oil Engine Oil & Filter (Diesel Engine Only) - Change WARNING The engine oil in a new engine becomes...
  • Page 202 Maintenance Section • Tightening Torque NOTICE Part Tightening Torque Servicing of the engine oil and oil filter element will Drain plug 3 kgf largely affect the engine performance as well as the • engine life. Engine oil and filter element must be changed after •...
  • Page 203 Maintenance Section 6. Remove the oil drain plug (Figure 5-2, (1)) from WARNING the engine oil pan. Allow oil to drain. NEVER overfill the engine with engine oil. 7. After all oil has been drained from the engine, ALWAYS keep the oil level between the upper reinstall the oil drain plug (Figure 5-2, (1)) and and lower lines on the oil cap/dipstick.

  • Page 204: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

    Maintenance Section Transmission Oil, Oil Filter & Remove the floor mat and the floor plate. Strainer - Check, Clean, Change Remove and discard the oil filter. WARNING Wipe off the filter base. Make certain that all of the old seal is removed. Hot oil and components can cause personal injury.

  • Page 205: 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 206: Parking Brake Adjusting

    Maintenance Section WARNING To prevent personal injury, the operator MUST be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move. Parking Brake Adjusting Park the lift truck on a level surface, lowered the forks, shift the transmission to NEUTRAL and shut OFF the engine and block the wheels securely.

  • Page 207: 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. -204-...

  • Page 208: 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. Engine Oil & Filter – Change DI/D24NAP, TIER-4 1.

  • Page 209: Air Intake System - Check, Clean

    Maintenance Section DI/D24NAP, TIER-4 Air Intake System - Check, Clean GCT/K25, TIER-3 13. Stop the engine and measure the oil level. Maintain the oil level to the FULL mark on the dip stick. 14. Close hood and seat assembly -206-...
  • Page 210 Maintenance Section To service the air cleaner, raise the hood and seat Air Intake System - Check, Clean assembly. Make certain the support cylinder securely holds the hood open. Loosen the cover Precleaner (If Equipped) latches and remove the cover. NOTICE Never service precleaner with the engine running.
  • Page 211 Maintenance Section Water-280kPa (40 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 212: Belts - Check, Adjust

    Maintenance Section Belts - Check, Adjust Mast Hinge Pin – Lubricate Typical Example Typical Examp 1. Check the condition and adjustment of the belt. Lower the forks and tilt the mast forward. Correct adjustment allows 10 mm (3/8 inch) deflection under 110 N (25 lb) of force. Lubricate the two fittings for the mast hinge pins, one on each side of the mast.

  • Page 213: Crosshead Rollers - Inspect

    Maintenance Section Mast Pivot Eyes - Lubricate Typical Example Typical Example To adjust the cylinder rod extension, move the Lubricate two fittings for the mast pivot eyes, one spacer to the rear and loosen the pinch bolt on the on each side of the pin. clevis.

  • Page 214: Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate

    Maintenance Section Mast, Carriage, Lift Chains & Transmission Oil Filter – Change Attachments - Inspect, Lubricate WARNING Operate the lift, tilt and attachment controls. Listen Hot oil and components can cause personal for unusual noises. These may indicate a need for injury.

  • Page 215: Overhead Guard - Inspect

    Maintenance Section Overhead Guard – Inspect Check tightness of overhead guard mounting bolts at 95 N m (70 lb ft). • • Wash the strainer assembly in clean, non Check overhead guard for bent or cracked sections. flammable solvent and dry it. Install the strainer Have repairs made if needed.

  • Page 216: Steering Mechanism - Check, Lubricate

    Maintenance Section Steering Mechanism - Check, Steer Suspension – Inspect Lubricate Inspect the suspension mounting bolts. Tighten suspension mounting bolts, if necessary, to 240 ± Lubricate the steer axle king pins, total of four 30 N·m (180 ± 20 lb·ft). fittings.

  • Page 217: Inching & Braking Control Shaft - Lubricate

    Maintenance Section Inching & Braking Control Shaft - Fuel Filter (Diesel Engine Only) - Lubricate Change D24A Diesel Engine Only The fuel filter element must be replaced on a regular basis to prevent foreign materials from entering the diesel fuel system. Stop and cool down the engine.

  • Page 218: Engine Intake/Exhaust Valve Clearance - Adjustment (Gct K25 Engine Only)

    Maintenance Section Engine Intake/Exhaust Valve Clearance – Adjustment (GCT K25 Engine Only) WARNING Adjustment must be made with the vehicle in hot condition. 1. Warm engine until engine coolant temperature gauge shows nearly center, and then stop it. Figure 5-8 2.

  • Page 219: Inspect Vacuum Lines And Fittings (Gct K25/G424P(E) Engine Only)

    Maintenance Section Inspect Vacuum Lines and Fittings PCV Valve System - Inspect, Clean (GCT K25/G424P(E) Engine Only) (GCT K25/G424P(E) Engine Only) 1. Visually inspect vacuum lines and fittings for GCT K25 LP and Duel Fuel Engines physical damage such as bittleness, cracks and kinks.

  • Page 220: Fuel Filter (Diesel Engine Only) - Change

    Maintenance Section 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. 1. Stop the engine and allow it to cool. 2.

