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Operation & Maintenance Manual

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1. DOOSAN DOOSAN G30P 5 G33P 5 G35C 5 3000 500 Ip 5 T rider seated rider seated rider p e ap 2 3230 3230 3000 9 152 152 152 10 TNI ET 3 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6 10 6 10 6 10 2700 1197 2165 4490 2183 1026 2365 2395 485 485 2850 2880 2050 18 19 18 19 18 5 19 5 24 500 600 500 600 420 600 510 460 1815 1805 1735 25 5 24 21 5 2 29 4380 4560 4750 30 6310 1050 1800 2780 1760 2800 1750 3000 32 2 2 2 2 2 2 33 28x9x15 12 250x15 18 34 6 50x10 10 6 50x10 12 6 50x10 12 1700 1700 1700 982 1000 982 1000 1026 1000 105 143 foot hyd foot hyd foot hyd hand mech hand mech hand mech a 12 65 G424F E G424F E G424F E 47 7 64 2550 47 7 64 2550 47 7 64 2550 182 135 2200 182 135 2200 182 135 2200 4 4 2405 powershift powershift powershift 37 General Section 16 37 13 4 14 General Section Specifications CHARACTERISTICS 1 MANUFACTURER DOO
2. p General Section Specifications CHARACTERISTICS 1 MANUFACTURER DOOSAN DOOSAN 2 MODEL G20P 5 G25P 5 3 CAPACITY at rated load center kg 2000 2500 4 LOAD CENTER distance mm 500 500 5 POWER TYPE electric diesel gas LPG gas Ip Ip 6 OPERATOR TYPE stand on ride seated rider seated rider seated 7 TIRES P pneumatic p p 8 WHEELS x driven number of front rear 2 2 2 2 DIMENSIONS 9 LIFT WITH STD maximum fork height with rated load mm 3230 3230 10 TWO STAGE MAST free lift mm 152 152 11 FORK CARRIAGE ISO class I I 12 FORKS thickness x width x length mm 40x100x1050 40x100x1050 13 fork spacing maximum x minimum mm 275x1035 275x1035 14 TILT OF MAST forward backward deg 6 10 6 10 15 length without forks mm 2530 2595 16 width mm 1170 1170 17 OVERALL mast lowered height mm 2175 2175 18 DIMENSIONS mast extended height mm 4490 4490 19 overhead guard height mm 2183 2183 20 seat height mm 1026 1026 21 OUTSIDE TURNING RADIUS mm 2220 2265 22 LOAD MOMENT CONSTANT mm 480 480 23 90 STACKING AISLE mm 2700 2745 23a 90
3. Specifications CHARACTERISTICS 1 MANUFACTURER 2 3 4 LOAD CENTER distance mm 5 POWER TYPE electric diesel gas LPG gas 6 7 TIRES C cushion P pneumatic 8 WHEELS x driven number of front rear DIMENSIONS 9 LIFT WITH STD TWO STAGE MAST maximum fork height with rated load mm 10 free lift mm 11 FORK CARRIAGE ISO class 12 FORKS thickness x width x length E 13 fork spacing maximum x minimum 14 TILT OF MAST forward backward 15 length without forks 16 width 17 OVERALL mast lowered height 18 DIMENSIONS mast extended height 19 overhead guard height 20 seat height 21 OUTSIDE TURNING RADIUS 22 LOAD MOMENT CONSTANT 23 90 STACKING AISLE 23a 90 INTERSECTING AISLE PERFORMANCE 24 travel loaded unloaded 25 lift loaded unloaded 26 lowering loaded unloaded 27 28 GRADEABILITY at 1 6km hr loaded unloaded time reached at max speed 29 ACCELERATION LO WEIGHT 30 TOTAL WEIGHT at unloaded kg 31 at loaded front rear kg 32 PALE ESAR at unloaded front rear kg CHASSIS 33 number of front rear 34 TIRES front size 35 rear size 36 WHEEL BASE mm 37 TREAD front rear mm 38 GROUND at loaded the lowest point 39 CLEARANCE at loaded center of wheelbase 40 SEVICE BRAKE 41 PARKING BRAKE DRIVE 42 43 manufacturer model 44 rated output rpm kw hp 45 ENGINE max torque rpm Nem Ibeft 46 cycle cylinders displacement 47 48 n
4. 62 Mast Channels Lubricate 158 Mast Hinge Pin Lubricate 176 Mast Pivot Eyes Lubricate 177 Mast Carriage Lift Chains amp Attachments Inspect EU 170 Metric Hardware 135 Mono Ped Control System 117 Mounting and Dismounting 11 Moving Fan 8 N No Riders 8 No Standing On Fork Warning 7 No Standing Under Fork Warning 7 Noise Vibration 42 O Oil Cooled Disc Brake Only 142 Operating in hot 124 Operating Techniques 121 Operating the Lift Truck 12 Operation Information 11 2 119 Operator s Warning and Identification Plate 62 Index Section Operator s Warning Plate 62 Operator Restraint System If Equipped 2 17 Operator s Station
5. Specifications CHARACTERISTICS 1 MANUFACTURER DOOSAN DOOSAN D20S 5 D25S 5 x MODEL YANMAR TIER2 YANMAR TIER2 3 CAPACITY at rated load center kg 2000 2500 4 500 5 POWER TYPE electric diesel gas LPG gas diesel dies el 6 OPERATOR TYPE stand on ride seated rider seated rider seated 7 TIRES P pneumatic p p 8 WHEELS x driven number of front rear 2 2 DIMENSIONS 9 LIFT WITH STD maximum fork height with rated load mm 3230 3230 10 TWO STAGE MAST free lift mm 152 152 11 FORK CARRIAGE ISO class II II 12 FORKS thickness x width x length mm 40x100x1050 40x100x1050 13 fork spacing maximum x minimum mm 275x1035 275x1035 14 TILT OF MAST forward backward deg 6 10 6 10 15 length to fork face mm 2530 2595 16 width mm 1170 1170 17 OVERALL mast lowered height mm 2175 2175 18 DIMENSIONS mast extended height mm 4490 4490 19 overhead guard height mm 2183 2183 20 seat height mm 1026 1026 21 OUTSIDE TURNING RADIUS 2265 22 LOAD MOMENT CONSTANT 480 23 90 STACKING AISLE 2745 75 90 INTERSECTING AISLE 2000 PERFORMANCE travel loaded unloaded km hr 21 21 5 21 21 5 SPEED lift loaded unloaded mm s 530 550 520 550 26 lowering loaded unloaded 510 460 510 460 DRAWBAR PULL at 1 6km hr loaded unloaded kg 1765 1740 DI BITA CE prEN 12053
6. 79 Lift Truck Operation 82 Mono Ped Control System 117 Auto Shift Controller ASC 100 If Equipped 118 Operating Techniques 121 Parking the LITE Truck 125 Lift Fork Adjustment 126 Storage Information 127 Transportation 128 Towing Information 129 Table of Contents Maintenance Section Inspection Maintenance and Repair of Lift Truck 130 Tire Inflation Information 134 Torque Specifications 135 Cooling System Specifications 137 Fuel Specifications 139 Lubricant Information 141 Lubricant Viscosities and Refill Capacities 143 Maintenance Intervals 144 When Required 148 Every 10 Service Hours or 155 First 50 100 Service Hours or a Week 161 First 250
7. 118 Disassembly u uuu uu uuu u 192 Display for Operator 119 Display for Troubleshooting 119 Displaying Fault Codes DFC from SECM Memory 99 Drive Axle Oil 164 Drive Axle Oil amp Strainer Change Clean 179 Drive Axle Oil Level 170 Drive Axle T 141 Drive Wheel Bearing Power Shaft Drive Wheel Reassenmble 196 Dual Fuel System 79 E Electrical Disconnect Switch If Equipped 66 Engine Compartment 66 Engine Oil amp Filter Diesel Engine Only Change X 161 183 Engine Oil amp Filter LP amp Gasoline Engine Only Change 171 Engine Oil DEO and EO 141 Engine Oil Level Check 155 Engine Valve Lash Diesel Engine Only Check PST sn 190 194 Environment 3 205 Index Section Environment 130 Every 10
8. 4 rl M 5 Warning Signs and Labels 5 Parking brake etc 9 General Hazard Information 10 Operation 11 Maintenance Information 14 Operator Restraint System lf Equipped 17 Avoiding Lift Truck Tipover 21 Safety 23 How to Survive a Tipover 28 General Section Specifications 30 Noise and Vibration 42 Capacity Chart Without Sideshifter Pneumatic 43 Capacity Chart With Sideshifter Pneumatic 47 Capacity Chart Without Sideshifter cushion 51 Capacity Chart With Sideshifter cushion B5 Serial Number 59 Operator s Warning and Identification Plate 62 Operation Section Operator s Station and Monitoring Systems 63 Seat Switch System If Equippeod 67 Lift Truck Controls 69 Refueling Et 71 Before Starting the 74 Starting the Engine 76 Dual Fuel System
9. 180 Steer Wheel Bearings Reassemble 194 Steering Mechanism Check Lubricate 170 Storage Information 127 T Table of Contents 1 Testing Fuel Lock off Operation LP Engine Only H 192 TO GOVINO M 70 Tilt Cylinders Check Adjust Lubricate 176 Tilt Steering Column 68 Timing Belt G420F E G424F E LP Gasoline Dual Fuel Engine Only Change 204 Tire Inflation Information 134 Tire Inflation Pressures Adjustment 134 Tire Inflation 134 Tire Shipping 134 Tires and Wheels D G Series Inspect Check154 To Operate the Lift Truck after a Long Time Storage sa 127 Torque for Metric Fasteners 136 Torque for Standard Bolts Nuts and Taperlock T 135 Torque for Standard Hose Clamps Worm Drive135 Torque 135 Torques for Bolts and Nuts with Standard Threads S SSS susan 135 Torques
10. Oo Sieering Mechanism id Check Lubricate 1700 lol Testing Fuel Lock off Operation LP Engine Ony 12 Jo heck Adj Tilt Cylinders 176 Lubricate Timing Belt G420F E G424F E LP Gasoline Dual Fuel ming elt E E asoline Dual Fue Change 204 Engine Only Tires and Wheels D G Series Inspect Check 154 o k Transmission Oil Oil Filter amp Strainer ee Glean 162 186 Universal Joint sss Joint Inspect fo C m m ssp a RS LEE Water Seperator Diesel Engine Only Check Drain 152 of WheelBolts amp Nuts ss msect 173 10 When Required 50 100 Service Hours or a Week o Ren gt a o gt o 2 o o e x gt x o o o 2 42 Lo N o Ren gt o o e 2 o 2 o o o x gt c o o e o RS e tO A gt c a c e 2 I I o LLL e 2000 Service Hours ora Yearly 2500 Service Hours 15 Months 3000 Service Hours or18 Months 147 Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety sectio
11. 7 Hook on type 126 Horn and Lights If Equipped Check 180 How to Survive in a 28 Hydraulic Oil Check Clean Change 201 Hydraulic Oil HYDO 141 Hydraulic Oil Level Check 169 Hydraulic Return Filter Change 166 Hydraulic Return Filter Breather amp Strainer Check uu Cm 185 Identification Lift Capacity and Attachment Plate 62 If Convenience Package Equipped 62 If Optional Suspension Seat weight adjusting type 18 If Parking Brake Alarm Equipped 125 Important Safety Information 4 Improper Modification or Repair 131 Inching amp Braking Control Shaft Lubricate 180 Inching into Loads 121 83 ie 205 Inspect Battery 201 Inspect Coolant Hoses LP Dual Fuel Engine Only 189 Inspect Electrical System G420F E G424F E Ime 181 Inspect Engine for Exhaust Leaks 157 Inspect Engine
12. 139 Fuel Tank Filter Cap and Screen If Equipped Clean 148 Fuel Trim Valve FTV Inspection G420F E G424F E Engine Only 181 PUG WV OSS accesses Rr 139 FUSES Cr 149 Fuses Bulbs Circuit Breaker amp Relay Change pisi SI 149 G G420F Engine G424F Engine 85 Q420F E Engine 191 202 G420F E Gasoline LP and Dual Fuel Engines 172 G420FE Engine and G424FE Engine 84 G424F E Engine 191 202 G424F E LP and Duel Fuel Engines 172 Gasoline and LP Engines 155 Gasoline Engine 76 Gasoline or Diesel Engine Equipped 71 Gasoline Specifications 140 Gasoline LP Engine Crankcase 171 GC Series Lift Trucks 196 General Fuel Information 139 General Hazard Information 10 General Warning to 6 Governor Lever and Engine Speed Control Diesel Engine Only Check Adjust 174 H Hand Placement
13. 28 GRADEABILITY at 1 6km hr loaded unloaded 33 28 29 ACCELERATION time reached at max speed loaded unloaded WEIGHT 30 TOTAL WEIGHT at unloaded kg 3580 3950 31 atloaded front rear kg 4930 650 5660 790 32 MAELOR at unloaded front rear kg 1720 1860 1650 2300 CHASSIS 33 number of front rear 2 2 2 2 34 TIRES front size 7 00x15 12 7 00x15 12 35 rear size 6 50x10 10 6 50x10 10 36 WHEEL BASE mm 1625 1625 37 TREAD front rear mm 975 1000 975 1000 38 GROUND at loaded the lowest point mm 115 115 39 CLEARANCE at loaded center of wheelbase mm 143 143 40 SEVICE BRAKE foot hyd foot hyd 41 PARKING BRAKE hand mech hand mech DRIVE 42 BATTERY voltage capacity 12 85 12 85 43 manufacturer model YANMAR 4TNV98 YANMAR 4TNV98 44 ENGINE rated output rom 46 3 62 1 2200 46 3 62 1 2200 45 max torque rpm 240 177 1320 240 177 1320 46 cycle cylinders displacement 4 4 3319 4 4 3319 47 TRANSMISSION type powershift powershift 48 number of speeds forward reverse 1 1 1 1 re s system attachment 181 156 195 156 equivelent continuous sound 50 NOISE LEVEL pressure level Leq at operator s ear dB A 30 DOOSAN DOOSAN DOOSAN 1 D30S 5 D33S 5 D35C 5 2 Y ANMAR TIER2 YANMAR TIER2 YANMAR TIER2 3000 3250 3500 3 500 500 500 4 diesel diesel diesel 5 rider seated rider seated rider seated 6 p p p 7 2 2 2 2 2 2 8 3230
