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Operation & Maintenance Manual

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1. 30 32 34 36 Stability and Center of 21 Starting From 24 12 Volt External Source 67 Starting the Engine centena Starting the Lift Truck Starting with Jumper 67 Steer Susension 170 Steer Wheel Bearings Reassemble 181 Steering Column Tilting Angle Adjustment 53 Steering Mechanism Check Lubricate 166 Storage Information csse 118 1 Test Fuel System for Leaks LP Engine Only 141 Testing Fuel Lock off Operation LP Engine Only 180 Table of Contents eene 1 TillGontroli u eee tee 59 Tilt Cylinders Check Adjust Lubricate 169 Tire Inflation Information sss 125 Tire Inflation Pressures Adjustment 125 Tire Shipping 125 Tires and Wheels Inspect 144 Tires Inflation ilo ACjUSt nina ue eite To Operate the Lift Truck After a Long Time Storage 118 Torque Specifications sss 126 Torques for Bolts and Nuts With Standard Threads 126 Torques for Metric Fasteners
2. 160 Engine Oil amp Filter LP Engine Only 163 Hydraulic Oil Level Check E Drive Axle Oil Level Check Mast Carriage Lift Chains amp Attachments Eis Lubricate mE 165 Steering Mechanism Check Lubricate 166 Battery Terminal Clean Inspect 167 Wheel Bolts amp Nuts 167 Every 500 Service Hours or 3 Months Belts Diesel E G Only Check Adjust 168 Mast Hinge Pins Lubricate Tilt Cylinders Check Adjust Lubricate Crosshead Rollers Inspect Transmission Oil Filter 2 Speed Only Parking Brake Test Adjust 169 Drive Axle OCDB Change Horn and Lights If Equipped Check Overhead Guard Inspect Steer Susension Inspect Universal Joint Inspect Lubricate Engine Oil amp Filter Diesel Engine Only Change 171 Inspect Vacuum Lines and Fittings G643 E Engine DAR 171 Fuel Trim Valve FTV Inspection G643E Engine pp Cm 171 Inspect Electrical System G643E Engine only 171 Every 1000 Service Hours or 6 Months Carburetor LP Gas Engine Only jud Clean Fuel Filter Check Clean Change 172 Air Intake System Change 172 Inspect Coolant Hoses LP Engines Only
3. 157 169 Parking Brake 59 Drakes eater ced 8 Parking the Lift Truck sess Power Shift Transmission Drive Axle Precleaner If Equipped Pressure Air Pressure 2 2222222 T Prestart Conditions sss 66 Priming the Fuel System Diesel Engine Only 140 Product Description conte 107 R Radiator Cap Clean Change Reading Diagnostic Fault Codes Refill Capacitios ctt 02 74 eee esce te tentntatatatanaua 60 Replace LP Fuel Filter Element LP Engine Only Replace Oxygen Sensor G643E Engine Only 186 Replace Valve and breather element Change LP Engine Only roce recon 186 Replace Spark Plugs LP Engine Only 178 S Safety Rules de onini aene 23 copa pe aan 2 5 Seat Check 142 Seat Adjustment sss 17 55 Seat Switch 52 Serial Number Service Foot Brake 58 Service Indicator tre 148 Servicing Filter Element sss 160 Shoe Brake 155 164
4. 2222222 2 162 Checking the TMAP Sensor LP Engine Only 185 Circuit Breaker iere ec 55 143 Clean Outside of Radiator 145 Clean Pressure 2 2 2 145 Cleaning Primary Filter Elements 162 Coolant Information esee Coolant Level Check Coolant Water Cooling System Clean Change Cooling System Specifications Crosshead Rollers Crushing or Cutting Prevention 14 Index Section D Daily Inspection Diagnostics 108 Diesel Engine 171 Diesel Engine 60 Diesel Engine esses 66 172 Diesel Specifications 2 22 22 2 130 Displaying Fault Codes DFC From SECM Memory Draining the Water From the Fuel Filter Drive Axle Oil Drive Axle Oil OCDB Change Drive Axle Oil Shoe Brake Only Change 178 Drive Axle Oil Level 164 Drive Axle aie
5. Mast Carriage Lift Chains amp Attachments Change LP Replace PCV Valve and breather element Engine Only Replace Spark Plugs LP Engine Only Check Lubricate Steer Susension Inspect Steer Wheel Bearings Reassemble Check Lubricate Seat Steering Mechanism Test Fuel System for Leaks LP Engine Only Testing Fuel Lock off Operation LP Engine Only Check Adjust Tilt Cylinders Lubricate Tires Wheels Inspect Check Transmission Oil amp Filter 3 Speed Only Change Transmission Oil amp Oil Filter Change Transmission Oil 2 Speed Only Change Transmission Oil Filter 2 Speed Only Change Transmission Oil Level Check Inspect Lubricate Walk Around Inspection Inspect Wheel Bolts amp Nuts Inspect Universal Joint 139 Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Engine Valve Lash Diesel E G Only Check Adjust NOTICE The valve clearances are to be adjusted at the times of the following situations e When the engine is overhauled and the cylinder heads are disassembled e When severe noise comes from valve train e When the engine is not normally operated even though there is no trouble in the fuel system A WARN
6. CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK Check that Post catalyst O2 sensor connections are OK O2 signal Pin 3 to SECM Pin B19 2 Pin 2 HEATER GND to SECM DRVG GNG Pins A16 B17 O2 Pin 1 HEATER PWR to Post O2 Heater Relay Relay pin 87 This relay turns on only after engine has been GasPostO2NotActive running for some time and seal Hos calculated that water condensation in Post catalyst O2 sensor 1 TumOnMil 742 inactive on LPG open O2 2 DisableGas exhaust has been fenus by heat Post O2 Heater Relay has SECM sensor signal or heater Post O2Ctrl leads defective O2 sensor DRVP 12V applied to the relay coil power The relay coil ground is controlled by SECM Pin A20 to activate the relay to flow current through the post O2 heater Verify O2 sensor heater circuit is operating by measuring heater resistance 2 10 0 40 O2 Pin 2 HEATER GND to Pin 1 HEATER PWR 743 Reserved GasO2FailedLean Check for vacuum leaks 751 Pre catalyst O2 sensor 1 TurnOnMil Check fuel trim valves e g leaking indicates extended lean 2 DisableGas O2Ctrl valve or hose operation on LPG Check for missing orifice s Correct other faults that may contribute to 752 e g faults pertaining to fuel trim GasPostO2FailedLean valves Pre Cat 2 Post Cat 2 Pre catalyst O2 sensor 1 sensor 752 indicates extended lean 2 DisableGas Check for vacuum leaks operation on LPG Post O2Ctrl C
7. 173 LP Regulator Converter Inspection LP Engine Only Fuel Lines amp Fittings Check Inspect Mixer Assembly LP Engine Only 173 Inspect Throttle Assembly LP Engine Only 173 Hydraulic Oil Return Filter Strainer amp Breather Check Clean 174 Transmission Oil amp Filter 3 Speed Only Change Transmission Oil 2 Speed Only Change Lift Chains Test Check Every 1500 Service Hours 9 Months Drive Axle Oil Shoe Brake Only Change 178 Inspect Ignition System LP Engine Only 178 Replace Spark Plugs LP Engine Only 178 Replace LP Fuel Filter Element LP Engine Only 179 Tesing F Fuel Lock off Operation LP Engine Only 180 Every 2000 Service Hours or Yearly Steer Wheel Bearings Reassemble Cooling System Clean Change Fork Inspect 212183 Every 2500 Service Hours 15 Months Inspect Battery 185 Checking the TMAP Sensor LP Engine Only 185 Inspect for Intake Leaks LP Engine 186 Replace PCV Valve and breather element Change LP Engine Only 186 Replace Oxygen Sensor G643E Engine Only 186 137 Maintenance Section Maintenance Section lt lt
8. 133 E Electronic Controlled Spark Ignition Engines 70 Engine Oil amp Filter Diesel Engine Only Change 171 Engine Oil amp Filter LP Engine Only Change 163 Engine Oil amp Oil Filter Diesel E G Only Change T ELE 152 Engine Oil DEO and 132 Engine Oil Level 147 Engine Valve Lash Diesel E G Only Check Environment Management Environment Protection sss Every 10 Service Hours or 147 Every 1000 Service Hours or 6 Months 172 Every 1500 Service Hours or 9 Months 178 Every 2000 Service Hours or Yearly 181 Every 250 Service Hours or Monthly 160 Every 2500 Service Hours or 15 Months 185 Every 500 Service Hours or Months 168 F Fatigue 122 POTN OS e 107 Fire or Explosion Prevention 15 First 250 Service Hours or a Month 159 First 50 100 Service Hours or a Week 152 First Installation ueritas Fluid Penetration Foreword Fork Inspect Fork Inspection 123 Fuel Filter Check Clean Change
9. 2150 International Standards organization Maintenance Section Cooling System Specifications Coolant Information NOTE The following information is generic and valid for lift trucks Engine operating temperatures have increased to improve engine efficiency This means proper cooling system maintenance is especially important Overheating overcooling pitting cavitation erosion cracked heads piston seizures and plugged radiators are classic cooling system failures In fact coolant is as important as the quality of fuel and lubricating oil NOTICE DOOSAN recommends that the coolant mixture contain a minimum of 3096 antifreeze or equivalent Never add coolant to an overheated engine engine damage can result Allow the engine to cool first All water is corrosive at engine operating temperature The cooling system should be protected with a 3 to 6 concentration of liquid supplemental coolant additive at times regardless of the concentration of antifreeze Excessive supplemental coolant additive greater the recommended 6 together with concentrations of antifreeze greater than 6596 can cause deposits to form and can result in radiator tube blockage overheating and or water pump seal damage If the machine is to be stored in or shipped to an area with freezing temperatures the cooling system must be protected to the lowest expected outside ambient temperature The engine cooling system i
10. lt A Indicates travel direction and gear selection See the figure below for more detailed information B Indicates normal operation and error codes For a list of error codes see Transmission Error Codes in When Required maintenance section NOTE Most codes are only two digits C Indicates that error codes have occurred and are stored 0 Indicates that operation must be stopped immediately to prevent damage to transmission and hazardous operation condition FORWARD INDICATOR GEAR RANGE INDICATOR BARS REVERSE INDICATOR The gear range indicator bars will indicate which gear is selected by displaying the corresponding number of bars The forward and reverse indicator bars will be OFF when the transmission is in MANUAL MODE When transmission is in AUTOMATIC MODE all the gear range indicator bars and both travel direction indicators will be ON Automatic Transmission Switch 3 Speed Only Automatic speed range FORWARD 3 speeds REVERSE 3 speeds MAN When this switch is in MAN manual position travel mode is switched to MANUAL and allows operator to choose speeds manually A 1 When this switch is in A 1s automatic 1 position gears are started from 1 speed and changed AUTOMATICALLY to the appropriate speed up to the limit set by the gear ratio according to travel load and engine rpm 2 When this switch is in
11. 281 TPS1AdaptLoMax Learned closed throttle end of TPS1 sensor range higher than expected None N A 282 TPS2AdaptLoMax Learned closed throttle end of TPS2 sensor range higher than expected None N A 291 TPS Sensors Conflict TPS sensors differ by more than expected amount NOTE The TPS is not serviceable item and can only be repaired by replacing the DV EV throttle assembly 1 TumOnMil 2 Engine Shutdown Fault actions shown are default values specified by the OEM Perform checks for DFCs 241 amp 242 93 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1 Manifold Absolute Pressure sensor GND sensor input is low normally TMAP Pin 3 to SECM Pin B24 331 setif the TMAP pressure None XDRP 5 Vdc 33 signal wire has been Check the MAP sensor by disconnected or shorted to disconnecting the TMAP connector and ground or the circuit has measuring at the sensor opened to the SECM TMAP Pin 1 GND to Pin 4 pressure signal KPA 2 4kO 8 2 TMAP Pin 3 power to Pin 4 pressure signal KPA 3 4kO 8 2 Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal
12. 105 Lift Truck Parking Lift Truck Shipping Lift Truck Stability Base Litt Truck Stability 5 canem 21 Lifting Drums or Round Objects 115 Lifting the Load 112 Literature Information eese 2 Load Backrest Must Be In Place Warning 7 LONG Time Storage tdt 118 LP Engine Crankcase 163 IB DI E 66 LP Regulator Converter Inspection LP Engine Only 173 LP Specifications necne 131 Lubricant Information ses 132 Lubricant 132 Lubricant Viscosities and Refill Capacities 135 Lubricant Viscosities 2 2 135 Lubricate Carriage Side Rollers 166 Lubricate Mast Side Rollers 166 Lubricating Grease sss 134 M Machine Lifting and Tiedown Information 119 Maintenance and 124 Maintenance Information 14 Maintenance 1 9 196 Index Section D S 3 Make proper antifreeze additions 129 Manual Mode Fail Safe mode Mast 46
13. 57 Avoiding Lift Truck 21 B Basic Troubleshooting sess 72 Battery Terminal Clean Inspect 167 Before Operating the Lift 12 Before Starting the Engine Before Starting the Lift 11 Before Storage teet eeets 118 Belts Diesel E G Only Check Adjust 168 Bent or Twisted Forks 122 Bleeding the Fuel 5 140 Brake OCDB 146 Index Section Capacity Chart With Side Shifter 41 42 Capacity Chart Without Side Shifter 39 40 Capacity Chart Without Side Shifter 40 Carburetor LP Gas Engine Only Adjust Clean M 172 Carriage Roller Extrusion Adjust 145 Causes of Fork Failure sess 122 Center of Gravity CG sss 21 Changing LP 22 2221 61 Changing Primary 172 Changing Secondary Element 172 Chassis Pivot Eyebolts Check for Equal Tension Check Inflation and Damage Checking
14. Every 500 Service Hours or 3 Months D N Put a small amount of clean oil on the seal gasket on the new filter Install the filter by hand When the filter contacts the base tighten it an additional 3 4 turn Close the hood and seat assembly Open the access door in the floor plate Typical Example 8 10 11 12 D50 60 70S 5 2 Speed G50 60 70S 5 Remove the stick filler cap Fill the compartment with oil See Refill Capacities Install the dip stick filter cap Startthe engine With the service brake applied and engine at low idle shift the transmission to forward and reverse to fill the clutches Shift the transmission into NEUTRAL Engage the parking brake the oil Loosen dipstick counter clockwise remove and clear it Insert the oil dipstick slowly into the oil level tube until contact is obtained and pull the dipstick out again 154 13 14 15 16 When the oil temperature is around 40 C the marking on the oil dipstick must be lying above the cold start mark COLD When the oil temperature is around 80 C the oil level must be lying in the zone HOT Install the oil dipstick again and tighten it clockwise Check for oil leaks at the filter and drain plug Stop the engine 155 Maintenance Section Drive Axle Oil Change Park the lift truck on a level surface parking brake applied transmission in
15. spark module Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details ETC_Sticking Check for debris or obstructions inside Electronic Throttle Control is the throttle body sticking This can occur if the Perform the throttle test using the throttle plate butterfly valve Service Tool and re check for fault inside the throttle bore is Check throttle plate shaft for bearing sticking The plate sticking wear can be due to some type of Check the ETC driver wiring for 461 obstruction a loose throttle 1 TURON open circuit 26 plate or worn components 2 EngineShutdown SECM Pin A17 to ETC Pin 1 shaft bearings 3 CutThrottle SECM Pin A18 to ETC Pin 4 NOTE The throttle Check the ETC internal motor drive by assembly is nota disconnecting the throttle connector serviceable item and can and measuring the motor drive only be repaired by resistance at the throttle replacing the DV EV TPS Pin 1 DRIVER to throttle assembly Pin 4 DRIVER 3 0 4 0Q Check the ETC driver wiring for an ETC_Open_Fault open circuit Electronic Throttle Control SECM Pin A17 to ETC Pin 1 Driver has failed normally SECM Pin A18 to ETC Pin 4 471 set if either of the ETC driver N Check the ETC internal motor drive by 4 signals have opened disconnecting the throttle connector become disconnected and measuring the motor drive electronic throttle or SECM is resistance at the throt
16. 172 Fuel Filter 179 Fuel Lines amp Fittings 173 Fuel 130 Fuel Sulfur Content esses 130 Fuel Tank Filter Cap amp Screen Clean 141 142 Fuel Trim Valve FTV Inspection G643E Engine Fuses Bulbs amp Circuit Breaker Change Reset 143 G G643 Electronic Controlled Engines lf Eguipped net aint 71 643E Engine eerte 70 General Description csse 71 General Fuel Information 130 General Hazard Information 10 General Warnings to 6 H Hand Placement Warning Horn and Lights If Equipped Check 170 How to Survive Tipover If Operator Restraint System 20 22 28 Hydraulic 132 Hydraulic Level 164 Hydraulic Oil Return Filter Strainer amp Breather Check Clean Change 174 Hydraulic Return Filter Change 159 1 Identification Lift Capacity and Attachment Plate 45 If Optional Suspension S
17. Retainer pins when struck with force can fly out and injure nearby persons Make sure the area is clear of people when driving retainer pins Wear protective glasses when striking a retainer pin to avoid injury to your eyes Chips or other debris can fly off objects when struck Make sure no one can be injured by flying debris before striking any object Falling Objects Protective Structure FOPS This is an attached guard located above the operator s compartment and secured to the lift truck To avoid possible weakening of the Falling Objects Protective Structure FOPS consult a DOOSAN dealer before altering by adding weight to welding on or cutting or drilling holes into the structure The overhead guard is not intended to protect against every possible impact The overhead guard may not protect against some objects penetrating into the operator s station from the sides or ends of the lift truck The lift truck is equipped with an overhead guard and FOPS as standard If there is a possibility of overhead objects falling through the guard the guard must be equipped with smaller holes or a Plexiglas cover Any altering done that is not specifically authorized by DOOSAN invalidates DOOSAN s FOPS certification The protection offered by this FOPS will be impaired if it has been subjected to structural damage Structural damage can be caused by an overturn accident by falling objects etc Do not mount any item such a
18. 13 8 11 2 2000 275 1480 200 11 Newton meter is approximately the same as 0 1 kg Torques for Taperlock Studs Thread Size Standard Taperlock Stud Torque 5 6 716 45 10 65 10 48 7 110 20 80 15 1 2 5 8 34 78 1 8 500 700 370 50 3 8 750 90 550 65 870 100 640 75 11 Newton meter is approximately the same as 0 1 127 Maintenance Section Torques for Metric Fasteners NOTICE Be very careful never to mix metric with U S customary standard fasteners Mismatched or incorrect fasteners will cause lift truck damage or malfunction and may even result in personal injury Original fasteners removed from the lift truck should be saved for reassembly whenever possible If new fasteners are needed they must be of the same size and grade as the ones that are being replaced The material strength identification is usually shown on the bolt head by numbers 8 8 10 9 etc The following chart gives standard torques for bolts and nuts with Grade 8 8 NOTE Metric hardware must be replaced with metric hardware Check parts book for proper replacement Thread Size Metric Standard Torque Nm tbat M 1224 6 8 M10 55 10 41 7 16 220 30 160 22 330 50 M20 450 70 M24 775 100 570 75 M30 1600 200 1180 150 M36 2700 400 2000 300 11 Newton meter 1 Nem is approximately the same as 0 1
19. IATRangeHigh wiring for a shorted circuit Intake Air Temperature TMAP Pin 2 to SECM Pin B12 signal Sensor Input is High TMAP Pin 1 to SECM Pin B1 381 normally set if the IAT TumOnMil sensor GND 38 temperature sensor wire has To check the IAT sensor of the TMAP been disconnected or the disconnect the TMAP connector and circuit has opened to the measure the resistance SECM Resistance is approx 2400 ohms at room temperature IAT IR Fault Check connections to TMAP sensor 391 Intake Air Temperature not None Check that TMAP sensor is properly mounted to manifold Fault actions shown are default values specified by the OEM 95 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A9 EST1 to OEM ignition EST1 Open System See application note 41 penest o TOM connecter defective spark module Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details Check coil driver wiring and connector for shorts EST Short SECM Pin A9 to ignition module Pin D 4 pin connector ESTI Output Shorey Verify GND on ignition module Pin 431 low EST1 signal shorted to TurnOnMil of both connectors ground or power or defective
20. It also prevents damage to the half shaft excessive tire wear and heat to the transmission Features Product Adaptable To ASC 200 D50 60 70S 5 2 Speed ASC 201 G50 60 70S 5 1 2 speed auto shift control 2 Prevent downshifting at high speed 3 Inhibit selecting direction at high speed outside of the design parameters Adjustments B10002P Adjustment Switch Low High Shift Point SW1 ASC 200 201 allows you to set the 2 speed Auto Gear Shift Point the maximum travel speed at which the Auto Shift Controller up shift or down shift the transmission automatically according to the vehicle speed For adjustment of 2 speed Auto Gear Shift speed the SW1 switch is used on the printed circuit board SW1 Low High SHIFT Tow Speed Auto Gear Shift Point Vehicle Speed Notch 200 ASC 201 0 2 5kmh 1 55mph 1 3 0kmAh 1 86mph 2 3 5km h 2 17mph 5 57kmh 3 46mph 3 4 0kmh 2 49mph 4 4 5km h 2 80mph 5 5 0km n 3 11mph 6 17km h 3 84mph 6 5 5kmh 3 42mph 6 78kmh 4 21mph 7 6 Okm h 3 73mph 7 29kmh 4 53mph 8 6 5km h 4 04mph 7 89kmh 4 90mph 9 7 0km h 4 35mph 840kmh 5 22mph For example if SW1 is put 5th notch the 2 speed auto gear shift speed will be 5 0km h 3 11mph in ASC 200 or 6 17km h 3 84mph in ASC 201 The factory setting value as a default for SW1 of each model is as follows Product Notch V
21. NOTE See the previous section Carriage Roller Extrusion in When Required for proper inner mast height 1 Lift the inner mast and put blocks under the inner mast to release the tension from the lift chains 2 Adjust nut 6 to make inner mast bottom flush with outer mast bottom 3 Make adjustment anchor nut 6 for equal chain tension 4 Raise the inner mast and check equal chain tension If not equal repeat the same procedure above step 1 through step 3 5 Put LOCTITE No 242 tread lock on the threads of the anchor nuts 6 after the adjustment is completed Maintenance Section Every 1500 Service Hours or 9 Months You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Drive Axle Oil Shoe Brake Only Change See topic Drive Axle Oil Change in First 50 100 Service Hours or a Week Inspect Ignition System LP Engine Only 1 Disconnect Battery Cables 2 Remove and inspect the spark plugs Replace as required 3 Test secondary cables with an Ohmmeter If maximum resistance is higher than 25 kOhms repair and or replace 4 Remove distributor cap and perform visual inspection Replace cap and rotor if corrosion is found on the contacts 5 Inspect the ignition coil for cracks and heat deterioration Visually inspect the coil heat sink fins If any fins are broken replace as requir
22. Repair or replace the positioning locks on hook type forks Repair or replace most fork retention devices used with other fork types A fork should be load tested before being returned to service on completion of repairs authorized and done in accordance with the manufacturer s recommendations Most manufacturers and standards require the repaired fork to be tested with a load 2 5 times the specified capacity and at the load center marked on the fork arm With the fork restrained in the same manner as its mounting on the lift truck apply the test load twice gradually and without shock Maintain the test for 30 seconds each time Check the fork arm before and after the second application of the test load It shall not show any permanent deformation Consult the fork manufacturer for further information as may be applicable to the specific fork involved Testing is not required for repairs to the positioning lock or the markings 124 Tire Inflation Information Tires Inflation A WARNING Personal injury or death could result when tires are inflated incorrectly Use a self attaching inflation chuck and stand behind the tread when inflating a tire Proper inflation equipment and training in using the equipment are necessary to avoid overinflation A tire blowout or rim failure can result from improper or misused equipment Always remove deflate all air from a single tire and from both tires on a dual asse
23. Sensor reference voltage 2 EngineShutdown B1 XDRG GND XDRP too low Verify transducer power at ETC with a multimeter ETC Pin 3 XDRP PWR to ETC Pin 2 XDRG GND Verify transducer power to the foot pedal with a multimeter 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 SECM with a multimeter 561 2ensVoltRangeHigh 1 TumonMi SECM Pin B24 5 Vdc to SECM Pin 56 Sensor reference voltage 2 EngineShutdown B1 XDRG GND XDRP too high Verify transducer power at ETC with multimeter ETC Pin 3 XDRP PWR to ETC Pin 2 XDRG GND Verify transducer power to the foot pedal with a multimeter Usually associated with additional ETC HardOverspeed faults 571 Engine speed has exceeded 2 1 Check for ETC Sticking or other ETC 57 the third level 3 of 3 of faults overspeed protection Verify if the lift truck was motored down a steep grade Fault actions shown are default values specified by the OEM 98 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK Usually associated with additional ETC MediumOverspeed 1 TumOnMil faults 572 Engine speed has exceeded 2 MediumRevLimit Check for ETC Sticking or other ETC the second level 2 of 3 of faults overspeed protection Verify if the lift truck was
24. boost battery Make final connection of negative cable to the stalled truck frame not battery negative post away from battery fuel or hydraulic lines or moving parts Start the engine on the boost lift truck or energize the charging system on the auxiliary power source Wait a minimum of two minutes for the batteries in the stalled lift truck to partially charge Attempt to start the stalled engine Refer to section on Engine Starting Immediately after starting the stalled engine disconnect the jumper cables in reverse order Conclude failure analysis starting charging system of the stalled lift truck as required with the engine running and charging system in operation After Starting the Engine Observe all indicator lights and gauges frequently during operation to make sure all systems are working properly A WARNING If any light comes on have corrections made before operating truck 4 Q lt 4 eo 1 Alternator indicator light will be OUT normal operation If the light comes ON with the engine running the alternator is not charging Typical Example 2 Observe fuel gauge and service hour meter frequently to assure they are operating properly Observe the brake air pressure gauge and indicator light frequently if equipped while engine is running Air pressure indicator must be in the green rang
25. 1 signal to SECM Pin A1 711 i FTV1 Pin 2 power to SECM DRVP 71 has opened or shorted to TurnOnMil Pin A23 4 Check FTV1 for an open coil by disconnecting the FTV connector and measuring the resistance 26Q 20 Check FTV1 for an open wire or FTV connector being disconnected or signal LSDFault_Dither2 shorted to GND Dither Valve 2 Fault signal FTV2 Pin 1 signal to SECM Pin A2 712 has opened or shorted to TurnOnMil FTV2 Pin 2 power to SECM DRVP ground or power or defective Pin 23 dither 2 valve Check FTV1 for an open coil by disconnecting the FTV connector and measuring the resistance 26Q 20 LSDFault_CheckEngine Check Engine Lamp Fault Check Check Engine Lamp for 714 signal has opened or shorted None open wire or shorted to GND to ground or power or defective check engine lamp Fault actions shown are default values specified by the OEM 100 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d x CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK LSDFault CrankDisable Crank Disable Fault signal 715 has opened or shorted to None N A ground or power or defective crank disable relay Check fuel lock off valve for an open wire or connector being disconnected LSDFault LockOff or signal shorted to GND Fuel lock off Valve Fault Lockoff Pin B signal to SECM Pin A11 717 signal has opened or s
26. 1400 4 6 4294 12 75 G643E TIER 3 69 0 93 2450 294 217 1600 4 6 4294 foot hydraulic hand mechanical 12 75 12 75 G643E TIER 3 G643E TIER 3 69 0 93 2450 69 0 93 2450 294 217 1600 294 217 1600 4 6 4294 4 6 4294 hand mechanical o Power Shift 2 2 Power Shift 2 2 o a gt a a Power Shift Power Shift 2 2 2 2 56 35 General Section Specifications type Transmission CHRACTERISTICS 1 Manufacturer 2 MODEL Capacity at rated load center kg 4 electric diesel gasoline L PG 6 2 stand on rider seated 7 Trewpe eceushion p pneumatic S Wneespcdrwen number ftonirear DIMENSIONS 9 Lift with STD maximum fork height with rated load mm mm Forks thickness x width x length fork spacing minimum x maximum mm deg Overall 18 dimensions mm overhead guard height mm z 21 Turning radius minimum outside mm Load moment constant mm mm 23a mm PERFORMANCE 25 Speed mmis mmis ig WEIGHT 32 Total weight unloaded kg 33 Axle load with loaded front rear kg CHASSIS number of front rear Tires size front size rear mm 39 Tread width front rear mm Ground clearance mm service brake parking brake DRIVE van manufacturer model Ene KWihp pm N m b tyrpm 56 no speeds forward reverse 36 Genera
27. 4 Install cap assembly A WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause fire 5 Drain moisture and sediment from fuel tank as required by prevailing conditions 142 Seat Check Lubricate Typical Example Check the operation of the seat adjuster rod Make sure that the seat slides freely on its track Lightly oil the seat slider tracks if necessary Maintenance Section Fuses Bulbs amp Circuit Breaker Fuse amp Relay LP Engine Only Change Reset een 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 1 Relay 2 Fuse Remove the front cover of fuse box The fuses are Located on top of engine located under the cover Circuit Breaker Fuse Protects an electrical circuit from an overload Opens filament separates 1 Raise the floor mat if an overload occurs Typical Example LP Engine Truck 2 The main circuit breaker is located on the rear of the support for the controls Typical Example NOTE To reset circuit breakers push on the button The button should stay in if the breaker is reset If the button will not stay in or comes out shortly after reset have the circuits checked Check the fuses Use a flas
28. 632 22 3924 3958 23 2990 3020 23a 25 26 5 24 5 26 5 24 0 26 5 24 415 445 415 445 415 445 25 490 460 490 460 490 460 26 4908 4875 4875 28 39 4 34 1 30 3 30 8395 9085 9810 32 12010 1385 13430 1655 14820 1990 33 4270 4125 4145 4940 3985 5830 34 m T5 52515148 525451268 20 15841550 176 176 176 40 205 2 205 41 foot hydraulic foot hydraulic foot hydraulic 42 hand mechanical hand mechanical hand mechanical 43 24 75 24 75 24 75 45 DOOSAN DB58S DOOSAN DB58S 49 69 1 93 1 2400 69 1 93 1 2400 69 1 93 1 2400 50 323 238 1600 323 238 1600 323 238 1600 51 4 6 5785 4 6 5785 4 6 5785 52 14201004 4 2 05 Power Shift Power Shift Power Shift 55 2 2 2 2 2 2 56 33 General Section Specifications CHRACTERISTICS TIER 2 1 Manufacturer DOOSAN DOOSAN 2 MODEL G50S 5 G60S 5 3 Capacity at rated load center kg 5000 6000 4 Load center distance mm 600 600 5 Power type electric diesel gasoline LPG LPG LPG 6 Operator type stand on rider seated rider seated rider seated 7 Tire type c cushion p pneumatic p p 8 Wheels x driven number front rear 4 2 42 DIMENSIONS 9 Lift with STD maximum fork height with rated load mm 3000 3000 10 two stage mast free lift mm 205 205 13 Forks thickness x width x length mm 60x150x 1200 60 180 1200 fork spacing minimum x maximum mm 350x2032 410x2032 14 Tilt of mast forward backward deg 15 10 15 10 15 length to face of
29. Check foot pedal connector APP2 potentiometer malfunction MIL Only Improper APP2 reading may be due to dirt or oxidation on the sensor traces 69 Pedali ToPedal2Difference MIN power Limit Check foot pedal connector Measured APP2 pedal position signal is different than 1 signal 71 AFRTrimValveOutput Stored Fault Code Check FTV for an open wire or FTV connector being disconnected 87 Operation Section Table a 04 Diagnostic Fault Codes Flash Codes FTV duty cycle at high rich limit Expected fault when FIV connector is unplugged G643E only MIL Disable Adaptive learns DFC Probable Fault Action Corrective Action First Check 72 AFRTrimValveLowerDC Stored Fault Code Engine measured Air Fuel ratio at duty cycle at lower lean MIL Disable Adaptive the O2 sensor is excessively lean limit learns If LP fuel in LP tank is not enough G643E only this fault code can be set If LP tank is frozen this fault code can be set too It is not system trouble e Check for intake manifold leaks e Check balance line vacuum hose connection the regulator e Check N CA55 500 TR mixer for heavy end build up and operation see mixer section e Check N2001 secondary for operation or low primary pressure see N2001 Regulator section 73 AFRTrimValveUpperDC Stored Fault Code Engine measured Air Fuel ratio at the O2 sensor is excessively rich Check FTV connector w
30. Clean Change Fuses Bulbs amp Circuit Breaker Hydraulic Oil Return Filter Strainer amp Breather Hydraulic Return Filter Change Inspect Mixer Assembly LP Engine Only Inspect Battery System Inspect Coolant Hoses LP Engines Only Inspect Electrical System G643E Engine only Inspect Engine for Exhaust Leaks Inspect Foot Pedal Operation LP Engine Only 138 Maintenance Section Quick Reference to Maintenance Schedule SERVICES 50 100 Service Hours or a Week 250 Service Hours or a Month 250 Service Hours or a Monthly 500 Service Hours or 3 Months 1000 Service Hours or 6 Months 1500 Service Hours or 9 Months 2000 Service Hours or Yearly 2500 Service Hours or 15 Months 10 Service Hours or Daily When Required Inspect for Intake Leaks LP Engine Only Inspect Ignition System LP Engine Only Inspect Throttle Assembly LP Engine Only Inspect Vacuum Lines and Fittings G643 E Engine only Inspection Engine for Fluid Leaks Lift Chains Test Check Adjust LP Regulator Converter Inspection LP Engine Only Mast Channels Lubricate Mast Hinge Pins Lubricate Inspect Lubricate Overhead Guard Inspect Parking Brake Test Adjust Parking Brake Test Adjust Priming the Fuel System Diesel Engine Only Radiator Cap Clean Change Replace LP Fuel Filter Element LP Engine Only Replace Oxygen Sensor G643E Engine Only