  • Page 221: Governor Lever And Engine Speed Control (Diesel Engine Only) - Check, Adjust

    Maintenance Section 16. Clean the fuel filter mounting surface (Figure Governor Lever and Engine Speed 5-15, (10)) and apply a small amount of diesel Control (Diesel Engine Only) - fuel to the gasket of the new filter. Check, Adjust 17. Install the new fuel filter (Figure 5-14, (2)) by turning it to the right (Figure 5-14, (4)) until it contacts the mounting surface.

  • Page 222: Wheel Bolts & Nuts - Inspect

    Maintenance Section Wheel Bolts & Nuts – Inspect Inspect Tightness Steer Wheels Typical Example Inspect tightness of wheel bolts in a sequence opposite each other 110 N·m (75 lb·ft). Drive Wheels Typical Example Inspect tightness of wheel nuts in a sequence opposite each other to 610 N·m (450 lb·ft).

  • Page 223: 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 224: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

    Maintenance Section Check for Equal Tension Transmission Oil, Oil Filter & 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 225 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 226: 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 Remove the primary air cleaner element. See topic “Servicing Filter Element.”...

  • Page 227: Inspect Coolant Hoses (Lp, Dual Fuel Engine Only)

    GCT K25 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 228: Inspect Mixer Assembly (Gct K25 / G424P(E) Engine Only)

    Maintenance Section Inspect Mixer Assembly (GCT K25 / Engine Valve Lash (Diesel Engine 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 229: Every 1500 Service Hours Or 9 Months

    Maintenance Section Every 1500 Service Hours or 9 Months Inspect Ignition System (LP, Dual Replace Spark Plugs (LP, Dual Fuel Fuel Engine Only) Engine Only) 1. Disconnect Battery Cables. 1. Disconnect Battery Cables. 2. Remove and inspect the spark plugs. Replace 2.

  • Page 230: 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 231: 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 procedure. 4. Remove the locknut, lock washer and flat Engine Valve Lash (Diesel Engine washer.

  • Page 232: 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 233 Observe the grease of the wheel hub inside. Add grease if necessary. Wheel bearing reassembling Consult your DOOSAN lift truck dealer for the proper wheel bearing reassembling procedure. Packing of bearings and adjustment procedure must be made by a trained mechanic or dealer personnel.

  • Page 234: 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 235 Maintenance Section 3. Open the radiator drain valve. Allow the coolant GCT K25 Engine to drain into a suitable container. Drain the recovery bottle. 1. Loosen the air relief plug on top of the water pump. Air Relief Plug 2. Open the radiator cap and infuse the cooling water.

  • Page 236: Forks - 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 Check the angle between the upper face of the Dealer for further information. blade and the front face of the shank. The fork...
  • Page 237 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.

  • Page 238: 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 Clean battery outer surfaces with a mixture of baking soda and water.

  • Page 239: Replace Oxygen Sensor (Lp, Dual Fuel Engine Only)

    Maintenance Section G424P(E) Engine Replace Oxygen Sensor (LP, Dual Fuel Engine Only) GCT K25 Engine When indicated by MIL, replace oxygen seasor on the exhaust manifold and oxygen sensor on muffler assembly. When indicated by MIL, replace oxygen seasor on 1.

  • Page 240: Checking The Tmap Sensor (G424P(E) Engine Only)

    Maintenance Section Checking the TMAP Sensor Replace PCV Valve and breather (G424P(E) Engine Only) element - Change (LP, Gasoline and Dual Fuel Engines) 1. Verify that the TMAP sensor (F) is mounted G424P(E) Engine tightly into the manifold adapter (E), with no leakage.

  • Page 241: 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 242: 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 243: Index

    Index Section Center of Gravity (CG) ..........21 Index Changing From Gasoline to LP – Gas....84 Changing From LP to Gasoline ......84 Changing LP Tanks ..........77 Changing Primary Element ........223 Changing Secondary Element ......223 12 Months Inspection ........... 168 Chassis Pivot Eyebolts - Lubricate ......
  • Page 244 Index Section Dual Fuel System ............84 Fuel Filter (Diesel Engine Only) - Change .. 214,217 Fuel Filter (LP Engine Only) ......... 227 Fuel Lines & Fittings - Check ....... 224 Fuel Selector Switch (GCT K25/G424P(E) Dual Fuel Only) ................. 72 Fuel Specifications ..........
  • Page 245 Index Section Improper Modification or Repair ......166 LP Regulator/Converter Inspection (LP, Dual Fuel Inching & Braking Control Shaft - Lubricate ..214 Engine Only) ............224 Inching into Loads ..........155 LP Specifications ........... 175 Inching ..............88 Lubricant Information ..........176 Index ..............
  • Page 246 Index Section Starting the Engine..........81 Starting the Lift truck ..........12 Steer Suspension – Inspect ......... 213 Parking Brake - Inspect ........196 Steer Wheel Bearings - Reassemble ....228 Parking Brake - Test, Adjust ......202,213 Steering Mechanism - Check, Lubricate ..... 213 Parking Brake Adjusting ........
  • Page 247 Index Section Walk - Around Inspection - Inspect ..... 194 Walk - Around Inspection ........79 Warning Signs and Labels ........5,17 Water Separator (Diesel Engine Only) - Check, Drain ..............188 Weight Scale Option (Load Cell Type)....58 Wheel Bolts & Nuts – Inspect ......219 When Required .............

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