14. 39 General Section General Section Specifications CHARACTERISTICS 1 MANUFACTURER DOOSAN 2 MODEL GC20P 5 3 4 500 5 6 OPERATOR stand on ride e rider Em 7 TIRES P pneumatic 8 WHEELS x driven number of front rear 22 DIMENSIONS 9 LIFT WITH STD maximum fork height with rated load mm 3230 10 TWO STAGE MAST free lift mm 152 11 FORK CARRIAGE ISO class I 12 FORKS thickness x width x length 40x100x1050 13 fork spacing maximum x minimum 14 TILTOF MAST forward backward deg 6 15 length without forks 16 width 17 OVERALL mast lowered height 18 DIMENSIONS mast extended height 19 overhead guard height 20 seat height 21 22 23 90 STACKING AISLE mm 2374 23a 90 INTERSECTING AISLE mm 1798 PERFORMANCE 24 travel loaded unloaded km hr 16 16 25 SPEED lift loaded unloaded mm s 530 600 26 lowering loaded unloaded mm s 510 460 27 DRAWBAR PULL at 1 6km hr loaded unloaded kg 2170 28 44 time reached at max speed 29 ACCELERATION 2 WEIGHT 30 31 at loaded front rear at unloaded front rear CHASSIS 33 number of front rear 2 2 34 TIRES front size 21x7 15 35 rear size 16x5 10 5 36 WHEEL BASE mm 1410
15. 74 Before Starting the Lift 11 Before Storage T 127 Belts Check Adjust 176 Bent or Twisted Forks 131 r ERI RE 142 Brake Oil Level 169 siio TNT E 149 Burn Prevention 15 C Capacity Chart With Sideshifter cushion 55 56 57 58 Capacity Chart With Sideshifter Pneumatic T S 47 48 49 50 Capacity Chart Without Sideshifter cushion 51 52 53 54 Capacity Chart Without Sideshifter Pneumatic 43 44 45 46 Carriage Roller Extrusion Adjust 154 Causes of Fork Failure 131 Center of Gravity CG 21 Changing From Gasoline to LP Gas 79 Changing From LP to Gasoline 79 Changing LP Tanks 72 Index Section Changing Primary Element 188 Changing Secondary Element 188 Chassis Pivot Eyebolts Lubricate 176 Check for Equal Tension 186 Che
16. TEM ILO1026P 7 Remove the dip stick filter cap Fill the compartment with oil See Refill Capacities Install the dip stick filter cap 8 Startthe engine 9 With the service brake applied and engine at low idle shift the direction control lever to forward and reverse to fill the clutches 10 Shift the direction control lever into NEUTRAL Engage the parking brake 11 Remove the dip stick filter cap Observe the oil level 163 Maintenance Section Drive Axle Oil Change Park the lift truck on a level surface Apply the parking brake Place the directional control lever in NEUTRAL and stop the engine Remove drain plug Allow the oil to drain into a suitable container Clean the magnetic drain plug Check O ring seal and replace if necessary Install the drain plug Remove the dip stick filter cap Fill the drive axle housing with oil See Refill Capacities Start the lift truck With the engine at low idle place the directional control lever to the NEUTRAL Maintain the oil level between lower mark and upper mark on the dip stick filter cap 6 Install the dip stick filter cap NOTE Tighten the dipstick plug fully not to allow foreign parts rain water etc to enter into drive axle 164 Parking Brake Test Adjust Parking Brake Testing NOTICE OSHA requires the parking brake to hold the lift truck with capacity load on a 1596 grade Testing requires a tes
17. 190 Maintenance Section Every 1500 Service Hours or 9 Months Inspect Ignition System LP Gasoline amp Dual Fuel Engines Only Disconnect Battery Cables 2 Remove and inspect the spark plugs Replace as required 3 Test secondary cables with an Ohmmeter If the maximum resistance is higher than 25 kOhms repair and or replace G424F E engine only 4 Inspect the ignition coil for cracks and heat deterioration Visually inspect the coil heat sink fins If any fins are broken replace as required G420F E Engine 1 Spark Plug Cables 2 Ignition Coil 191 Replace Spark Plugs G424F E LP Dual Fuel Engine Only 1 2 Disconnect Battery Cables Using a gentle twisting motion remove the high voltage cables from the spark plugs Replace any damaged cables Remove the spark plugs 4 Gap the new spark plugs to the proper specifications G424F E Engine 0 9 mm Apply anti seize compound to the spark plug threads and install G424F E Engine 25 Nem 18 Ib ft A WARNING DO NOT OVERTIGHTEN THE SPARK PLUGS 6 Re install the high voltage cables Maintenance Section Replace LP Fuel Filter Element LP Dual Fuel 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
18. APP2AdaptHiMin Check APP connector and pins for 652 Learned full pedal end of APP2 TurnOnMil ZH S Cycle the pedal several times and sensor range lower than expected check APP sianal at SECM Pin B16 Check APP connector and pins for APP1 AdaptLoMax corrosion ud Th 22 Cycle the pedal several times check APP1 signal at SECM Pin B7 Check APP connector and pins for APP2AdaptLoMax 662 Learned dle end of APP2 sensor TurnOnMil poston range higher than expected Cycle the pedal several times and check APP2 signal at SECM Pin B16 Check APP connector and pins for corrosion APP Sensors Conflict Cycle the pedal several times and 691 APP position sensors do no not track 1 TurnOnMil check APP1 signal at SECM Pin 69 well intermittent connections to APP 2 Cut Throttle B7 or defective pedal assembly Cycle the pedal several times and check APP2 signal at SECM Pin B16 Fault actions shown are default values specified by the OEM 111 Operation Section Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION CORRECTIVE ACTION FIRST CHECK PROBABLE FAULT LSDFault_Dither1 Dither Valve 1 Fault signal has opened or shorted to ground or power or defective dither 1 valve 1 TurnOnMil 2 Disable GasO2 Ctrl 3 Disable GasPost O2Ctrl Check FTV1 for an open wire or FTV connector being disconnected FTV1 Pin 1 signal to SECM Pin A1 FTV1 Pin 2 power to
19. Engine Valve Lash Diesel Engine Only Check C a 194 Steer Wheel Bearings Reassemble 194 Drive Wheel Bearing Power Shaft and Drive Wheel Reassemble 196 Cooling System Clean Change 197 Forks Inspect 199 Every 2500 Service Hours or 15 Months Hydraulic Oil Check Clean Change 201 Inspect Battery 201 Replace Oxygen Sensor G420F E G424F E Engine 202 Replace Spark Plugs G420F E Engine Only 202 Checking the TMAP Sensor G420F E G424F E Engine ua 203 Inspect for Intake Leaks G420F E G424F E Engine MM 203 Every 3000 Service Hours or 18 Months Timing Belt G420F E G424F E LP Gasoline Dual Fuel Engine Only Change 204 145 Maintenance Section Maintenance Section Quick Reference to Maintenance Schedule Reference to Maintenance Schedule FIRST ITEMS SERVICES Air Cleaner Indicator Sone 57 Air Intake System Change 188 Air Intake System Check Clean 167 Bate Terminal 1 Clean inspect i175 KRK pI IE I III IIIIII IIIIIIIU UT TTTYEIIOIFUNE Brake Oil Level Check 19 Semen e Only a a aa 115111
20. Priming the Fuel System Diesel Engine Only 4TNV98 Diesel Engine Only The fuel system needs to be primed under certain conditions e Before starting the engine for the first time e After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the water separator or replacing a fuel system component To prime the fuel system 1 Turn the key to the ON position for 10 to 15 seconds This will allow the electric fuel pump to prime the fuel system 2 NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheating and damage the coils pinion and ring gear 4TNE96 Diesel Engine Only The fuel system needs to be primed under certain conditions e Before starting the engine for the first time e After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the fuel filter water separator or replacing a fuel system component To prime the fuel system on engines equipped with an electric fuel pump Place an approved container under the air bleed port Loosen the air bleed port 2 or 3 turns 3 Turn the key to the ON position for 10 to 15 seconds or until the fuel coming out of the air bleed port is free of bubbles Tighten the air bleed port Maintenance Section 5 W
21. Specifications CHARACTERISTICS 1 MANUFACTURER DOOSAN DOOSAN D20S 5 D25S 5 x MODEL YANMAR TIER3 YANMAR TIER3 3 CAPACITY at rated load center kg 2000 2500 4 500 5 POWER TYPE electric diesel gas LPG gas diesel diesel 6 OPERATOR TYPE stand on ride seated rider seated rider seated 7 TIRES C cushion P pneumatic p p 8 WHEELS x driven number of front rear 2 2 DIMENSIONS 9 LIFT WITH STD maximum fork height with rated load mm 3230 3230 10 TWO STAGE MAST free lift mm 152 152 11 FORK CARRIAGE ISO class II II 12 FORKS thickness x width x length mm 40x100x1050 40x100x1050 13 fork spacing maximum x minimum mm 275x1035 275x1035 14 TILT OF MAST forward backward deg 6 10 6 10 15 length to fork face mm 2530 2595 16 width mm 1170 1170 17 OVERALL mast lowered height mm 2175 2175 18 DIMENSIONS mast extended height mm 4490 4490 19 overhead guard height mm 2183 2183 20 seat height mm 1026 1026 21 OUTSIDE TURNING RADIUS 2265 22 LOAD MOMENT CONSTANT 480 23 90 STACKING AISLE 2745 75 90 INTERSECTING AISLE 2000 PERFORMANCE travel loaded unloaded km hr 19 19 5 19 19 5 SPEED lift loaded unloaded mm s 530 550 520 550 26 lowering loaded unloaded 510 460 510 460 DRAWBAR PULL at 1 6km hr loaded unloaded kg 1765 1740 DI BITA CE prEN 12053 28 GRADEABILITY at 1 6km hr loaded unloaded 33
22. 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 the fork service prior to failing 131 Maintenance Section 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
23. MAST 4960mm MAST C 4730mm MAST D 5560mm MAST E 6010mm MAST soc HEHHE 2030 3950mm MAST A 3900mm MAST 4350mm 5 4290mm MAST C 4960mm 5 4 30mm MAST D 5560mm MAST E 6010mm MAST D30S 5 G30E 5 G30P 5 49 General Section Capacity Chart With Sideshifter Pneumatic MODEL DOUBLE TIRE STD FFL wot A 2030 5950 MFH MAST A 3900mm MAST 4350mm MAST B 4290mm MAST 4960mm 5 C 4730mm 5 D 5560mm MAST E 6010mm MFH MAST mnr P LLL D35C 5 G35C 5 A 1800 3805mm MAST 3555 3950mm MAST B 4205mm MAST 4380mm MAST C 4805mm MFH MAST C 4820mm MFH MAST D 5205mm MAST 5655mm MAST 50 General Section Capacity Chart Without Sideshifter cushion wa NARROW TIRE STD FFL nad co asBBBEHH p mA Do GC20E 5 GC20P 5 E 2030 4350mm MFH MAST 5900 4290mm MFH MAST B 4960mm MFH MAST B 4730mm MFH MAST C 5560mm MFH MAST D 6010mm MFH MAST I LLULLLLLI A 2050 4550mm MAST 3900mm MAST B 4960mm MAST 4290mm MAST 4730mm MAST 565 mm MAST 6010mm MFH MAST LO N o o LO N Un DI C BEEHSEEE 2030 395
24. e Drain off foreign matter and water from the hydraulic oil tank and fuel tank e Remove the head cover from the engine cylinder Oil valves and rocker shaft and check each valve for proper operation e Add cooling water to the specified level Charge the battery and mount it on the machine Connect the cables e Perform pre operational checks carefully refer to Before Starting the Engine e Warm up the machine Operation Section 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 loading 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 IAOQ US1P 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 Tilt the mast forward and lower forks to the floor Turn the ignition switch to the OFF position and remove the key If LP equipped s
25. throttle lever pedal etc of the machine are connected together by a throttle cable or rod If the cable becomes stretched or the connections loosen the governor lever may not respond to change of engine speed control position This may make operation of the machine unsafe Check the cable periodically and adjust if necessary NEVER force the throttle cable or pedal to move This may deform the governor lever or stretch the cable and cause irregular operation of the engine speed control Checking and adjusting the governor lever 1 Check that the governor lever Figure 5 11 1 makes uniform contact with the high idle Figure 5 11 2 and low idle Figure 5 11 3 speed limit screws when the engine speed control is in the high idle speed or low idle speed position Figure 5 11 2 If the governor lever does not make contact with the high idle or low idle speed limit screw adjust the throttle cable 3 some engine speed control applications loosen the throttle cable lock nut Figure 5 11 4 and adjust the cable so the governor lever makes proper contact with the high low idle speed limit screw 174 A WARNING NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor 4 98 Diesel E
26. 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 137 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 Maintenance Section 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 form