31. DOWN on the service foot brake pedal to hold the lift truck until ready to move it 3 RELEASE the parking brake Typical Example 4 Select the direction of travel by PUSHING the directional lever FORWARD for forward direction or PULLING the lever BACK for reverse direction 5 Rotate the speed range control to first low speed range NOTE From a stopped position move the lift truck in first low range ONLY Operation Section A WARNING A lift truck with the engine running but without an operator can move slowly creep if the transmission is left engaged This could result in personal injury Always place the transmission control levers in the NEUTRAL center position and apply the parking brake before dismounting from the lift truck 6 RELEASE the service foot brake 7 PUSH DOWN on the accelerator pedal to obtain the desired travel speed RELEASE the pedal to decrease travel speed 8 Transmission speed changes to second and third speed range can be made on the go without deceleration or braking When faster travel speed is needed NOTICE Come to a complete stop before changing direction of travel A WARNING Sudden reversal of a loaded lift truck traveling forward can cause the load to fail or the lift truck to tip over Stop the loaded lift truck completely before shifting to reverse Failure to comply could result in personal injury 9 To change the lift truck directi
32. Lift Truck Test brakes steering controls horn and other devices for proper operation Report any faulty performance Do not operate lift truck until repaired Learn how your lift truck operates Know its safety devices Know how the attachments work Before moving the lift truck look around Start turn and brake smoothly An operator must constantly observe his lift truck for proper operation 12 Operating the Lift Truck Always keep the lift truck under control Obey all traffic rules and warning signs Never leave the lift truck with the engine operating or with the parking brake disengaged Operate the engine only in a well ventilated area Lower the mast with or without load before turning or traveling Tip over could result Watch out for overhead obstructions Always observe floor load limits and overhead clearance Start turn and brake smoothly Slow down for turns grades slippery or uneven surfaces Watch the road carefully for any obstacle when driving the truck Do not go fast over bumps pot holes or other rough grounds otherwise the engine might go OFF by a severe impact In case of engine going OFF press the brake pedal at one time as hard as possible in order to stop the truck Pressing the brake pedal several times has a risk that the brake would not work 0 0131 Use special care when operating on grades Do not angle across or turn on grades Do not use a lift truck on
33. MAPRangeLow TMAP Pin 1 to SECM Pin B1 Manifold Absolute Pressure sensor GND sensor input is low normally TMAP Pin 3 to SECM Pin B24 332 setif the TMAP pressure 1 TurnOnMil XDRP 5 Vdc signal wire has been 2 CutThrottle Check the MAP sensor by disconnected or shorted to disconnecting the TMAP connector and ground or the circuit has measuring at the sensor opened to the SECM TMAP Pin 1 GND to Pin 4 pressure signal KPA 2 4kQ 8 2kQ TMAP Pin 3 power to Pin 4 pressure signal KPA 3 4 8 2kQ MAPTimeRangeHigh Check TMAP connector and MAP Manifold Absolute Pressure signal wiring for a shorted circuit Sensor Input is High TMAP Pin 4 to SECM Pin B18 signal normally set if the TMAP TMAP Pin 1 to SECM Pin B1 pressure signal wire has sensor GND become shorted to power TMAP Pin 3 to SECM Pin B24 341 shorted to the IAT signal the None XDRP 5 Vdc 34 has failed or the Check the MAP sensor by SECM has failed disconnecting the TMAP connector and measuring at the sensor TMAP Pin 1 GND to Pin 4 pressure signal KPA 2 4kQ 8 2kQ TMAP Pin 3 power to Pin 4 pressure signal KPA 3 4kQ 8 2kQ 94 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d pressure than expected MAP_STICKING CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK MAPRangeHigh Check TMAP connector and MAP Manifold Absolute Pressure signal wiring for a shorted
34. Mast Channels Lubricate 150 Mast Hinge Pins Lubricate 168 Mast Pivot Ey6s eterne 169 Mast Carriage Lift Chains amp Attachments Inspect l bricate 5 ceca dta 165 Mixer Idle Screw Power Valve Adjust G643 Engine Only 79 Mounting and Dismounting 11 Moving Fan 8 No Riders Warning eese 8 No Standing On Forks Warning No Standing Under Forks Warning 7 N Oil Cooled Disc Brake OCDB Type 156 165 Only for D50 60 70 80 90S 5 3 Speed 175 Only for D50 60 70S 5 2 Speed G50 60 70S 5 ERE 169 175 Only for Oil Cooled Disc 146 Operating in Hot 115 Operating Techniques Operating the Lift Truck sss 12 Operation Information cesse 11 Operation eene niens 109 Operator s Warning and Identification Plate 45 Operator s Warning 45 Operator Restraint System If Equipped 2 17 Operator s Station and Monitoring Systems 47 Overhead Guard 170 Overhead Guard Must Be In Place Warning 8 Overloading P Parking Brake Test
35. Now turn ON the key but do not start the engine As soon as you turn the key to the ON position you must cycle the foot pedal by depressing it to the floor and then fully releasing the pedal pedal maneuver You must fully cycle the foot pedal three 3 times within five 5 seconds to enable the display codes feature of the SECM Simply turn the key OFF to exit display mode The code list will continue to repeat until the key is turned OFF Table 2 07 Diagnostic Fault Codes Flash Codes Operation Section CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK NONE 12 Signifies the end of one pass NONE Mae od through the fault list Check ECT sensor connector and wiring for a short to GND adi ECTRangeLow Signal Pin B15 To ECT Pin 3 14 Coolant Sensor failure or TurnOnMil SECM Sensor GND Pin B1 to ECT shorted to GND Pin 1 SECM System GND Pin A16 B17 1 TumOnMil Check if ECT sensor connector is ECTRangeHigh 2 DelayedEnain disconnected or for an open ECT circuit Coolant sensor disconnected 2 DelayedEngine SECM Signal Pin B15 to ECT Pin 3 15 NA Shutdown or open circuit 3 CheckEngineLight SECM Sensor GND Pin B1 to 8 CheckEngineLight EOT pin 1 Check coolant system for radiator ECTOverTempFault blockage proper coolant level and for Engine coolant temperature 1 TumOnMil ig GND check elayedEngine measured an excessi
36. Pin2 ground or the sensor has SEOM system GND Pin A16 B17 failed FuelTempRangeHigh Check if fuel temp sensor connector is Fuel Temperature Sensor disconnected or for an open FTS circuit Input is High normally set if SEOM signal Pin B14 to FTS Pin 1 932 the fuel temperature sensor TurnOnMil SECM sensor GND Pin B1 to FTS Pin 2 TransOilTemp 933 Excessive transmission oil temperature 1 TurnOnMil 2 Delayed EngineShutdown Refer to drivetrain manufacturer s transmission service procedures ServiceFault1 Perform service procedure related to reached replace timing belt 991 Service Interval 1 has been None Service Interval 1 reached determined by OEM ServiceFault2 Perform service procedure related to 992 Service Interval 2 has been None Service Interval 2 reached determined by OEM ServiceFault3 Perform service procedure related to 993 Service Interval has been None Service Interval 3 reached determined by OEM ServiceFault4 994 Service Interval 4 has been TurnOnMil Replace Pre catalyst HEGO sensor reached replace HEGO Replace Post catlyst HEGO sensor sensors ServiceFault5 995 Service Interval 5 has been TurnOnMil Replace engine timing belt Fault actions shown are default values specified by the OEM 104 Lift Truck Operation Power Shift Transmission Drive Axle 1 Start the engine See item Starting the Engine Typical Example 2 PUSH
37. Vacuum Lines and Fittings G643 E Engine only e Visually inspect vacuum lines and fittings for physical damage such as brittleness cracks 3 and kinks Repair replace as required e Solvent or oil damage may cause vacuum lines to become soft resulting in a collapsed line while the engine is running Visually inspect the Fuel trim valve 3 for abrasions or cracking Replace as necessary To ensure the valve is not leaking a blow by test can be performed With the engine off disconnect the electrical connector to the FTV Disconnect the vacuum line from the FTV to the pressure regulator converter at the converter s tee connection ightly blow through the vacuum line connected to the FTV Air should not pass through the FTV when de energized If air leaks past the FTV when de energized replace the FTV If abnormally soft lines are detected replace as Inspect Electrical System G643E necessary Engine only 1 LP fuel lock off 2 LP regulator converter 3 Fuel Trim Valve FTV G643E only 4 LP mixer 5 Vacuum lines 6 Coolant lines 7 LP fuel line 171 Check for loose dirty or damaged connectors and wires on the harness including Fuel lock off TMAP sensor O2 sensor Electronic throttle Control Relays Fuel Trim Valve Foot Pedal and Distributor sensor Repair and or replace as necessary Maintenance Section Every 1000 Service Hours or 6 Months You must read and un
38. WARNING 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 Follow the recommendations below to properly perform the towing procedure These towing instructions are for moving a disabled lift truck a short distance at low speed no faster than 2 km h 1 2 mph to a convenient location for repair These instructions are for emergencies only Always transport the lift truck if long distance moving is required Shield must be provided on the towing lift truck to protect the operator if the tow line or bar should break Do not allow riders on the lift truck being towed unless the operator can control the steering and or braking Before towing make sure the tow line or bar is in good condition and has enough strength for the towing situation involved Use a towing line or bar with a strength of at least 1 5 times the gross weight of the towing lift truck for a disabled lift truck stuck in the mud or when towing on a grade Keep the tow line angle to a minimum Do not exceed a 30 angle from the straight ahead position Connect the tow line as low as possible on the lift truck that is being towed Quick lift truck movement could overload the tow line or bar and cause it to break Gradual and smooth lift truck movement will work better Normally the towing lift tru
39. be applied when leaving the lift truck and when starting the engine If the operator leaves the seat without applying the parking brake an audible alarm will sound A WARNING When leaving machine apply parking brake Parking brake is not automatically applied Alarm will sound if parking brake is not applied A 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 Safety Section Safety Section General Hazard Information 14101011 Attach not Operate similar warning tag to start switch or controls before servicing or repairing the lift truck Do not start or service the lift truck when a DO NOT OPERATE or similar warning tag is attached to the start switch or controls Wear a hard hat protective glasses and other protective equipment as required by job conditions Know the width of your attachments so proper clearance can be maintained when operating near fences boundary obstacles etc Do not wear loose clothing or jewelry that can catch on controls or other parts of the lift truck Keep the lift truck especially the deck and steps free of foreign material such as debris oil tools and other items which are not
40. be underinflated if the machine works in freezing temperatures Low pressure shortens the life of a tire Maintenance Section Metric Hardware This lift truck is almost totally metric design Specifications are Torque Specifications given in metric and U S Customary measurement Metric hardware must be replaced with metric hardware Check parts books for proper replacement NOTE Use only metric tools on most hardware for proper fit Other tools could slip and possibly cause injury Torques for Standard Hose Clamps Worm Drive Band Type NOTICE The following chart gives the torques for initial installation of hose clamps on new hose and for reassembly or retightening of hose clamps on existing hose Initial Installation Clamp Width Torque On New Hose 16 mm 625 in 13 5 mm 531 in 8 mm 312 in 7 5405 4 5 0 5 0 9 02 Reassembly or Retightening Clamp Width Torque On Existing Hose 4 5 0 5 40 5 13 5 mm 531 in 3 0 0 5 2545 8mm 312in 07202 11 Newton meter is approximately the same as 0 1 kgem 16 mm 625 in 126 Torques for Standard Bolts Nuts and Taperlock Studs NOTICE The following charts give general torques for bolts nuts and taperlock studs or SAE Grade 5 or better quality Torques for Bolts and Nuts With Standard Threads 1 4 12 4 9 3 5 16 3 8 1 2 100 15 75411 9 16 5 8 3 4 7 8 1 875 100 640 75 11 8 11 4
41. by wire DBW system connecting the accelerator pedal to the electronic throttle through the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle position in relation to the accelerator pedal position sensor APP feedback Even engine coolant temperature and adequate oil pressure is monitored by the SECM The SECM controller has full adaptive learning capabilities allowing it to adapt control function as operating conditions change Factors such as ambient temperature fuel variations ignition component wear clogged air filter and other operating variables are compensated Operation Section Basic Troubleshooting The EMS 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 Small Engine Control Module SECM Below are basic checks that should be made before referring to the Advanced Diagnostics section if engine or drivability problems are encountered Locating a problem in a propane engine is done exactly the same way as with a gasoline engine Consider all parts of the ignition and mechanical systems as well as the fuel system Problem Probable Cause Corrective Action Engine Cranking but Wil
42. circuit Sensor Input is High TMAP Pin 4 to SECM Pin B18 signal normally set if the TMAP TMAP Pin 1 to SECM Pin B1 pressure signal wire has sensor GND become shorted to power TMAP Pin 3 to SECM Pin B24 342 shorted to the IAT signal the 1 TurnOnMil XDRP 5 Vdc TMAP has failed or the 2 CutThrottle Check the MAP sensor by SECM has failed disconnecting the TMAP connector and measuring at the sensor TMAP Pin 1 GND to Pin 4 pressure signal KPA 2 4kQ 8 2kQ TMAP Pin 3 power to Pin 4 pressure signal KPA 3 4kQ 8 2kQ Check for vacuum leaks Check that 351 MAP sensor indicates higher None TMAP sensor is mounted properly pressure than expected Possible defective TMAP sensor MAP IR LO 352 MAP sensor indicates lower None Possible defective TMAP sensor Check that TMAP sensor is mounted changing as expected 353 MAP sensor not changing as None properly Possible defective TMAP expected sensor Check TMAP connector and signal wiring for a shorted circuit e TMAP Pin 2 to SECM Pin B12 signal TMAP Pin 1 to SECM Pin B1 371 Sensor Input is Low normally sensor GND 37 set if the IAT temperature TurnOnMil To check the IAT sensor of the TMAP sensor wire has shorted to he connector and chassis ground or the sensor disconnect te has failed measure the resistance Resistance is approx 2400 ohms at room temperature Check TMAP connector and signal
43. electrical disconnect switch if equipped 3 Disconnect the fuel supply line Operation Section 4 Grasp the tank support bar 1 Pull and release the latch switch 2 5 Grasp the tank support bar 1 and rotate cradle slowly to the rear of a tank 6 Pull the release knob 1 and then push down the tank IDGOM044 7 Lock the tank cradle by knob 1 Loosen the retaining clamps 2 and remove the tank 8 Check the mounting to be sure the locating pin dowel is not missing or broken NOTICE If the location pin dowel is missing or broken be sure the pin is replaced Operation Section 0023 9 Check to be sure that the LP warning plate is position on the lift truck and is legible 10 Check to be sure the replacement tank is of the correct type 11 Inspect the replacement tank for damage such as dents scrapes or gouges and for indication of leakage at valves or threaded connections I mm 12 Check for debris in the relief valve for damage to various valves and liquid level gauge 13 Inspect the quick disconnect couplings for deterioration damage or missing flexible seals IAOO025P 14 Position the replacement tank so that the locating pin dowel is in place A UTION The LP tank must not extend past the counterweight 15 Grasp a new tank and clamp securely Pull the release knob 1 and push the tank cradle upward when lock
44. for anticipated outside ambient temperatures Do not exceed the recommendations provided with the commercially available automotive antifreezes regarding the coolant mixture of antifreeze to water Make proper antifreeze additions Adding pure antifreeze as a makeup solution for cooling system top up is an unacceptable practice It increases the concentration of antifreeze in the cooling system which increase the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system Add antifreeze mixed with water to the same freeze protection as your cooling system Use the chart below to assist in determining the concentration of antifreeze to use Antifreeze Concentrations Protection Temperature Concentrations 30 antifreeze and 70 water 40 antifreeze and 60 water 50 antifreeze and 50 water 60 antifreeze and 40 water Protection to 15 5 Protection to 23 C 10 F Protection to 37 C 34 F Protection to 51 C 60 F Maintenance Section Fuel Specifications General Fuel Information Use only fuel as recommended in this section NOTICE Fill the fuel tank at the end of each day of operation to drive out moisture laden air and to prevent condensation Maintain a constant level near the top of the day tank to avoid drawing moisture into the tank as the level decreases Do not fill the tank to the top Fuel expands as it gets
45. forks mm 3507 3568 16 width mm 2108 2108 17 Overall mast lowered height mm 2500 2500 18 dimensions mast extended height mm 4340 4340 19 overhead guard height mm 2455 2455 20 seat height mm 1333 1333 21 Turning radius minimum outside mm 3301 3331 22 Load moment constant mm 632 632 23 90 stacking aisle add load length and clearance mm 3924 3958 23a 90 intersecting aisle mm 2990 3020 PERFORMANCE 24 travel loaded unloaded km h 24 0 25 4 23 8 25 4 25 Speed lift loaded unloaded mm s 380 410 380 410 26 lowering loaded unloaded mm s 490 460 490 460 28 Drawbar pull at 1 6 km h loaded kg 5010 4990 30 Gradeability at 1 6 km h loaded 40 9 35 5 WEIGHT 32 Total weight unloaded kg 8235 8905 33 Axle load with loaded front rear kg 11840 1395 13260 1645 34 without loaded front rear kg 4100 4135 3975 4930 CHASSIS 35 number of front rear 4 2 4 2 36 Tires size front 8 25x15 14PR 8 25x15 14PR 37 size rear 8 25x15 14PR 8 25x15 14PR 38 Wheel base mm 2250 2250 39 Tread width front rear mm 1584 1550 1584 1550 40 loaded at the lowest point mm 176 176 Ground clearance 41 loaded at center of wheelbase mm 205 205 42 service brake foot hydraulic foot hydraulic 43 Brakes parking brake DRIVE 45 Battery voltage capacity 12 75 12 75 49 manufacturer model G643E TIER 2 G643E TIER 2 50 Engine rated output at rom KW hp rpm 69 0 2450 69 0 2450 51 max torque N m b ft rpm 301 1400 301 1400 52 cycle cylinders displacement
46. front and rear tires to prevent unintentional movement of the lift truck 4 Remove the Controller cover plate screws and cover plates 5 Locate the FWD RVS selection switch 1 and the High Low H L selection switch 2 on the printed circuit board 6 Move the switches indicated up for Automatic AUTO operation or down for Manual MANUAL operation Typical Example of ASC 200 NOTE In ASC 200 factory setting controller automatic mode is selected for both direction inhibit and two speed auto shift control as a default on the PCB Printed Circuit Board In ASC 201 factory setting controller manual mode Fail Safe Mode is selected as a default for direction inhibit while automatic mode is selected as a default for two speed auto shift control 7 Replace the Controller cover plate and screws 8 Turn ON the electrical disconnect switch if equipped 9 Start engine check the Controller LED indication for A For indications other than A see following section on Fault Diagnosis NOTE After operating the truck manually by selecting the Manual Mode switch on PCB Printed Circuit Board the position of mode must be checked before operating the truck automatically 111 Operation Section Operation Section Operating Techniques Inching into Loads 1A000371 Typical Example 1 Move the lift truck slowly FORWARD into position and engage the load The truck should be square with load forks sp
47. hazards and use common sense Persons must also have the necessary training skills and tools before attempting to perform these functions Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Safety precautions and warnings are provided in this manual and on the product If these hazard warnings are not heeded bodily injury or death could occur to you or other persons The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as WARNING as shown below A WARNING The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The message that appears under the warning explaining the hazard can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard and common sense is always required 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 an
48. in this area Do not touch lean on or reach through the mast or permit others to do so ICOS003P Located on the mast Safety Section No Standing On Forks Warning No Standing Under Forks Warning A WARNING 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 IAOYOOS5I Located on the lift cylinder Load Backrest Must Be In Place Warning A WARNING Operation without this device in place may be hazardous 05003 Located on the load backrest Safety Section Overhead Guard Must Be In Place Warning A WARNING Operation without this device in place may be hazardous This guard conforms to A N S 1 B56 1 and F E M Section IV This design has been tested with an impact of appropriate value Located on the Overhead Guard No Riders Warning A WARNIN To avoid personal injury allow no riders A lift truck is designed for only one operator and no riders Located beside the operator s station Moving Fan Warning A WARNING To avoid personal injury stay clear of moving fan 2 IAOYOOSI Located inside the engine compartment cover 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
49. information about the engine s performance Engine speed is monitored by the SECM through a variable reluctance VR or Hall Effect sensor Intake manifold air temperature and absolute pressure are monitored with a TMAP sensor 07 is drive by wire DBW system connecting the accelerator pedal to the electronic throttle through the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle position in relation to the accelerator pedal position sensor APP command Even engine coolant temperature and adequate oil pressure are monitored by the SECM The SECM controller has full adaptive learning capabilities allowing it to adapt control function as operating conditions change Factors such as ambient temperature fuel variations ignition component wear clogged air filter and other operating variables are compensated 70 Operation Section G643 Electronic Controlled LP Engines If Equipped General Description EMS Lad Fault Light Key switch amp Fuel Filter Main PWR Foot Pedal Relay APP Coolant Line Air Cleaner Ignition Coil Muffler Ja LP Fuel Line E Cm Fuel Lock Vacuum Line SECM Coolant Temperature Sensor Engine speed is monitored by the SECM through a variable reluctance VR sensor Intake manifold air temperature and absolute pressure is monitored with a TMAP sensor The MI 04 is a drive
50. install the filter cap 146 Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Inspection Engine for Fluid Leaks 1 Start the engine and allow it to reach operating temperatures 2 Turn the engine off 3 Inspect the entire engine for oil and or coolant leaks 4 Repair as necessary before continuing Engine Oil Level Check 1 Raise the hood and seat assembly A WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 1L01017P Typical Example 2 Maintain oil level between the MAX and MIN marks on the dipstick Coolant Level Check A WARNING At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand Remove the filter cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury Typical Example LP Engine Truck 1 Observe the coolant level with engine cold Maintain coolant level to the proper line on expansion bottle If the expansion bottle has no coolant it will be necessary to check coola
51. instructions provided HOLD ON TIGHT INSO048l Hold on tight coded AS WARNING _IN CASE OF TIPOVER 4n FASTEN SEAT BELT BRACE FEET INSO046l 1 500491 Always use operator restraint system mum 8 AS m o INCASEOF TIPOVER Brace your feet and keep them within the operator s compartment DON T JUMP 1 500471 Don t jump 28 Safety Section Eae IRAE INCASE OF TIPOVER CASE OF TIPOVER LEAN AWAY 1 500501 Lean away from the direction of fall WARMING CASE TIPOVER LEAN FORWARD 1 500511 Lean forward 29 General Section Specifications CHRACTERISTICS 3 Speed 1 Manufacturer DOOSAN DOOSAN 2 MODEL 0505 5 0605 5 Capacity at rated load center kg 5000 6000 4 Load center distance mm 600 600 5 Power type electric diesel gasoline LPG diesel diesel 6 Operator type stand on rider seated rider seated rider seated 7 Tire type p pneumatic p p 8 Wheels x driven number front rear 4 2 4 2 DIMENSIONS 9 Lift with STD fork height with rated mm 3000 3000 10 two stage mast free lift mm 205 205 13 Forks thickness x width x length mm 60x150x1200 60x180x1200 fork spacing minimum x maximum mm 350x2032 410x2032 14
52. light will come ON when the parking lever is applied 9 Levering light If Equipment Indicates tilt and lift control lever v The light comes on when lift and tild lever move forward backward with installed solenoid valve 10 Seat Belt Warning Light Indicates when the seat belt dose not fastened by operator The light will come on when the ignition switch is turned to the on position The light should go off after engine is started 11 Seat Leaving warning Light When operator leaves seat without engine stop hydraulic control lever cannot operate 12 Transmission Neutral Position Light Indicates the neutral position of transmission 13 Engine Malfunction Indicator Lamp Engine control systems are equipped with built in fault diagnostics Detected system faults can be displayed by the Malfunction Indicator Lamp MIL as Diagnostic Fault Codes DFC or flash codes and viewed in detail with the use of service tool software When the ignition key is turned ON the MIL will perform a self test illuminate once and then go OFF If a detected falut condition exists the fault or faults will be stored in the memory of the engine control unit ECM Once a fault occurs the MIL will illuminate and remain ON This signals the operator that a faults has been detected by the ECU Operation Section 14 Directional Turning Indicator Light cS Pull the lever to activate the right turn signal Push the leve
53. must be performed by qualified and authorized personnel only NOTICE Careless disposal of waste oil can harm the environment and can be dangerous to persons Always dispose of waste oil to an authorized personnel only When Required Engine Valve Lash Diesel E G Only Check Priming the Fuel System Diesel Engine Only 140 Test Fuel System for Leaks LP Engine Only 141 Fuel Tank Filter Cap amp Screen Clean 21 Seat Check Lubricate Fuses Bulbs amp Circuit Breaker Change Reset 143 Tires and Wheels Inspect Radiator Cap Clean Change Carriage Roller Extrusion Adjust Brake Oil OCDB Check Every 10 Service Hours or Daily Inspection Engine for Fluid Leaks Engine Oil Level Check Coolant Level Check Air Cleaner Indicator Check Inspect Foot Pedal Operation LP Engine Only 149 Inspect Engine for Exhaust Leaks Walk Around Inspection Inspect Mast Channels Lubricate Transmission Oil Level Check First 50 100 Service Hours or a Week Engine Oil amp Oil Filter Diesel E G Only Change Transmission Oil amp Oil Filter odd Drive Axle Oil Change A Parking Brake Test Adjust ose 157 First 250 Service Hours or a Month Hydraulic Return Filter 159 Every 250 Service Hours or Monthly Air Intake System Check
54. not drive on slippery surfaces Sand gravel ice or mud can cause a tipover If unavoidable slow down Safety Section Do not permit anyone to stand or walk under the load or lifting mechanism The load can fall and cause injury or death to anyone standing below Do not elevate the load with the mast tilted forward Do not tilt the elevated loads forwards This will cause the lift truck to tip over forward Look out for overhead obstructions when raising or stacking loads Do not travel with a raised load Do not travel with the mast raised The lift truck can roll over and cause injury or death to you or other personnel Do not move loose loads that are higher than the load backrest Be alert for falling loads when stacking Travel with the load tilted back and the forks as low as possible This will increase stability to the truck and load and permit better visibility for you Do not jump off if your truck starts to tip over Stay in your seat to survive Go up ramps in forward direction and down ramps in reverse direction when moving loads Never elevate a load with the forklift truck on an incline Go straight off and straight down Use an assistant when going up or down a ramp with a bulky load Safety Section Do not stack or turn on ramps Do not attempt to pick up or deposit a load unless the lift truck is level Do not turn on or drive across a
55. not use solvent gasoline etc You must replace a label if it is damaged missing or cannot be read If a label is on a part that is replaced make sure a new label is installed on the replaced part See you DOOSAN Lift Truck dealer for new labels The most effective method of preventing serious injury or death to yourself or others is to familiarize yourself with the proper operation of the lift truck to be alert and to avoid actions or conditions which can result in an accident A WARNING Tipover can occur if the truck is improperly operated In the event of tipover injury or death could result Survive in tipover decal 45 5 IN CASE TIPOVER WARNING 1 900002 Survive in tipover decal 1B900003 Safety Section Fasten seat belt decal Survive in tipover decal 1 900004 The Survive tipover warning is located on the overhead guard It shows the proper use of the operator restraint system Seat Adjustment re 1 900005 Move the lever slide the seat to the desired position and release the lever Adjust the seat before operating the lift truck After adjusting set the seat to make sure it is properly locked Do not adjust the seat while the truck is in motion A WARNING Do not place your hand or fingers under the seat Injury may occur as the seat moves up and down Safety Section If Optional Suspension Seat
56. of the manual Greases are classified according to the National Lubricating Grease Institute NLGI based on ASTM D217 68 worked Penetration characteristics which give a defined consistency number Engine Oil DEO and EO The following oil specifications provide guidelines for the selection of commercial products Gasoline LP Engine API SJ Diesel Engine API CH4 or ACEA E5 NOTICE Failure to follow the oil recommendations can cause shortened engine life due to carbon deposits or excessive wear Consult the EMA Lubricating Oils Data Book for a listing of oil brands NOTE The percentage of sulfur in the fuel will affect the engine oil recommendations For fuel sulfur effects the Infrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of engine oil The sulfur products formation depends on the fuel sulfur content oil formulation crankcase blowby engine operating conditions and ambient temperature Hydraulic Oil HYDO The following commercial classifications can be used in the hydraulic system ISO 6743 4 HM AFNOR NFE 48 603 HM DIN 51524 TEIL 2 H LP HAGGLUNDS DENISON HFO HF2 CINCINNATI P68 69 70 Viscosity ISO VG32 Industrial premium hydraulic oils that have passed the Vickers vane pump test 35VQ25 These oils should have antiwear antifoam antirust and antioxidation additives for heavy duty use as stated by the oil supplier ISO viscosity gr
57. of the area represented by the shaded area in the above drawing Dry nitrogen N2 gas is recommended for inflation of tires If the tires were originally inflated with air nitrogen is still preferred for adjusting the pressure Nitrogen mixes properly with air Nitrogen inflated tires reduce the potential of a tire explosion because nitrogen does not support combustion Also nitrogen helps prevent oxidation and the resulting deterioration of rubber and corrosion of rim components Proper nitrogen inflation equipment and training in its use are necessary to avoid over inflation A tire blowout or rim failure can result from improper or misused equipment Stand behind the tread and use a self attaching chuck when inflation a tire Servicing changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures If correct procedures are not followed while servicing tires and rims the assemblies could burst with explosive force and cause serious personal injury or death Follow carefully the specific information provided by your tire or rim servicing personnel or dealer Operator Restraint System If Equipped Warning Signs and Labels Your DOOSAN lift truck has the following tipover warning decals Make sure that you can read all safety signs Clean or replace these if you cannot read the words or see the pictures When cleaning the labels use a cloth water and soap Do
58. operation they should be checked every six months 1 Inspect the forks carefully for cracks Special attention should be given to the heel section A all weld areas and mounting brackets B Inspect the top and bottom hooks on forks used on hook type carriages and tubes on shaft mounted forks Forks with cracks should be removed from service Wet Test magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results Portable equipment is usually recommended so it can be moved to the lift truck Inspectors should be trained and qualified in accordance with The American Society for Non Destructive Testing Level Il Qualifications 14104093 Check the angle between the upper face of the blade and the front face of the shank The fork should be withdrawn from service if angle C exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees as may be found in some special application forks 183 Maintenance Section E 1A104094 3 Check the straightness of the upper face of blade D and the front face of shank E with a straight edge The fork should be withdrawn from service if the deviation from straightness exceeds 0 5 percent of the length of the blade and or the height of the shank respectively 5 mm 1000 mm 0 18 36 14104095 Check the difference in height of o
59. pounds at 24 inch load center will be stamped 1500X24 A fork rated at 2000 kg at 600 mm load center will be stamped 2000X600 The manufacturer identification and year and date of manufacture is also usually shown Some countries have standards or regulations which apply specifically to the inspection and repair of forks 121 Users may also refer to the International Organization For Standardization ISO Technical Report 5057 Inspection and Repair of Fork Arms and ISO Standard 2330 Fork Arms Technical Characteristics and Testing While there are no specific standards or regulations in the United States users should be familiar with the requirements for inspection and maintenance of lift trucks as provided by the 29 Code Federal Register 1910 178 Powered Industrial Truck and ANSI ASME Safety Standard s B56 1 B56 5 or B56 6 as applicable to the type of machine s in use Environment Protection When servicing this lift truck use an authorized servicing area and an approved container to collect coolant oil fuel grease electrolyte and any other potential environmental pollutant before any lines fittings or related items are disconnected or removed After servicing dispose of those materials in an authorized place and container When cleaning the lift truck be sure to use an authorized area Maintenance Section Causes of Fork Failure Improper Modification or Repair Fork failure can occur as a result of a field modi
60. sure they are in place and working Hook type forks use a spring loaded pin M located in the top hook to engage notches in the top carriage bar to hold the fork in place When adjusting the fork spacing the forks are prevented from sliding off the end of the carriage by stop blocks These stop blocks are at both ends of the carriage and in the path of the bottom fork hook The load backrest extension may be used in place of the stop blocks in some cases 184 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 1C100102 Check fork markings N for legibility Renew markings as required to retain legibility a Lift the mast and operate the tilt control lever until the top surface of the forks is parallel with the floor Place two straight bars that are the same width as the carriage across the forks as shown b Measure the distance from the bottom of each end of the two bars to the floor The forks must be parallel within 3 mm 12 in for Full Tapered and Polished FTP forks all other forks 6 4 mm 25 in for their complete length c Putone fork one third from the tip under a fixture that will not move Then operate the tilt control with caution until the rear of the truck lifts just off the floor Follow the same procedure with the s
61. tension If not equal repeat the same procedure as step 1 through step 3 5 Put LOCTITE No 242 tread lock on the threads of the anchor nuts 1 after the adjustment is completed Typical example for carriage chain of FFT mast Make sure that carriage height is correct if correct adjust chain for equal tension If not adjust chain for correct carriage height by adjusting anchor nuts 2 NOTE See the previous section Carriage Roller Extrusion in When Required for proper carriage height 1 Fully lower the carriage and tilt mast forward or lift the carriage and put blocks under the carriage to release the tension from the lift chains 2 Remove bolt 3 washer 4 and stopper 5 and adjust nut 2 to get proper distance from bottom of inner upright to the bottom of carriage bearing 3 Make adjustment anchor nut 2 for equal chain tension 4 Set the mast vertical and raise the carriage and check equal chain tension If not equal repeat the same procedure as step 1 through step 3 5 Put LOCTITE No 242 tread lock on the threads of the anchor nuts 2 after the adjustment is completed Maintenance Section Mast Chain Adjustment FFT JD60M036 Typical example for FFT mast Make sure that mast height is correct If correct adjust chain for equal tension If not adjust mast chain for correct mast height by adjusting anchor nuts 6
62. the ground for SECM pin B1 sensor GND to the sensor has opened ETC Pin2 Check the throttle connector and pins for corrosion To check the TPS di h TPS1AdaptLoMin o check the TPS disconnect the throttle connector and measure the 241 Learned closed throttle end N i 24 of TPS1 sensor range lower PUR resistance Trom ihan exp cted TPS Pin 2 GND to Pin 6 TPS1 Sree PRES SIGNAL 0 7 Q 30 TPS Pin 3 PWR to Pin 6 TPS1 SIGNAL 1 4 Q 30 Fault actions shown are default values specified by the OEM 92 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d DFC 242 PROBABLE FAULT TPS2AdaptLoMin Learned closed throttle end of TPS2 sensor range lower than expected FAULT ACTION None CORRECTIVE ACTION FIRST CHECK Check the throttle connector and pins for corrosion To check the TPS disconnect the throttle connector and measure the resistance from TPS Pin 2 GND to Pin 5 TPS2 SIGNAL 1 3K Q 30 TPS PIN 3 PWR to PIN 5 TPS2 SIGNAL 0 6K Q 30 251 25 TPS1AdaptHiMax Learned WOT end of TPS1 sensor range higher than expected None N A 252 TPS2AdaptHiMax Learned WOT end of TPS2 sensor range higher than expected None N A 271 TPS1AdaptHiMin Learned WOT end of TPS1 sensor range lower than expected None N A 272 TPS2AdaptHiMin Learned WOT end of TPS2 sensor range lower than expected None N A
63. the transmission NEUTRAL and the engine stopped and cool Typical Example 1 Turn the radiator cap slowly to relieve the pressure then remove the cap 2 Remove the block drain plug 3 10 11 12 13 Open radiator drain valve Allow the coolant to drain Drain the recovery bottle Close radiator drain valve and install block drain plug Fill the cooling system with 1 kg 2 Ib sodium bisulphate per 40 liters 10 gallons of water Most commercial cooling system cleaners can be used Start and run the engine for 30 minutes Stop the engine and drain the cleaning solution Flush the system with clean water until draining water is clear Close the drain valve and install the block drain plug Fill the system with neutralizing solution 250 0 1 2 Ib sodium carbonate per 40 liters 10 gallons of water Start and run the engine for 10 minutes Stop the engine and drain the neutralizing solution Flush the system with clean water until draining water is clear Close the drain valve and install the block drain plug Add coolant to the top of the filter neck Start and run the engine to stabilize the coolant level See topic Coolant level Check in Every 10 Service Hours or Daily Fork Inspect 0941 Forks should be inspected at minimum every 12 months If the truck is being used in a multi shift or heavy duty
64. warm and can overflow Do not fill the fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to the fuel system parts Drain the water and sediment from main fuel storage tank before it is refilled This will help prevent water and or sediment from being pumped from the fuel storage tank into the engine fuel tank Diesel Specifications Fuel Types DOOSAN Diesel Engines have the ability to burn a wide variety of fuels These fuels are divided into two general groups preferred and permissible The Preferred Fuels provide maximum engine service life and performance They are distillate fuels They are commonly called diesel fuel MDO diesel furnace oil gas oil or kerosene for cold weather operation Experience has proven that distillate fuels meeting the following basic specifications will result in optimum engine performance and durability DOOSAN strongly encourages the use of fuels that meet the Preferred Fuels specification The permissible fuels are crude oils or blended fuels Use of these fuels can result in higher maintenance costs and reduced engine service life Crude oil is used to describe oils fuels that are not refined and are in the original state as when pumped from the ground Certain types of crude oils can be burned in DOOSAN Engines PREFERRED DISTILLATE FUEL FOR DIESEL ENGINES Specifications Requirements Aromatics AST D1319 35 Max Ash AS
65. welding or flame cutting on them Remove all flammable materials such as fuel oil and other debris before they accumulate on the lift truck Do not expose the lift truck to flames burning brush etc if at all possible Shields which protect hot exhaust components from oil or fuel spray in the event of a line tube or seal failure must be installed correctly Do not operate in areas where explosive gases exist or are suspected Safety Section Fire Extinguisher Have a fire extinguisher type BC and 1 5KG minimum capacity on rear overhead guard leg with latch and know how to use it Inspect and have it serviced as recommended on its instruction plate Ether Ether is poisonous and flammable Breathing ether vapors or repeated contact of ether with skin can cause personal injury Use ether only in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 39 C 102 F Discard cylinders in a safe place Do not puncture or burn cylinders Keep ether cylinders out of the reach of unauthorized personnel Lines Tubes and Hoses Do not bend or strike high pressure lines Do not install bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cau
66. working with batteries Typical Example 1 Install steer wheel Put two nuts opposite each other 180 Tighten bolt 2 Inspect tightness of wheel nuts in a sequence opposite each other 610 680 N m 370 450 Ib ft m Y Typical Example Diesel Engine Truck Drive Wheels Typical Example LP Engine Truck Typical Example 1 Clean the top of the battery and terminals 1 Install drive wheel Put two nuts opposite each other 180 2 Check terminals for corrosion Coat terminals with heavy grease 2 Inspect tightness of wheel nuts in a sequence opposite each other to 500 600 N m 370 450 Ib ft 167 Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Belts Diesel E G Only Check Adjust Typical Example Typical Example D50 60 70 80S 5 3 Speed NOTICE Failure to loosen the alternator mounting bolt 2 will cause excessive stress and break the alternator mounting ear 2 To adjust the alternator drive belt loosen adjusting bracket nut 1 mounting bolt and nut 2 and nut 3 Move the nut 1 in or out as required Tighten the mounting bolt and nut 1 2 3 amos Mast Hinge Pins Lubricate Typical Example D50 60 70S 5 2 Speed 4 1 Check the condition and adjustm
67. your local technological society library or college DOOSAN recommends infrared analysis conjunction with wear metal analysis of used oil in determining the effectiveness of oil TBN and acid neutralization For fuel with sulfur exceeding 1 5 by weight use an oil with a TBN of 30 and reduce the oil change interval by one half Also infrared analysis and wear metal analysis should be used to establish oil change intervals Periodically request fuel sulfur content information from your fuel supplier Fuel sulfur content can change with each bulk delivery 131 Maintenance Section LP Specifications LP is liquefied petroleum gas The exact composition of LP varies slightly between different parts of the country and different refineries HD5 is recommended for DOOSAN forklift trucks Remember LP is heavier than air and will sink to the lowest spot possible Avoid areas near floor drains or lubrication pits where escaped fuel may collect Composition of HD5 Propane CsHs Propylene Butane C4H 0 iso Butane Methane CHa Total Maintenance Section Lubricant Specifications Lubricant Information Some classifications and abbreviations we use in this section follow S A E Society of Automotive Engineers J754 nomenclature and others follow S A E J183 All MIL specifications are U S A Military Recommended oil viscosities are given in the Lubricant Viscosities chart later in this section
68. 0 60 70 80 908 5 D50 60 708 5 G50 60 70S 5 0 4 Test course Concrete road 38 General Section Capacity Chart Without Side Shifter gt FFT 4550mm MAST B FFT 5000mm MAST C FFT 5600mm MAST D FFT 6050mm MAST D50S 5 G50S 5 eoe A FFT 4550mm MAST B FFT 5000mm MAST C FFT 5600mm MAST D FFT 6050mm MAST 19 o a A FFT 4550mm MAST B FFT 5000mm MAST C FFT 5600mm MAST D FFT 6050mm MAST D70S 5 G70S 5 39 General Section Capacity Chart Without Side Shifter 600 70 800 900 1000 1100 1200 600 710 80 900 1000 1100 1200 roo oooc gt mm A FFT 4350 5400mm MAST B FFT 5850mm MAST 600 70 80 900 1000 1100 1200 600 70 800 900 1000 1100 1200 oooc gt mm ooo mm A FFT 4350 5400mm MAST B FFT 5850mm MAST 40 General Section Capacity Chart With Side Shifter soccomm 3000 4000 mm 118 in 158 in FFT 4550mm MAST MFH MAST FFT 5000mm MAST 4500 mm 177 in MFH MAST FFT 5600mm MAST 5000 mm 197 in MFH MAST FFT 6050mm MAST 5500 mm 217 in MFH MAST 6000
69. 0451 Typical Example 4 Lower the carriage and forks to the travel position or to the park position 114 Turning 1 When turning sharp corners keep close to the inside corner Begin the turn when the inside drive wheel meets the corner 14103041 2 In narrow aisles keep away from the stockpile when turning into the aisle Allow for counterweight swing Lifting Drums or Round Objects 00481 1 Block drums or round objects Tilt the mast FORWARD and side the fork tips along the floor to get under the load 14000491 2 Before lifting tilt the mast BACK slightly until the load is cradled on the forks 115 Operation Section Operating in Hot Weather Keep the following points in mind when you operate the lift truck in hot weather 1 Check the radiator Clogging can cause the overheating Clean them out regularly with a blast of compressed air Also check the leakage of water 2 Check the fan belt tension and adjust to proper tension 3 Even if the engine overheats and the coolant boils over let the engine idle for a while with opening engine hood until temperature falls before shut off the engine Operation Section Parking the Lift Truck Typical Example Park the lift truck level with the forks lowered and the mast tilted forward until the fork tips touch the floor Block the drive wheels when parking on an incline 1 Park in aut
70. 127 Torques for Standard Bolts Nuts and Taperlock Index Section Torques for Standard Hose Clamps Worm Drive Band Type Torques for Taperlock Studs Towing Informations sissa 120 Training Required To Operate or Service Warning 5 Transmission Display 3 Speed Only 56 Transmission Inching Control Pedal 58 Transmission Oil amp Filter 3 Speed Only Change 175 Transmission amp Oil Filter Change 153 Transmission 2 Speed Only Change 175 Transmission Oil TDTO Transmission Oil Filter 2 Speed Only Change 169 Transmission Oil Level 151 Transportation Hints seen 119 Traveling with the 113 TUMING 114 U Universal Joint Inspect Lubricate Unloading V Vibration weighted overall value 38 Walk Around Inspection Inspect Walk Around Inspection Warning Light Warning Signs and 5 17 Water 280 kPa 40 psi Maximum Pressure 162 Wheel Bolts amp Nuts 167 When 2 221 140
71. 45 Identification Lift Capacity and Attachment Plate Typical Example Located on the cowl to the right side of the steering column Lift Truck Capacity Rating DO NOT exceed allowable lift truck working capacity load ratings The capacity of the lift truck is given by weight and distance to the load center For example a capacity of 1200kg 2640 Ib at 600mm 24in means that the lift truck can lift 1200kg 2640lb if the load center is 600 mm 24in from both the vertical and horizontal faces of the forks Before attempting to lift any load ensure that the weight and load center combination is within the capacity of the lift truck as shown on the capacity rating plate To determine the load center measure the distance from the face of the carriage to the gravitational center of the load The rated capacity on the plate refers to the capacity of the lift truck as it left the factory Subsequent changes of any form to the equipment or battery can alter the lift truck s rating The rated capacity of the lift truck applies to operating conditions where the lift truck is on level ground The capacity of the lift truck is reduced on inclines General Section Below are abbreviations that may appear on the Identification Lift Capacity and Attachment Plate and their meanings Mast Abbreviations STD FF FFT QUAD NOTE Standard Mast single inner member low free lift Full Free Lift Mast single i
72. A 2 D50 60 70 80 908 5 3 Speed No Description Raiga Capacity 1 Engine Start 10A 2 Engine Stop Motor Relay Coil Preheat 10A System 1503691 Valve 3 TEUM Control Unit Ignition T M 10A Display 4 Cabin Relay Coil Aircon Relay Coil 15A 5 Gague Panel Stop Lamp Strobe Light 15A 6 Horn 10A 7 TCU T M Control Unit Power 10A Head Lamp Relay Coil Rear Lamp Turn 8 Signal Lamp 15A Clearance Lamp 9 Head Lamp Hi Beam Head Lamp Low 15 10 Cigar Lighter Power Socket CD Player 15 Wiper Motor CABIN 11 Ignition Switch St Ign Acc 30A 12 Aircon Heater 30A 54 Circuit Breaker Typical Example Diesel Engine Truck Circuit Breaker protects the main electrical circuit It is located in the engine compartment on the left side To reset the circuit breaker push the button in If the button comes back out have the electrical circuits checked Seat Seat Adjustment NOTE Seat arrangements may vary Basic operation will be similar Seat adjustment should be checked at the beginning of each shift and when operators change Lock the seat into position before operating to prevent an unexpected seat change 006 Adjust seat to allow full brake pedal travel with operator s back against seat back NOTE The seat can only be correctly adjusted with the operator fully seated Operation Section 55 Operation Section Lift Truck
73. A 2 automatic 2 position gears are started from 2 speed and changed AUTOMATICALLY to the appropriate speed up to the limit set by the gear ratio according to travel load and engine rpm Operation Section Inching Switch 3 Speed Only This switch changes over the modes of the inching control pedal inching and no inching DR In this position the NO INCHING mode is selected In the NO INCHING mode the inching pedal control is disabled but braking function by pushing on the inching pedal is still active OP In this position the INCHING mode is selected In the INCHING mode normal inching function is enabled by pushing on the inching pedal NOTE When driving a middle or long distance without using the inching function set this switch to DR position to prevent the transmission clutch pedals from unnecessary wear or overheat Operation Section Transmission Inching Control Pedal Typical Example Inching Control Pedal Pushing down on the inching pedal modulates the hydraulic pressure to the clutch packs permitting disc slippage Further pushing on the pedal completely relieves clutch pack pressure and applies the service brakes to stop and hold the lift truck NOTE The purpose of the inching control pedal is to provide precise inching control at slow travel speed with high engine rpm This is used for fast hydraulic lift during load approach pickup or positioning Ser
74. Controls Direction Control Lever Typical Example Forward Reverse F Forward N Neutral R Reverse Speed Select 1 1st 2 2nd 3 3rd 3 speed ONLY Rotating the direction control lever changes the speed of travel With handle rotated counter clockwise towards the operator the lift truck is in FIRST speed Rotate the lever clockwise away from the operator forthe SECOND and THIRD speeds Always brake to a full stop before reversing the direction of travel Do not fail to place the forward reverse lever in the neutral position before starting the engine Neutral Lever Lock 3 Speed Only A transmission neutral lever lock is in base of the direction control lever This neutral lever lock prevents the direction control lever from being moved out of NEUTRL N NEUTRAL LOCK position Prevents the direction control lever to be moved out of NEUTRAL D DRIVE position Allows the direction control lever to be moved from NEUTRAL to FORWARD and REVERSE A WARNING LOCK the direction control lever Whenever machine is parked LOCK the direction control lever in NEUTRAL to prevent accidental machine movement Transmission Display 3 Speed Only A transmission display is to the right of the steering wheel on the dash The LCD indicates gears direction of travel and error codes NZ NZ NZ UN E B C D U04U 11110 gt
75. 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 If trailer is not coupled to tractor make sure the trailer landing gear is properly secured in place On Safety Section some trailers extra supports may be needed to prevent upending or corner dipping Be certain dock plates are in good condition and properly placed and secured Do not exceed the rated capacity of dock boards or bridge plates Lift Truck Parking When leaving the operator station park the lift truck in authorized areas only Do not block traffic e Park the lift truck level with the forks lowered and the mast tilted forward until the fork tips touch the floor e Move the direction control lever to NEUTRAL e Engage the parking brake e Turn the key switch off and remove the key e Turn the disconnect switch to OFF e Block the drive wheels when parking on an incline Safety Section Maintenance Information Perform all maintenance unless otherwise specified as follows e Park the lift truck in authorized areas only e Park the lift truck level with the forks lowered and the mast tilted forward until the fork tips touch the floor e Place the transmission controls in neutral e Engage the parking brake Sto
76. Equipped Forward and Backward Adjustment The seat can be adjusted by pushing the lever on the right side of seat ce Forward and Adjustment Adjust the seat before operating the lift truck After adjusting set the seat to make sure it is properly locked DO NOT adjust the seat while the truck is in motion Weight adjustment Pull the weight adjustment lever upwards and move right or left side Adjust to driver s weight in 7 steps 50 110 kg NOTICE Do not place your hand or fingers under the seat Injury may occur as the seat moves up and down Backrest Inclination The backrest angle can be adjusted by using the lever on the left side of seat Backrest Inclination 1C100086 Seat Belt The Operator Restraint System Prevents the operator from the operator s compartment in the event of forward or side tipover The system is designed to keep the operator on the seat and in the operator s compartment in the event of tipover Inspection INSO017S 1 If the seat belt is torn if pulling motion is interrupted during extension of the belt or if the belt cannot be inserted into the buckle properly replace the seat belt assembly 2 Belt Maintenance Every 500 service hours Check that the belt fastening works properly and that winding device is free from run lock when jerked Check that the belt is suitably fastened to the seat Check that th
77. Full Auto Full Auto o A a m o a 31 General Section Specifications type Transmission CHRACTERISTICS 1 Manufacturer 2 MODEL Capacity at rated load center kg 4 electric diesel gasoline LPG 6 2 stand on rider seated 7 Trewpe e cushion p pneumatic 8 Wneespcdrven number ftonirear DIMENSIONS 9 Lift with STD maximum fork height with rated load mm mm Forks thickness x width xlength mm fork spacing minimum x maximum mm deg Overall 18 dimensions mm overhead guard height mm z 21 Turning radius minimum outside mm Load moment constant mm mm 23a mm PERFORMANCE Speed mmis mmis ig 30 Gradeability at 1 6 km h loaded WEIGHT 32 Total weight unloaded kg m a CHASSIS number of front rear Tires size front size rear 38 Wheel base mm Tread width front rear mm 8 mm round clearance mm parking brake DRIVE 45 Battery voltage capacity v ah 49 manufacturer model Eis KWihgyrom max torque N m Ib ft rpm E no speeds forward reverse 32 General Section 2 Speed DOOSAN DOOSAN DOOSAN 5755 2 5000 6000 7000 3 diese 5 fderseated 5 7 a 27 oe 3000 3000 3000 f 9 60 150 1200 60x180x1200 60x180x1200 1570 _ us 3507 218 2500 4340 2455 Ye 1888 11 26 3301 2i t 632
78. GND 912 voltage out of range low 2 Disable LPG O2 signal Pin 3 to SECM Pin B19 sensor signal shorted to Post catalyst O2Ctrl Possible sources SECM DRVG GND ground Pins A16 B17 and SECM XDRG sensor GND Pin B1 O2RangeHigh Check if O2 sensor installed before Pre catalyst O2 sensor 1 TumOnMil catalyst is shorted to 5Vdc or battery 921 voltage out of range high 2 DisableGas O2Ctr O2 signal Pin to SECM Pin B13 sensor signal shorted to SECM XDRP 5V Pin B24 power SECM DRVP 12V Pin 23 O2 PostCatRangeHigh Check TOZ sensor installed after catalyst is shorted to 5Vdc or battery Post catalyst O2 sensor 1 TumOnMil 2 signal Pin to SECM Pin B19 922 voltage out of range low 2 Disable LPG sensor signal shorted to Post catalyst O2Ctrl Possible voltage sources SECM ond 9 y XDRP 5V Pin B24 and SECM 9 DRVP 12V Pin A23 Fault actions shown are default values specified by the OEM 103 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d wire has been disconnected or the circuit has opened to the SECM x CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK FuelTempRangeLow Check fuel temp sensor connector and Fuel Temperature Sensor wiring for a short to GND Input is Low normally set if SEOM signal Pin B14 to FTS Pin 1 931 the fuel temperature sensor TurnOnMil SECM sensor GND Pin B1 to wire has shorted to chassis FTS
79. ING To prevent possible injury when adjusting diesel engines Do not use the starter motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before measuring valve clearance NOTICE Measure the valve lash with the engine stopped To obtain an accurate measurement allow at least 20 minutes for the engine cylinder head and block to cool Set the clearance to the nominal appropriate clearance given in the Valve Clearance Setting chart shown below Valve Clearances 5 8 Liter Clearance Exhaust Valves 40 mm 16 in 08585 Diesel intake Valves 40 mm 16 in Refer to the Service Manual for the complete valve adjustment procedure NOTE In case of LP Engine no valve adjustment is necessary Priming the Fuel System Diesel Engine Only Bleeding the Fuel System After changing the fuel filter or after having serviced any part of the fuel system make sure that the air is bled from the system 1 Release the feed pump cap 1 on the injection pump 2 Release an air bleed nut 2 on the injection pump 3 Operate feed pump vertical until completely remove an air 4 Tighten air bleed nut 2 5 Make sure to check leakage of injection pump amp filter after operating feed pump many times Draining the Water From the Fuel Filter Diesel Engine Only Typical Example 1 Turn the wing nut counter clockwise to o
80. Malfunction Indicator Light MIL O conE12 ON OFF ON ON 81 Operation Section Operation Section Table a 04 Diagnostic Fault Codes Flash Codes DFC Probable Fault Action Corrective Action First Check 12 NONE Signifies the end of one pass through the fault list NONE None used as a beginning and end of the fault list identification TPS1 potentiometer malfunction Improper TPS reading may be due to dirt or oxidation on the sensor traces MIL Only 14 ECTSensorlnputLow Stored Fault Code Check ECT sensor connector and Coolant sensor failure or shorted MIL Only wiring for a short to GND to GND 15 ECTSensorlnputHigh Stored Fault Code Check if ECT sensor connector is Coolant sensor disconnected or MIL Only disconnected or for an open open circuit circuit 16 ECTRangeHigh Delayed Engine Check coolant system for radiator blockage proper coolant level and E h h ngine Overeating Shutdown for leaks in the system Possible ECT short to GND check ECT signal wiring Check regulator for coolant leaks 22 ThrottleSensorInputLo Disable Throttle Check throttle connector connection TPS1 signal disconnected or and TPS1 sensor for an open circuit open circuit Expected faults when ETC connector is unplugged CODES 22 amp 24 23 ThrottleSensorInputHi Disable Throttle Check throttle connector and TPS1 TPS1 sensor failure or short
81. NEUTRAL applying the service brakes 8 Maintain the oil level between lower mark and upper mark on the dip stick filter cap 9 Install the dip stick filter cap xn Typical Example 3 Engage the parking brake and slowly release the service brake 4 If the parking brake has the correct adjustment the lift truck will be hold in place If the parking brake does not hold adjust the parking brake 157 Maintenance Section To Adjust Park the lift truck level with the forks lowered transmission in NEUTRAL the engine stopped and the wheels securely blocked Typical Example 1 Release the parking brake 2 Turn the adjustment knob clockwise to tighten the brake 3 Test the parking brake adjustment Repeat the adjustment procedure if necessary 158 Maintenance Section First 250 Service Hours or a Month 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 Change 4 Clean the filter housing with a clean nonflammable solvent WARNING 5 Clean the housing base R 6 Inserta new filter element into the filter housing Hot oil and components can cause personal injury Do not allow hot oil or components to 7 Inspect the filter housing seal Replace if contact skin necessary 8 Apply a small amount of clean oil to the filter Park the lif
82. Quick Reference to Maintenance Schedule SERVICES 50 100 Service Hours or a Week 250 Service Hours or a Month 10 Service Hours or Daily 250 Service Hours or a Monthly 500 Service Hours or 3 Months 1000 Service Hours or 6 Months 1500 Service Hours or 9 Months 2000 Service Hours or Yearly 2500 Service Hours or 15 Months When Required Air Cleaner Indicator Check Air Intake System Change Air Intake System Check Clean Battery Terminal Clean Inspect Belts Diesel E G Only Check Adjust Brake Oil OCDB Check Carburetor LP Gas Engine Only Adjust Clean Carriage Roller Extrusion Adjust Checking the TMAP Sensor LP Engine Only Coolant Level Check Clean Change Crosshead Rollers Inspect Drive Axle Oil Change Drive Axle Oil OCDB Change Drive Axle Oil Shoe Brake Only Change Drive Axle Oil Level Check Engine Oil amp Filter Diesel Engine Only Change Engine Oil amp Filter LP Engine Only Change Engine Oil amp Oil Filter Diesel E G Only Change Engine Oil Level Check Engine Valve Lash Diesel E G Only Check Adjust Fork Inspect Check Clean Fuel Filter Change Fuel Lines amp Fittings Check Fuel Tank Filter Cap amp Screen Clean Fuel Tank Filter Cap amp Screen Clean Fuel Trim Valve FTV Inspection G643E Engine only Cooling System Change Reset Horn and Lights If Equipped Check Hydraulic Oil Level Check Check
83. SB2356E01 Operation amp Maintenance Manual LIFT TRUCKS D50S 5 D60S 5 D70S 5 D80S 5 D90S 5 G50S 5 G60S 5 G70S 5 0705 A WARNING Do not start operate or service this machine unless you have read and understood these instructions and received proper training Unsafe or improper use of the machine may cause serious injury or death Operators and maintenance personnel must read this manual and receive training before operating or maintaining the machine This manual should be kept with the machine for reference and periodically by the machine operator by all personnel who will come into contact with it The following warning is provided pursuant to California Health amp Safety Code Sections 25247 5 et seq WARNING California Proposition 65 Engine Exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING Table of Contents Information Section FONGWON eee 2 Safety Section Safety Warning Signs and Labels General Hazard Information Operation Information Maintenance Information Operator Restraint System I
84. Service Manual Restricted exhaust system Check exhaust system e Measure exhaust back pressure Incorrect ignition control Incorrect air fuel control Incorrect throttle position See Advanced Diagnostics amp See Engine Service Manual 77 Operation Section Problem Probable Cause Corrective Action Excessive Fuel Air Fuel Mixer malfunction Check mixer Consumption LPG e See Engine Service Manual Exhaust Smell Air filter clogged Check air filter e Clean replace as required Vacuum leak Check system vacuum hoses from regulator to FTV and mixer e Repair replace as necessary Pressure regulator malfunction fuel pressure too high Test pressure regulator operation e See Engine Service Manual Faulty FTV G643E only Check FTV for housing cracks or obstructions e See Advanced Diagnostics FTV operation e Repair and or replace as necessary Weak ignition and or spark control See Advanced Diagnostics Incorrect air fuel control See Advanced Diagnostics Exhaust system leaks Repair exhaust system Oxygen sensor failure Replace as necessary e See Advanced Diagnostics 78 Mixer Idle Screw Power Valve Adjust G643 Engine Only Forklift have Unstable Idle RPM You can adjust idle screw Idle Screw turn to rich side turn in screw Forklift have Poor High Speed Performance you can adjust power valve po