27. Cooling System Clean Change 197 Jo Crankcase Breather System 4TNV98 Diesel Engine Only Inspect_ 393 CrossheadRollers 17 o y Drive Axe Ol Change 14 o P DiveAxeOil amp Staier Change Clean 179 tol Drive Axle Oil Level Check 170 jo y Drive Wheel Bearing Power Shaft and Drive Wheel Reassemie 1 Jol Engine Oil amp Filter Diesel Engine Ony 16 59 o Jol Engine Oil amp Filter LP amp Gasoline Engine Only Change m o EnieOillevl 58 Engine Valve Lash Diesel Engine Only Check Adust_ 190 194 Jol Jol Fors _ 39 p y Fuel Filter Diesel Engine Ony Chane 1 8 Por P E Inspect Clean Fuel Injectors Diesel Engine Only Test Fuel Lines amp Fittings Fuel Tank Filter Cap and Screen If Equipped Fuel Trim Valve FTV Inspection G420F E G424F E Engine Only Fuses Bulbs Circuit Breaker amp Relay Change Reset G L dE S d Control Di IE Sis aS T Horn and Lights If Equipped If Equipped Check Hydraulic Oil Check Clean pss Oil Level Hydraulic Return Filter Breather amp Strainer Check Chan
28. ILO1043P T Install the dip stick filter cap Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and engine stopped 1 Remove drain plug Allow the oil to drain into a suitable container Clean the magnetic drain plug Check O ring seal and replace if necessary 2 Install the drain plug TE um ILO1044P 3 Wash the strainer assembly in clean non flammable solvent and dry it Install the strainer assembly and reconnect the hose 4 Remove the dip stick filter cap Fill the drive axle housing with oil See Refill Capacities 5 Start the lift truck with engine at low idle place the directional control lever to the NEUTRAL 6 Maintain the oil level between lower mark and upper mark on the dip stick filter cap 179 Maintenance Section Steer Suspension Inspect 4066 1 Inspect the suspension mounting bolts Tighten suspension mounting bolts if necessary to 240 30 Nem 180 20 Ibeft IA3M4067 2 Look for leaks at the power steering hose connections 3 Remove any trash buildup on the suspension or the steer axle Parking Brake Test Adjust See topic Parking Brake Test Adjust in First 50 100 Service Hours or a Week 180 Inching amp Braking Control Shaft Lubricate 1 Lubricate three fittings for the inching and brake pedal control shaft Horn and Lights If Equipped Check
29. water separator Figure 5 1 1 to collect the contaminants 2 Loosen the drain cock Figure 5 1 2 at the bottom of the fuel filter water separator Drain any water collected inside 3 tighten the drain cock 4 Be sure to prime the diesel fuel system when you are done See Priming the Fuel System 00008620 5 1 153 Maintenance Section Test Fuel System for Leaks LP and Dual Fuel Engines Only Check Points L Obtain a leak check squirt bottle or pump spray bottle 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 at the storage container Wait approximately 15 60 seconds then perform a visual inspection of the fuel system Leaks will cause the solution to bubble Repair any leaks before continuing 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 Repair any fuel leaks before continuing A WARNING Prior to any service or maintenance activity Test Fuel System for Leaks Maintenance Section Tires and Wheels D G Series Inspect Check WARNING Servicing and changing tires and rims can be dangerou
30. 37 TREAD front rear mm 932 983 38 GROUND at loaded the lowest point mm 90 39 CLEARANCE at loaded center of wheelbase 40 SEVICE BRAKE foot hyd 41 PARKING BRAKE hand mech DRIVE 42 BATTERY voltage capacity V AH 12 65 43 manufacturer model G424F E 44 ENGINE rated output rom kw hp 47 7 64 2550 45 max torque rpm Nem Ibeft 182 135 2200 46 cycle cylinders displacement cc 4 4 2405 47 powershift 48 TRANSMISSION number of speeds forward reverse 1 1 49 system attachment 181 156 equivelent continuous sound 50 NOISE LEVEL pressure level Leq at operator s ear DI BITA CE prEN dB A 12053 40 37 13 General Section 21 TN DOOSAN DOOSAN DOOSAN 1 GC25P 5 GC30P 5 GC33P 5 2 2500 3000 3000 6500LBS 3 500 500 600 4 LP LP LP 5 rider seated rider seated rider seated 6 C C C 7 2 2 2 2 2 2 8 3230 3230 3230 9 152 152 152 10 lI III III 11 40x100x1050 45x125x1050 45x125x1050 12 297x905 282x954 282x954 13 6 8 6 8 6 8 14 2268 2333 2368 15 1110 1110 1110 16 2130 2130 2130 17 4480 4480 4480 18 2150 2150 2150 19 1038 1038 1038 20 2045 2105 2135 21 367 373 373 22 2419 2479 2509 23 1822 1872 1907 23a 16 16 16 16 16 16 24 510 600 500 600 500
31. 55 10 95 15 150 20 220 30 450 70 775 100 1600 200 1180 150 2700 400 2000 300 4 Newton meter 1 is approximately the same as 0 1 kgem 2150 International Standards organization cO 18 55 41 7 70 11 110 15 160 22 330 50 570 75 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 50 commercially available automotive antifreeze and 5096 water The coolant mix with concentration of antifreeze smaller than 30 does not provide sufficient corrosion protection Concentrations over 60 adversely affect freeze protection and heat transfer rates Never add coolant to an overheated engine engine damage can result Allow the engine to cool first 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 is normally protected to
32. B 4350mm MAST 4960mm MAST 47 A 3900mm MAST 4290 5 C 4730mm MAST D 5560mm MFH MAST E 6010mm MFH MAST 3900mm MAST B 4290mm MFH MAST C 4730mm MAST D 5560mm MAST E 6010mm MFH MAST A 3900mm MFH MAST B 4290mm MFH MAST C 4730mm MFH MAST C 5560mm MAST C 6010mm MFH MAST General Section General Section Capacity Chart With Sideshifter Pneumatic SINGLE TIRE STD FFL 2030 3800mm MAST A 3900mm MFH MAST B 3950mm MAST B 4290mm MFH MAST C 4350mm MAST 4730mm MFH MAST D 4960mm MAST D 5560mm MFH MAST E 6010mm MFH MAST m Im um nu E Jum x zm na w D35C 5 G35C 5 5 A 3555 3960mm MAST po aee RE Yel B 4380mm MFH MAST C 4805mm MAST C 4820 MFH 5 D 5205mm MFH MAST E 5655mm MAST 48 General Section Capacity Chart With Sideshifter Pneumatic DOUBLE TIRE STD FFL 2 BBB SBB A 2030 3950mm MAST 3900mm MAST B 4350mm MAST B 4290 5 C 4960mm MAST C 4730mm MFH MAST D 5560mm MAST E 6010mm MFH MAST D20S 5 G20E 5 G20P 5 0 1 0 o 10 170 1500 5 7 E NI i j 2050 5950mm MFH MAST 3900 MFH MAST B 4350mm MAST 4290mm
33. Battery Terminal Clean Inspect WARNING Batteries give off flammable fumes that can explode Do not smoke when observing the battery electrolyte levels Electrolyte is an acid and can cause personal injury if it contacts skin or eyes Always wear protective glasses when working with batteries 1 Clean the top of the battery and terminals 2 Check terminals for corrosion Coat terminals with heavy grease 171 Maintenance Section Engine Oil amp Filter LP amp Gasoline Engine Only Change Gasoline LP Engine Crankcase 1 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 2 Raise rear of lift truck off ground and block securely A WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin ILOM024P 3 Remove the crankcase drain plug and allow oil to drain into a suitable container Clean and install drain plug 4 Raise the hood and seat assembly IB1O1014 5 Remove and discard oil filter element 6 Wipe sealing surface of oil filter element mounting base Make sure the entire old gasket is removed Maintenance Section 10 11 12 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 g
34. INTERSECTING AISLE mm 1970 2000 PERFORMANCE 24 travel loaded unloaded km hr 19 20 19 20 25 SPEED lift loaded unloaded mm s 530 600 510 600 26 lowering loaded unloaded mm s 510 460 510 460 27 DRAWBAR PULL at 1 6km hr loaded unloaded kg 1750 1725 28 GRADEABILITY at 1 6km hr loaded unloaded 96 33 28 29 ACCELERATION time reached at max speed loaded unloaded WEIGHT 30 TOTAL WEIGHT atunloaded kg 3570 3940 31 atloaded front rear kg 4940 630 5670 770 32 at unloaded front rear kg 1730 1840 1660 2280 CHASSIS 33 number of front rear 2 2 2 2 34 TIRES front size 7 00x15 12 7 00x15 12 35 rear size 6 50x10 10 6 50x10 10 36 WHEEL BASE mm 1625 1625 37 TREAD front rear mm 975 1000 975 1000 38 GROUND atloaded the lowest point mm 115 115 39 CLEARANCE at loaded center of wheelbase mm 143 143 40 SEVICE BRAKE foot hyd foot hyd 41 PARKING BRAKE hand mech hand mech DRIVE 42 BATTERY voltage capacity V AH 12 65 12 65 43 manufacturer model G424F E G424F E 44 ENGINE rated output rpm kw hp 47 7 64 2550 47 7 64 2550 45 max torque rpm Nem Ibeft 182 135 2200 182 135 2200 46 cycle cylinders displacement cc 4 4 2405 4 4 2405 47 type powershift powershift 48 MENSES SIN number of speeds forward reverse 1 1 1 1 C eps sas system attachment bar 181 156 195 156 equivelent continuous sound 50 NOISE LEVEL pressure level Leq at operators ear dB A DI BITA CE prEN 12053 36
35. Park the lift truck level with the forks lowered parking brake engaged direction control lever in NEUTRAL and the engine stopped ILO1045P J 1 Remove the floor mat and the floor plate Remove and discard the oil filter 2 Wipe off the filter base Make certain that all of the old seal is removed 3 Apply a small amount of clean oil on the seal of the new filter 4 Install the filter by hand When the filter contacts the base tighten an additional 3 4 turn 5 Startthe engine 6 With the service brake applied and engine at low idle shift the direction control lever to forward and reverse to fill the clutches 7 Shift the direction control lever into NEUTRAL Engage the parking brake 8 Remove the dip stick filter cap Observe the oil level 9 Maintain the oil level between the Min and Max marks on the dip stick filter cap When the oil temperature is 40 C approximately the cold side mark on the dipstick is applicable When the oil temperature is 80 approximately the hot side mark on the dipstick is applicable 10 Check for oil leaks at the filters 11 Stop the engine Install the floor mat and floor plate 178 Overhead Guard Inspect 1 Check tightness of overhead guard mounting bolts at 95 Nem 70 Ib ft 2 Check overhead guard for bent or cracked sections Have repairs made if needed Maintenance Section Drive Axle Oil amp Strainer Change Clean
36. Remove the engine oil filter as follows 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Figure 5 2 3 using a filter wrench TOKA Figure 5 2 Clean the engine oil filter mounting face Lightly coat the gasket on the new oil filter with engine oil Install the new engine oil filter manually by turning it clockwise Figure 5 2 4 until it contacts the mounting surface Tighten to 14 17 ftelb 19 6 23 5 Nem 2 0 2 4 kgfem or one additional turn using the filter wrench Add new engine oil to the engine as specified in Adding Engine Oil on page 4 14 Maintenance Section A WARNING NEVER overfill the engine with engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick 5 Warm up the engine by running it for five minutes and check for any engine oil leaks 6 After engine is warm shut it off and let it sit for 10 minutes 7 Recheck the engine oil level 8 Add engine oil Figure 5 3 5 as needed until the level is between the upper Figure 5 3 2 and lower lines Figure 5 3 3 shown on the dipstick Figure 5 3 1 Figure 5 3 9 Reinstall the oil filler cap Figure 5 3 4 If any engine oil is spilled wipe it away with a clean cloth 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 aft
37. Remove the floor mat and floor plate 4 Make sure the parking brake lever is released 5 Make sure the brake lever 1 is held against stop pin 2 If the brake lever 1 is held against the stop pin 2 go to step 7 If the brake lever 1 is NOT held against the stop pin 2 go to step 6 6 Remove the pin 3 and the cotter pin 4 Tighten the nut 6 to compress the spring 7 further and pull downward and turn the clevis 5 until the pin 3 fits into the brake lever when the lever 1 is held against the stop pin 2 Then install the pin 3 and the cotter pin 4 and return the nut 6 to the clevis 5 165 Maintenance Section T Loosen lock nut 5 Tighten screw 6 to 6 to 7 Nem 50 to 60 Ib in Loosen the screw 6 1 1 6 turns and tighten the lock nut 5 NOTICE Turn the adjustment screw 6 clockwise to tighten Turning the screw 6 too far counterclockwise could allow parts to fall into the bottom of the transmission The transmission would than require disassembly to remove the parts 8 Reinstall the floor plate and floor mat 9 Engage the parking brake remove the tire chocks and test the parking brake Refer to Parking Brake Testing in the preceding section 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 procedu