85. Stability and Center of Gravity CG truck Combined CG CG load 50025 The stability of the lift truck is determined by the location of its CG or if the truck is loaded the combined CG of the truck and load The lift truck has moving parts and therefore has a CG that moves The CG moves forward or backward as the mast is tilted forward or backward The CG moves up or down as the mast moves up or down The CG and therefore the stability of the loaded lift truck are affected by a number of factors such as e the size weight shape and position of the load e the height to which the load is lifted e the amount of forward or backward tilt e lire pressure e dynamic forces created when the lift truck is accelerated braked or turned e condition and grade of surfaces on which the lift truck is operated Combined CG y 2 Sai lana CG truck e 4 1 500261 These same factors are also important for unloaded ift trucks They tip over sideways easier than a loaded lift truck carrying its load in the lowered position Safety Section Lift Truck Stability Base CG Truck will tip over INS00271 For the lift truck to be stable not tip over forward or to the side the CG must stay within the area of the lift truck stability base a triangular area between the front wheels and the pivot of the steer wheels If the CG moves forward of the front axle the lift truck wil
86. Stalls Fuel Lock off malfunction Repair replace Fuel Lock off e See Engine Service Manual Faulty vapor connection between the pressure regulator converter and the mixer Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Pressure regulator freezes Check level in cooling system e Must be full check coolant strength e 35F minimum Check coolant hoses e Watch for kinks and or pinched hoses e Verify one pressure hose and one return hose Pressure regulator malfunction Test pressure regulator operation e See Engine Service Manual Vacuum leak Check for vacuum leaks e Between mixer and throttle body e Between throttle body and intake manifold e Between intake cylinder head manifold Air Fuel Mixer malfunction Check mixer e See Engine Service Manual Engine Mechanical See Engine Manufacturers Service Manual Rough Idle Faulty vapor connection between the pressure regulator converter and the mixer Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Pressure regulator malfunction Test pressure regulator operation e See Engine Service Manual Vacuum leak Check for vacuum leaks e Between mixer and throttle body e Between throttle body and intake manifold e Between intake cylinder head manifold Air Fuel Mixer
87. TM D482 0 02 Weight Max 35 Min for 45 Max 40 Min for DI Engines Cetane Number ASTM D613 Not Above Lowest Expected Cloud Point ASTM D97 Ambient Temperature Gravity API ASTM D287 30 Min and 45 Max 6 C 10 F Below Ambient Min 0 5 Max See Sulfur Topic 20 0 cSt Max 1 4 cSt Min Pour Point ASTM D97 Sulfur ASTM D2788 D3605 or D1552 Viscosity Kinematic 38 C 100 F ASTM D445 Water amp Sediment ASTM D1796 As delivered to fuel system 0 01 Max Fuel Sulfur Content The percentage of sulfur in the fuel will affect the engine oil recommendations Fuel sulfur is chemically changed during combustion to form both sulfurous and sulfuric acid These acids chemically attack metal surfaces and cause corrosive wear Certain additives used in lubricating oils contain alkaline compounds that are formulated to neutralize these acids The measure of this reserve alkalinity in lubricating oil is known as its Total Base Number TBN TBN is essential to neutralize the acids from combustion gases and to minimize corrosive wear Any API classification performance of should have sufficient TBN for fuels with less than 0 5 sulfur For fuels with 0 5 to 1 5 sulfur by weight engine oil must have a TBN of 20 times the percentage of fuel sulfur as measured by the ASTM American Society of Testing Materials D 2896 method ASTM D 2896 can normally be found at
88. Tilt of mast forward backward deg 15 10 15 10 15 length to face of forks mm 3507 3568 16 width mm 2108 2108 17 Overall mast lowered height mm 2500 2500 18 dimensions mast extended height mm 4340 4340 19 overhead guard height mm 2455 2455 20 seat height mm 1333 1333 21 Turning radius minimum outside mm 3301 3331 22 Load moment constant mm 632 632 23 90 stacking aisle add load length and clearance mm 3924 3958 23a 90 intersecting aisle mm 2990 3020 PERFORMANCE 24 travel loaded unloaded km h 29 6 32 4 29 1 32 2 25 Speed lift loaded unloaded mm s 500 530 490 530 26 lowering loaded unloaded mm s 501 450 501 450 28 Drawbar pull at 1 6 km h loaded kg 5990 5945 30 Gradeability at 1 6 km h loaded 96 49 2 42 4 WEIGHT 32 Total weight unloaded kg 8570 9240 33 Axle load with loaded front rear kg 12175 1395 13585 1655 34 without loaded front rear kg 4435 4135 4300 4940 CHASSIS 35 number of front rear 4 2 4 2 36 Tires size front 8 25x15 14PR 8 25x15 14PR 37 size rear 8 25x15 14PR 8 25x15 14PR 38 Wheel base mm 2250 2250 39 Tread width front rear mm 1584 1550 1584 1550 40 loaded at the lowest point mm 176 176 Ground clearance 41 loaded at center of wheelbase mm 205 205 42 Brakes service brake foot hydraulic foot hydraulic 43 parking brake hand mechanical hand mechanical DRIVE 45 Battery voltage capacity 24 75 24 75 49 manufacturer model DOOSAN DB58S DOOSAN DB58S 50 Engine rated output at rpm KW hp r
89. Transmission Display Typical Example 19 Hour Counter 20 Warning Light Typical Example 21 Hazard Lamp Switch 22 Automatic Transmission 23 Eco amp Power Switch Inching Switch 24 Light Switch 25 Wiper Switch 26 Engine Emergency stop Switch 27 Engine Diagnostic Switch 28 Empty plug 29 Air Conditioner 30 Fan 31 Heater 32 Cigar Jack Connector 33 Power Jack Connector 47 Operation Section Instrument Panel 1 Engine Ignition Start Switch The key switch is a four position switch Position 1 is ACCESSORY ON Position 2 is OFF Position 3 is ON or RUN and accessory ON Position 4 is START which 1000003 engages the starter After the key has been turned to the START position the key must be returned to the OFF position before it can be turned to the START position again 0006 Indicates coolant temperature If the pointer moves beyond the green band while operating the lift truck overheating is indicated Park the lift truck and stop the engine Check the cooling system for a malfunction The point will be at the end of the green band when the coolant temperature reaches approximately 103 C 217 F on all engines 3 Transmission Oil Temperature Gauge Bs 000071 Indicates transmission oil temperature If the pointer moves beyond the green band while operating the lift truck excessive transmissio
90. aced evenly between pallet stringers and as far apart as load permits Typical Example 2 Move the lift truck FORWARD until the load touches the carriage Lifting the Load 1 Lift the load carefully and tilt the mast back a short distance Typical Example 2 Tilt the mast further back to cradle the load Typical Example 3 Operate the lift truck in reverse until the load is clear of the other material 4 Lower the cradled load to the travel position NOTE Lift and tilt speeds are controlled by engine rpm Traveling with the Load NOTICE Travel with the load as low as possible while still maintaining ground clearance 14000411 Typical Example 1 Carry the load as low as possible but maintain clearance 2 On grades always travel with the load on the UPHILL side as shown above IAOYO13I Typical Example 3 For better vision travel in reverse with bulky loads Operation Section Unloading 1A000421 Typical Example 1 Move the lift truck into the unloading position IKOO038l Typical Example 2 Tilt the mast FORWARD only when directly over the unloading area A WARNING Do not tilt the mast forward with the load unless directly over the unloading area even if the power is off Operation Section Typical Example 3 Deposit the load and BACK away carefully to disengage the forks 1400
91. ade of 32 would normally be selected Transmission Oil NOTICE These oils are formulated for transmissions and drive trains only and should not be used in engines Shortened engine life will result NOTE Multi grade oils are not blended by DOOSAN for use transmissions Multi grade oils which use high molecular weight polymers viscosity index improvers lose their viscosity effectiveness by permanent and temporary shear of the viscosity index improver and therefore are not recommended for transmission and drive train compartments NOTE Failure to follow this recommendation can cause shortened transmission life due to material incompatibility inadequate frictional requirements for disk materials and or excessive gear wear Select Oil that meets below specifications e 050 60 70 80 905 5 3 Speed API CD TO 2 or MIL L 2104D E e D50 60 708 5 2 Speed G50 60 70S 5 GM DEXRON Drive Axle Oil NOTE Failure to follow the recommendation will cause shortened life due to excessive gear wear Shoe Brake 1A700008 Select oil that meets below specifications e APIGL 5 e MIL L 2105 C D Gear Oil offers maximum protection against the scoring and pitting of gear teeth and rolling element bearings Gear Oil can also provide excellent stability under high temperature conditions and has superior low temperature performance It will also give protection against rust and corrosion Oi
92. ading or shifting in transit remove ice snow or other slippery material from the loading dock and the truck bed before loading NOTICE Obey all state and local laws governing the height weight width and length of a load Observe all regulations governing wide loads NOTICE Remove ice snow or other slippery material from the shipping vehicle and the loading dock 14103049 Typical Example Always block the trailer or the rail car wheels before loading the lift truck Position the lift truck on the truck bed or the rail car Apply the parking brake and place the transmission control in NEUTRAL Turn ignition switch to the OFF position and remove the key If LP equipped remove the LP fuel tank Block the wheels and secure lift truck with tiedowns Operation Section Machine Lifting and Tiedown Information NOTICE Improper lifting or tiedowns can allow load to shift and cause injury and or damage 1 Weight is given on the serial plate 2 Use proper rated cables and slings for lifting Position the crane for level lift truck lift 3 Spreader bar widths should be sufficient to prevent contact with the lift truck 4 Use the tiedown locations provided for lift truck tiedown 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 119 Operation Section Towing Information A
93. aintain the oil level to the FULL mark on the dip stick filter cap assembly Transmission Oil amp Filter 3 Speed Only Change Only for D50 60 70 80 90S 5 3 Speed See topic Transmission Oil amp Oil Filter Change in First 50 100 Service Hours or a Week Transmission Oil 2 Speed Only Change Only for D50 60 70S 5 2 Speed G50 60 70S 5 See topic Transmission Oil amp Oil Filter Change First 50 100 Service Hours or a Week 175 Maintenance Section Lift Chains Test Check Adjust Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller When the chain bends over the roller the movement of the parts against each other causes wear Inspect to be sure that chain link pins Do not extend outside of the link hole If any single link pin is extended beyond its connecting corresponding link it should be suspected of being broken inside of its link hole Lift chains are required to check for weare about every 1 000 service hours or 6 months Chain wear test is a measurement of wear of the chain links and pins Take the following steps to check chain wear 1 Lift the mast and carriage enough for getting tension on lift chains Typical example 2 Measure precisely ten links of chain distance at the center of pins in millimeter Calculate chain wear rate If the chain wear rate is 2 or more replace the lift chain Maintenance S
94. air of lift truck forks It also provides general information on the design and application of forks and the common cause of fork failures Lift truck forks can be dangerously weakened by improper repair or modification They can also be damaged by the cumulative effects of age abrasion corrosion overloading and misuse A fork failure during use can cause damage to the equipment and the load A fork failure can also cause serious injury A good fork inspection and maintenance program along with the proper application can be very effective in preventing sudden failures on the job Repairs and modifications should be done only by the fork manufacturer or a qualified technician who knows the material used and the required welding and heat treatment process Users should evaluate the economics of returning the forks to the manufacturer for repairs or purchasing new forks This will vary depending on many factors including the size and type of fork Forks should be properly sized to the weight and length of the loads and to the size of the machine on which they are used The general practice is to use a fork size such that the combined rated capacity of the number of forks used is equal to or greater than the Standard or rated Capacity of the lift truck The individual load rating in most cases will be stamped on the fork in a readily visible area This is generally on the top or side of the fork shank e A fork rated at 1500
95. ally due to noise on the None SECM Sensor GND Pin B1 to Crank signal or an intermittent sensor Pin 2 connection on the crankshaft Switched 12V to Crank sensor Pin 1 sensor Check for defective Crank sensor TPS1RangeLow Check throttle connector connection and TPS1 sensor for an open circuit or TPS1 sensor voltage out of GND range low normally set if the 21 EY y TurnOnMil SECM Pin B23 signal to ETC Pin 6 22 TPS1 signal has shorted to A SECM Pin B1 sensor GND to ground circuit has opened or sensor has failed ER Pe SECM system GND Pin A16 B17 TPS2RangeLow Check throttle connector connection and TPS2 sensor for an open circuit or TPS2 sensor voltage out of range low normally set if the GND 222 15S 1 Man ed TurnOnMil SECM Pin B4 signal to ETC Pin 5 ee SECM Pin 1 sensor GND to ground circuit has opened or ETC Pin 2 sensor has failed SECM system GND Pin A16 B17 TPS1RangeHigh Check throttle connector and TPS1 TPS1 sensor voltage out of tes fae 231 range hiah normally set if sensor wiring for a shorted circuit 23 m pale els y TurnOnMil SECM Pin B23 signal to ETC Pin 6 e SECM Pin B1 sensor GND to to power or the ground for A ETC Pin 2 the sensor has opened TPS2RangeHigh Check throttle connector and TPS1 TPS2 sensor voltage out of sensor wiring for a shorted circuit 232 range high normally set if TurnOnMil Pin 4 signal to the TPS2 signal has shorted Pin5 to power or
96. apacities 11 Start the engine and allow the oil to fill the filter and passages 12 Check for oil leaks 13 Stop the engine and measure the oil level Maintain the oil level between the MAX and MIN marks on dip stick 14 Close side cover NOTICE Servicing of the engine oil and oil filter element will largely affect the engine performance as well as the engine life Engine oil and filter element must be changed after the first 50 100 Service hours or a week 1A3M4060 Typical Example D50 60 708 5 2 Speed G50 60 708 5 1 Remove drain plug Allow the oil to drain NOTICE Careless disposal of waste oil can harm the environment and can be dangerous to persons Always dispose of waste oil to authorized and licensed personnel only 153 Maintenance Section 4 1 4061 Typical Example 2 Typical Example D50 60 708 5 2 Speed G50 60 708 5 Wash the strainer screen spring and drain plug in clean nonflammable solvent Dry the strainer spring and drain plug D50 60 705 5 2 Speed G50 60 70S 5 Only Install the drain plug 050 60 70 80 905 5 3 Speed 1A3M4030 Typical Example 4 D50 60 708 5 2 Speed G50 60 708 5 Rotate the oil filter counter clockwise to remove it Replacement Interval of Transmission Oil Filter D50 60 70S 5 3 Speed Every 1 000 Service Hours or 6 Months D50 60 70S 5 2 Speed G50 60 70S 5
97. ation Section Operation Section Starting the Engine Prestart Conditions NOTE The engine will not start unless the transmission directional control lever is in the NEUTRAL position TED Typical Example 1 Engage the parking brake engaged if not already 2 Place the transmission directional control lever in NEUTRAL position Diesel Engine Starting a Cold Diesel Engine 1 Turn the ignition key to the ON position The start preheat light will come ON The preheat light will stay ON approximately seven seconds depending on the ambient air temperature NOTICE Do not engage the starter for more than 10 seconds 2 When the preheat light goes OFF turn the ignition key to the START position with the accelerator pedal fully depressed 3 Release the ignition key when the engine starts and release the accelerator pedal to a low idle position If the engine stalls or does not start turn the ignition key to the OFF position then repeat steps 1 thru 3 Starting a Warm Diesel Engine 1 Turn the ignition key to the ON position and then to START position without waiting for the preheat light to go OFF At the same time fully depress the accelerator 2 Release the ignition key when the engine starts and release the accelerator pedal to a low idle position LP Engine WARNING LP fuel is flammable and can cause personal injury Inspect LP fuel lines and fitting for leaks Inspec
98. ault Disable Throttle Check ETC driver wiring for a Throttle driver over current or shorted circuit driver signals shorted ETC PIN1 to SECM PIN 22 ETC PIN 4 to SECM PIN 24 Perform Throttle test and with the Service Tool and re check for fault Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS PIN 1 DRIVER to PIN 4 DRIVER 3 00 30 33 Disable Throttle Check TMAP connector and MAP MAP signal disconnected open signal wiring for an open circuit circuit or sensor malfunction Expected faults when TMAP connector is unplugged CODES 33 amp 38 83 Operation Section Table a 04 Diagnostic Fault Codes Flash Codes over current DFC Probable Fault Action Corrective Action First Check 34 MapSensorlInputHigh Disable Throttle Check TMAP connector and MAP TMAP sensor failure or shorted signal wiring for a shorted circuit circuit 37 IATSensorinputLow Stored Fault Code Check TMAP connector and IAT TMAP sensor failure or shorted MIL Only signal wiring for a shorted circuit circuit 38 IATSensorInputHigh Stored Fault Code Check TMAP connector and IAT IAT signal disconnected open MIL Only signal wiring for an open circuit circuit or sensor malfunction TMAP PIN 2 to SECM PIN 4 SIGNAL TMAP PIN 1 to SECM PIN 1 GND TMAP PIN 3 to SEOM PIN 18 XDCR 5VDC To
99. axle housing and both wheel ends Allow the oil to drain into a suitable container Clean the magnetic drain plugs Check O ring seal and replace if necessary 10 Remove the wood blocking and Lower the 2 Install the drain plug carriage 3 Remove strainer assembly 11 Operate the lift truck for a few minutes And align the planetary hub drain fillAevel plugs to the horizontal position Remove the plugs 12 Fill the planetary hubs through the drain fillAevel hole until the oil reaches the hole See the section Refill Capacities 13 Clean and reinstall the planetary hub drain fill level plugs 4 Wash the nonflammable solvent and dry it strainer assembly clean 5 Install the strainer assembly and reconnect the hose and harness 156 Maintenance Section Parking Brake Test Adjust A 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 1A700004 NOTE Be sure area around the lift truck is clear of 6 Remove the dip stick filter cap Fill the drive axle personnel and obstructions housing with oil See Lubricant Specification Drive Axle Oil and Refill Capacity 1 Drive the lift truck with a rated load up a 15 incline 7 Start the lift truck With the engine at low idle place the directional control lever to the 2 Halfway up the incline stop the lift truck by
100. bent or twisted blades and shanks Make sure positioning lock is in place and working Lock the forks in position before using the truck See 2000 Service Hours or Yearly in Maintenance Intervals 3 Remove all defective forks from service Maintenance Section 12 Months Inspection Forks should be inspected at a minimum every 12 months If the truck is being used in a multi shift or heavy duty operation they should be checked every six months See Forks in the 2000 Service Hours or Yearly in Maintenance Intervals Maintenance and Repair 1 Repair forks only accordance with the manufacturer s recommendations Most repairs or modifications should be done only by the original manufacturer of the forks or an expert knowledgeable of the materials design welding and heat treatment process The following repairs or modifications SHOULD NOT be attempted Flame cutting holes or cutouts in fork blades Welding on brackets or new mounting hangers Repairing cracks or other damage by welding Bending or resetting The following repairs MAY be performed Forks may be sanded or lightly ground to remove rust corrosion or minor defects from the surfaces Heel sections may be ground with a carbon stone to remove minor surface cracks or defects Polish the inside radius of the heel section to increase the fatigue life of the fork Always grind or polish in the direction of the blade and shank length
101. brake engaged transmission in NEUTRAL and the engine stopped ET N IPMO075P 1 Remove the hydraulic tank drain plug located on the bottom of the frame Allow the oil to drain in a suitable container Clean and install the plug IDOMO39P 2 Loosen the bolts of the hydraulic tank cover 3 Remove the strainer from the tank 4 Install the new strainer by hand 5 Install the hydraulic tank cover and fasten the bolts Remove the breather Wash the breather solvent and dry it in clean nonflammable Fill the hydraulic tank See Refill Capacities topic Install the breather 10 11 12 13 14 15 16 17 18 Remove the floor plate Remove bolts and filter housing Remove and discard filter element from filter housing Clean the filter housing with clean nonflammable solvent Clean the housing base Insert a new filter element into the filter housing Inspect the filter housing seal necessary Replace if Apply a small amount of clean oil to the filter element seal and housing seal Install the filter housing with filter to the housing base Install bolts and tighten 20 to 30 Nem 15 to 20 Ib ft 19 Start the engine and operate the hydraulic controls and the steering system through a few cycles to fill the lines Look for oil leaks 20 Stop the engine and check the oil level With all cylinders retracted m
102. cc 4 6 4294 4 6 4294 55 Transmission type 56 no speeds forward reverse Power Shift Power Shift 34 2 General Section TIER 3 DOOSAN DOOSAN G70S 5 G50S 5 DOOSAN DOOSAN G70S 5 6000 7000 5000 600 600 LPG LPG rider seated rider seated i 600 7000 600 LPG rider seated 23 4 2 4 2 4 2 2 Tl Minimum Aisle 90 Stac 3000 3000 3000 3000 9 f 205 205 205 205 0 60 180 1200 60 150 1200 410 2032 350 2032 410 2032 410 2032 gt F GERM eG AG 9 21 S 632 632 632 632 22 4000 3058 3924 2990 e 3958 3020 4000 3058 23 6 25 4 380 410 490 460 4965 24 0 25 4 380 410 490 460 5010 23 8 25 4 380 410 490 460 4990 23 6 25 4 380 410 490 460 313 40 9 35 5 30 4965 31 3 9635 14650 1985 3815 5820 8235 11840 1395 4100 4135 EG 4 2 8 25x15 14PR 8 25x15 14PR 2250 1584 1550 176 4 8 25x15 14PR 8 25x15 14PR 2250 1584 1550 176 ajjaja o N ala 8905 9635 13260 1645 14650 1985 3975 4930 3815 5820 4 2 8 25x15 14P 8 25x15 14P 2250 1584 1550 176 32 3 R R 8 25x15 14PR 8 25x15 14PR 2250 1584 1550 205 foot hydraulic 205 foot hydraulic 4 2 5 205 41 foot hydraulic 176 20 hand mechanical hand mechanical 12 75 G643E TIER 2 69 0 2450 301
103. cessary 3 Install the cap Maintenance Section Clean Outside of Radiator Core A 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 Compressed air high pressure water or steam can be used to remove dust leaves and general debris from a radiator Clean as required by condition of radiator The use of compressed air is preferred Carriage Roller Extrusion Adjust 1 Set the mast vertical 2 Lower the carriage completely 3 On full free lift and full free triple lift models the bottom of the inner mast must be flush with the bottom of the stationary mast Carriage roller extrusion 18206381 4 Measure the distance from the bottom of the inner upright to the bottom of carriage bearing 5 The measurement A must be as follows in Chart below Height of carriage roller extrusion A STD mast FF mast FFT mast D50 60 70S 5 3 Speed 2 Speed G50 60 70S 5 23 26 D80 90S 5 3 Speed Maintenance Section Brake Oil OCDB Check Only for Oil Cooled Disc Brake The brake reservoir is located on the left side of the steering column 1 Remove the filter cap 2 Maintain the brake fluid level to the fluid level mark on the brake system reservoir 3 Clean and
104. check the IAT sensor of the TMAP disconnect the connector and measure the IAT resistance See the IAT table in Chapter 6 0 42 EST1Low Stored Fault Code Check coil driver wiring and Coil driver signal low or MIL Only connector for shorts under current SECM PIN 7 EST1 to COIL PINA Verify GND on COIL PIN B Verify GND on COIL PIN C Verify GND on COIL PIN D Verify 12vdc on COIL PIN E To check the Smart Coil internal circuit disconnect the coil connector and measure the resistance from pin to pin See Smart Coil resistance check in Chapter 6 0 43 EST1High Stored Fault Code Check coil driver wiring for an open Coil driver signal high MIL Only circuit or disconnected connector 84 Table 04 Diagnostic Fault Codes Flash Codes Operation Section 8 0 VDC DFC Probable Fault Action Corrective Action First Check 53 BatterySensorlnputLow Stored Fault Code Check battery voltage Battery voltage measured below MIL Only Perform maintenance check on electrical connections to the battery and chassis ground e Check battery voltage during starting and with the engine running to verify charging System and alternator function e Measure battery power at the SEOM with a multimeter 54 BatterySensorlnputHigh Battery voltage measured above 415 9 VDC Stored Fault Code MIL Only Check battery and charging system voltage Check battery voltage during starting and with the engine running Ch
105. ck Close hood and seat assembly 163 Maintenance Section Hydraulic Oil Level Check Drive Axle Oil Level Check A WARNING A 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 Remove the filter cap slowly to relieve pressure 1 Operate the lift truck for a few minutes to warm the oil Park the lift truck on a level surface with the forks lowered mast tilted back parking brake engaged transmission in NEUTRAL and the engine stopped 2 Raise the hood and seat assembly Make sure the air lift cylinder securely holds the hood open Typical Example 3 Check the oil level 4 Maintain the oil level to the FULL mark on the dip stick filter cap assembly 5 Install the dip stick filter cap assembly Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Shoe Brake Type Park the lift truck on a level surface parking brake applied transmission in neutral 1 Raise the carriage high enough to access the drive axle hosing level fill plug 2 Block the bottom of the carriage with a block of wood to hold the carriage in the raised position 3 Turn the ignition switch OFF 4 Remove the drive axle housing level fill plug 5 Check if oil reaches the bottom of level fill h
106. ck should be as large as the disabled lift truck Satisfy yourself that the towing lift truck has enough brake capacity weight and power to control both lift trucks for the grade and the distance involved To provide sufficient control and braking when moving a disabled lift truck downhill a larger towing lift truck or additional lift trucks connected to the rear could be required This will prevent uncontrolled rolling The different situation requirements cannot be given as minimal towing lift truck capacity is required on smooth level surfaces to maximum on inclines or poor surface conditions Consult your DOOSAN Lift Truck dealer for towing a disabled lift truck Typical Example 1 Release the parking brake NOTICE Release the parking brake to prevent excessive wear and damage to the parking foot brake system 2 Check that the service foot brake pedal is released 3 Key switch is in the OFF position 4 Direction control lever is in neutral 5 Fasten the tow bar to the lift truck 6 Remove the wheel blocks Tow the lift truck slowly Do not tow any faster than 2 km h 1 2 mph A WARNING Be sure all necessary repairs and adjustments have been made before a lift truck that has been towed to a service area is put back into operation Maintenance Section Inspection Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for inspection maintenance and rep
107. ck to coast but not automatically stop 3 To restore the lift truck to normal operation while sitting in the operator s seat depress the brake pedal to hold the lift truck return the directional lever to the neutral position and then reselect a direction of travel either forward or reverse The transmission will then re engage 4 If seat or seat switch replacement becomes necessary be sure to use genuine DOOSAN Infracore lift truck parts Lift trucks should never be operated without an operational SEAT SWITCH SYSTEM Steering Column Tilting Angle Adjustment Typical Example The tilting angle of the steering wheel is adjustable within a range of 15 degrees to suit individual operators The steering column is unlocked by turning the lever counter clockwise and locked by turning it clockwise Tow Eye Typical Example It is for emergency use in towing a disabled vehicle or being towed by another truck when your truck is disabled Use wire rope strong enough according to the weight and size of the vehicle to be towed 53 Operation Section Fuse Box Typical Example Fuse Locations 6 7 8 9 10 11 12 BAT 2 3 4 5 BAT 6 7 EEEE T ja ia 198 is is X amp X A t ji m d 4 2 4 J 4 BAT ST C Li ia dm do d9 is 51 1 IGN 1 IGN 2 ACC 1 2 J 1 2 3 4 5 Fu
108. cking or other ETC faults e Verify if the lift truck was motored down a steep grade 61 PedaliSensorInputLo MIN Power Limit Check foot pedal connector APP1 signal disconnected open circuit or sensor malfunction Expected faults when APP connector is unplugged CODES 61 amp 66 62 1 MIN Power limit Check foot pedal connector APP1 sensor failure or shorted circuit 63 Pedal1SensorRangeLo Stored Fault Code Check foot pedal connector APP1 potentiometer malfunction MIL Only Improper APP1 reading may be due to dirt or oxidation on the sensor traces 64 Pedal1 SensorRangeHi Stored Fault Code Check foot pedal connector 86 Table 04 Diagnostic Fault Codes Flash Codes Operation Section FTV modulation driver signal fault G643E only MIL Disable Adaptive learns DFC Probable Fault Action Corrective Action First Check 65 Pedal2SensorlnputLo MIN power Limit Check foot pedal connector APP2 sensor failure or shorted circuit 66 Pedal2SensorlnputHi MIN power Limit Check foot pedal connector 2 signal disconnected open circuit or sensor malfunction Expected faults when APP connector is unplugged CODES 61 amp 66 67 Pedal2SensorRangeLo Stored Fault Code Check foot pedal connector APP2 potentiometer malfunction MIL Only Improper APP2 reading may be due to dirt or oxidation on the sensor traces 68 Pedal2SensorRangeHi Stored Fault Code
109. d loose rollers 5 Inspect the carriage forks or attachments for wear damage and loose or missing bolts 6 Inspect the tires and wheels for cuts gouges foreign objects inflation pressure and loose or missing bolts 63 Operation Section Typical Example LP Engine 10 Inspect the engine compartment for oil coolant and fuel leaks Typical Example LP Engine 11 Measure the engine crankcase oil level with the dip stick Maintain the oil level between the MAX and MIN or FULL and ADD notches on the dip stick Typical Example Diesel Engine Typical Example LP Engine 12 Observe the engine coolant level in the coolant recovery bottle With the engine cold maintain the level to the COLD mark If the recovery bottle is empty also fill the radiator at the top tank Typical Example 13 Observe the fuel level gauge after starting the truck Add fuel if necessary A WARNING Personal injury may occur from accidents caused by improper seat adjustment Always adjust the operator s seat before starting the lift truck engine Seat adjustment must be done at the beginning of each shift and when operators change 060 016 Typical Example 14 To position the seat PUSH the lever away from the seat track and move the seat forward or backward to a comfortable position 15 Inspect seat belt for wear and correct operation 65 Oper
110. d 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 The information specifications and illustration in this publication are on the basis of information available at the time it was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes can affect the service given to the product Obtain the complete and most current information before starting any job DOOSAN dealers have the most current information available Safety The safety rules and regulations in this section are representative of some but not all rules and regulations noted under the Occupational Safety and Health Act OSHA and are paraphrased without representation that the OSHA rules and regulations have been reproduced verbatim Please refer to 1910 178 in Federal Register Vol 37 No 202 the National Fire Protection Association No 505 NFPA American National Standard ANSI B56 1 Safety Standard for Low lift and High Lift Trucks and subsequent revisions for a complete list of OSHA rules and regulations as to the safe operation of powered industrial lift trucks Since regulations vary from country to country outside in U S A operate this lift truck in accordance with local regulations DOOSAN lift trucks are manufactured according to the regulations and standards laid down
111. d up grade 7 Watch out for pedestrians and obstructions Check overhead clearances 8 Do not permit riders on forks or machine at any time 9 Do not allow anyone to stand or pass under the elevated portion of any machine 10 11 12 13 14 15 16 17 18 Be sure operating surface can safely support machine Operate machine and attachments only from operator s position Do not handle unstable or loosely stacked loads Use minimum tilt when picking up or depositing a load Use extreme care when handling long high or wide loads Forks should be completely under load and spread apart as far as load permits Machine should be equipped with overhead guard or equivalent protection Where load requires it use load backrest extension Use extreme caution if operating without these devices Parking Lower lifting mechanism to floor Put directional control or shift lever in neutral Set parking secondary brake Turn ON OFF Switch off Chock wheels if machine is on incline Disconnect battery when storing electric machines Observe safety rules when handling fuel for engine powered machine and when changing batteries for electric machines Pressure Warning A WARNING Contents under pressure may be hot Allow to cool before opening 0031 Located on the radiator top tank by the radiator cap Hand Placement Warning A WARNING No hands Do not place hands
112. derstand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Carburetor LP Gas Engine Only Adjust Clean If the engine is hard to start or the exhaust is smoking the carburetor may need cleaning and adjusting Before adjusting the carburetor make sure the engine is at normal operating temperature Park the lift truck with the forks lowered parking brake applied transmission in neutral and the engine stopped For the complete procedure and specifications for your specific engine see the Service Manual Fuel Filter Check Clean Change Diesel Engine Park lift truck with the forks lowered parking brake applied transmission in neutral engine stopped and cool 1 Raise the right side cover A WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Turn the disconnect switch OFF or disconnect the battery when changing fuel filters Typical Example Diesel Engine Truck 2 Remove fuel filter cartridge assembly 3 Before installing a new cartridge assembly apply a small amount of clean fuel to the filter cartridge gasket NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts 4 Install the new fuel filter cartridge assembly 5 Turn the new fuel filter cartridge assembly until the fi
113. e If light comes on it indicates loss of air pressure NOTE Do not idle engines for prolonged periods of time These engines can be started easily even when hot Operation Section NOTE At an oil temperature in the shifting circuit lower than 12 C the transmission must be warmed up for some minutes This must be carried out in Neutral with an increased engine speed about 1500 rpm Until this oil temperature is reached the Electronics remains in Neutral and the symbol of the cold start phase will be indicated on the Transmission Display Indication on the Transmission Display P lt After the indication on the Transmission Display is extinguished the full driving program can be utilized out of NEUTRAL 4 The engine oil pressure indicator light 1 will not come ON with the engine running unless there is low or no oil pressure Stop the engine immediately if the light comes ON 5 The G643E engine MIL Malfunction indicator Light will not come ON with engine running unless the fault or faults are stored in the memory of the engine control module ECM Stop the engine and check the electric engine control system if the light comes ON Refer G643E Engine of this section io 7 6 o E 62 1 2 1 Engine oil pressure indicator light 2 Engine malfunction indicator light 69 Operation Section Electronic Controlled Spark Ignition Engines G643E Engine EMS E
114. e backrest and centered on the forks NOTICE 1 Capacity Nameplates originally attached to forklifts sold by DOOSAN shall not be removed altered or replaced without DOOSAN s approval 2 DOOSAN assumes no responsibility for lift trucks placed in service without a valid DOOSAN Nameplate 3 If necessary to change your specification contact your DOOSAN lift truck dealer 22 Safety Rules LICENSE Only properly trained and authorized personnel should operate forklift trucks Wear a hard hat and safety shoes when operating a lift truck Do not wear loose clothing Inspect and check the condition of your forklift truck using the operator s check list before starting work Immediately report to your supervisor any obvious defects or required repairs Do not operate your truck in unauthorized areas Know your forklift truck and think safety Do not compromise safety Follow all safety rules and read all warning signs Safety Section Do not operate a lift truck unless you are in the operators seat Keep hands and feet inside the operator s compartment Do not put any part of the body outside of the operator s compartment Never put any part of body into the mast structure or between the mast and the truck Do not start stop turn or change direction suddenly or at high speed Sudden movement can cause the lift truck to tip over Slow the speed of your truck and
115. e Hours or a Week Maintenance Section Horn Lights If Equipped Check Typical Example 1 Press horn button to determine if horn is operational 2 Check and replace all defective gauges 3 Check all lights such as warning directional backup driving and flood lights for correct operation Replace all burned out bulbs Have repairs made if needed Overhead Guard Inspect Typical Example 1 Check tightness of overhead guard mounting bolts at 240 Nem 175 lb ft 2 Check overhead guard for bent or cracked sections Have repairs made if needed Steer Susension Inspect 1 Inspect the suspension mounting bolts Tighten suspension each four mounting bolts total eight bolts if necessary to 240 40Nem 177 29 Ibeft 2 Look for leaks at the power steering hose and tube connections 3 Remove any trash buildup on the suspension or steer axle Universal Joint Inspect Lubricate Typical Example Check for worn or damaged bearings Check for loose retaining bolts and nuts Tighten the bolts and nuts if necessary 55N m 41 lb ft Lubricate one fitting on the universal joint Maintenance Section Engine Oil amp Filter Diesel Engine Fuel Trim Valve FTV Inspection Only Change G643E Engine only Diesel Engine Crankcase See topic Engine Oil amp Filter Diesel E G Only Change in First 50 100 Service Hours or a Week Inspect
116. e 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 NOTICE Do not clean the elements by bumping or tapping them Inspect filter elements after cleaning Do not use a filter with damaged pleats gaskets or seals When cleaning with pressure air use 205 kPa 30 psi maximum pressure to prevent filter element damage When cleaning with pressure water use 280 kPa 40 psi maximum pressure to prevent filter element damage Have spare elements on hand to use while cleaning used elements The primary element should be replaced after a years service or after cleaning no more than 6 times Air 205 kPa 30 psi Maximum Pressure IAOM4010 Direct air on the inside and outside of the element along the length of the pleats Check the element for any tears rips or damage Water 280 kPa 40 psi Maximum Pressure 4011 Direct water the inside and outside of the element along the length of the pleats Air dry it thoroughly and then examine it Detergent 1 Wash the element in warm water and mild household detergent 2 Rinse the element with clean water See instructions in preceding topic for cleaning with water 3 Air dry it thoroughly and then examine it Checking Element IAOM4012 1 Insert a light insid
117. e seat is correctly secured to the hood and the chassis On visual inspection fastenings must be intact otherwise contact the safety manager A 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 Safety Section 3 In the event of 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 e Cutorfrayed strap e Worn or damaged hardware including anchor points e Buckle or retractor malfunction Loosen stitching A WARNING The seat belt may cause the operator to bend at the waist If you are pregnant or have suffered from some abdominal disease consult a doctor before you use the seat belt Fasten the Seat Belt Buckle 1 Grip the plate connector of the belt and pull the belt from the retractor Then insert the plate into the slot of the buckle until a snap is heard Pul on the belt to confirm it is latched 2 Make sure the belt is not twisted Safety Section A WARNING Release the Seat Belt If you fasten the belt across your abdomen the belt may injure your abdomen in an accident P
118. e the clean dry element and examine it Discard the element if tears rips or damage are found 2 Wrap and store good elements in a clean dry place Engine Oil amp Filter LP Engine Only Change LP Engine Crankcase 1 A WARNING Operate lift truck a few minutes to warm oil Park the lift truck with the forks lowered parking brake applied transmission in neutral and the engine stopped Raise rear of lift truck off ground and block securely Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 1A3M4095 Remove the crankcase drain plug and allow oil to drain Clean and install drain plug Raise the hood and seat assembly Remove and discard oil filter element Wipe sealing surface of oil filter element mounting base Make sure all of the old gasket is removed Before installing a new filter element apply a small amount of clean engine oil to the filter element gasket Install the new filter element When the gasket contacts the base tighten it 3 4 of a turn more Do not overtighten Raise the lift truck remove the blocking and lower the lift truck 13 14 Maintenance Section Fill the crankcase See Refill Capacities Start the engine and allow the oil to fill the filter and passages Check for oil leaks Stop the engine and measure the oil level Maintain the oil level to the FULL mark on the dip sti
119. eat Equipped 18 Improper Modification or Repair 122 Inching into Loads 112 Inching Switch 3 Speed Only 57 INCHING sists Hie edi Inspect Battery System Inspect Coolant Hoses LP Engines Only 173 Inspect Electrical System G643E Engine only 171 Inspect Engine for Exhaust 1 149 Inspect Foot Pedal Operation LP Engine Only 149 Inspect for Intake Leaks LP Engine Only 186 Inspect Ignition System LP Engine Onlly 178 Inspect Mixer Assembly LP Engine 173 Inspect Throttle Assembly LP Engine Only 173 Inspect 6 222 2 2 167 Inspect Vacuum Lines and Fittings G643 E Engine ene hne eet alae 171 Inspection Engine for Fluid Leaks 147 Inspection Maintenance and Repair of Lift Truck FOKS ML EL Reo Led 121 Instrument Panel ceci 48 n m 187 Index Section L Lift Chain Adjustment Lift Chain Wear Test Lift Chains Test Check itt eni taire ties 59 Lift Fork Adjustment 117 Lift Truck Capacity Rating 45 Lift Truck Controls entree 56 Lift Truck Operation
120. eck voltage regulator alternator and charging system Check battery and wiring for overheating and damage Measure battery power at the SECM with a multimeter 55 XDRPSensorinputLow 5VDC Transducer power supplied by the SECM to the sensors is below 4 60VDC Expected faults Transducer power is lost CODES 22 24 33 62 64 66 68 amp 69 when Engine Shutdown Measure transducer power at the TMAP connector with a multimeter Verify transducer power at the SEOM with a multimeter Verify transducer power at ETC with a multimeter Verify transducer power to the foot pedal with a multimeter 85 Operation Section Table 04 Diagnostic Fault Codes Flash Codes DFC Probable Fault Action Corrective Action First Check 56 XDRPSensorlnputHigh 5VDC Transducer power supplied by the SECM to the sensors is above 5 20VDC Engine Shutdown Measure transducer power at the TMAP connector with a multimeter Verify transducer power at the SECM with a multimeter Verify transducer power at ETC with a multimeter Verify transducer power to the foot pedal with a multimeter APP1 potentiometer malfunction Improper APP1 reading may be due to dirt or oxidation on the sensor traces MIL Only 57 Engine OverSpeed Engine Shutdown Usually associated with additional Engine RPM increased beyond ETC faults maximum RPM set point e Check for ETC Sti
121. econd fork Repeat Step a Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Inspect Battery System Checking the TMAP Sensor LP Engine Only e Clean battery outer surfaces with a mixture of baking soda and water 1 Verify that the TMAP sensor 2 is mounted e Inspect battery outer surfaces for damage and tightly into the manifold adapter 3 with no replace as necessary leakage 2 If the TMAP is found to be loose remove the TMAP retaining screw and the TMAP sensor from the manifold adapter 3 Visually inspect the TMAP O ring seal for damage Replace as necessary 4 Apply a thin coat of an approved silicon lubricant to the TMAP o ring seal 5 Re install the TMAP sensor into the manifold adapter and securely tighten the retaining screw e Remove battery cable and clean repair and or replace as necessary 1 Adapter Throttle body 2 TMAP sensor 3 Adapter Manifold 4 Throttle body 185 Maintenance Section Inspect for Intake Leaks LP Replace Oxygen Sensor G643E Engine Only Engine Only 1 Visually inspect the intake manifold throttle assembly 4 and manifold adapters 3 for looseness and leaks Repair as necessary Replace PCV Valve and breather element Change LP Engine Only 1 Loosen the hose c
122. ection Check for Equal Tension Typical example Lift the carriage and the mast high enough for getting tension on lift chains Check the chains and make sure the tension is the same Lift chains are required to check for equal tension about every 1 000 service hours or 6 months A WARNING Personal injury can be caused by sudden movement of the mast and carriage Keep hands and feet clear of any parts that can move Lift Chain Adjustment U Typical example for carriage equal tension If the tension is not the same on both chains take the procedure as follows NOTE If carriage height is not correct make adjustments by following procedures Carriage Chain Adjustment STD Mast D Typical example for carriage chain of STD mast Make sure that carriage height is correct If correct adjust chain for equal tension If not adjust chain for correct carriage height by adjusting anchor nuts 1 NOTE See the previous section Carriage Roller Extrusion in When Required for proper carriage height 1 Fully lower the carriage and tilt mast forward or lift the carriage and put blocks under the carriage to release the tension from the lift chains 2 Adjust nut 1 to get proper distance from the bottom of inner upright to the bottom of carriage bearing 3 Make adjustment anchor nut 1 for equal chain tension 4 Set the mast vertical and raise the carriage and check equal chain
123. ed Replace Spark Plugs LP Engine Only 1 Disconnect Battery Cables 2 Using a gentle twisting motion remove the high voltage cables from the spark plugs Replace any damaged cables 3 Remove the spark plugs 4 Gap the new spark plugs to the proper specifications G643 E Engine 0 9mm 0 035 inch 5 Apply anti seize compound to the spark plug threads and install G643 E Engine 30 Nem 22 Ib ft A CAUTION DO NOT OVERTIGHTEN THE SPARK PLUGS 6 Re install the high voltage cables IAOM017P p V 1 _ WIRE Replace LP Fuel Filter Element LP Engine Only Park the lift truck in an authorized refueling area with the forks lowered parking brake applied and the transmission in Neutral 1 Close the fuel shutoff valve on the LP Fuel tank Run the engine until the fuel in the system runs out and the engine stops N Turn off the ignition switch e Scribe a line across the filter housing covers which will be used for alignment purposes when re installing the filter cover 1 SCREW 4 Remove the cover retaining screws 1 Maintenance Section Fuel Filter Disassembly 5 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 6 Replace the filter element 7 7 Check bottom cover O ring seal 6 for damage Replace if necessary 8 Re assemble the filter assembly aligning the sc
124. ed 16 Rotate the tank cradle forward of the truck and lock it with latch Connect the fuel supply line 17 Open the fuel valve by slowly turning the valve counterclockwise If the fuel valve is opened too quickly a back pressure check valve will shut off the fuel supply If this happens close the fuel valve completely Wait five seconds and then open the fuel valve very slowly 18 Inspect the LP fuel lines and fittings with a soap solution after filling the tank or when looking for leaks Operation Section Before Starting the Engine Walk Around Inspection 7 Inspect the overhead guard for damage and loose or missing mounting bolts 8 Inspect the hydraulic system for leaks worn Make a thorough walk around inspection before hoses or damaged lines mounting the lift truck or starting the engine Look for such items as loose bolts debris buildup oil or 9 coolant leaks Check condition of tires mast carriage forks or attachments Have repairs made Look for transmission and drive axle leaks on the lift truck and on the ground Typical Example 1 Inspect the operator s compartment for loose items and cleanliness 2 Inspect the instrument panel for broken or damaged indicator lights or gauges 3 Test the horn and other safety devices for proper operation Typical Example Diesel Engine 2 speed Typical Example 4 Inspect the mast and lift chains for wear broken links pins an
125. ed sensor wiring for a shorted circuit circuit 24 ThrottleSensorRangeLo Stored Fault Code Check the throttle connector and TPS1 potentiometer malfunction MIL Only pins for corrosion Improper TPS reading may be due to dirt or oxidation on the sensor traces 25 ThrottleSensorRangeHi Stored Fault Code Check the throttle connector and pins for corrosion 82 Table a 04 Diagnostic Fault Codes Flash Codes Operation Section DFC Probable Fault Action Corrective Action First Check 26 ETCSticking Engine Shutdown Check for debris or obstructions Throttle plate sticking inside the inside the throttle body throttle body or the ETC driver Check throttle plate shaft for signal is open bearing wear e Check the ETC driver wiring for an open circuit 27 PredictedTPSDifference Engine Shutdown Check for manifold leaks between Measured TPS1 is different than the throttle and the engine SECM Calculated throttle position Note Fault Code 27 is predicted TPS This fault means that the throttle calculated prediction for throttle Do not agree This code often comes up as suspected during transient manuevers It is not system trouble If the fault really sets then the engine will shut down 28 ETCSpringTestFailed Power Limit Perform throttle spring test by Upon initial key up the internal oe key throttle return spring has become TE ETECO TIAL weak 29 ETCDriverF
126. efer to the topic Walk around Inspection in Every 10 Service Hours or Daily section of this manual Adjust the seat so that full brake pedal travel can be obtained with the operator s back against the seatback Make sure the lift truck is equipped with a lighting System as required by conditions Make sure all hydraulic controls are in the HOLD position Make sure the direction control lever is in the NEUTRAL position Make sure the parking brake is engaged Make sure no one is standing and or working on underneath or close to the lift truck before operating the lift truck 11 Safety Section Operate the lift truck and controls only from the operator s station Make sure the lift truck horn lights backup alarm if equipped and all other devices are working properly Check for proper operation of mast and attachments Pay particular attention to unusual noises or erratic movement which might indicate a problem Make sure service and parking brakes steering and directional controls are operational Make sure all personnel are clear of lift truck and travel path Refer to the topic Lift Truck Operation in the Operation Section of this manual for specific starting instructions Starting the Lift Truck 14101011 Do not start the engine or move any of the controls if there is DO NOT OPERATE or similar warning tag attached to the start switch or controls Before Operating the
127. ehicle Speed ASC 200 5 5 0km h 3 11mph ASC 201 6 6 78km h 4 21mph Operation Section Direction Inhibit Point SW2 Auto Shift allows you to set the Direction Inhibit Speed the maximum travel speed at which the transmission can be reversed For adjustment of direction inhibit speed the SW2 switch is used on the printed circuit board Using a philips screwdriver turn the SW1 adjustment until the white dot is next to the notch corresponding to the selected vehicle speed You may reset Inhibit Speed to one of ten settings between a minimum of 3 3km h 2 05mph and a maximum of 6 0km h 3 75mph travel speed SW2 FWD RVS SHIFT Direction Inhibit Point Notch Vehicle Speed 3 3km h 2 05mph 3 6km h 2 24mph 3 9km h 2 42mph 4 2km h 2 61mph 4 5km h 2 80mph 5 1km h 3 17mph 5 4km h 3 36mph 5 7km h 3 54mph A Ww Pp 4 8km h 2 98mph 6 0km h 3 73mph For example if SW2 is put 7th notch the Direction nhibit Speed will be 5 4km h 3 36mph which is factory setting value as a default Product Notch Adaptable ASC 200 7 5 4km h 3 36mph ASC 201 3 4 2km h 2 61 mph NOTICE The transmission of your lift truck may be reversed under full power up to a travel of 6 0 km h 3 73 mph But the Inhibit Speed of Auto Shift is set by the factory at 4 5 km h 2 5 3 2 mph because reversing the transm
128. eight of the load is centered on the truck 4 After adjustment set the hook pins to keep the forks in place 117 Operation Section Storage Information Before Storage Before storing your lift truck clean and inspect as per the following procedures 1 Wipe away grease oil etc adhering to the body of the truck with waste cloth and use water if needed While cleaning the truck check general condition of the truck Especially check the truck body for dents or damage and tires for wear or nails or stones in the tread Fill the fuel tank with fuel specified Check for leakage of hydraulic oil engine oil fuel or coolant etc Apply grease where needed Check for looseness of nuts and bolts especially hub nuts Check mast rollers to see that they rotate smoothly Prime the oil into the lift cylinders by actuating the lift lever all the way several times Drain off coolant completely in cold weather if antifreeze is not used Long Time Storage Perform the following service and checks in addition to the Parking the lift truck services 1 N e Taking the rainy season into consideration park the machine on higher and hard ground Avoid parking on soft grounds such as an asphalt ground in summer Dismount the battery from the machine Even though the machine is parked indoors if the place is hot or humid the battery should be kept in a dry coo
129. ent of the belt Correct adjustment allows 10 mm 3 8 inch deflection under 110 N 25 Ib of force Xi 14704018 1 Lower the forks and tilt the mast forward 2 Lubricate the two fittings for the mast hinge pins one on each side of the mast 168 Tilt Cylinders Check Adjust Lubricate Chassis Pivot Eyebolts Typical Example 1 Lubricate two fittings for the pivot eyebolts one on each tilt cylinder 2 Check the pivot eye pins for loose retainer bolts and wear Mast Pivot Eyes Typical Example 1 Lubricate two fittings for the mast pivot eyes one on each side of the mast 2 Check the pivot eye pins for loose retainer bolts and wear Maintenance Section Crosshead Rollers Inspect 1 Operate the mast through a lift cycle Watch the chains move over the crosshead rollers Make sure the chain is tracking over the rollers properly 2 Check for damaged crosshead rollers guards and retainer rings Transmission Oil Filter 2 Speed Only Change Only for D50 60 70S 5 2 Speed G50 60 70S 5 See topic Transmission Oil amp Oil Filter Change in First 50 100 Service Hours or a Week Parking Brake Test Adjust See topic Parking Brake Test Adjust First 50 100 Service Hours or a Week Drive Axle Oil OCDB Change See topic Drive Axle Oil Change in First 50 100 Servic
130. er safety devices for proper operation Diesel Engine 2 Speed Maintenance Section 8 10 LP Engine Inspect engine compartment for oil coolant and fuel leaks Inspect the cooling system for leaks worn hoses and debris buildup Inspect the carriages forks or attachments for wear damage and loose or missing bolts Visually inspect forks for cracks especially in the heel section around the mounting brackets and all weld areas Inspect for broken or jagged fork tips bent or twisted blades and shanks Make sure positioning lock is in place and working Lock the forks in position before using the truck See Step 7 of Forks in Every 2000 Service Hours or Yearly Remove all defective forks from service 150 Mast Channels Lubricate E Typical Example The channels on the roller type mast require a break in period Apply a light film of lubricant on the channels where the rollers ride This will prevent metal peel until the rollers set a pattern Transmission Oil Level Check A 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 transmission reaches normal operating temperature about 80 C 2 Park the lift truck level with the forks lowered parking brake applied and the transmission controls in NEUTRAL 3 With the service brake applied and the engine a
131. ervice Hours or Monthly 160 Every 500 Service Hours or 3 Months 168 Every 1000 Service Hours or 6 Months 172 Every 1500 Service Hours or 9 Months 178 Every 2000 Service Hours or Yearly 181 Every 2500 Service Hours or 15 Months 185 Index Section 187 Information Section Foreword Literature Information This manual should be stored in the operator s compartment in the literature holder or seat back literature storage area This manual transportation information contains safety lubrication operation maintenance Some photographs or illustrations in this publication show details or attachments that can be different from your lift truck Guards and covers might have been removed for illustrative purposes Continuing improvement and advancement of product design might have caused changes to your lift truck which are not included in this publication Read study and keep this manual with the lift truck Whenever a question arises regarding your lift truck or this publication please consult your DOOSAN dealer for the latest available information Safety The Safety Section lists basic safety precautions In addition this section identifies the text and locations of warning signs and labels used on the lift truck Read and understand the basic precautions listed in the Safety Section before operating or performing lubrication maintenance and repair on t
132. evels Electrolyte is an acid and can cause personal injury if it contacts skin or eyes Always wear protective glasses when working with batteries Safety Section Fire or Explosion Prevention All fuels most lubricants and some coolant mixtures are flammable Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling area Do not smoke in areas where batteries are charged or where flammable materials are stored Batteries in series can be located in separate compartments When using jumper cables always connect positive cable to positive terminal of battery connected to starter solenoid and negative cable from external source to starter negative terminal If not equipped with starter negative terminal connect to engine block See the Operation Section of this manual for specific starting instructions Clean and tighten all electrical connections Check daily for loose or frayed electrical wires Have all loose or frayed electrical wires tightened repaired or replaced before operating the lift truck Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons Store all oily rags or other flammable material in a protective container in a safe place Do not weld or flame cut on pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before
133. f Equipped Avoiding Lift Truck Tipover 21 Safety Rules ed How to Survive in a Tipover If Operator Restraint System Equipped 28 General Section Specifications Noise amp Vibration Capacity Chart Without Side Shifter Capacity Chart With Side Shifter Serial Operator s Warning and Identification Plate 45 Operation Section Operator s Station and Monitoring Systems 47 Seat Switch System 52 Lift Truck Controls 56 Refueling 60 Before Starting the Engine 63 Starting the Engine 66 After Starting the Engine 69 Lift Truck Operation Auto Shift Controller ASC 200 201 If Equipped 107 Operating Techniques Parking the Lift Truck Lift Fork Adjustment Storage Information Transportation Hints Towing Information Table of Contents Maintenance Section Inspection Maintenance and Repair of Lift Truck go Ce 121 Tire Inflation Information sss 125 Torque Specifications Cooling System Specifications Fuel Specifications Lubricant Specifications Maintenance Intervals 136 When Required 140 Every 10 Service Hours or Daily 147 First 50 100 Service Hours or a Week 152 First 250 Service Hours or a Month 159 Every 250 S
134. f insoluble chemicals especially after a number of heating and cooling cycles DOOSAN prefers the use of distilled water or deionized water to reduce the potential and severity of chemical insolubility Acceptable Water Limits PPM Water Content Chlorides Cl Sulfates SOs Total hardness 50 maximum 50 maximum 80 mg l Total solids 250 maximum PH 6 0 to 8 0 ppm parts per million Using water that meets the minimum acceptable water requirement may not prevent drop out of these chemical compounds totally but should minimize the rate to acceptable levels Antifreeze NOTICE DOOSAN recommends using automotive antifreeze suitable for gasoline engines having aluminum alloy parts Antifreeze of poor quality will cause corrosion of the cooling system and thus always use automotive antifreeze prepared by a reliable maker and never use it mixed with antifreeze of different brand DOOSAN recommends that the coolant mix contain 50 commercially available automotive antifreeze or equivalent and acceptable water to maintain and adequate water pump cavitation temperature for efficient water pump performance Premix coolant solution to provide protection to the lowest expected outside ambient temperature Pure undiluted antifreeze will freeze at 23 C 10 F Maintenance Section Use a greater concentration above 50 of commercially available automotive antifreeze only as needed
135. fication involving welding flame cutting or other similar processes which affect the heat treatment and reduces the strength of the fork In most cases specific processes and techniques are also required to achieve proper welding of the particular alloy steels involved Critical areas most likely to be affected by improper processing are the heel section the mounting components and the fork tip Bent or Twisted Forks Forks can be bent out of shape by extreme overloading glancing blows against walls or other solid objects or using the fork tip as a pry bar Bent or twisted forks are much more likely to break and cause damage or injury They should be removed from service immediately Fatigue Parts which are subjected to repeated or fluctuating loads can fail after a large number of loading cycles even though the maximum stress was below the static strength of the part The first sign of a fatigue failure is usually a crack which starts in an area of high stress concentration This is usually in the heel section or on the fork mounting As the crack progresses under repetitive load cycling the load bearing cross section of the remaining metal is decreased in size until it becomes insufficient to support the load and complete failure occurs Fatigue failure is the most common mode of fork failure It is also one which can be anticipated and prevented by recognizing the conditions which lead up to the failure and by removing
136. following procedure 1 Make initial determination as to failure of lift truck to crank Procedure applies even if lift truck does not have diagnostic connector Place the directional control in NEUTRAL on the stalled lift truck Engage the parking secondary brake Lower all attachments to the ground Move all controls to HOLD CENTER On stalled lift truck turn the start switch to OFF Turn off all accessories On stalled lift truck turn on the disconnect switch if equipped close Move boost start lift truck near enough to stalled lift truck for cables to reach but DO NOT ALLOW LIFT TRUCKS TO TOUCH Stop the engine on the boost lift truck Or if using an auxiliary power source turn off the charging system Make sure battery caps are all in place and tight on both lift trucks Boost Battery Discharged Battery Stalled Truck Frame 00411 Typical Example of 24 Voltage 8 Connect positive jumper cable red to positive cable terminal of discharged battery or battery set on the stalled lift truck Do not allow positive cable clamps to touch any metal other than battery terminals Connect the other end of this positive jumper cable red to positive terminal of boost battery Use procedure of Step 8 to determine correct terminal 68 10 11 12 13 14 15 16 Connect one end of the negative jumper cable to the other terminal negative of the
137. hange any factory set adjustment values including engine rpm setting unless you have both authorization training Especially Safety equipment and switches may not be removed or adjusted incorrectly Repairs adjustments and maintenances that are not correct can make a dangerous operating condition For any checkup repair adjustments maintenance and all other work concerning your forklift truck please contact your DOOSAN dealer We would like to draw your attention to the fact that any secondary damages due to improper handling insufficient maintenance wrong repairs or the use of other than original DOOSAN spare parts waive any liability by DOOSAN Safety Section Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully Clean your shoes and wipe your hands before mounting Face the lift truck when mounting and dismounting Use both hands face the lift truck when mounting and dismounting Use the handgrips for mounting and dismounting Do not try to climb on or off the lift truck when carrying tools or supplies Never get on or off a moving lift truck Do not use any controls as handholds when entering or leaving the operator s station Never get on or off a moving lift truck Never jump off the lift truck Keep hands and steering wheel free of slippery material Before Starting the Lift Truck Perform a walk around inspection daily and at the start of each shift R