38. 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 electrolyte levels the battery Electrolyte is an acid and can cause personal injury if it contacts skin or eyes Always wear protective glasses when working with batteries 15 Safety Section Fire or Explosion Prevention All fuels most lubricants and some coolant mixtures
39. XDRP 5V Pin B24 SECM DRVP 12V Pin A23 Check if O2 sensor installed after catalyst is shorted to 5Vdc or battery O2 signal Pin 3 to SECM Pin B19 Possible voltage sources SECM XDRP 5V Pin B24 and SECM DRVP 12V Pin A23 FuelTempRangeLow Fuel Temperature Sensor Input is Low normally set if the fuel temperature sensor wire has shorted to chassis ground or the sensor has failed TurnOnMil Check fuel temp sensor connector and wiring for a short to GND SECM signal Pin B14 to FTS Pin 1 SECM sensor GND Pin B1 to FTS Pin 2 SECM system GND Pin A16 B17 FuelTempRangeHigh Fuel Temperature Sensor Input is High normally set if the fuel temperature sensor wire has been disconnected or the circuit has opened to the SECM TurnOnMil Fault actions shown are default values specified by the OEM 115 Check if fuel temp sensor connector is disconnected or for an open FTS circuit SECM signal Pin B14 to FTS Pin 1 SECM sensor GND Pin 1 to FTS Pin 2 Operation Section Table 2 Diagnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION 1 TurnOnMil 2 DelayedEngine Shutdown TransOilTemp Excessive transmission oil temperature CORRECTIVE ACTION FIRST CHECK Refer to drivetrain manufacturer s transmission service procedures ServiceFault1 Service Interval 1 has been reached None Perform service procedure related to Service Interval 1 det
40. amp See Engine Service Manual 91 Operation Section Problem Excessive Fuel Consumption LP G Exhaust Smell Probable Cause Air Fuel Mixer malfunction Corrective Action Check mixer e See Engine Service Manual Air filter clogged Check air filter e Clean replace as required Vacuum leak Check system vacuum hoses from regulator to FTV and mixer e Hepair replace as necessary Pressure regulator malfunction fuel Test pressure regulator operation pressure too high e Engine Service Manual Faulty FTV Check FTV for housing cracks or obstructions e See Advanced Diagnostics 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 92 Replace as necessary e See Advanced Diagnostics Basic Troubleshooting Gasoline Operation Section Problem Probable Cause Corrective Action Engine Cranking but Will Not Start Gas Fuel tank empty Fill container The tank should be at least 1 4 full to properly prime the fuel pump e Fuelselect switch is noton GAS Clogged fuel filter Repair replace as required e See Maintenance section Primary and Secondary Fuel Filter replacement Faulty vapor connection between the pressure regulator converter
41. 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 addition to the Parking the lift truck services in e Taking the rainy season into consideration park the machine at a higher and hard ground e 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 cool place Charge the battery once a month e Apply antirust to the exposed parts which tend to rust Cover components such as the breather and air cleaner which may be caught with humidity e 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 127 Operation Section To Operate the Lift Truck after a Long Time Storage Remove covers and antirust from each of the components and exposed parts e Drain the engine crankcase transmission clutch type machine differential and final reduction gear clean the inside of them and add new oil
42. 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 e 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 e 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 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 133 Maintenance Section 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
43. 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 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 14 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 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
44. specification WARNING G420F E is dual over head CAM engine If timing belt is not replaced on time engine could be damaged 204 Index 12 Months Inspection 133 4 98 Diesel Engine Only 150 153 175 182 4TNV98 Diesel Engine Only 150 152 174 182 A Accelerator Pedal 69 eto Ran Nahe ME aa NN Mns d 118 Advanced Diagnostics 99 After Starting the 81 Air Cleaner Indicator Check 157 Air Intake System 188 Air Intake System Check Clean 167 Lu us uu TH 138 Attachment Abbreviations Includes Special Forks 61 Auto Shift Controller ASC 100 If Equipped 118 Automatic mode Direction Inhibit mode 119 Avoiding Lift Truck Tipover 21 B Basic Troubleshooting Gasoline 93 Basic Troubleshooting LP 86 Battery Terminal Clean Inspect 171 Before Operating the Lift Truck 12 Before Starting the
45. the lift truck in hot weather 1 Check the radiator Clogging can cause overheating Clean them out regularly with a blast of compressed air also check for leakage of water 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 shutting off the engine Parking the Truck NOTE Park the lift truck level with the fork lowered and the mast tilted forward until the fork touches the floor Block the drive wheels when parking on an incline Park in an authorized area only Do not block traffic If LP equipped do not park near elevator shafts or any other area where LP could collect in a pocket low area causing a potentially dangerous condition 2 Place the transmission controls in NEUTRAL 3 Engage the parking brake 4 Tilt the mast forward and lower the fork to the ground 4A WARNING Blocking the wheels will prevent unexpected lift truck movement which could cause personal injury 125 Operation Section 5 Turn the key in the ignition switch to the OFF position and remove the key ILOQ018P NOTE LP equipped lift truck is stopped or parked for an indefinite or prolonged period of time shut off the LP fuel tank valve 6 Actuate each loading lever several times to remove the residual pressure in the respective cy
46. to SECM Pin A16 DRVG SECM Pin A23 DRVP to SECM Pin B17 DRVG 1 TurnOnMil 2 DelayedEngine Shutdown LowOilPressureFault Low engine oil pressure SysVoltRangeLow System voltage too low SysVoltRangeHigh System voltage too high Fault actions shown are default values specified by the OEM 109 Operation Section PROBABLE FAULT Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION CORRECTIVE ACTION FIRST CHECK SensVoltRangeLow Sensor reference voltage XDRP too low SensVoltRangeHigh Sensor reference voltage XDRP too high HardOverspeed Engine speed has exceeded the third level 3 of 3 of overspeed protection MediumOverspeed Engine speed has exceeded the second level 2 of 3 of overspeed protection 1 TurnOnMil 2 DelayedEngine Shutdown 1 TurnOnMil 2 DelayedEngine Shutdown 1 TurnOnMil 2 HardRevLimit 3 EngineShutdown 1 TurnOnMil 2 MediumRevLimit 3 DelayedEngine Shutdown 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 SECM Pin B24 5 Vdc to SECM Pin B1 XDRG GND Verify transducer power at ETC with a multimeter ETC Pin 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
47. transmission in NEUTRAL and the engine stopped NOTE The procedure is shown on a GC Series lift truck It is the same for D G Series lift trucks ILOMO36P Typical Example 1 Lift the steer wheels off the ground Place stands or blocking under the frame and steer axle to support the lift truck Typical Example 2 Remove the hub cap which is pressed into the wheel hub 3 Straighten the lock washer tangs 11010461 4 Remove the locknut lock washer and flat washer Remove the outer wheel bearing E res g m Do 101057 5 Remove the wheel assembly the seal for damage and wear Replace the seal if necessary 6 Remove the inner bearing Clean and lubricate the steering knuckle Reassemble both the inner and outer bearing cones 7 Install the inner bearing Lubricate the seal install the wheel assembly on the knuckle 195 Maintenance Section 8 Install the outer wheel bearing and the out washer Install a new lock washer and fit the locknut ILO1055P Typical Example 9 Tighten the locknut to 135 Nem 100 Ib ft while turning wheel hub to seat the bearing 10 Loosen the locknut Retorque it to 50 5Nem 37 4 16 Bend the lock washer tang to secure locknut 11 Install the hub cap 12 Raise the lift truck and remove the blocking Lower the lift truck to the ground Maintenance Section Drive Wheel Bearing Power Shaft and Driv
48. 3230 3000 9 152 152 152 10 III III III 11 45x125x1050 45x125x1050 45x125x1050 12 286x1044 286x1044 286x1044 13 6 10 6 10 6 10 14 2700 2730 2765 15 1197 1197 1255 16 2165 2165 2165 17 4490 4490 4260 18 2183 2183 2183 19 1026 1026 1026 20 2365 2395 2420 21 485 485 495 22 2850 2880 2915 23 2050 2100 2170 23a 20 20 5 20 20 5 20 5 21 24 500 550 490 550 480 550 25 510 460 510 460 510 460 26 1830 1820 1750 27 25 23 5 21 5 28 29 4450 4630 4810 30 6580 870 6940 940 7340 970 31 1840 2610 1800 2830 1780 3030 32 2 2 2 2 2 2 33 28x9x15 12 28x9x15 12 250x15 18 34 6 50x10 10 6 50x10 12 6 50x10 12 35 1700 1700 1700 36 982 1000 982 1000 1026 1000 37 105 105 105 38 143 143 143 39 foot hyd foot hyd foot hyd 40 hand mech hand mech hand mech 41 12 85 12 85 12 85 42 YANMAR 4TNV98 YANMAR ATNV98 YANMAR ATNV98 43 46 3 62 1 2200 46 3 62 1 2200 46 3 62 1 2200 44 240 177 1320 240 177 1320 240 177 1320 45 4 4 3319 4 4 3319 4 4 3319 46 powershift powershift powershift 47 1 1 1 1 1 1 48 216 156 216 156 216 156 49 50 31 General Section e General Section
49. Capacity Chart With Sideshifter cushion GC20E 5 GC20P 5 LO N O 5 u LLI LO N O 5 STD FFL 2030 3950 MAST 4350mm MAST C 4960mm MFH MAST A 2030 3950mm MAST 4550mm MAST 4960mm MAST WIDE TIRE A 3900 MAST 4290mm MAST 4750 5 D 5560mm MAST E 6010mm MAST A 3900mm MFH MAST B 4290mm MFH MAST C 4730mm MFH 5 D 5560mm MFH MAST E 6010mm MFH MAST General Section GC30E 5 GC30P 5 2050 5950 MFH MAST 4350mm MAST C 4960mm MAST 57 3900mm MAST 4290mm MAST C 4730mm MAST D 5560mm MAST E 6010mm MAST General Section Capacity Chart With Sideshifter cushion MODEL GC33E 5 GC33P 5 STD FFL BSSEBUSHEESS 2050 3950mm MAST B 4350mm MAST C 4360mm MAST WIDE TIRE A 3900mm MFH MAST B 4290mm MAST 4730mm MAST D 5560mm MAST E 6010mm MFH MAST 58 Serial Number Serial Number Locations For quick reference record your lift truck s serial numbers in the spaces provided below the photographs Lift Truck Serial Number 3 3 liter Diesel Engine 4TNE98 Serial Number 59 General Section 2 0 liter Spark lgni
50. Example Check the fuses Use a flashlight if necessary Fuses are identified as follows Horn 10 amps Head Rear Lamp 15 amps Fwd Rev Solenoid lamp Relay amp Back up Lamp alarm 10 amps Instrument Panel amp Fuel Shutoff 15 amps Turn Signal Lamp Stop Strobe Lamp amp C S D Start Relay 5 amp HEAD LAMP 15 STOP LAMP START RELAY INST PANEL FIR CONTROL 1 GONT GP FUEL LOCK IGNITION gt lt Lu cc a gt 3 5 es LO LO Check the fuses Use a flashlight if necessary 149 Maintenance Section Remove the front cover from the fuse box located under the cowl Fuse Protects an electrical circuit from an overload Opens filament separates if an overload occurs Bulbs Bulbs are identified as follows 1 Bulb head lamp halogen 12V 35W 2 Bulb back up 12V 10W 3 Bulb turn signal 12V 23W 4 Bulb stop amp tail 12V 23 8W Optional lamp or light Maintenance Section Circuit Breaker 1 Raise the hood and seat assembly Make sure the support cylinder securely holds the hood open 2 The main circuit breaker is located on the rear of the support for the hydraulic controls NOTE To reset circuit breakers push in 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 150
51. 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 25 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 an incline Do not go over rough terrain If unavoidable slow down Cross railroad tracks slowly and 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
52. 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 Maintenance Section Fork Inspection Establish a daily and 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 capacity Also list any special 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 e 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 132 First Installation 1 Inspect forks to ensure they are the correct size for the truck
53. Service Hours or Daily 155 Every 1000 Service Hours or 6 Months 185 Every 1500 Service Hours or 9 Months 191 Every 2000 Service Hours or Yearly 194 Every 250 Service Hours or Monthly 167 Every 2500 Service Hours or 15 Months 201 Every 3000 Service Hours or 18 Months 204 Every 500 Service Hours or Months 176 F gsm 131 Fire or Explosion Prevention 15 First 250 Service Hours or a Month 166 First 50 100 Service Hours or a Week 161 First Installation 132 Fluid Penetration 14 FONG WOM us a unu 2 Fork Inspection 132 Forks Inspect 199 Fuel Filter Diesel Engine Only Change 182 Fuel Filter LP Engine Only 192 Fuel Injectors Diesel Engine Only Inspect Clean i r ECT 193 Fuel Lines amp Fittings Check 189 Fuel Selector Switch G420F E G424F E Dual PUG OMIM a 68 Fuel Specifications 139 Fuel Sulfur Content
54. Service Hours or a Month 166 Every 250 Service Hours or Monthly 167 Every 500 Service Hours or 3 Months 176 Every 1000 Service Hours or 6 Months 185 Every 1500 Service Hours or 9 Months 191 Every 2000 Service Hours or Yearly 194 Every 2500 Service Hours or 15 Months 201 Every 3000 Service Hours or 18 Months 204 Index Section Information Section Foreword Literature Information This manual should be stored in the operators compartment in the literature holder or seat back literature storage area This manual contains safety operation transportation lubrication and maintenance information 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
55. Shipping 128 Lift Truck Stability 22 Lift Truck Stability 21 Lifting Drums or Round Objects 124 Lifting the Load 121 Literature Information 2 Load Backrest Must Be In Place Warning 7 Long Time 127 unu u dee 77 LP Regulator Converter Inspection LP Dual Fuel Engine Only T 189 LP Specifications 140 Lubricant Information 141 Lubricant Viscosities and Refill Capacities 143 Lubricant Viscosities 143 Lubricating Grease MPQGWM 142 M Machine Lifting and Tiedown Information 128 Maintenance and 133 Maintenance Information 14 Maintenance Intervals 3 144 uu uuu uuu u Ru E E 3 Make proper antifreeze additions 138 Manual Mode Fail Safe 120 Mast
56. Vdc to TMAP Pin 1 XDRG GND Verify transducer power at the SECM with a multimeter SECM Pin B24 5 Vdc to SECM Pin B1 GND 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 Usually associated with additional ETC faults e Check for ETC Sticking or other ETC faults Verify if the lift truck was motored down a steep grade Usually associated with additional ETC faults e Check for ETC Sticking or other ETC faults Verify if the lift truck was motored down a steep grade SoftOverspeed Engine speed has exceeded the first level 1 of 3 of overspeed protection APP1RangeLow APP1 sensor voltage out of range low normally set ifthe APP1 signal has shorted to ground circuit has opened or sensor has failed 1 TurnOnMil 2 SoftRevLimit TurnOnMil 110 Usually associated with additional ETC faults e Check for ETC Sticking or other ETC faults Verify if the lift truck was motored down a steep grade Check foot pedal connector e Check APP1 signal at SECM PIN B7 Fault actions shown are default values specified by the OEM Table 2 Diagnostic Fault Codes Flash Codes cont d Operation Section CORRECTIVE ACTION FIRST DFC PROBABLE FAULT FAULT ACTION CHECK APP2RangeLow 612 2 sensor voltage out of range Check foot pedal connector 65 low normally set if the APP2
57. an electrical control system specially designed for use on forklift trucks with internal combustion engines Its primary purpose is to prevent the operator from driving the truck outside of the design parameters e g selecting the reverse gear when traveling in excess of 5 1 km h 3 17 mph in a forward direction and vice versa The Autoshift controller is mounted on a convenient position away from excessive heat sources and the truck s electrical system is retrofitted An inductive speed sensor is mounted on the differential housing where it will pick up a pulse from a yoke 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 The Autoshift controller prevents strain and abuse to the transmission It also prevents damage to the half shaft excessive tire wear and heat to the transmission 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 For safe operation carefully read and follow this Operation and Maintenance Manual 118 Adjustments Direction Inhibit Point 4 2 km h 2 61 mph xwe 4 5 km h 2 80 mph 4 8 km h 2 98 mph 5 1 km h 3 17 mph 5 4 km h 3 36 mph 5 7 km h 3 54 6 0 km h 3 73 mph xwe RS RS op am OX Direction Inhibit Point e This i
58. and Monitoring Systems 63 Overhead Guard 178 Overhead Guard Must Be In Place Warning 8 OVENOACING RN 131 Parking Brake Inspect 159 Parking Brake Test Adjust 164 180 Parking Brake Adjusting 165 Parking Brake 70 Parking Brake Testing 164 PARKING BRAKE 160 Parking Brake Ec 9 Parking the Lift Truck 125 PCV Valve System Inspect Clean 172 Power Shift Transmission Drive axle 82 Precleaner If Equipped 167 Pressure Air M 14 Pressure Warning 7 Prestart Conditions 76 Priming the Fuel System Diesel Engine Only 150 Product Description 118 R Reading Diagnostic Fault Codes 99 Refill ADACIIOS RERO 143 Refueling M 71 Replace LP Fuel Filter Element LP Dual Fuel OMY RCRUM 192 Replace Oxygen Sensor G420F E G424F E E
59. and operate the lift truck until the engine reaches normal operating temperature 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 at low idle shift the directional control lever to forward and then to reverse to fill the clutches 4 Shift the direction control lever to the NEUTRAL position 5 Remove the dip stick filter cap Observe the oil level 6 Maintain the oil level between the Min and Max marks on the dip stick filter cap When the oil temperature is 40 approximately the cold side mark on the dipstick is applicable When the oil temperature is 80 approximately the hot side mark on the dipstick is applicable 159 Maintenance Section Parking Brake Inspect Inspection from Operator s Seat Engine OFF Grasp the parking brake lever with your hand and press down the release button with your thumb The lever should move freely forward and backward Remove your thumb from the release button The lever should resist movement when pulled fully back and a clicking sound should be heard The lever should remain fully back until you press the release button with your thumb Report a missing damaged or loose parking brake lever any inability or difficulty engaging and releasing the parking brake lever or any restricted movement of the parking brake lever Inspection from Op
60. and the mixer LPG Check connection e Verify no holes in hose e Clamps must be tight Look for kinked pinched and or collapsed hose Electric Fuel Pump malfunction GAS Check electrical connection e Check Relay and fuse Turn key ON and verify pump is operating Fuel Pressure regulator malfunction Fuel Injector malfunction Test pressure regulator operation e See Engine Service Manual Test Injector operation e See Engine Service Manual Incorrect air fuel or ignition spark control No VR Sensor Signal 93 See Advanced Diagnostics Verify the VR signal is present e See Advanced Diagnostics Operation Section Problem Probable Cause Corrective Action m Fuel tank almost empt Fuel Pump Cavitations Difficult to Start ii e E should be at least 1 4 full to Gas properly prime the fuel pump e Fuel select switch is not on GAS Clogged fuel filter Repair replace as required e See Maintenance section Primary Secondary Fuel Filter replacement Electric Fuel Pump malfunction Check electrical connection GAS Check Relay and fuse Tum key ON and verify pump is operating e See Engine Service Manual Pressure regulator malfunction Test pressure regulator operation e See Engine Service Manual Fuel Injector malfunction Test Injector operation e See Engine Service Manual Air filter clogged Check air filter e Clean replace as required Incorrect air fuel or ignition contro
61. can cause the load to fall or the lift truck to tip If the controller fails An operator can operate the truck manually by selecting the Manual mode with the Fail Safe mode switch on the PCB Printed Circuit Board Bir d X oe i e ka sat IB1O001P Fail Safe mode switch NOTICE Direction Inhibit Function is usable in factory setting controller If you don t want to use this function make sure to select the manual mode with the Fail Safe mode switch on PCB 120 Operating Techniques Inching into Loads lAOO0D371 Typical Example 1 Move the lift truck slowly FORWARD into position and engage the load The lift truck should be square with load forks spaced 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 121 Operation Section Lifting the Load 1 Lift the load carefully and tilt the mast back short distance IAO0O0391 Typical Example 2 Tiltthe 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 Operation Section Traveling With the Load NOTICE Travel with the load as low as possible while still maintaining ground clearance lAG0O0441 Typical Examp
62. 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 operators 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 as 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 Burn Prevention Coolant At operating temperature the engine coolant is hot and under pressure
63. for cleaning with water Air dry it thoroughly and then examine it Maintenance Section Checking Element Hydraulic Oil Level Check WARNING At operating temperature the hydraulic tank is hot and under pressure Hot oil can cause burns Remove the filter cap only when the engine is stopped and the cap is cool enough to touch with your bare hand Remove the filter cap slowly to relieve pressure ILO1010P 1 Operate the lift truck for a few minutes to warm 1 Inserta light inside the clean dry element and the oil Park the lift truck on a level surface with examine it Discard the element if tears rips or the forks lowered mast tilted back parking damage are found brake engaged transmission in NEUTRAL and the engine stopped 2 Wrap and store good elements in a clean dry place 2 Raise the hood and seat assembly Make sure the air lift cylinder securely holds the hood open Brake Oil Level Check 3 Remove the dip stick filter cap Maintain the oil level to the FULL mark on the dip stick filter The brake reservoir is located on the left side of the cap steering column Remove the filler 2 Maintain the brake fluid level to the fluid level mark on the brake system reservoir 3 Clean and install the filler cap 169 Maintenance Section Drive Axle Oil Level Check Park the lift truck on a level surface Apply the parking brake The engine at low
64. guard This manual contains information necessary for Safe Operation Before operating a lift truck make sure that the necessary instructions 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 ltems 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 du
65. idle Place the directional control lever in NEUTRAL 1 Remove the dip stick filter cap Observe the oil level 2 Maintain the oil level between the lower mark and upper marks on the dip stick filter cap Mast Carriage Lift Chains amp Attachments Inspect Lubricate 1 Operate the lift tiit and attachment controls Listen for unusual noises These may indicate a need for repair 2 Inspectfor loose bolts and nuts on the carriage Remove any debris from the carriage and mast 3 Inspect the forks and attachments for free operation and damage Have repairs made if necessary ILOMO23P 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 applications where the lift truck is operating in an atmosphere which could cause corrosion components or when lift truck must work in rapid lift cycles 6 Inspect the chain anchors and individual links for wear loose pins or cracked leaves Steering Mechanism Check Lubricate 101013 1 Lubricate the steer axle king pins total of four fittings Two on the right side and two on the left side 2 Lubricate the steering link bearings total of four fittings Two on the right side and two on the left side 3 Check for any worn or loose components of the steering mechanism Remove any debris or trash as