138. he MIL will flash one time 1 pause then flash two times 2 This identifies a twelve 12 which is the beginning of the fault list It will then pause for 1 2 seconds long pause and flash two times 2 pause then flash six times 6 This identifies a twenty six 26 which is the ETCSticking fault If any additional faults were stored the SECM would again have a long pause then display the next fault by flashing each digit Since no other faults were stored there will be a long pause then one flash 1 pause then two flashes 2 This identifies a twelve meaning the fault list will begin again Displaying Fault Codes DFC From SECM Memory To enter code display mode you must turn OFF the ignition key Now turn ON the key but Do not start the engine As soon as you turn the key to the ON position you must cycle the foot pedal by depressing it to the floor and then fully releasing the pedal pedal maneuver You must fully cycle the foot pedal three 3 times within five 5 seconds to enable the display codes feature of the SECM Simply turn the key OFF to exit display mode The code list will continue to repeat until the key is turned OFF An automatic code display feature is activated if a foot pedal fault condition exists This feature enables the service technician to view the fault codes by turning the key to the ON position if a foot pedal malfunction is preventing the retrieval of the stored fault codes from the SECM
139. heck for leaks in exhaust catalytic converter HEGO sensors repair leaks Check all sensor connections see fault 742 corrective actions GasO2FailedRich Check fuel trim valves e g plugged 771 Pre catalyst O2 sensor 1 TurnOnMil valve or hose 77 indicates extended rich 2 DisableGas O2Ctrl Check for plugged orifice s operation on LPG Fault actions shown are default values specified by the OEM 102 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d 5 CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK Correct other faults that may contribute to 772 e g faults pertaining 2FailedRich 2 Eo ao 1 TurnOnMil Pre Cat O2 Post Cat O2 sensor 772 au y 2 DisableGas Look for leaks in exhaust catalytic indicates extended rich PostO2Ctrl converter HEGO sensors repair leaks operation on LPG Check all sensor connections see fault 742 corrective actions 843 Reserved Check if O2 sensor installed before the O2RangeLow catalyst is shorted to GND or sensor Pre catalyst O2 sensor 911 voltage out of range low 1 OND 2 do 2 2 DisableGas 2 O2 signal Pin 3 to SECM Pin B13 tend 0 SECM DRVG GND Pins A16 B17 3 SECM XDRG sensor GND Pin B1 Check if O2 installed after the catalyst O2 PostCatRangeLow sensor is shorted to GND or sensor Post catalyst O2 sensor 1 TurnOnMil
140. his lift truck Operator Restraint System If Equipped This manual contains safety operation and maintenance information for the DOOSAN operator restraint system Read study and keep it handy WARNING Your DOOSAN truck comes equipped with an 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 Photographs or illustrations guide the operator through correct procedures of checking operation and maintenance of the DOOSAN operator restraint system SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness on the part of the operator To develop this skill the operator should read and understand the Safe Driving Practices contained in this manual Forklift trucks seldom tipover but in the rare event they do the operator may be pinned to the ground by the lift truck or the overhead guard This could result in serious injury or death Operator training and safety awareness is an effective way to prevent accidents but accidents can still happen The DOOSAN operator restraint system can minimize injuries The DOOSAN operator restraint system keeps the operator substantially within the confines of the operator s compartment and the overhead guard This manual contains information necessary for Safe Operation Before operating a lift truck make sure that the necessary instructi
141. hlight if necessary Fuses are identified as follows 1 Horn 10 amp 2 Head Lamp 15 amp 3 Fwd Rev Solenoid lamp Relay amp Back up Lamp alarm 10 amp 4 Instrument Panel amp Fuel Shutoff 15 amp 5 Turn Signal Lamp Stop Strobe Lamp 15 amp 6 Start Relay 10 amp 143 Maintenance Section Bulbs Bulbs are identified as follows Diesel Engine Bulb head lamp halogen 24V 70 75W Bulb rear 24V 55W Bulb turn signal Front 24V 25 10W Bulb turn signal Rear 24V 25W Bulb stop amp tail 24V 25 10W Bulb back up 24V 10W gare Oa LP Engine Bulb head lamp halogen 12V 60 55W Bulb rear 12V 55W Bulb turn signal Front 12V 23 8W Bulb turn signal Rear 12V 23W Bulb stop amp tail 12V 23 8W Bulb back up 12V 10W o gt Tires Wheels Inspect Check A WARNING Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures Deflate tire before removing wheel nuts from the truck If correct procedures are not followed while servicing tires and rims the assemblies could burst with explosive force and cause serious physical injury or death Follow carefully the specific information provided by your tire servicing man or dealer Check Inflation and Damage Inspect tires for wear cuts gouges and foreign objects Look for bent rims and correct seating of locking ring Check tire
142. horized area only Do not block traffic Typical Example 2 Place the transmission controls in NEUTRAL 3 Engage the parking brake 14000451 Typical Example 4 Lower the forks to the ground A WARNING Blocking the wheels will prevent unexpected lift truck movement which could cause personal injury 5 Turn the ignition key switch to the OFF position and remove the key parked for an indefinite or prolonged period of time close the fuel shutoff valve on the LP tank Run the engine until fuel in the line runs out and the engine stops Turn off the ignition switch and disconnect switch if equipped Actuate each loading lever several times to remove the residual pressure in the respective cylinders and hoses Block the drive wheels if parking on an incline 116 Operation Section Lift Fork Adjustment A WARNING A WARNING When adjusting the fork spread be careful not to Make sure the forks are locked before carrying a pinch your hand between forks and the carriage load slot For load stability always adjust the forks as wide as possible Position the load evenly on both forks Typical Example of Hook on type Fork 1 Move up the hook pin 1 in each fork to slide the fork 2 on the carriage bar 2 Adjust the forks in the position most appropriate for the load and as wide as possible for load stability 3 When adjusting the forks make sure that the w
143. horted TurnOnMil Lockoff Pin A power to SECM DRVP to ground or power or Pin A23 defective Fuel lock off valve Check CSV for an open coil by disconnecting the CSV connector and measuring the resistance 26Q LSDFault MIL Malfunction Indicator Lamp Check MIL lamp for an open wire or 718 Fault signal has opened or None short to GND shorted to ground or power or defective MIL lamp GasFuelAdaptRangeLo Check for vacuum leaks 721 In LPG mode system had to Check fuel trim valves e g leaking TurnOnMil 72 adapt rich more than valve or hose expected Check for missing orifice s GasFuelAdaptRangeHi Check fuel trim valves e g plugged 731 In LPG mode system had to TumOnMil valve or hose 73 adapt lean more than Check for plugged orifice s expected Check that Pre catalyst O2 sensor connections are OK O2 signal Pin 3 to SECM Pin B13 O2 Pin 2 HEATER GND to SECM GasO2NotActive DRVG GNG Pins A16 B17 741 2 sensor 1 TumOnMil O2 Pin 1 PWR to SECM 74 inactive on LPG open 2 2 DisableGas O2Ctrl DRVP 12V Pin A23 sensor signal or heater Verify O2 sensor heater circuit is leads defective 2 sensor operating by measuring heater resistance 2 10 0 40 O2 Pin 2 HEATER GND to Pin 1 HEATER PWR Fault actions shown are default values specified by the OEM 101 Operation Section Table 2 07 Diagnostic Fault Codes Flash Codes cont d
144. ications where the lift truck is operating in a atmosphere which could cause corrosion of components or when lift truck must work in rapid lift cycles 6 Checkthe air cleaner housing for loose latches Maintenance Section Lubricate Mast Side Rollers Steering Mechanism Check Lubricate 14704015 5 015 Typical l 1 Lubricate the 2 fittings on the inner mast COPS 1 Lubricate the steer axle king pins total of four fittings Two on the right side and two on the left Lubricate Carriage Side Rollers side 2 Lubricate the steering link bearings total of four fittings Two on the right side and two on the left side 1111111 3 Check for any worn or loose components of the steering mechanism Remove any debris or trash as required Typical Example 1 Lubricate the 4 fittings for the carriage side rollers two on each side of the carriage side rollers 14704017 Typical Example 2 Lubricate the 2 fittings for the carriage middle rollers one on each side of the carriage middle rollers 166 Maintenance Section Battery Terminal Clean Inspect Wheel Bolts amp Nuts Inspect A WARNING Inspect Tightness Batteries give off flammable fumes that can explode Steer Wheels 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
145. icator stays locked in the visible position with the engine stopped 1 To service the air cleaner raise the side cover Loosen the cover latches and remove the cover 160 Diesel Engine Truck Dual Element Typical Example LP Engine Truck Typical Example 2 Replace the nut or clamp 1 3 Remove the element to separate it from its base and remove it from the air cleaner housing Clean and inspect the element 2 Clean the inside of air cleaner housing and the cover Inspect all connections between the air cleaner and carburetor Check intake hose for cracks damage and loose clamps Tighten or replace parts as necessary to prevent leakage NOTICE Do not allow dirty air to enter the intake hose when cleaning the inside of the cleaner housing 6 Check the air cleaner housing for loose latches 7 Reset the air cleaner service indicator 8 Install the air filter element 9 Install the cover and tighten the cover latches 161 Maintenance Section 10 Start the engine and observe the position of the indicator If the indicator shows RED after the installation of the primary element install another clean or a new element or replace the secondary element See topic Air Intake System Change in Every 1000 Service Hours or 6 months section 11 Stop the engine and close the right side cover Maintenance Section Cleaning Primary Filter Elements A WARNING Pressure air can caus
146. in EU Machinery Directive 98 37 EC and EMC directive 89 336 EC Please refer to the Directives 89 655 EC and 89 391 EC and its amendments for the safe use of DOOSAN lift trucks The most effective method of preventing serious injury or death to the lift truck operator or others is for the lift truck operator to be familiar with the proper operation of the lift truck to be alert and to avoid actions or conditions which can result in an accident Do not operate a lift truck if in need of repair defective or in any way unsafe Report all defects and unsafe conditions immediately Do not attempt any adjustments or repairs unless trained and authorized to do so Safety Section Warning Signs and Labels There are several specific safety signs on your lift truck Their exact location and description of the hazard are reviewed in this section Please take the time to familiarize yourself with these safety signs Make sure that you can read all warning and instruction labels Clean or replace these labels if you cannot read the words or see the pictures When cleaning the labels use a cloth water and soap Do not use solvent gasoline etc You must replace a label if it is damaged missing or cannot be read If a label is on a part that is replaced make sure a new label is installed on the replaced part See your dealer for new labels Training Required To Operate or Service Warning Located on the right side of the fire
147. ion clutch discs to slip 2 Vary the position of inching pedal and the accelerator pedal to control the inching speed and distance 3 Pushing down further on the inching pedal will disengage the transmission completely and apply the service brakes fully to stop and hold the lift truck This will provide full engine power for fast hydraulic lift Operation Section Auto Shift Controller ASC 200 201 If Equipped Product Description The Autoshift controller is electrical control system specially designed for use on forklift trucks with internal combustion engines Its primary purpose is to prevent the operator from operating the truck outside of the design parameters e g selecting the reverse gear when travelling in excess of 5 km h 3 11 mph in a forward direction and vice versa The Autoshift controller is mounted on a convenient position away from excessive heat sources and retrofits into the truck s electrical system An inductive speed sensor is mounted the transmission case where it will pick up a pulse from a gear tooth pattern This pulse is used to monitor the truck in motion and its travel speed To enable the system to change gears smoothly the shift points for offset speed are adjustable An operator no longer has to change gears with his hands therefore he can be more productive The Autoshift controller prevents strain and abuse to the transmission by changing gears up and down automatically
148. ion to the oil 52 Low engine oil pressure Shutdown pressure switch 3 CheckEngine Light SECM Pin B9 to Oil Pressure Switch Check battery voltage Perform maintenance check on electrical connections to the battery and chassis ground Check battery voltage during starting and with the engine running to verify 531 SysVoltRangeLow TurnOnMil charging system and alternator 53 System voltage too low function Measure battery power at SECM with a multimeter with key on SECM Pin A23 DRVP to SECM Pin A16 DRVG SECM Pin A23 DRVP to SECM Pin B17 DRVG Fault actions shown are default values specified by the OEM 97 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK Check battery and charging system voltage Check battery voltage during starting and with the engine running Check voltage regulator alternator and charging system 541 SysVoltRangeHigh TurnOnMil Check battery and wiring for 54 System voltage too high overheating and damage Measure battery power at SECM with a multimeter with key on SECM Pin A23 DRVP to SECM Pin A16 DRVG SECM Pin A23 DRVP to SECM Pin B17 DRVG 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 SECM 55i 1 TumOnMil Vdc to SECM Pin 55
149. iring for an open circuit e Check N CA55 500 TR mixer for heavy end build up and operation see mixer section e Check N2001 secondary for operation see N2001 Regulator section 88 Operation Section Table a 04 Diagnostic Fault Codes Flash Codes DFC Probable Fault Action Corrective Action First Check 74 O2SensorSwitching Stored Fault Code Note If LP fuel in LP tank is not O2 sensor is not switching across MIL Disable Adaptive this fault code can be set the reference AFR voltage learns If LP tank is frozen this fault code G643E onl can be set too It is not system only trouble Check the FTV for proper operation e Check FTV Hose Connections 77 OxygenSensorInputHigh Stored Fault Code Check if O2 sensor is shorted to O2 sensor SECM driver signal is MIL Disable Adapts 5VDC or Battery shorted to power G643E only AFRTrimValveLowerDC fault should also occur 89 Operation Section Advanced Diagnostics G643E Engine Only MI 07 systems are equipped with built in fault diagnostics Detected system faults can be displayed by the Malfunction Indicator Lamp MIL as Diagnostic Fault Codes DFC or flash codes and viewed in detail with the use of the Service Tool software When the ignition key is turned on the MIL will illuminate and remain on until the engine is started Once the engine is started the MIL lamp will go out unless one or more fault condi
150. ission at lower travel speeds prolongs the lift of the transmission axle shafts and tires 108 Diagnostics Features 14700014 ASC 200 201 has internal indicator on the right side of the controller for displaying the selected gear and the abnormal condition WARNING Do not diagnose or repair Auto Shift Controller Faults unless trained and authorized to do so Improper performance of maintenance procedures is dangerous and could result in personal injury or death Below is a description applicable for many ASC 200 201 implementations Display for Operator Display Description Remark A Automatic operation H High speed At 2nd shift gear L Low speed At 1st shift gear PT M Speed sensor open Flashing E G Speed sensor Flashing F Controller fault Flashing 5 H L Sol Short Flashing 6 Forward Sol Short Flashing 7 Reverse Sol Short Flashing This information is given during normal operating when something special happens For example ASC 200 201 s with the speed sensor one of the indicators is used to indicate a sensor problem Display for Troubleshooting Display Description Remark A Automatic operation 2 High speed s w input Lever inputtest 3 Forward s w input Lever inputtest 4 Reverse s w input Lever inputtest This information is input for signal diagnostics This test is used to verify operation of direction con
151. ity Also list any specia characteristics specified in the fork design Record the date and results of each inspection making sure the following information is included e Actual wear conditions such as percent of original blade thickness remaining Any damage failure or deformation which might impair the use of the truck e Note any repairs or maintenance An ongoing record of this information will help in identifying proper inspection intervals for each operation in identifying and solving problem areas and in anticipating time for replacement of the forks 123 Maintenance Section 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 If the forks are rusted see Maintenance and Repair Make sure fork blades are level to each other within acceptable tolerances See Forks Step 4 in the 2000 Service Hours or Yearly in Maintenance Intervals Make sure positioning lock is in place and working Lock forks in position before using truck See Forks Step 7 in the 2000 Service Hours or Yearly in Maintenance Intervals Daily Inspection 1 Visually inspect forks for cracks especially in the heel section around the mounting brackets and all weld areas Inspect for broken or jagged fork tips
152. ks lowered parking brake applied transmission in neutral and the engine stopped 2 Raise rear of lift truck off the ground and block securely A WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Typical Example Diesel Engine Truck 152 NOTICE Careless disposal of waste oil can harm the environment and can be dangerous to persons Always dispose of waste oil to authorized and licensed personnel only Remove the crankcase drain plug and allow oil to drain Clean and install drain plug 4 Raise the left side cover 5 Remove and discard oil filter element 6 Wipe sealing surface of oil filter element mounting base Make sure all of the old gasket is removed 7 Before installing a new filter element apply a small amount of clean engine oil to the filter element gasket 8 Install the new filter element When the gasket contacts the base tighten it 3 4 of a turn more Do not overtighten 9 Raise the lift truck remove the blocking and lower the lift truck Maintenance Section Transmission Oil amp Oil Filter Change A WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped Typical Example Diesel Engine Truck 10 Fill the crankcase See Refill C
153. l Not Continuously Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container e Do not exceed 80 of capacity liquid Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait for a click sound Slowly open liquid valve Clogged fuel filter Repair replace as required e See Maintenance Section LP Fuel Filter replacement Plugged fuel line Remove obstruction from the fuel line e Close liquid fuel valve e Using caution disconnect the fuel line some propane may escape e Clear obstruction with compressed air e Re connect fuel line e Slowly open liquid fuel valve amp Leak test Pressure regulator freezes Check level in cooling system e Must be full check coolant strength e 35F minimum Check coolant hoses e Watch for kinks and or pinched hoses e Verify one pressure hose and one return hose Fuel Lock off malfunction Repair replace Fuel Lock off e See Engine Service Manual Incorrect idle speed or ignition problem See Advanced Diagnostics Engine Mechanical See Engine Service Manual Will Not Accelerate Hesitat ion During Acceleration Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container e Do not exceed 8096 of capacity liquid Excess flow valve closed Reset excess flow valve Close liquid valve e Wait for a click sound e Slowly open
154. l Cooled Disc Brake OCDB Select oil that meets below specifications Universal Transmission Tractor Oil UTTO The following UTTO products are authorized for use TRANSMISSION MP MOBIL FLUID 424 Maintenance Section Brake Oil Only for OCDB As brake oil for oil cooled disc brake system OCDB use the oil that has the same specifications with hydraulic oil The following commercial classifications can be used in the brake system ISO 6743 4 HM AFNOR NFE 48 603 HM DIN 51524 TEIL 2 H LP HAGGLUNDS DENISON HFO HF2 CINCINNATI P68 69 70 Viscosity ISO VG32 These oils should have antiwear antifoam antirust and antioxidation additives for heavy duty use as stated by the oil supplier ISO viscosity grade of 32 would normally be selected The following products are authorized for use TOTAL AZOLLA ZS SHELL TELLUS MOBIL DTE20S CALTEX RANDO HD ESS NOTO H CASTROL HYSPIN AWS Maintenance Section Lubricating Grease NOTICE Use MPGM for heavily loaded bearings and joints where an extreme pressure grease will maximize the life of DOOSAN equipment This NLGI No 2 grade is suitable for most temperatures If MPGM is not available use a multipurpose type grease which contains 3 to 5 molybdenum This NLGI no 2 grade is recommended for light duty automotive type applications where a_ high temperature up to 175 C 350 F is required This grease offers excellent mecha
155. l Not Start Fuel container empty Fill fuel container e Do not capacity exceed 80 of liquid Liquid valve closed Slowly open liquid valve Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait for a click sound e Slowly open liquid valve Plugged fuel line Remove obstruction from the fuel line e Close liquid fuel valve e Using caution disconnect the fuel line some propane may escape e Clear obstruction with compressed air e Re connect fuel line e Slowly open liquid fuel valve e Leak test Broken Fuse SECM Replace Fuse for SECM e See Maintenance Section Fuses replacement Clogged fuel filter Repair replace as required e See Maintenance Section LP Fuel Filter replacement and the mixer Faulty vapor connection between the pressure regulator converter Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Fuel Lock off malfunction Repair replace Fuel Lock off e See Engine Service Manual Pressure malfunction regulator converter Test pressure regulator converter operation e See Engine Service Manual control Incorrect air fuel or ignition spark See Advanced Diagnostics 72 Operation Section Problem Probable Cause Corrective Action Engine Cranking but Will Not Start No VR Sensor Signal Verify the VR signal is pre
156. l Section DOOSAN Gmss 2 5000 60 600 LPG PG rider seated rider seated a 1 az az 3000 3000 3000 9 205 205 60x150x1200 60x180x1200 350x2032 410x2032 15 10 15 10 15 10 2108 2500 4340 2455 2455 2455 19 1333 1333 3301 3331 21 632 632 22 3924 3958 4000 23 2990 3020 3058 23a 14201004 24 0 25 4 23 8 25 4 23 6 25 4 380 410 380 410 380 410 25 490 460 490 460 490 460 26 5010 4990 4965 28 30 35 5 31 3 emi 8905 9635 32 3 11840 1395 13260 1645 14650 1985 3 4100 4135 3975 4930 3815 5820 34 4 2 42 42 35 8 25x15 14PR 8 25x15 14PR 8 25x15 14PR 3 6 8 25x15 14PR 8 25x15 14PR 8 25x15 14PR 37 2250 2250 38 1584 1550 1584 1550 1584 1550 39 176 205 foot hydraulic hand mechanical Po 12 75 0643 69 93 2450 69 93 2450 50 301 222 1400 301 222 1400 51 46 4294 gt NS 37 General Section Noise amp Vibration Noise Noise Level Unit dB A Sound Pressure Level at By stander position Guaranteed Sound Sound Pressure Level at Operator s ear Leq AS 3713 Power Level Lwa AS 3713 prEN 12053 Lifting Mode d D50S 5 D60S 5 W O Cabin D70S 5 D80S 5 D90S 5 i 3 speed With Cabin D50S 5 D60S 5 0708 5 W O Cabin 2 speed G50 60 70S 5 W O Cabin Test Model D70S 5 3 Speed D70S 5 2 Speed G70S 5 Vibration weighted overall value Unit m sec Measuring Place Steering 05
157. l not move call a service technician Forklift trucks may only be refueled at specially reserved locations Switch off the engine when refueling Smoking and handling of naked flames during refueling are strictly prohibited This prohibition also applies during the changing of the LPG liquefied Propane gas tank Mop up spilt fuel and Do not forget to close the fuel tank before restarting the engine Park your lift truck in authorized areas only Fully lower the forks to the floor put direction lever in NEUTRAL position engage the parking brake and turn the key to the OFF position Remove the key and put blocks behind the wheels to prevent the truck from rolling Shut off your forklift truck when leaving it unattended Check the condition of your forklift truck after the day s work internal contains carbon monoxide a colorless odorless tasteless poisonous gas Exposure to carbon Exhaust from all combustion engines monoxide can cause serious injury or health problems including death and avoid unnecessary idling of the engine If nausea dizziness or headaches are experienced stop the truck and seek fresh air 27 Safety Section How to Survive in a Tipover If EOM System 4 41978 OF TIPOVER In the event of tipover the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the
158. l place Charge the battery once a month Apply antirust to the exposed parts which tend to rust 118 Cover components such as the breather and air cleaner which may be caught with humidity The machine should be operated at least once a week Fill the cooling system if cooling water is discharged and mount the battery Start the engine and warm up thoroughly Move the machine a little forwards and backwards Operate the hydraulic controls several times To Operate the Lift Truck After a Long Time Storage ET Remove covers and antirust from each of the components and exposed parts Drain the engine crankcase transmission clutch type machine differential and final reduction gear clean the inside of them and add new oil Drain off foreign matter and water from the hydraulic oil tank and fuel tank Remove the head cover from the engine cylinder Oil valves and rocker shaft and check each valve for proper operation Add cooling water to the specified level Charge the battery and mount it on the machine Connect the cables Perform pre operational checks carefully refer to Before Starting the Engine Warm up the machine Transportation Hints Lift Truck Shipping Check travel route for overpass clearances Make sure there is adequate clearance if the lift truck being transported is equipped with a high mast overhead guard or cab To prevent the lift truck from slipping while lo
159. l tip forward If the CG moves outside of the line on either side of the stability base the lift truck will tip to the side A WARNING Dynamic forces braking acceleration turning also affect stability and can produce tipover even when the CG is within the stability triangle Capacity Load Weight and Load Center 1 500281 The capacity load of the lift truck is shown the capacity nameplate riveted to the truck It is determined by the weight and load center The load center is determined by the location of the CG of the load The load center shown on the nameplate is the horizontal distance from the front face of the forks or the load face of an attachment to the CG of the load The location of the CG in the vertical direction is the same as the horizontal dimension Remember that unless otherwise indicated the capacity load shown on the nameplate is for a standard lift truck with standard backrest forks and mast and having no special purpose attachment In addition the capacity load assumes that the load center is no further from the top of the forks than it is from the face of the backrest If these conditions Do not exist the operator may have to reduce the safe operating load because the truck stability may be reduced The lift truck should not be operated if its capacity nameplate does not indicate capacity load NOTE If the load is not uniform the heaviest portion should be placed closer to th
160. lamps and remove the PCV valve 2 Assemble new PCV valve and hose 3 Tighten the hose clamps Muffler Ass y When indicated by MIL replace oxygen sensors on the exhaust tube and muffler assembly 1 2 186 Stop engine and wait until the exhaust pipe and exhaust pipe is cooled Disconnect the electrical connector of oxygen sensor Remove oxygen sensor Assemble new oxygen sensor Tightening torque 45 Nem 32 5 Ibeft Connect the electrical connector of oxygen sensor Index 12 Months Inspection 2 22 124 A Accelerator 58 Adj stmenls man mein ehe 107 Advanced 80 Advanced Diagnostics G643 Engine Only 80 Advanced Diagnostics G643E Engine Only After Starting the 69 Air 205 kPa 30 psi Maximum Pressure 162 Air Cleaner Indicator 148 Air Intake System 172 Air Intake System Check Clean 160 Atilifreezo 5 ense tco 129 Attachment Abbreviations includes Special Forks HU ERES 46 Auto Shift Controller ASC 200 201 If Equipped 107 Automatic mode eese 109 Automatic Transmission Switch 3 Speed Only
161. liquid valve 74 Operation Section Problem Probable Cause Corrective Action Will Not Clogged fuel filter Repair replace as required Accelerate Hesitat e See Maintenance Section LP Fuel ion During Filter replacement Acceleration Faulty vapor connection between the pressure regulator converter and the mixer Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Throttle butterfly opening or sticking valve not Foot Pedal signal incorrect or intermittent Incorrect air fuel or ignition control See Advanced Diagnostics Engine Mechanical See Engine Service Manual Engine Stalls Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container e Do not exceed 80 of capacity liquid Excess flow valve closed Reset excess flow valve Close liquid valve e Wait for a click sound Slowly open liquid valve Clogged fuel filter Repair replace as required e See Maintenance Section LP Fuel Filter replacement Plugged fuel line Remove obstruction from the fuel line e Close liquid fuel valve e Using caution disconnect the fuel line some propane may escape e Clear obstruction with compressed air e Re connect fuel line e Slowly open liquid fuel valve amp Leak test 75 Operation Section Problem Probable Cause Corrective Action Engine
162. lose hood and seat assembly Inspect Foot Pedal Operation LP Engine Only 1 Verify foot pedal travel is smooth without sticking A WARNING When the acceleration pedal harness is connected or disconnected should be worked key OFF condition If not occurred malfunction can cause the personal injury Inspect Engine for Exhaust Leaks 1 Start the engine and allow it to reach operating temperatures 2 Perform visual inspection of exhaust system Repair any all leaks found Walk Around Inspection Inspect For maximum service life of the lift truck make a thorough walk around inspection 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 Have any repairs made and debris removed as needed Typical Example 1 Inspect the tires and wheels for cuts gouges foreign objects inflation pressure and loose or missing bolts 2 Inspect the mast and lift chains for wear broken links pins and loose rollers Maintenance Section Inspect the hydraulic system for leaks worn hoses or damaged lines Look for transmission and driveaxle leaks on the lift truck and on the ground RS Typical Example 5 Typical Example Inspect the operator s compartment for loose items and cleanliness Inspect the instrument panel for broken gauges and indicator lights Test the and oth
163. lter gasket is fitted against the sealing face 6 Turn the fuel filter cartridge assembly an additional 2 3 of turn Air Intake System Change Changing Primary Element See topic Air Intake System Check Clean in Every 250 Service Hours or Monthly Changing Secondary Element Replace the secondary element after the primary element has been cleaned three times or yearly 1 Remove the primary air cleaner element See topic Servicing Filter Element Clean the inside of the air cleaner housing and cover A p 2 Remove the secondary element Inspect the gasket between the air cleaner housing and the engine inlet Replace the gasket if it is damaged Always replace the secondary element Do not attempt to reuse it by cleaning Install a new secondary element Install a new or cleaned primary element Install the cover Tighten the latches Start the engine and observe the air cleaner service indicator If the indicator shows RED after installing a new secondary element and a cleaned primary outer element replace the cleaned primary filter with a new element 5 Stop the engine Close the hood and seat assembly Inspect Coolant Hoses LP Engines Only Visually inspect coolant hoses and clamps Remember to check the two coolant lines that connect to the pressure regulator converter Replace any hose that shows signs of swelling cracking abrasion or deterioratio
164. ly Examine the wheel for damage and wear Replace the wheel if necessary 5 Remove the inner bearing Clean and lubricate the steering knuckle Reassemble both the inner and outer bearing cones Typical Example 1 Lift the steer wheels off the ground Place 6 Install the inner bearing Lubricate the seal and stands or blocking under the frame and steer install the wheel assembly on the knuckle le to support the lift truck e 7 Install the outer wheel bearing and the outer nut 2 R the hub cap and gasket 8 Tighten the nut to 200 148 16 while turning wheel hub to seat the bearing 9 Install the pin 10 Install the hub cap 11 Raise the lift truck and remove the blocking Lower the lift truck to the ground IDOMO65I Typical Example 3 Remove the pin 1 and nut 2 Remove the outer wheel bearing 181 Maintenance Section Cooling System Clean Change A WARNING At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand Remove the filter cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury Use all cleaning solutions with care The lift truck must be level the forks lowered the parking brake engaged
165. malfunction Check mixer e See Engine Service Manual 76 Operation Section Problem Probable Cause Corrective Action Rough Idle Incorrect Idle speed control Incorrect timing or spark control See Advanced Diagnostics amp See Engine Service Manual Engine Mechanical See Engine Service Manual High Idle Speed Incorrect Idle speed control Throttle sticking See Advanced Diagnostics amp See Engine Service Manual Foot pedal sticking or incorrect pedal signal Check pedal return spring travel for binding e See Advanced Diagnostics Poor High Speed Performance Clogged fuel filter Repair replace as required e See Maintenance section Filter replacement Fuel Plugged fuel line Remove obstruction from the fuel line e Close liquid fuel valve e Using caution disconnect the fuel line some propane may escape e Clear obstruction with compressed air e Re connect fuel line e Slowly open liquid fuel valve amp Leak test Air filter clogged Check air filter e Clean replace as required Faulty vapor connection between the pressure regulator converter and the mixer Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Pressure regulator malfunction Test pressure regulator operation e See Engine Service Manual Air Fuel Mixer malfunction Check mixer e See Engine
166. mbly before changing them NOTICE When changing tires change them in sets even if only one of the tires is damaged If new and used tires are used on the same axle tilting of the mast and rapid tire wear will result The mounting faces of the hub wheel nuts and wheels must be free of any foreign material and lubricants of any kind Tighten wheel nuts again after 24 hours of operation Do not reinflate a tire that has been driven on while flat or underinflated without first checking to be sure the locking ring on the wheel is not damaged and in position Always deflate tires before changing them Maintenance Section Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures Shipping Pressure kPa psi 14PR 790 115 16PR 880 128 14PR 790 115 Rating Or Strength Index Size 8 25 x 15 8 25 x15 9 00 x 20 Standard tire ply rating and inflation pressures The operating inflation pressure is based on the weight of ready to work machine without attachments at rated payload and in average operating conditions Pressures for each application may vary and should always be obtained from your tire supplier NOTE Fill tires to the recommended pressures listed 35 kPa 5 psi Tires can be filled with nitrogen Tire Inflation Pressures Adjustment A tire inflation in a warm shop area 18 1 21 65 to 70 F will
167. mission at lower travel speeds prolongs the lift of the transmission axle shafts and tires Two Speed Auto Shift Control While traveling forward with the high speed gear that is 2nd gear selected the ASC 200 201 can upshift or down shift the transmission automatically according to the vehicle speed by its own speed ratio control so that the appropriate gear may be engaged in every situation NOTICE Two Speed Auto Shift Control function can be accomplished only when the direction control lever is placed in the high speed 2nd gear position Manual Mode Fail Safe mode In case that the controller is broken down or you don t want to use the functions of the Auto Shift Controller you can select Manual Mode In Manual Mode you can operate your lift truck in the same manner as any lift truck without Auto Shift Controller You can select the Manual mode or the Automatic mode by doing following procedures A 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 over 1 Park the lift truck in a designed service area 2 Lower the lift trucks forks or lode engaging attachment to the travel surface shift the direction control lever to NEUTRAL engage the parking brake shut OFF the engine and remove the key 3 Turn OFF the electrical disconnect switch if equipped Chock the
168. mm 236 in MFH MAST D50S 5 G50S 5 snc comm 3000 4000 mm 118 in 158 in FFT 4550mm MAST MFH MAST FFT 5000mm MAST 4500 mm 177 in MFH MAST FFT 5600mm MAST 5000 mm 197 in MFH MAST FFT 6050mm MAST 5500 mm 217 in MFH MAST 6000 mm 236 in MFH MAST o ui o a 3000 4000 118 158 4500 mm 177 MAST 5000 197 D 5500 mm 217 MAST 6000 mm 236 in MAST A FFT 4550mm MAST B FFT 5000mm MAST C FFT 5600mm MAST D FFT 6050mm MAST D70S 5 G70S 5 41 General Section Capacity Chart With Side Shifter 600 70 800 900 1000 1100 1200 600 700 800 900 1000 1100 1200 oooc gt mm cooc gt mm 3100 3600mm MAST 4350mm MAST 4100mm MAST 4800mm MAST 4600mm MAST 5400mm MAST 5100mm MAST 5850mm MAST 5600mm MAST 600 70 80 900 1000 1100 1200 600 70 80 900 1000 1100 1200 oo
169. motored down a steep grade Usually associated with additional ETC SoftOverspeed faults 573 Engine speed has exceeded e EA Check for ETC Sticking or other ETC the first level 1 of 3 of faults overspeed protection Verify if the lift truck was motored down a steep grade APP1RangeLow APP1 sensor voltage out of 611 range low normally set if the 5 Eee Light Check foot pedal connector 61 1 signal has shorted to gine 1911 Check APP1 signal at SECM PIN B7 ground circuit has opened or sensor has failed APP2RangeLow APP2 sensor voltage out of 612 range low normally set if the TurnOnMil Check foot pedal connector 65 APP2 signal has shorted to Check APP2 signal at SECM PIN B16 ground circuit has opened or sensor has failed APP1RangeHigh APP1 sensor voltage out of 621 range high normally set if 1 TurnOnMil Check foot pedal connector 62 the APP1 signal has shorted 2 CheckEngine Light Check APP1 signal at SECM PIN B7 to power or the ground for the sensor has opened APP2RangeHigh APP2 sensor voltage out of 622 range high normally set if TurnOnMil Check foot pedal connector 66 the APP2 signal has shorted Check APP2 signal at SECM PIN B16 to power or the ground for the sensor has opened APP1AdaptLoMin Check APP connector and pins for 631 Learned idle end of APP1 corrosion 63 sensor range lower than Nong Cycle the pedal several times and expected check APP1 signal at SECM Pin B7 APP2AdaptLoMin Check APP connec
170. n LP fuel lock off LP regulator converter Fuel Trim Valve FTV LP mixer Vacuum lines Coolant lines LP fuel line 1 2 3 4 5 6 7 173 Maintenance Section LP Regulator Converter Inspection LP Engine Only Visually inspect the pressure regulator converter housing 2 for coolant leaks Refer to the pressure regulator converter section of the service manual if maintenance is required NOTE For pressure testing and internal inspection of the pressure regulator converter refer to the pressure regulator converter section of the service manual Fuel Lines amp Fittings Check Visually inspect fuel lines and fittings for physical damage Replace as required Inspect Mixer Assembly LP Engine Only Refer to the LP mixer section of the engine service manual for procedures Inspect Throttle Assembly LP Engine Only Visually inspect the throttle assembly motor housing for coking cracks and missing cover retaining clips Repair and or replace as necessary NOTE Refer to the LP mixer and throttle section of the service manual for procedures on removing the mixer and inspecting the throttle plate Maintenance Section Hydraulic Oil Return Filter Strainer amp Breather Check Clean Change A WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Park the lift truck level with the forks lowered parking
171. n incline Do not drive in forward direction when loads restrict your visibility Operate your lift truck in reverse to improve visibility except when moving up a ramp Do not go over rough terrain If unavoidable slow down Cross railroad tracks slowly diagonally whenever possible A railroad crossing can give a loaded forklift truck a real jolt For smoother crossing cross the railroad diagonally so one wheel crosses at a time Avoid running over loose objects Look in the direction of travel Look out for other persons or obstructions in your path of travel An operator must be in full control of his lift truck at all times Be careful when operating a lift truck near the edge of a loading dock or ramp Maintain a safe distance from the edge of docks ramps and platforms Always watch tail swing The truck can fall over the edge and cause injury or death Do not operate on bridge plates unless they can support the weight of the truck and load Make sure that they are correctly positioned Put blocks on the vehicle you enter to keep it from moving Safety Section Do not operate your truck close to another truck Always keep a safe distance from other trucks and make sure there is enough distance to stop safely Never overtake other vehicles Do not use your lift truck to push or tow another truck Do not let another push or tow your truck If a truck wil
172. n oil temperature is indicated Park the lift truck and stop the engine Check the system for a malfunction The pointer will be at the end of the green band when the transmission oil temperature reaches approximately 120 C 248 F 4 Fuel Level Gauge Indicates fuel level in the fuel tank 00081 48 5 Hour Counter Indicates the total number of hours the engine and the lift truck have operated The hour meter will operate when the ignition switch is in the ON position whether the engine is running or not The hour meter is used to determine lubrication and maintenance intervals 6 Speed meter Indicates the truck speed km h travelling 7 Turn Signal Lever This is the lever to indicate the Jf ws turning direction of the lift truck 2 this lever is maneuvered the Ox signal lamp blinks R Turn to the right 10040041 Neutral L Turn to the left 8 Horn Switch To give alarm to fellow worker s around and in the path of your truck press the rubber at the center of the handwheel 10040031 A WARNING Don t run the truck while the alarm is sounding It is dangerous to do so since poor effect is expected 9 Light Switch 1 2 Switch Light Ste Ste Clearance Lamp Lamp X License plate Lamp X Instrument Lamp X Head Lamp means lights on X mean
173. nd or load Do not drive lift truck up to anyone standing in front of an object Obey all traffic rules and warning signs Keep hands feet and head inside the operator station Do not hold onto the overhead guard while operating the lift truck Do not climb on any part of the mast or overhead guard or permit others to do so Do not allow unauthorized personnel to ride on the forks or any other part of the lift truck at any time When working in a building or dock observe floor load limits and overhead clearances Inhaling Freon gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting Freon can cause bodily harm or death Do not smoke when servicing air conditioners or wherever Freon gas may be present Never put maintenance fluids into glass containers Use all cleaning solutions with care Do not use steam solvent or high pressure to clean electrical components Report all needed repairs 10 Inspect the part of the chain that is normally operated over the crosshead roller When the chain bends over the roller the movement of the parts against each other causes wear Inspect to be sure that chain link pins Do not extend outside of the bore hole If any single link pin is extended beyond its connecting corresponding link it should be suspected of being broken inside of its bore hole Inspect the chain anchor and the anchor links for wear Do not c
174. ne fork tip to the other when mounted on the fork carrier A difference in fork tip height can result in uneven support of the load and cause problems with entering loads The maximum recommended difference in fork tip elevation F is 6 5 mm 0 25 for pallet forks and 3 mm 0 125 for fully tapered forks The maximum allowable difference fork tip elevation between the two or more forks is 3 percent of blade length L Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference Contact your local DOOSAN Lift Truck Dealer for further information Maintenance Section t 14104096 5 Check the fork blade J and shank for wear with special attention to the heel G The fork should be withdrawn from service if the thickness is reduced to 90 percent or less of the original thickness Fork blade length may also be reduced by wear especially on tapered forks platens Remove the forks from service when the blade length is no longer adequate for the intended loads 1A104097 Check the fork mountings K for wear crushing and other local deformation which can cause excessive side to side wobble of the forks Excessive clearance on hook type forks may allow them to fall from the carrier Forks which show visible signs of such damage should be removed from service Check the positioning lock and other fork retention devices to make
175. neutral WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Shoe Brake Type laa 1 704011 1 Raise the carriage high enough to access the drive axle housing level fill plug with breather Block the bottom of the carriage with a block of wood to hold the carriage in the raised position Turn the ignition switch OFF Remove the drive axle housing level fill plug with breather Wash them in clean nonflammable solvent Place an appropriate container under the axle to catch the oil as it drains Remove the drive axle housing drain plug Allow the oil to drain completely out Discard the old oil according to local regulations Clean and reinstall the drive axle housing drain plug Maintenance Section Oil Cooled Disc Brake OCDB Type Park the lift truck on a level surface Apply the parking brake Place the directional control level in NEUTRAL and stop the engine Typical Example 8 Remove planetary hub level drain fill plugs Allow the oil to drain completely out Reinstall the planetary hub plugs 9 Fill the drive axle housing with sufficient fresh oil through the drive axle housing levelAill plug opening until it reaches the bottom of the hole See the section Lubricant the Viscosities and Refill Capacities for the type and amount of oil to use Remove three drain plugs of the drive
176. ngine management system of G643E engine is a closed loop system utilizing a catalytic muffler to reduce the emission level in the exhaust gas In order to obtain maximum effect from the catalyst an accurate control of the air fuel ratio is required A small engine control module SECM uses two heated exhaust gas oxygen sensors HEGO in the exhaust system to monitor exhaust gas content One HEGO is installed in front of the catalytic muffler and one is installed after the catalytic muffler CAN Coolant Temp Ignition Switch Dual Dither Valves Fuel Select Ignition Coil Driver ea Feo 1 i i CAM Sensor i SECM 48 Crankshaft Sensor Fuel Lockoff Oil coo Light Manifold Pressure Temperature Sensor AN y D N 2007 Regulator Catalytic Muffler Bosch Electronic Throttle Transmission Oil Temp Switch Pre CAT 02 Sensor Post CAT 02 Sensor EMS schematic of G643E LP engine The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air fuel mixer by modulating the dual fuel trim valves FTV connected to the regulator Reducing the fuel pressure leans the air fuel mixture and increasing the fuel pressure enriches the air fuel mixture To calculate any necessary corrections to the air fuel ratio the SECM uses a number of different sensors to gain
177. nical stability high resistance to oxidation good rust protection and excellent breakaway torque If this grease is not available use similar multipurpose grease 134 Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities LUBRICANT VISCOSITIES Refill D50 60 70 neo go708 5 FOR AMBIENT OUTSIDE TEMPERATURES Capacities 80 90S 5 2 speed 550 60 705 5 i Approximate 3 speed Compartment Oil C Compartment or System pu Min Max or System ngine z Engine Crankcase 10W30 a o 645 LP and Lift SAE w Filter Chains 5W30 30 Cooling System API SJ w Coolant Engine Recovery Bottle Crankcase Fuel Tank Diesel Duet Diesel API CH4 or Power Shift ACEA E5 Transmission Power Shift SAE 10W Hydraulic PIU Power Transmission oN Liters APICD TO 2 SAE 30 ndi System Hydraulic and ISO VG32 Power Steering ISO VG46 System ISO 6743 4 HM SO VG68 Shoe Brake SAE Brake Reservoir Drive API 80W90 Only for Axle 5 OCDB Housing bd OCDB UTTO Brake Reservoir Only for OCDB IISO VG32 ISO 6743 4 HM ISO VG68 The SAE grade number indicates the viscosity of oil A proper SAE grade number should be selected according to ambient temperature 135 Maintenance Section Maintenance Intervals NOTICE All maintenance and repair except every 10 service hours or daily on the lift truck
178. ning Light 12 Transmission Neutral Position Light 13 Engine Malfunction Indicator Light 14 Directional Turning Indicator Lights 4 Diesel Engine Start Preheat Indicator Light The light will come ON when the key is turned to the ON position from the OFF position This indicates that the glow plugs are preheating the pre combustion chambers for easier starting The amount of time needed to preheat the pre combustion chambers is approximately seven seconds depending on the surrounding air temperature When the light goes OFF the maximum pre combustion chamber temperature has been reached and the key can be turned to the START position to start the engine 5 Air Dryer heater Light This indicates that air dryer heater begins to work to steam up water vapor from the air chamber After water vapor is eliminated the lamp should go off If the lamp doesn t go off for a long ting check the air brake system for a malfunction 6 Front Floodlights Push down on the switch 14 to the first ae step to turn the front floodlights on 7 Engine Oil Pressure Indicator Light Indicates insufficient engine oil pressure The light will come on when the ignition switch is turned to the ON position The light should go off after the engine is started If the light turns on while operating the lift truck insufficient engine oil pressure is indicated Park the lift truck and stop the engine 8 Parking indicator light The
179. nner member with high free lift duplex cylinder Triple Lift Mast two inner members with either low or full free lift characteristics Quadruple Quad Mast with three inner members When only a mast type is listed on the identification plate a standard carriage and forks are used 46 Attachment Abbreviations includes Special Forks SC 555 HSS cw SF SWS RAM 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 CR TH CTH LPP cc RC LS PWH SS ST Hydraulic Fork Positioner Crane Arm or Crane Boom Tire Handler Container Handler Load Push Pull Device Carton Clamp Roll Clamp Load Stabilizer Pulp Wood Handler Sideshift Side Tilt Carriage Operation Section Operator s Station and Monitoring Systems 1 Horn Switch 2 Steering Handwheel 3 Turn Signal Lever 4 Instrument Panel 5 Parking Brake Lever 6 Lift Lever 7 Tilt Lever 8 Direction Control Lever 9 Engine Ignition Start Switch 10 Accelerator Pedal 11 Service Foot Brake Pedal 12 Inching Control Pedal 14 Transmission oil temperature gauge 15 Speed Meter 16 Fuel Level Gauge 17 Engine coolant gauge 18
180. nt at the radiator filter neck Maintenance Section Remove the radiator cap Fill radiator to the top of the filter neck Inspect radiator cap Replace if damaged Install the radiator cap Typical Example 3 Start and run the engine to stabilize the coolant level in the filter neck If low add coolant until it reaches the top of the filter neck Install the radiator cap Observe coolant level the expansion bottle If necessary add coolant to bring the coolant to the appropriate line on the expansion bottle Stop the engine Inspect the cooling system for leaks hose cracks or loose connections A WARNING Pressure air can cause personal injury When using pressure air for cleaning wear a protective face shield protective clothing and protective shoes Maximum air pressure must be less than 205 kPa 30 psi for cleaning purposes 6 Blow any dust and lint from the radiator fins 148 Air Cleaner Indicator Check Service Indicator Typical Example Diesel Engine Truck Observe the air cleaner service indicator Service the air cleaner when the RED band in the service indicator locks in the visible position See topic Air Intake System Check Clean in Every 250 Service Hours or Monthly NOTE Service the element more frequently as required in severe dust or lint conditions Also service it more frequently where the operator is required to wear a respirator 3 C
181. oc gt mm oooc gt mm 3100 3600mm MAST 4350mm MAST 4100mm MAST 4800mm MAST 4600mm MAST 5400mm MAST 5100mm MAST 5850mm MAST 5600mm MAST 42 General Section Serial Number Serial Number Locations For quick reference record your lift truck s serial numbers in the spaces provided below the photographs Typical Example Lift Truck Serial Number 050 60 70 80 905 5 3 speed Transmission Serial Number Typical Example Diesel Engine 5 8 liter DB58S Diesel Engine Serial Number 050 60 705 5 2 speed G50 60 708 5 Transmission Serial Number Typical Example G50 60 708 5 4 3 liter GM Vortec Engine Serial Number G643 43 General Section 050 60 70 80 905 5 3 speed G50 60 708 5 Transmission Serial Number D50 60 70S 5 2 speed G50 60 70S 5 DRIVE AXLE Serial Number Shoe type 44 General Section Operator s Warning and Identification Plate Familiarize yourself with the Operators WARNING Plate and IDENTIFICATION LIFT CAPACITY and ATTACHMENT PLATES DO NOT exceed Capacity as equipped load ratings A WARNING The load capacity of lift truck should never be exceeded Overloading of the lift truck could be a hazard to the safety of others material or damage the truck Operator s Warning Plate Typical Example Located by the right side of the operator s seat
182. oint in the controller Auto Shift will shift the transmission to NEUTRAL until the lift truck s travel speed slows to the pre selected direction change speed and then shift the transmission to the direction selected You should be prepared to help slow the lift truck to the pre selected direction change speed by pressing down on the service brake pedal Operation Section A WARNING When you want to change the travel direction you must press down on the service brake pedal to reduce the travel speed Be cautious that the lift truck s stopping distance may be longer than in manual mode because the lift truck continues to travel forward regardless of the selection of reverse with the direction control lever until the vehicle speed is sufficiently reduced 8 The direction of travel will change automatically when the vehicle speed is reduced as much as the pre selected speed in the controller A WARNING Bring the loaded lift truck to a complete stop before changing travel direction Changing travel direction while traveling may cause the lift truck to lose the load or tip over 9 When the direction change is completed continue to push down on the accelerator pedal to obtain the desired travel speed NOTICE The transmission of your lift truck may be reversed under full power up to a travel of 6 0 km h 3 73 mph But the Inhibit Speed of Auto Shift is set by the factory at 4 5 km h 2 5 3 2 mph because reversing the trans
183. ole 6 Maintain oil level to the bottom of level fill hole 7 Install the drive axle housing level fill plug 8 Remove the wood blocking and lower the carriage o Align planetary hub level drain fill plugs to the horizontal position 10 Remove the plugs and check if oil reaches the level drain fill hole 11 Maintain the oil level to the hole 12 Install the planetary hub level drain fill plugs Oil Cooled Disc Brake OCDB Park the lift truck on a level surface Apply the parking brake The engine is at the low idle Place the directional control level in NEUTRAL 1 Remove the dip stick filter cap Observe the oil level 2 Maintain the oil level between lower mark and upper mark on the dip stick filter cap 3 Install the dip stick filter cap Maintenance Section Mast Carriage Lift Chains amp Attachments Inspect Lubricate 1 Operate the lift tilt and attachment controls Listen for unusual noises These may indicate a need for repair 2 Check for loose bolts and nuts on the carriage Remove any debris from the carriage and mast 3 Check the forks and attachments for free operation and damage Have repairs made if necessary ILOMO23P Typical Example 4 Brush a film of oil on all links of the chain 5 Raise and lower the carriage a few times to allow lubricant to enter into the chain links NOTICE Lubricate chains more frequently than normal in appl
184. on of travel RELEASE the accelerator pedal 10 PUSH DOWN on the service foot brake pedal to bring the lift truck to a complete stop 11 SHIFT the directional lever to the desired direction of travel Rotate the speed selector lever to first low speed range if it is not already in this position 12 RELEASE the service foot brake PUSH DOWN on the accelerator pedal to obtain the desired travel speed Operation Section A WARNING Watch the road carefully for any obstacle when driving the truck Do not go fast over bumps pot holes or other rough grounds otherwise the engine might go OFF by a severe impact In case of engine going OFF press the brake pedal at one time as hard as possible in order to stop the truck Pressing the brake pedal several times has a risk that the brake would not work Typical Example 13 To stop the lift truck when travelling in either direction RELEASE accelerator pedal 1 14 PUSH DOWN on service foot brake pedal 2 and bring the lift truck to smooth stop Inching NOTE The purpose of the inching pedal is to provide precise lift truck inching control at very slow travel speed and high engine rpm This is used for fast hydraulic lift during load approach pick up or load positioning Typical Example 1 To inch creep in either direction slowly push down on the inching pedal This will start to apply the service foot brakes and allow the transmiss
185. ons are available and understood Operation The Operation Section is a reference for the new operator and a refresher for the experienced one This section includes a discussion of gauges switches lift truck controls attachment controls transportation and towing information Photographs and illustrations guide the operator through correct procedures of checking starting operating and stopping the lift truck Operating techniques outlined in this publication are basic Skill and techniques develop as the operator gains knowledge of the lift truck and its capabilities Maintenance The Maintenance Section is a guide to equipment care The illustrated step by step instructions are grouped by servicing intervals Items without specific intervals are listed under When Required topics Items in the Maintenance Intervals chart are referenced to detailed instructions that follow Maintenance Intervals Use the service hour meter to determine servicing intervals Calendar intervals shown daily weekly monthly etc can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading Recommended service should always be performed at the interval that occurs first Under extremely severe dusty or wet operating conditions more frequent lubrication than is specified in the Maintenance Intervals chart might be necessary Perform se
186. p the engine e Remove the start switch key and turn the disconnect switch OFF if equipped e Block the drive wheels when parking on an incline Pressure Air 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 Fluid Penetration Always use a board or cardboard when checking for a leak Escaping fluid under pressure even a pinhole size leak can penetrate body tissue causing serious injury and possible death If fluid is injected into your skin it must be treated by a doctor familiar with this type of injury immediately Crushing or Cutting Prevention Support equipment and attachments properly when working beneath them Do not depend on hydraulic cylinders to hold it up Any attachment can fall if a control is moved or if a hydraulic line breaks Never attempt adjustments while the lift truck is moving or the engine is running unless otherwise specified Where there are attachment linkages the clearance in the linkage area will increase or decrease with movement of the attachment Stay clear of all rotating and moving parts Keep objects away from moving fan blades They will throw or cut any object or tool that falls or is pushed into them Do not use a kinked or frayed wire rope cable Wear gloves when handling the wire rope cable
187. part of the lift truck Secure all loose items such as lunch boxes tools and other items which are not part of the lift truck Know the appropriate work site hand signals and who gives them Accept signals from one person only Always use the overhead guard The overhead guard is intended to protect the lift truck operator from overhead obstructions and from falling objects A truck that is used for handing small objects or uneven loads must be fitted with a load backrest If the lift truck must be operated without the overhead guard in place due to low overhead clearance use extreme care Make sure there is no possibility of falling objects from any adjacent storage or work area Make sure the load is stable and fully supported by the carriage and the load backrest extension if equipped Do not raise loads any higher than necessary and never raise a load higher than 1830 mm 72 in with the overhead guard removed Always use load backrest extension when the carriage or attachment does not fully support the load The load backrest extension is intended to prevent the load or any part of the load from falling backwards into the operator s station When operating the lift truck Do not depend only on flashing lights or back up alarm if equipped to warn pedestrians Always be aware of pedestrians and Do not proceed until the pedestrians are aware of your presence and intended actions and have moved clear of the lift truck a
188. pen the drain valve on the bottom of the fuel filter 2 Drain some fuel and any water until clean fuel flows from the filter Maintenance Section Test Fuel System for Leaks LP Engine Only M EI 5 ru e Obtain a leak check squirt bottle or pump spray bottle e Fill the bottle with an approved leak check solution Spray a generous amount of the solution on the fuel system fuel lines and connections starting atthe storage container e Wait approximately 15 60 seconds then perform a visual inspection of the fuel system Leaks will cause the solution to bubble e Repair any leaks before continuing e Crank the engine through several revolutions This will energize the fuel lock off and allow fuel to flow to the pressure regulator converter Apply additional leak check solution to the regulator converter fuel connections housing Repeat leak inspection as listed above e Repair any fuel leaks before continuing WARNING Prior to any service or maintenance activity Test Fuel System for Leaks Maintenance Section Fuel Tank Filter Cap amp Screen Clean Park the lift truck with the forks lowered parking brake applied transmission in neutral and the engine stopped Typical Example 1 Raise the left side cover 2 Remove the filter cap assembly Separate the cap from the screen Clean both in clean nonflammable solvent 3 Dry and assemble cap and screen
189. pm 73 6 99 2 2200 73 6 99 2 2200 51 max torque N m Ib ft rpm 363 268 1600 363 268 1600 52 cycle cylinders displacement cc 4 6 5785 4 6 5785 Transmission 56 speeds forward reverse Full Auto Full Auto 30 General Section 3 Speed DOOSAN DOOSAN DOOSAN D70S 5 0805 5 0905 5 7000 8000 9000 600 600 600 diesel diesel diesel rider seated rider seated rider seated 42 42 42 3100 3100 215 215 60 180 1200 70 180 1200 70 180 1200 410 2032 410 2092 410 2092 15 10 15 10 15 10 3647 3970 4040 2108 2230 2230 2500 2835 2835 4340 4375 4375 2455 2648 2648 1333 1526 1526 3380 3610 3680 632 725 725 4000 4330 4355 3058 3308 3327 22 23 23a 285520 298558 28 30 32 1A201004 28 5 32 0 29 8 33 8 27 7 33 4 445 470 430 470 430 470 499 450 500 450 500 450 5915 5498 5449 37 2 30 6 28 6 9970 11545 12195 14980 1990 14920 4360 16920 4705 4150 5820 4600 6500 4680 7315 4 2 4 2 4 2 8 25x15 14PR 9 00x20 14PR 9 00x20 14PR 8 25x15 14PR 9 00x20 14PR 9 00x20 14PR 2250 2500 2500 1584 1550 1640 1750 1646 1750 176 258 258 205 205 205 foot hydraulic foot hydraulic foot hydraulic hand mechanical hand mechanical hand mechanical Bl wlo a oa oa o o o o o 24 75 24 75 24 75 DOOSAN DB58S DOOSAN DB58S DOOSAN DB58S 73 6 99 2 2200 73 6 99 2 2200 73 6 99 2 2200 363 268 1600 363 268 1600 363 268 1600 4 6 5785 4 6 5785 4 6 5785 Full Auto
190. 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 NOTICE Do not allow the lift truck to become low on fuel or completely run out of fuel Sediment or other impurities in the fuel tank could be drawn into the fuel system This could result in difficult starting or damage to components Fill the fuel tank at the end of each day of operation to drive out moisture laden air and to prevent condensation In the cold weather the moisture condensation can cause rust in the fuel system and hard starting due to its freezing Do not fill the tank to the top Fuel expands when it gets warm and may overflow Typical Example 1 Park the lift truck only at a designated safe location Place the transmission in NEUTRAL Lower the forks to the ground Engage the parking brake Stop the engine 60 Typical Example 2 Remove the filter cap 3 Fill the fuel tank slowly See topic Refill Capacities in maintenance section Install the filter cap If spillage occurs wipe off excess fuel and absorb any excess fuel with absorbent material NOTE Drain water and sediment from fuel tank as required by prevailing conditions Also drain water and sediment from the main fuel storage tank weekly and before the tank is refilled Thi
191. r or the lift truck Do not smoke when checking battery electrolyte levels Electrolyte is an acid and can cause personal injury if it contacts skin or eyes Always wear eye protection when starting a lift truck with jump cables Improper jump procedures can cause an explosion resulting in personal injury Always connect battery positive to battery positive and battery negative to be battery negative Jump only with a battery source and with the same voltage as the stalled lift truck Turn off all lights and accessories on the stalled lift truck Otherwise they will operate when the jump source is connected NOTICE When starting from another machine make sure the machines Do not touch This could prevent damage to engine bearings and electrical circuits Turn on close the disconnect switch prior to the boost connection to prevent damage to electrical components on the stalled machine Severely discharged maintenance free batteries might not fully recharge by the alternator alone after jump starting The batteries must be charged to the proper voltage by the battery charger Many batteries thought to be unusable are still rechargeable This machine has a 24 volt starting system Use only equal voltage for jump starting Use of a welder or higher voltage equipment will damage the electrical system Operation Section Use of Jumper Cables When auxiliary start receptacles are not available use the