66. indicator shows RED after installing a new secondary element and a cleaned primary outer element replace the cleaned primary filter with a new element Stop the engine Close the hood and seat assembly Inspect Coolant Hoses LP Dual Fuel Engine Only 1 Visually inspect coolant hoses and clamps Remember to check the two coolant lines that connect to the pressure regulator converter Replace any hoses that shows signs of swelling 1 LP Regulator Converter 2 Coolant hoses LP Regulator Converter Inspection LP Dual Fuel Engine Only 1 Visually inspect the pressure regulator converter housing 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 189 Maintenance Section Fuel Lines amp Fittings Check Visually inspect fuel lines and fittings for physical damage Replace as required 1 Fuel lines 2 LP mixer 3 Throttle Assembly Inspect Mixer Assembly G420F E G424F E Engine Only Refer to the LP mixer section of the engine service manual for procedures Inspect Throttle Assembly G420F E G424F E Engine Only 1 Visually inspect the throttle assembly motor housing for coking cracks and missing cover retaining clips Repair and or replace as
67. is mounted properly Possible defective TMAP sensor IATRangeLow Intake Air Temperature Sensor Input is Low normally set if the IAT temperature sensor wire has shorted to chassis ground or the sensor has failed TurnOnMil 104 Check TMAP connector and IAT signal wiring for a shorted circuit TMAP Pin 2 to SECM Pin B12 signal TMAP Pin 1 to SECM Pin 1 sensor GND To check the IAT sensor of the TMAP disconnect the TMAP connector and measure the IAT resistance Resistance is approx 2400 ohms at room temperature Fault actions shown are default values specified by the OEM PROBABLE FAULT IATRangeHigh Intake Air Temperature Sensor Input is High normally set if the IAT temperature sensor wire has been disconnected or the circuit has opened to the SECM Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION TurnOnMil Operation Section CORRECTIVE ACTION FIRST CHECK Check TMAP connector and IAT signal wiring for a shorted circuit TMAP Pin 2 to SECM Pin B12 signal TMAP Pin 1 to SECM Pin B1 sensor GND To check the IAT sensor of the TMAP disconnect the TMAP connector and measure the IAT resistance Resistance is approx 2400 ohms at room temperature IAT_IR_Fault Intake Air Temperature not changing as expected EST1 Open EST1 output open possibly open EST1 signal or defective spark module TurnOnMil Check connections to TMAP sensor Check that TMAP sensor i
68. on tapered forks platens Remove the forks from service when the blade length is no longer adequate for the intended loads IAOMOS9 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 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 200 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 IAOM1001 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
69. problem also exists in LPG mode then the root cause is most likely to something other than the fuel system See Advanced Diagnostics amp Dual Fuel Engine Service Manual Clogged fuel filter Repair replace as required See Maintenance section 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 He connect fuel line e Slowly open liquid fuel valve amp Leak test Air filter clogged and the mixer Faulty vapor connection between the pressure regulator converter Pressure regulator malfunction Check air filter e Clean replace as required Check connection e Verify no holes in hose e Clamps must be tight Look for kinked pinched and or collapsed hose Test pressure regulator operation e See Dual Fuel Engine Service Manual Problem Probable Cause Corrective Action Poor High Speed Performance Gas Air Fuel Mixer malfunction Restricted exhaust system Check mixer e See Engine Service Manual Check exhaust system e Measure exhaust back pressure Incorrect ignition control Incorrect air fuel control Incorrect throttle position See Advanced Diagnostics amp Engine Service Manual 98 Advanced Diagnostics MI 07 systems are equipped with built in fault diagnosti
70. sensor assembly to the right Figure 5 15 9 Install the drain plug Figure 5 15 1 on the new fuel filter Figure 5 15 3 by turning the drain plug to the right Figure 5 15 8 Hand tighten only Clean the fuel filter mounting surface Figure 5 15 10 and apply a small amount of diesel fuel to the gasket of the new filter 183 17 18 19 20 21 Maintenance Section Install the new fuel filter Figure 5 14 2 by turning it to the right Figure 5 14 4 until it contacts the mounting surface Tighten one additional turn Open all fuel cocks in the fuel line the fuel filter sensor connector Figure 5 14 1 Prime the fuel system See Priming the Fuel System Check for fuel leaks Engine Oil amp Filter Diesel Engine Only Change See topic Engine Oil amp Filter Diesel Engine Only Change in First 50 100 Service Hours or a Week Maintenance Section Water Separator 4TNV98 Diesel Engine Only Clean Periodically clean the fuel filter water separator element and inside cup 1 Position an approved container under the cup Figure5 16 1 of the fuel filter water separator to collect the contaminants Figure5 16 Close 5 16 the fuel cock 5 16 3 2 Loosen the drain cock Figure5 16 4 and drain the contaminants See Drain Fuel FillerWater Separator Turn the retaining ring F
71. than expected TPS1AdaptHiMax Learned WOT end of TPS1 sensor range higher than expected TPS2AdaptHiMax Learned WOT end of TPS2 sensor range higher than expected TPS1AdaptHiMin Learned WOT end of TPS1 sensor range lower than expected Fault actions shown are default values specified by the OEM 102 PROBABLE FAULT TPS2AdaptHiMin Learned WOT end of TPS2 sensor range lower than expected Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION Operation Section CORRECTIVE ACTION FIRST CHECK TPS1AdaptLoMax Learned closed throttle end of TPS1 sensor range higher than expected TPS2AdaptLoMax Learned closed throttle end of TPS2 sensor range higher than expected N A TPS Sensors Conflict TPS sensors differ by more than expected amount NOTE The TPS is nota serviceable item and can only be repaired by replacing the DV EV throttle assembly MAPTimeRangeLow Manifold Absolute Pressure sensor input is low normally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the circuit has opened to the SECM MAPRangeLow Manifold Absolute Pressure sensor input is low normally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the circuit has opened to the SECM 1 TurnOnMil 2 CutThrottle TurnOnMIil 1 TurnOnMil 2 EngineShutdown Fault actions shown are default val
72. the disconnect switch is in the ON closed position 76 Gasoline Engine NOTICE Do not leave the key in ON position when engine is not running Do not engage the starter more than 10 seconds at any one time 1 Don t press accelerator pedal and turn the ignition switch to the START position 2 Once the engine starts release the ignition switch 3 Ifthe engine does not start repeat step 1 4 If engine coolant is cold engine speed could be higher than low idle speed Don t drive forklift until engine speed becomes normal low idle speed NOTICE If the inside of engine cylinder is wet by gasoline the engine could not start this case press accelerator pedal fully and turn the ignition switch to ON position for 10 seconds The inside of cylinder would be dry because ECM does not allow gasoline fuel injection Repeat it three times Don t press accelerator pedal and turn the Ignition switch to the START position to start engine WARNING LP fuel is flammable and can cause personal injury Inspect LP fuel lines and fitting for leaks Inspect tank for secure mounting ILOO018P 1 Turn the tank fuel valve ON by slowly turning the valve counterclockwise Observe the LP gauge if equipped 2 Don t press accelerator pedal and turn the ignition switch to the START position 3 Once the engine starts release the ignition switch 4 Ifthe engine does not start repe
73. wires on the harness including Fuel lock off TMAP sensor O2 sensor Electronic throttle Control Relays Fuel Trim Valve Foot Pedal and crank sensor 2 Repair and or replace as necessary Maintenance Section Fuel Filter Diesel Engine Only Change 4TNV98 Diesel Engine Only Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow 1 Stop the engine and allow it to cool 2 Close the fuel cock of the fuel filter water separator 3 Remove the fuel filter with a filter wrench turning it to the left Figure5 13 1 When removing the fuel filter carefully hold it to prevent the fuel from spilling Wipe up all spilled fuel agpon SA Figure5 13 4 Clean the filter mounting surface and apply a small amount of diesel fuel to the gasket of the new fuel filter 5 Install the new fuel filter to the right Figure5 13 2 and hand tighten it only until it comes in contact with the mounting surface Tighten to 14 17 6 19 6 23 5 Nem 2 0 2 4kgfem or one additional turn using the filter wrench 6 Open the fuel cock of the fuel filter water separator 7 Prime the fuel system See topic Priming the Fuel System in When Required 8 Check for leaks 182 4 98 Diesel Engine Only Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow 1
74. 0 MAST 4350mm MAST 4 30mm MAST 4960mm MAST 9560mm MAST D 6010mm 5 GC30E 5 GC30P 5 51 General Section Capacity Chart Without Sideshifter cushion GC33E 5 GC33P 5 STD FFL nap 2030 3950 MFH MAST 4350mm MAST C 4960mm MAST 3900mm MAST B 4290mm 5 4730 5 D 5560 5 E 6010 MAST 52 General Section Capacity Chart Without Sideshifter cushion wa WIDE TIRE STD FFL z ooo HES ZERESEE GC20E 5 GC20P 5 2030 4350 MAST A 5900 4290mm MFH MAST B 4960mm MFH MAST B 4730mm MFH MAST C 5560mm MAST D 6010mm MAST 2228888 8 2030 3950mm MAST 3900 5 4350mm 5 4290mm 5 C 4960mm MAST 4730mm MAST 0 5560 5 E 6010mm MAST R LO N vd LO N O SEBHEERS coors A 2030 35950mm MAST 3900 4290mm MAST 4330mm MAST 4730mm MAST 4960mm MAST 5560mm MAST D 6010mm MAST GC30E 5 GC30P 5 53 General Section Capacity Chart Without Sideshifter cush
75. 0 Stop the engine and close the hood and seat assembly Maintenance Section Cleaning Primary Filter Elements 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 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 6 months service or after cleaning no more than 3 times 168 Air 205 kPa 30 psi Maximum Pressure 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 280kPa 40 psi Maximum Pressure p 1 ILO1009P Direct water on 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 Rinse the element with clean water See instructions in preceding topic
76. 14 Open the fuel valve by slowly turning it 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 15 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 Make a thorough walk around inspection before mounting the lift truck or starting the engine Look for such items as loose bolts debris buildup oil or coolant leaks Check condition of tires mast carriage forks or attachments Have repairs made as needed and all debris removed Inspect the operators compartment for loose items and cleanliness 2 Inspect the instrument panel for broken or damaged indicator lights or gauges 3 Test the and other safety devices for proper operation 4 Inspect the mast and lift chains for wear broken links pins and loose rollers ILO1052P 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 74 7 Inspect the overhead guard for damage and loose or missing mounting bolts 8 Inspect the hydraulic system for leaks worn hoses or damaged lin