192. r to activate the left turn signal 51 Operation Section Seat Switch System The lift truck is equipped with a SEAT SWITCH SYSTEM In normal operation if the direction lever is placed in either forward or reverse the lift truck will move at a speed proportional to the accelerator pedal s position If the operator leavers the seat without setting the parking brake within three seconds after leaving the seat the SEAT SWITCH SYSTEM will automatically disengage the transmission The directional lever however will remain in that forward or reverse location although internally the transmission will have shifted into neutral Before exiting the lift truck the parking brake should always be applied A WARNING WHEN LEAVING MACHINE APPLY PARKING BRAKE PARKING BRAKE APPLIED IS NOT AUTOMATICALLY NOTE Some trucks may be equipped ask your dealer if this applies to your truck with an alarm that will sound if the parking brake is not applied when leaving the machine 52 NOTICE Prior to operating the lift truck be sure to understand and check the SEAT SWITCH SYSTEM 2 While in normal operation and level ground select direction with the derectional lever and with the park brake released You will note that the truck will move slowly in the selected direction If you lift yours hips off of the seat within three seconds the SEAT SWITCH SYSTEM will desengage the transmission allowing the tru
193. ribe lines on the top and bottom covers 9 Install the cover retaining screws tightening the Screws in an opposite sequence across the cover 10 Open the fuel valve by slowly turning the valve counterclockwise 11 Crank the engine several revolutions to open the fuel lock off DO NOT START THE ENGINE Turn the ignition key switch to the off position 12 Check the filter housing fuel lines and fittings for leaks Repair as necessary Maintenance Section Testing Fuel Lock off Operation LP Engine Only e Start engine e Locate the electrical connector for the fuel lock e Disconnect the electrical connector e The engine should run out of fuel and stop within a short period of time e Turn the ignition key switch off and re connect the fuel lock off connector NOTE The length of time the engine runs on trapped fuel vapor increases with any increase in distance between the fuel lock off and the pressure regulator converter 1 LP fuel lock off 2 LP regulator converter 180 Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Steer Wheel Bearings Reassemble Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped Typical Example 4 Remove the wheel assemb
194. rvice on items at multiples of the original requirement For example at Every 500 Service Hours or 3 Months also service those items listed under Every 250 Service Hours or Monthly and Every 10 Service Hours or Daily Information Section Environment Management Note that DOOSAN INDUSTRIAL VEHICLE DIVISION is ISO 14001 certified which is harmonized with ISO 9001 Periodic ENVIRONMENTAL AUDITS amp ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by internal and external inspection entities LIFECYCLE ANALYSIS has also been made through out the total product life ENVIRONMENT MANAGEMENT SYSTEM includes DESIGN FOR ENVIRONMENT from the initial stage of the design ENVIRONMENT MANAGEMENT SYSTEM considers environmental laws amp regulations reduction or elimination of resource consumption as well as environmental emission or pollution from industrial activities energy saving environment friendly product design lower noise vibration emission smoke heavy metal free ozone depleting substance free etc recycling material cost reduction and even environmentally oriented education for the employee Information Section Important Safety Information Most accidents involving product operation maintenance and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential
195. s lights off These lamps light up regardless of position of the ignition switch 10 Hazard Lamp Switch Push the button to active the hazard lamp Hazard lamp put the same with turn signal lamp 49 Operation Section Operation Section Warning Light Gb sb d Eis 5 4 12 9 14 14 1 Upper Indicator Light 2 Air Cleaner Indicator Light 3 Alternator Indicator Light 4 Diesel Engine Start Preheat Indicator Light 5 Air Dryer Heater Light 6 Front Flood Light 7 Engine Oil Pressure Indicator Light 1 Upper Indicator Light Indicates the upper indicator light is on 2 Air Cleaner Indicator Light Indicates that the air filter is blocked If the light stays on after starting the engine stop the engine remove the air filter element and clean it thoroughly using compressed air Refit the filter and check that the light goes out when the engine is started 3 Alternator Indicator Light Indicates if the battery charging system is operational The light will come on when the ignition switch is turned to the ON position The light should go off after the engine is started indicating the alternator is producing sufficient voltage to charge the battery If the light turns on with the engine running check the alternator charging system for a malfunction 8 Parking Indicator Light 9 Levering Light 10 Seat Belt Warning wight 11 Seat Leaving War
196. s fire extinguishers first aid kits and lights by welding brackets to or drilling holes in any FOPS structure See your DOOSAN dealer for mounting guidelines 14 Burn Prevention Coolant At operating temperature the engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot water or steam Any contact can cause severe burns Steam can cause personal injury Check the coolant level only after engine has been stopped and the filter cap is cool enough to remove with your bare hand Remove the cooling system filter cap slowly to relieve pressure Cooling system additive contains alkali that can cause personal injury Avoid contact with the skin and eyes and Do not drink Allow cooling system components to cool before draining Oils Hot oil and components can cause personal injury Do not allow hot oil or components to contact the skin At operation temperature the hydraulic tank is hot and can be under pressure Remove the hydraulic tank filter cap only after the engine has been stopped and the filter cap is cool enough to remove with your bare hand Remove the hydraulic tank filter cap slowly to relieve pressure Relieve all pressure in air oil fuel or cooling systems before any lines fittings or related items are disconnected or removed Batteries Batteries give off flammable fumes which can explode Do not smoke when observing the battery electrolyte l
197. s for proper inflation See Tire Inflation Pressures To inflate tires always use a clip on chuck with a minimum 60 cm 24 inches length of hose to an inline valve and gauge Always stand behind the tread of the tire NOT in front of the rim a 1A704004 Typical Example Do not reinflate a tire that has been run while flat or underinflated without first checking to make sure the rim is not damaged and is in the correct position When tires are changed be sure to clean all rim parts and if necessary repaint to stop detrimental effects of corrosion Sand blasting is recommended for removal of rust Check all components carefully and replace any cracked badly worn damaged and severely rusted or corroded parts with new parts of the same size and type If there is any doubt replace with new parts Do not under any circumstances attempt to rework weld heat or braze any rim components Radiator Cap Clean Change Clean Pressure Cap The radiator cap is located on the left side of the lift truck Diesel Engine Truck The radiator cap is located on the right side of the lift truck LP Engine Truck A WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 1 Remove the radiator cap slowly to relieve pressure 2 Inspect the cap for damage deposits or foreign material Clean the cap with a clean cloth or change the cap as ne
198. s normally protected to 28 C 20 F with antifreeze when shipped from the factory unless special requirements are defined Check the specific gravity of the coolant solution frequently in cold weather to ensure adequate protection Clean the cooling system if it is contaminated the engine overheats or foaming is observed in the radiator Old coolant should be drained the system cleaned and new coolant added every 2000 service hours or yearly Refer to topic Cooling System Clean Change in Every 2000 Service Hours or Yearly section Filling at over 20 liters 5 U S gallons per minute can cause air pockets in the cooling system After draining and refilling the cooling system operate the engine with the radiator cap removed until the coolant reaches normal operating temperature and the coolant level stabilizes Add coolant as necessary to fill the system to the proper level Never operate without a thermostat in the cooling system Cooling system problems can arise without a thermostat 128 Coolant Water Hard water or water with high levels of calcium and magnesium ions encourages the formation of insoluble chemical compounds by combining with cooling system additives such as silicates and phosphates The tendency of silicates and phosphates to precipitate out of solution increases with increasing water hardness Hard water or water with high levels of calcium and magnesium ions encourages the formation o
199. s will help prevent water or sediment being pumped from the storage tank into the lift truck fuel tank Changing LP Tanks A WARNING Only trained authorized personnel should fill or exchange LP tanks Personnel engaged in filling of LP containers should wear protective clothing such as face shield long sleeves and gauntlet gloves Do not refuel or store LP powered lift trucks near any underground entrance elevator shafts or any other place where LP could collect in a pocket causing a potentially dangerous condition Examine all LP containers before filling and again before reuse for damage to various valves liquid gauge fittings and hand valve wheels All defective or damaged LP containers must be removed from service Explosive fumes may present refueling Do not smoke in refueling areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to indoor locations Stop the engine and get off the lift truck during refueling The careless handling of LP containers can result in a serious accident Use extreme care when transporting containers to prevent damage to them during 1 Park the lift truck on level ground with the parking brake applied the transmission NEUTRAL the forks lowered and the engine running at low idle 2 Close the fuel inlet valve at the LP Gas tank Run the engine until it stops then turn off the ignition switch and the
200. se 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 See Fluid Penetration in the Safety Section for more details Tighten all connections to the recommended torque Replace if any of the following conditions are found e End fittings damaged or leaking e Outer covering chafed or cut and wire reinforcing exposed e Outer covering ballooning locally e Evidence of kinking or crushing of the flexible part of hose e Armoring embedded in the outer cover e End fittings displaced Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during operation Tire Information Explosions of air inflated tires have resulted from heat induced gas combustion inside the tires The heat generated by welding heating rim components external fire or excessive use of brakes can cause gaseous combustion A tire explosion is much more violent than a blowout The explosion can propel the tire rim and axle components as far as 500 m 1500 ft or more from the lift truck Both the force of the explosion and the flying debris can cause personal injury or death and property damage AT LEAST 15m 50 ft AT LEAST 500m 1500 ft 0 0121 Do not approach a warm tire closer than the outside
201. sent e See Advanced Diagnostics Difficult to Start Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container e Do not exceed 80 of capacity liquid Excess flow valve closed Reset excess flow valve e Close liquid valve e Wait for a click sound Slowly open liquid valve Clogged fuel filter Repair replace as required e See Maintenance Section LP Fuel Filter replacement Plugged fuel line Remove obstruction from the fuel line e Close liquid fuel valve e Using caution disconnect the fuel line some propane may escape e Clear obstruction with compressed air e Re connect fuel line e Slowly open liquid fuel valve e Leak test Faulty vapor connection between the pressure regulator converter and the mixer Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Pressure malfunction regulator converter Test pressure regulator converter operation e See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container e Do not exceed 8096 of capacity liquid Air filter clogged Check air filter e Clean replace as required Incorrect air fuel or ignition control See Advanced Diagnostics Engine Mechanical See Engine Service Manual 73 Operation Section Problem Probable Cause Corrective Action Wil
202. ses protect the electrical system from damage caused by overloaded circuits Change a fuse if the element separates If the element of a new fuse separates have the circuit checked and repaired Operation Section 1 050 60 705 5 2 Speed 3 650 60 705 5 2 Speed oer Rated ar Rated No Description Capacity E Description Capacity 1 Engine Start 10A 1 Engine Start 10A 2 51 10 ECU Engine Control Unit Main Relay Coil TUR System 1503691 Valve 1503691 Valve 3 Solenoid Valve Control Sys 10A 3 Solenoid Valve Control Sys 10A 3 Gabin Relay Goll Alrcon Helay Coil 15 4 Cabin Relay Coil Aircon Relay 15A 5 Gague Panel Stop Lamp Strobe Light 15 5 Gague Panel Stop Lamp Strobe Light 15 Hom 6 Hom 10 7 Spare 10 Head Lamp Relay Coil Rear Lamp Turn 7 Spare Signal Lamp 15A Head Lamp Relay Coil Rear Lamp Turn Clearance Lamp 8 Signal Lamp 15A 9 Far AMPHI Ream Head een 15A TA Head Lamp Low Beam 8 ami 15 10 Cigar Lighter Power Socket CD Player 15 Cigar Lighter Power Socket CD Player Wiper Motor CABIN 10 3 i 15 11 Ignition Switch St Ign Acc 30A Wiper Metor CABIN 12 Aircon Heater 30A 11 gnition Switch St Ign Acc 30A 12 Aircon Heater 30
203. slippery grades Travel with forks downgrade when unloaded Travel with load upgrade Do not overload or handle offset unstable or loosely stacked loads Refer to load capacity plate on the lift truck Use extreme caution when handling suspended long high or wide load 0381 an elevated load forward only when directly over unloading area and with load as low as possible Do not stunt ride or indulge in horseplay Always look and keep a clear view of the path of travel Travel in reverse if load or attachment obstructs visibility Use extreme caution if visibility is obstructed Stay in designated travel path clear of dock edges ditches other drop offs and surfaces which cannot safely support the lift truck Slow down and use extra care through doorways intersections and other location where visibility is reduced Slow down for cross aisles turns ramps dips uneven or slippery surfaces and in congested areas and avoid pedestrians other vehicles obstruction pot holes and other hazards or objects in the path of travel Always use overhead guards except where operation conditions Do not permit Do not operate lift truck in high stacking areas without overhead guards When stacking watch for falling objects Use load backrest extension and overhead guard Refer to the topic Operation Techniques in the Operation Section of this manual Loading or Unloading Trucks Trailers
204. t low idle shift the directional control lever to forward and then to reverse to fill the clutches Typical Example D50 60 708 5 2 Speed G50 60 708 5 Maintenance Section Shift the transmission into NEUTRAL Engage the parking brake Loosen the dipstick counter clockwise remove and clear it Insert the oil dipstick slowly into the oil level tube until contact is obtained and pull the dipstick out again When the oil temperature is around 40 C the marking on the oil dipstick must be lying above the cold start mark COLD When the oil temperature is around 80 C the oil level must be lying in the zone HOT Install the oil dipstick again and tighten it clockwise Check for oil leaks at the filter and drain plug Stop the engine Maintenance Section First 50 100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Engine Oil amp Oil Filter Diesel E G Only Change The percentage of sulfur in the fuel will affect the engine oil recommendations If the fuel has over 0 5 sulfur content the engine oil must have a TBN of 20 times the percentage of fuel sulfur TBN as measured by the ASTM D 2896 method Your oil supplier should be able to furnish the correct oils 1 Operate lift truck a few minutes to warm oil Park the lift truck with the for
205. t tank for secure mounting 1 Open the tank fuel valve by slowly turning the valve counterclockwise Observe the LP gauge if equipped 2 Turn the ignition switch to the START position Release it when the engine starts 3 If the engine does not start Do not press on the accelerator pedal Turn the starter switch to OFF position the repeat step 2 and depress the accelerator pedal slightly during cranking Allow the engine to warm up slowly 66 Starting From 24 12 Volt External Source A WARNING Sparks occurring near the battery could cause vapors to explode Always connect the external power source ground cable to a point away from and below the battery and well clear of fuel system components L NN Typical Example Diesel Engine Truck Typical Example LP Engine Truck NOTICE Do not reverse battery cables It can cause damage to the alternator Always connect the external power source cables in parallel with the lift truck battery cables 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 Operation Section Starting with Jumper Cables A WARNING Batteries give off flammable fumes that can explode Prevent sparks near the batteries They could cause vapors to explode Do not allow jump cable ends to contact each othe
206. t truck level with the forks lowered element seal and housing seal parking brake engaged transmission in NEUTRAL and the engine stopped 9 Install the filter housing with filter to the housing base Install bolts and tighten 20 to 30 15 to 20 Ibeft 10 Start the engine and operate the hydraulic controls and the steering system through a few cycles to fill the lines Look for oil leaks 11 Stop the engine and check the oil level With all cylinders retracted maintain the oil level to the FULL mark on the dip stick filter cap assembly FILTER IDGOM027 1 Remove the floor plate 2 Remove bolts and filter housing 3 Remove and discard filter element from filter housing 159 Maintenance Section Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Air Intake System Check Clean Servicing Filter Element Precleaner If Equipped NOTICE Never service filter with the engine running NOTICE Never service precleaner with the enginerunning Typical Example 1 Check the precleaner bowl for dirt build up If the dirt is up to the line remove the precleaner bowl and empty it Periodically wash the cover and bowl in water Typical Example LP Engine Truck Service the air cleaner when the red target in the service ind
207. the fork service prior to failing e Repetitive Overloading Repetitive cycling of loads which exceeds the fatigue strength of the material can lead to fatigue failure The overload could be caused by loads in excess of the rated fork capacity and by use of the forks tips as pry bars Also by handling loads in a manner which causes the fork tips to spread and the forks to twist laterally about their mountings e Wear Forks are constantly subjected to abrasion as they slide on floors and loads The thickness of the fork blade is gradually reduced to the point where it may not be capable of handling the load for which it was designed e Stress Risers Scratches nicks and corrosion are points of high stress concentration where cracks can develop These cracks can progress under repetitive loading in a typical mode of fatigue failure Overloading Extreme overloading can cause permanent bending or immediate failure of the forks Using forks of less capacity than the load or lift truck when lifting loads and using forks in a manner for which they were not designed are some common causes of overloading 122 Fork Inspection 10500019 Establish daily 12 month inspection routine by keeping a record for the forks on each lift truck Initial information should include the machine serial number on each the forks are used the fork manufacturer type original section size original length and capac
208. tions are present If a detected fault condition exists the fault or faults will be stored in the memory of the small engine control module SECM Once an active fault occurs the MIL will illuminate and remain ON This signals the operator that a fault has been detected by the SECM 0 NE e 1 1 Malfunction Indicator Lamp MIL for Engine control system 90 Reading Diagnostic Fault Codes All MI 07 fault codes are three digit codes When the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 0 5 seconds between digits and a long pause 1 2 seconds between fault codes A code 12 is displayed at the end of the code list EXAMPLE code 461 ETCSticking has been detected and the engine has shut down and the MIL has remained ON When the codes are displayed the MIL will flash four times 4 pause then flash six times 6 pause then flash one time 1 This identifies four sixty one 461 which is the ETCSticking fault If any additional faults were stored the SECM would again have a long pause then display the next fault by flashing each digit Since no other faults were stored there will be a long pause then one flash 1 pause then two flashes 2 This identifies a twelve signifying the end of the fault list This list will then repeat Displaying Fault Codes DFC from SECM Memory To enter code display mode you must turn OFF the ignition key
209. tle defective TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0Q Fault actions shown are default values specified by the OEM 96 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d A CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK ETCSpringTest Electronic Throttle Control Spring Return Test has failed The SECM will perform a safety test of the throttle return spring following engine shutdown If 1 TumOnMil 481 this spring has become weak 2 EngineShutdown Perform throttle spring test by cycling 28 the throttle will fail the test 9 the ignition key and re check for fault and set the fault NOTE The throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly Check ETC driver wiring for a shorted HbridgeFault ETC EM Pin A17 to ETC Pin 1 7 SECM Pin A18 to ETC Pin 4 Indeterminate fault oh Perform the throttle test using the 491 Service Tool and re check for fault Hbridge driver for electronic TurnOnMil 29 tirate control Possibly Check the ETC internal motor drive by either or ETC driver disconnecting the throttle connector signals have been shorted to and measuring the motor drive resistance at the throttle ground TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0Q 1 TurnOnMil Check engine oil level 521 LowOilPressureFault 2 DelayedEngine Check electrical connect
210. tor and pins for 632 Learned idle end of APP2 corrosion 67 sensor range lower than None Cycle the pedal several times and expected check APP2 signal at SECM Pin B16 APP1 AdaptHiMax 641 Learned full pedal end of 64 APP1 sensor range higher None N A than expected APP2AdaptHiMax 642 Learned full pedal end of 68 APP2 sensor range higher Mong than expected Fault actions shown are default values specified by the OEM 99 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK APP1 AdaptHiMin 651 Learned full pedal end of None NA APP1 sensor range lower than expected APP2AdaptHiMin Learned full pedal end of 832 2 sensor range lower Nong than expected APP1AdaptLoMax 661 Learned idle end of APP1 None NA sensor range higher than expected APP2AdaptLoMax 662 Learned idle end of APP2 N A sensor range higher than expected APP Sensors Conflict connector and pins for APP position sensors do no 691 j 1 TurnOnMil Cycle the pedal several times and o Nottrack well intermittent 5 evel1PowerLimit check APP1 signal at SECM Pin B7 connections to APP or defective pedal assembly Cycle the pedal several times and check APP2 signal at SECM Pin B16 Check FTV1 for an open wire or FTV connector being disconnected 7 Pin
211. trol lever 109 Operation Section Operation This system can be basically operated in two preselected modes automatic mode and manual mode NOTE ASC 200 factory setting controller automatic mode is selected for both direction inhibit and two speed auto shift control as a default on the PCB Printed Circuit Board In ASC 201 factory setting controller manual mode Fail Safe Mode is selected as a default for direction inhibit while automatic mode is selected as a default for two speed auto shift control Automatic mode Direction Inhibit 1 Start the engine with the direction control lever in NEUTRAL and the parking brake engaged Press down on the service brake pedal disengage the parking brake and move the direction control lever to FORWARD NOTE Release the parking brake before using the directional control lever Observe the LED on the Auto Shift Controller The LED should indicate A while the direction control lever is in FORWARD NEUTRAL and REVERSE Report Auto Shift as faulty if the LED indicates anything other than A Keep the service brake pushed down until ready to move the truck To change directions of a traveling lift truck when the Auto Shift Controller LED displays A shift the direction control lever to the opposite direction and wait for the lift truck to change direction If however your travel speed is higher than the pre selected direction change speed as direction inhibit p
212. use the horn near corners exits entrances and near people Never operate a lift truck with wet hands or shoes Never hold any controls with grease on your hands Your hands or feet will slide off of the controls and cause an accident Safety Section Do not raise anyone on the forks of your lift truck Do not let other people ride on the truck Lift trucks are designed to carry loads not people Do not operate your truck without the load backrest extension and overhead guard Keep the load against the backrest with the mast tilted backward Do not lift or move loads that are not safe Do not pick up an off center load Such a load increases the possibility of a tipover to the side Make sure loads are correctly stacked and positioned across both forks Always use the proper size pallet Position the forks as wide as possible under the load Position loads evenly on the forks for proper balance Do not lift a load with one fork Do not overload Always handle loads within the rated capacity shown on the capacity plate Do not add extra counterweight to the truck An overload can cause the truck to roll over and cause injury to personnel and damage to the lift truck Do not drive on soft ground Observe all signs especially those on maximum permitted floor loadings elevator capacities and clearance heights Handle loads carefully and check them closely for stability and balance Do
213. ush the button of the buckle to release the belt The belt will automatically retract when released Hold the plate of the belt and allow the belt to slowly retract 3 Be sure to fasten the belt across your hips not across your abdomen NOTE The belt is designed to automatically adjust to your size and movement A quick pull on the belt will confirm that the automatic adjuster will hold the belt position in the event of an accident 20 Avoiding Lift Truck Tipover Lift Truck Stability 1 500231 Counterbalanced lift truck design is based on the balance of two weights on opposite sides of a fulcrum the front axle The load on the forks must be balanced by the weight of the lift truck The location of the center of gravity of both the truck and the load is also a factor This basic principle is used for picking up a load The ability of the lift truck to handle a load is discussed in terms of center of gravity and both forward and sideways stability Center of Gravity CG E CG 1 500241 The point within an object at which the whole weight of the object may be regarded as_ being concentrated is called the center of gravity or CG If the object is uniform its geometric center will coincide with its CG If it is not uniform the CG could be at a point outside of the object When the lift truck picks up a load the truck and load have a new combined CG Safety Section
214. ve 16 Shutdown SECM Signal Pin B15 to ECT Pin 3 coolant temperature typically MM 3 CheckEngineLight SECM Sensor GND Pin B1 to due to the engine overheating ECT SECM System GND Pin A16 B17 Check regulator for coolant leaks m Check for coolant system problems 171 Engine coolant temperature None e g defective or stuck thermostat not changing as expected FuelSelectConflict Check fuel select switch connection for Conflict in fuel select signals a short to GND 181 normally set if both of the TurnOnMil SECM SIGNAL Pin A12 fuel select signals are SECM SIGNAL Pin A15 shorted to ground SECM Sensor GND Pin B1 Check Crankshaft sensor connections SECM SIGNAL Pin 5 to Crank No crankshaft signal when 4 3 engine is known to be 193 SECM Sensor GND PIN 1 to Crank rotating broken crankshaft sensor leads or defective nonnina Switched 12V to Crank sensor Pin 1 crank sensor Check for defective Crank sensor Fault actions shown are default values specified by the OEM 91 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d CORRECTIVE ACTION DFC PROBABLE FAULT FAULT ACTION FIRST CHECK CrankSyncFault Check Crankshaft sensor connections Loss of synchronization on SECM SIGNAL Pin B5 to Crank the crankshaft sensor sensor Pin 3 194 norm
215. vice Foot Brake Pedal Typical Example Accelerator Pedal Push DOWN on the brake pedal to slow or stop the lift truck RELEASE the brake pedal to allow the lift truck to move Typical Example eS Push DOWN on the pedal to increase engine rpm speed RELEASE the pedal to decrease engine rpm speed Parking Brake Lever NOTICE Do not engage the parking brake while the lift truck is moving unless an emergency exists The use of the parking brake as a service foot brake in regular operation will cause severe damage to the parking brake system The parking brake lever is located at the left side of the steering wheel Lift Control The forks can be raised or lowered by pulling backwards or pushing forwards on this lever The lift speed is controlled by tilt angle of the lever and accelerator pedal effort The lowering speed can be controlled by tilt angle of the lever The engine speed or accelerator pedal has nothing to do with the lowering speed of the forks 59 Operation Section Tilt Control The mast can be tilted by operation of this tilt lever Pulling on this lever backwards will tilt the mast backwards and pushing it forwards will tilt the mast forwards The tilt speed can be controlled by tilt angle of the lever and accelerator pedal effort Operation Section Refueling Diesel Engine Equipped A WARNING Explosive fumes may be
216. wall A WARNING Improper operation or maintenance could result in injury or death Do not operate or work on the lift truck unless you are properly trained 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 Safety Section General Warnings to Operator Located on the right side of the operator s seat A WARNING Only trained and authorized personnel may Operate this machine For safe operation read and follow the operation and maintenance Manual furnished with this lift truck and observe the following warnings 1 Before starting machine Check all controls and warning devices for proper operation 2 Refer to machine identification plate for allowable machine capacity Do not overload Operate machines equipped with attachments as partially loaded machines when not handling a load 3 Put directional control or shift lever in neutral before ON OFF switch is turned on 4 Start turn and brake smoothly Slow down for turns slippery or uneven surfaces Extremely poor surfaces should be repaired Avoid running over loose objects or holes in the roadway surfaces Use extreme caution when turning on inclines 5 Travel with load as low as possible and tilted back If load interferes with visibility travel with load trailing 6 On grade operations travel with loa
217. wer valve turn to rich side Power valve marked R and L R is rich side and L is lean side Operation Section Operation Section Advanced Diagnostics G643 Engine Only Advanced Diagnostics The MI 04 systems are equipped with built in fault diagnostics Detected system faults be displayed by the Malfunction Indicator Lamp MIL as Diagnostic Fault Codes DFC or flash codes and viewed in detail with the use of service tool software When the ignition key is turned ON the MIL will perform a self test illuminate once and then go OFF If a detected fault condition exists the fault or faults will be stored in the memory of the small engine control module SECM Once a fault occurs the MIL will illuminate and remain ON This signals the operator that a fault has been detected by the SECM ico Gq amp v 4 u EE o gt 1 1 Malfunction Indicator Lamp MIL for Engine control system 80 Reading Diagnostic Fault Codes All 04 fault codes are two digit codes When the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 0 5 seconds between digits and a long pause 1 2 seconds between fault codes A code 12 is displayed at the beginning of the code list EXAMPLE A code 26 has been detected ETCSticking and the engine has shutdown and the MIL has remained ON When the codes are displayed t

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