77. 28 29 ACCELERATION time reached at max speed a loaded unloaded WEIGHT 30 TOTAL WEIGHT at unloaded kg 3580 3950 31 at loaded front rear kg 4930 650 5660 790 32 MAELOR at unloaded front rear kg 1720 1860 1650 2300 CHASSIS 33 number of front rear 2 2 2 2 34 TIRES front size 7 00x15 12 7 00x15 12 35 rear size 6 50x10 10 6 50x10 10 36 WHEEL BASE mm 1625 1625 37 TREAD front rear mm 975 1000 975 1000 38 GROUND at loaded the lowest point mm 115 115 39 CLEARANCE at loaded center of wheelbase mm 143 143 40 SEVICE BRAKE foot hyd foot hyd 41 PARKING BRAKE hand mech hand mech DRIVE 42 BATTERY voltage capacity 12 85 12 85 43 manufacturer model YANMAR 4TNE98 YANMAR 4TNE98 44 ENGINE rated output 43 7 58 6 2300 43 7 58 6 2300 45 max torque rpm N m lbeft 181 133 1600 181 133 1600 46 cycle cylinders displacement 4 4 3319 4 4 3319 47 type powershift powershift 48 Teoh number of speeds forward reverse 1 1 1 1 E system attachment 181 156 195 156 equivelent continuous sound 50 NOISE LEVEL pressure level Leo at operator s ear dB A 32 DOOSAN DOOSAN DOOSAN 1 D30S 5 D33S 5 D35C 5 2 Y ANMAR TIER3 YANMAR TIER3 YANMAR TIER3 3000 3250 3500 3 500 500 500 4 diesel diesel diesel 5 rider seated rider seated rider seated 6 p p p 7 2 2 2 2 2 2 8 3230 3230 3000 9 152 152 152 10 III III III 11 45x125x1050
78. 3 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 199 Maintenance Section IAONMOQS6I 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 Omg Check the difference in height of one 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 in 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 IAQM0981 5 Check the fork blade J and shank H 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
79. 45x125x1050 45x125x1050 12 286x1044 286x1044 286x1044 13 6 10 6 10 6 10 14 2700 2730 2765 15 1197 1197 1255 16 2165 2165 2165 17 4490 4490 4260 18 2183 2183 2183 19 1026 1026 1026 20 2365 2395 2420 21 485 485 495 22 2850 2880 2915 23 2050 2100 2170 23a 18 18 5 18 18 5 18 5 19 24 500 550 490 550 420 550 25 510 460 510 460 510 460 26 1830 1820 1750 27 25 23 5 21 5 28 29 4450 4630 4810 30 6580 870 6940 940 7340 970 31 1840 2610 1800 2830 1780 3030 32 2 2 2 2 2 2 33 28x9x15 12 28x9x15 12 250x15 18 34 6 50x10 10 6 50x10 12 6 50x10 12 35 1700 1700 1700 36 982 1000 982 1000 1026 1000 37 105 105 105 38 143 143 143 39 foot hyd foot hyd foot hyd 40 hand mech hand mech hand mech 41 12 85 12 85 12 85 42 YANMAR 4TNE98 YANMAR ATNE98 YANMAR ATNE98 43 43 7 58 6 2300 43 7 58 6 2300 43 7 58 6 2300 44 181 133 1600 181 133 1600 181 133 1600 45 4 4 3319 4 4 3319 4 4 3319 46 powershift powershift powershift 47 1 1 1 1 1 1 48 216 156 216 156 216 156 49 50 33 General Section e General Section
80. 5 2349 02 Operation Maintenance Manual LIFT TRUCKS D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 G20E 5 G25E 5 G30E 5 GC20E 5 GC25E 5 GC30E 5 GC33E 5 G20P 5 G25P 5 G30P 5 G33P 5 G35C 5 GC20P 5 GC25P 5 GC30P 5 GC33P 5 0712 WARNING Do nol start operate service this machine unless you read 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 reviewed by the machine operator and 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 binh 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 gel cm eneen 2 Safety Section Important Safety Information
81. 600 25 510 460 510 460 510 460 26 2050 2125 2115 27 37 31 29 28 29 3730 4200 4370 30 5510 720 6340 860 6500 870 31 1470 2260 1490 2710 1430 2940 32 2 2 2 2 2 2 33 21x7 15 21x8 15 21x8 15 34 16x5 10 5 16x6 10 5 16x6 10 5 35 1410 1410 1410 36 932 983 907 956 907 956 37 90 90 90 38 135 135 135 39 foot hyd foot nyd foot hyd 40 hand mech hand mech hand mech 41 12 65 12 65 12 65 42 G424F E G424F E G424F E 43 47 7 64 2550 47 7 64 2550 47 7 64 2550 44 182 135 2200 182 135 2200 182 135 2200 45 4 4 2405 4 4 2405 4 4 2405 46 powershift powershift powershift 47 1 1 1 1 1 1 48 195 156 216 156 216 156 49 50 25 General Section Noise and Vibration Sound Pressure Level at Whole body Vibration Operator s ear Leq Level according to EN12053 By 0156 DISCO according to 13059 2000 14 Guaranteed Sound m s Uncertainty Power level Lwa TIER Il ATNV98 E G D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 W O Cabin TIER Ill ATNE98 E G D20S 5 D25S 5 D30S 5 0338 5 D35C 5 W O Cabin TIER Ill G424F E E G G20P 5 G25P 5 G30P 5 G33P 5 G35C 5 W O Cabin TIER IIl G420F E E G GC20E 5 GC25E 5 GC30E 5 GC33E 5 W O Cabin TIER III G424F E E G GC20P 5 GC25P 5 GC30P 5 GC33P 5 W O Cabin dB A dB A TIER G420F E E G G20E 5 G25E 5 G30E 5 82 104 W O Cabin NENNEN NA Not Applicable 42 General Section Capacity Chart Without Sideshifter
82. 7 116 1600 46 cycle cylinders displacement cc 4 4 1975 47 powershift 48 TRANSMISSION number of speeds forward reverse 1 1 49 50 OPERATING PRESSURE system attachment 181 156 NOISE LEVEL equivelent continuous sound pressure level Leq at operator s ear DI BITA CE prEN 12053 dB A 38 DOOSAN DOOSAN 1 GC25E 5 GC33E 5 2 2500 3000 6500LBS 3 500 500 600 4 LP LP LP 5 rider seated rider seated rider seated 6 C C C 7 2 2 2 2 2 2 8 3230 3230 3230 9 152 152 10 l H i 11 40x100x1050 45x125x1050 12 297x905 282x954 13 6 8 6 8 14 2268 2368 15 1110 1110 16 2130 2130 17 4480 4480 18 2150 2150 19 1038 1038 20 2045 2105 2135 21 367 373 373 22 2412 2478 2508 23 1822 1872 1907 23a 16 16 16 16 16 16 24 510 600 500 600 500 600 25 510 460 510 460 26 1775 1740 27 30 23 5 28 29 3710 4350 30 5500 710 6490 860 31 1460 2250 1420 2930 32 2 2 2 2 2 2 33 21x7 15 21x8 15 21x8 15 34 16x5 10 5 16x6 10 5 16x6 10 5 35 1410 1410 1410 36 932 983 907 956 907 956 37 90 90 90 38 135 135 135 39 foot hyd foot hyd 40 hand mech hand mech 41 12 45 12 45 12 45 42 G420F E G420F E G420F E 43 39 9 53 5 2500 39 9 53 5 2500 39 9 53 5 2500 44 157 116 1600 157 116 1600 157 116 1600 45 4 4 1975 4 4 1975 4 4 1975 46 powershift powershift 47 1 1 1 1 1 1 48 195 156 216 156 216 156 49 50
83. Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked collapsed hose pinched and or Pressure regulator freezes Check level in cooling system e Must be full check coolant strength 35F minimum Check coolant hoses Watch for kinks and or pinched hoses Verify one pressure hose and one return hose Pressure regulator malfunction Test pressure regulator operation e Engine Service Manual Vacuum leak Check for vacuum leaks e Between mixer and throttle body e Between throttle body intake manifold e Between intake manifold and cylinder head Air Fuel Mixer malfunction Check mixer e Engine Service Manual Engine Mechanical Faulty vapor connection between the pressure regulator converter and the mixer See Engine Manufacturers Service Manual Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked collapsed hose pinched and or Pressure regulator malfunction Test pressure regulator operation See Engine Service Manual Vacuum leak Air Fuel Mixer malfunction Check for vacuum leaks e Between mixer and throttle body e Between throttle body intake manifold e Between intake manifold and cylinder head Check mixer e Engine Service Manual 90 Operation Section Problem Probable Cause Corrective Action n h Idi Incorrect Idle speed control See Advanced Diagno
84. 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 Maintenance Section Tire Inflation Information Tire Inflation SNA P x N WS LE MAD i e Ke S EN N N N N Ween IAOMOO1S 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 over inflation A tire blowout or rim failure can result from improper or misused equipment NOTICE Set the tire inflation equipment regulator at no more than 140 kPa 20 psi over the recommended tire pressure 134 Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures Shipping Pressure kPa psi 1 Standard tire ply rating and inflation pressures Ply Rating or Strength Index The operating inflation pressure is based on the weight of a 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 t
85. D20S 5 G20E 5 G20P 5 2050 4550 MAST 3900 4 750mm MAST 4960mm MAST 5560mm MAST C 6010mm MAST j PIT BBEB SEEE Zu HE a Fil WE D W gt mm 2030 4350 MAST A 3900 4730mm MAST B 4960mm MAST B 5560 MAST C 6010mm MFH MAST D30S 5 G30E 5 G30P 5 45 General Section Capacity Chart Without Sideshifter Pneumatic DOUBLE TIRE STD FFL 50 BO X NX 2030 4550 MAST 3900 4290mm MAST 4960mm 4730mm 5 C 5560 MAST D 6010mm 5 xm um e p n zm ne m D35C 5 G35C 5 dun A 3555 3960mm MAST 5 SICHER TET MAST 4380mm MFH MAST 4805mm MAST 4820mm MAST D 5205mm MFH MAST E 5655mm MFH MAST 46 Capacity Chart With Sideshifter Pneumatic MODEL D20S 5 G20E 5 G20P 5 D30S 5 G30E 5 G30P 5 STD FFL once Z A 2300 3950mm MAST B 4350mm MFH MAST C 4960mm MFH MAST SINGLE TIRE L wW lI 1 lI S PE TT __ L 27 ELI 2030 3950mm MAST B 4350mm MAST 4960mm MAST 2030 3950mm 5
86. GHTEN THE SPARK PLUGS 1 Ignition wiring harness 2 Ignition Coil Assy 3 Spark plug Checking the Sensor G420F E G424F E Engine Only 1 Verify that the TMAP sensor F is mounted tightly into the manifold adapter E with no leakage 2 f 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 Maintenance Section Inspect for Intake Leaks G420F E G424F E Engine Only 1 Visually inspect the intake manifold throttle assembly 2 and manifold adapters 3 for looseness andleaks Repair as necessary Replace PCV Valve and breather element Change LP Gasoline and Dual Fuel Engines G420F E Engine 1 Loosen the hose clamps and remove the PCV valve 2 Assemble new PCV valve and hose 3 Tighten the hose clamps Maintenance Section Every 3000 Service Hours or 18 Months You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Timing Belt G420F E G424F E LP Gasoline Dual Fuel Engine Only Change See the Service manual for the procedure and
87. L and the engine running 2 Close the fuel valve on the LP tank hood open Operation Section 3 Move lever 1 from the LPG 3 POSITION to the OFF 2 position Allow the engine to run until the fuel in the line runs out and engine stops 4 Move lever 1 from the LPG 3 position to the GAS 4 position 5 Turn the ignition switch key to the OFF position 6 Turn the ignition switch key to the START position and start the engine Release it when the engine starts 80 After Starting the Engine Observe all indicator lights and gauges frequently during operation to make sure all systems are working properly The entire indicator lights will come ON with the ignition switch in the ON position before the engine is started Diesel 12V 1 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 2 alternator indicator light 2 should not come ON during normal operation The alternator is not charging if the light comes ON with the engine running 3 spark ignition G420 424F E engine MIL Malfunction Indicator Light 3 will not come ON with the engine ru
88. ON FIRST CHECK Check TMAP connector and MAP signal wiring for a shorted circuit TMAP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin 1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by disconnect ing 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 MAPRangeHigh Manifold Absolute Pressure Sensor Input is High normally set if the TMAP pressure signal wire has become shorted to power shorted to the IAT signal the TMAP has failed or the SECM has failed 1 TurnOnMil 2 Engine Shutdown Check TMAP connector and MAP signal wiring for a shorted circuit TMAP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by 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 4kO 8 2kQ MAP IR MAP sensor indicates higher pressure than expected MAP IR LO MAP sensor indicates lower pressure than expected TurnOnMil TurnOnMil Check for vacuum leaks Check that TMAP sensor is mounted properly Possible defective TMAP sensor Possible defective TMAP sensor MAP_STICKING MAP sensor not changing as expected TurnOnMil Check that TMAP sensor
89. PY Only ra o 2 5 8 gt Inspect Mixer Assembly G420F E G424F E Engine Only 189 ropes Tt ey AsO EN Inspect Tightness WE lol Inspect Vacuum Lines and Fittings G420F E G424F E Engine Only T heck Lift Chains Adjust LP Regulator Converter Inspection LP Dual Fuel Engine HLH Only EJ d 2 Mast Mast Hinge Pin Pin Lubricate o Inspect Mast Carriage Lift Chains amp Attachments Lubricate 4 45 t9 o j PakingBrake 164180 of o PcVVaveSysiem mspctClea 17 JO Priming the Fuel System Diesel Engine Only 05 lo j j j Replace LP Fuel Filter Element LP Dual Fuel Engine Only 12 Jo Replace Oxygen Sensor G420F E G424F E Engine Only 2 Of Replace Spark Plugs G420F E Engine Only 22 o Replace Spark Plugs G424F E Dual Fuel Engine Ony lol Seat Hood Latch amp Support Cylinder Check Lubricate 148 ol SteerSuspension meet 10 lol j SteerWheelBearings 1944
90. Pneumatic SINGLE TIRE STD FFL 2 sausage 2030 4350mm MFH MAST A 5900 4290mm MAST 4960mm MAST B 4730mm MFH MAST 5560mm MAST D 6010mm MAST D20S 5 G20E 5 G20P 5 k E I zw 2100 1 TQ 190 i pos A 2050 4550mm MAST A 5900 4290mm MAST B 4960mm MAST B 4730mm MAST C 5560mm MFH MAST D 6010mm MAST nry P mi A 2050 4550 MAST 3900 4730mm MFH MAST 4960mm MAST B 5560mm MAST C 6010mm MFH MAST D30S 5 G30E 5 G30P 5 43 General Section Capacity Chart Without Sideshifter Pneumatic wa SINGLE TIRE STD FFL 2030 3800mm MFH MAST A 3800 4290mm MAST 3950 4350mm MAST B 4730mm MAST C 4960mm MAST 5560mm MAST D 6010mm MFH MAST nm Um M me xm e m A 3555 3960mm MAST E MEN LAST mel B 4380mm MFH MAST C 4805mm MAST C 4820mm MFH 5 D 5205mm MFH MAST E 5655mm MAST D35C 5 G35C 5 44 General Section Capacity Chart Without Sideshifter Pneumatic DOUBLE TIRE STD FFL 2030 4350mm MAST 3900 4290 MAST B 4960mm MAST 4730mm 5 5560mm MFH MAST 6010mm MFH MAST
91. Press horn button to determine if horn is operational Check and replace all defective gauges 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 Inspect Vacuum Lines and Fittings G420F E G424F E Engine Only 1 Visually inspect vacuum lines and fittings for physical damage such as bittleness cracks and kinks Repair replace as required 2 Slovent or oil damage may cause vacuum lines to become soft resulting in a collapsed line while the engine is running 3 If abnormally soft lines are detected replace as necessary 1 Fuel Trim Valve FTV 2 Vacuum lines Fuel Trim Valve FTV Inspection G420F E G424F E Engine Only 1 Visually inspect the Fuel trim valve for abrasions or cracking Replace as necessary 2 To ensure the valve is not leaking a blow by test can be performed 3 With the engine off disconnect the electrical connector to the FTV 4 Disconnect the vacuum lines form the FTV to the pressure regulator converter at the converter s tee connection 5 Lightly 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 replace the FTV 181 Maintenance Section Inspect Electrical System 1 G420F E G424F E Engine Only Check for loose dirty or damaged connectors and
92. Read and understand the basic precautions listed the Safety Section before operating or performing lubrication maintenance and repair on this 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 A 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 operators compartment and the overhead
93. SAN 2 MODEL GC20E 5 3 CAPACITY at rated load center 4 5 6 7 TIRES P pneumatic 8 WHEELS x driven number of front rear 2 2 DIMENSIONS 9 WITH STD maximum fork height with rated load mm 3230 10 TWO STAGE MAST free lift mm 152 11 FORK CARRIAGE ISO class II 12 FORKS thickness x width x length mm 40x100x1050 13 fork spacing maximum x minimum mm 297x905 14 15 length without forks mm 16 width 17 OVERALL mast lowered height 18 DIMENSIONS mast extended height 19 overhead guard height mm 20 seat height mm 21 22 23 90 5 AISLE 2367 23a 90 INTERSECTING AISLE mm 1798 PERFORMANCE 24 travel loaded unloaded km hr 16 16 25 SPEED lift loaded unloaded mm s 530 600 26 lowering loaded unloaded mm s 510 460 27 DRAWBAR PULL at 1 6km hr loaded unloaded kg 1795 28 time reached at max speed 29 ACCELERATION 2 WEIGHT 30 31 atloaded front rear kg 4770 640 32 ee saa at unloaded front rear kg 1540 1870 CHASSIS 33 number of front rear 2 2 34 TIRES front size 21x7 15 35 rear size 16x5 10 5 36 WHEEL BASE mm 1410 37 TREAD front rear mm 932 983 38 GROUND at loaded the lowest point mm 90 39 CLEARANCE at loaded center of wheelbase mm 135 40 SEVICE BRAKE foot hyd 41 PARKING BRAKE hand mech DRIVE 42 BATTERY voltage capacity V AH 12 45 43 manufacturer model G420F E 44 ENGINE rated output rom kw hp 39 9 53 5 2500 45 max torque Nem Ibeft 15
94. SECM DRVP Pin A23 Check FTV1 for an open coil by disconnecting the FTV connector and measuring the resistance 260 20 LSDFault_Dither2 Dither Valve 2 Fault signal has opened or shorted to ground or power or defective dither 2 valve 1 TurnOnMil 2 Disable GasO2 Ctrl 3 Disable GasPost O2Ctrl Check FTV1 for an open wire or FTV connector being disconnected or signal shorted to GND FTV2 Pin 1 signal to SECM Pin A2 FTV2 Pin 2 power to SECM DRVP Pin A23 Check FTV1 for an open coil by disconnecting the FTV connector and measuring the resistance 260 20 LSDFault CSValve None N A LSDFault CheckEngine Check Engine Lamp Fault signal has opened or shorted to ground or power or defective check engine lamp LSDFault CrankDisable Crank Disable Fault signal has opened or shorted to ground or power or defective crank disable relay None Check Check Engine Lamp for an open wire or shorted to GND N A LSDFault FuelPump Fuel pump fault signal has opened shorted to ground or power or defective fuel pump LSDFault LockOff Fuel lock off Valve Fault signal has opened or shorted to ground or power or defective Fuel lock off valve TurnOnMil TurnOnMil Check fuel pump for an open wire or connector being disconnected or signal shorted to GND Fuel Pump Pin B signal from SECM Pin A13 Fuel Pump Pin A power from main relay 1 Pin A23 Check Fuel Pump for an open coil by disconne
95. SO viscosity grade of 32 would normally be selected NOTICE Make up oil added to the hydraulic tanks must mix with the oil already in the systems Use only petroleum products unless the systems are equipped for use with special products If the hydraulic oil becomes cloudy water or air is entering the system Water or air in the system will cause pump failure Drain the fluid retighten all hydraulic suction line clamps purge and refill the system Consult your DOOSAN Lift Truck dealer for purging instructions Drive Axle Oil NOTE Do not use Gear Oil in the final drives or differentials Gear Oil can cause seal material to fail and possibly leak oil NOTE Failure to follow the recommendation will cause shortened life due to excessive gear wear The API CD TO 2 specification or MIL L 2104D Eor F oils could be used NOTE Multi grade oils are not blended by DOOSAN for use in transmissions Multi grade oils which use high molecular weight polymers as 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 141 Maintenance Section Lubricating Grease MPGM Use Multipurpose Molybdenum Grease MPGM for all lubrication points If MPGM grease can not be used multipurpose type grease which contains 396 to 596 molybdenum disulfide can be used NLGI No 2 grade is suita
96. See Sulfur Topic Viscosity Kinematic 20 0 cSt Max 38 C 100 F ASTM 0445 1 4 cSt Min Water amp Sediment 5 ASTM D1796 delivered to fuel system 0 5 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 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 oil should have sufficient TBN for fuels with less than 0 596 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 your local technological society library or college Maintenance Section 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 oil with a TBN of 30 and reduce the oil change inter
97. Stop the engine and allow it to cool 2 Close all fuel cocks in fuel line 3 Disconnect the fuel filter sensor connector Figure 5 14 1 Figure 5 14 4 Place an approved container under fuel filter 5 Carefully open the drain plug Figure 5 15 1 to drain fuel from the fuel filter 6 Remove the fuel filter Figure 5 14 2 by turning it to the left Figure 5 14 3 Wipe up all spilled fuel 7 Remove the drain plug Figure 5 15 1 from the fuel filter Figure 5 15 2 by turning it to the left Figure 5 15 3 8 Check the condition of the drain plug O ring Figure 5 15 4 if damaged Replace the O ring 10 11 12 13 14 15 16 1 5 15 Set the drain plug aside for reinstallation Remove the fuel filter sensor assembly Figure 5 15 5 by turning it to the left Figure 5 15 3 Carefully remove the in line fuel filter Figure 5 15 7 from the output nipple Figure 5 15 8 that goes to the fuel injection pump Dispose of the fuel fuel filters and O ring if replaced properly Follow the guidelines of the EPA or other government agency Carefully install the new in line fuel filter Figure 5 15 7 into the output nipple Figure 5 15 8 Carefully install the fuel filter sensor assembly Figure 5 15 5 in the new fuel filter using the new O ring supplied with the fuel filter Figure 5 15 2 by turning the fuel filter
98. ULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK Check ETC driver wiring for a shorted circuit HbridgeFault ETC SECM Pin A17 to ETC Pin 1 Electronic Throttle Control SECM Pin A18 to ETC Pin 4 Driver has failed Perform the throttle test using the Service Indeterminate fault on Tool and re check for fault Hbridge driver for 2 Check the ETC internal motor drive by electronic throttle control disconnecting the throttle connector and Possibly either or measuring the motor drive resistance at the ETC driver signals have throttle been shorted to ground TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 00 Check engine oil level Check electrical connection to the oil pressure switch SECM Pin B9 to Oil Pressure Switch Check battery voltage e Perform maintenance check on electrical connections to the battery and chassis ground Check battery voltage during starting and with the engine running to verify charging TurnOnMil system and alternator function e 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 Check battery and charging system voltage Check battery voltage during starting and with the engine running Check voltage regulator alternator and charging system 1 TurnOnMil Check battery and wiring for overheating 2 DelayedEngine and damage Shutdown Measure battery power at SECM with a multimeter with key on SECM Pin A23 DRVP
99. age to the alternator Always connect the external power source cables 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 78 Dual Fuel System Changing From Gasoline to LP Gas NOTE The Underwriters Laboratory U L requires that the gasoline tank must be at least one quarter full when operating on LP This will allow the lift truck to be restarted on gasoline and moved to an approved refueling area when operating in a hazardous area 1 Park the lift truck level in an authorized refueling area with the forks lowered the parking brake applied the transmission in NEUTRAL and the engine running 2 Move lever 1 on the fuel selector switch to the OFF 2 position Leave lever 1 in this position until the engine stops 3 Move lever 1 to the LPG 3 position 79 Operation Section ILOO018P a 4 Open the fuel valve on the LP tank by slowly turning the valve counterclockwise 5 Turn the ignition switch key to the OFF position and then to the START position to start the engine Release it when the engine starts Changing From LP to Gasoline 1 Park the lift truck level in an authorized refueling area with the forks lowered the parking brake applied the transmission in NEUTRA
100. an Pre catalyst O2 sensor indicates extended lean operation on LPG GasPostO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on LPG 1 TurnOnMil 2 DisableGas O2Ctrl 3 Disable GasPost O2Ctrl 1 TurnOnMil 2 DisableGasPost O2Ctrl Check for vacuum leaks Check dual dither valves e g leaking valve or hose Check for missing orifice s Correct other faults that may contribute to 752 e g faults pertaining to dither valves Pre Cat O2 Post Cat O2 sensor Check for vacuum leaks Check for leaks in exhaust catalytic converter HEGO sensors repair leaks Check all sensor connections see fault 742 corrective actions GasO2FailedRich Pre catalyst O2 sensor indicates extended rich operation on LPG 1 TurnOnMil 2 DisableGas O2Ctrl 3 DisableGasPost O2Ctrl Check dual dither valves e g plugged valve or hose Check for plugged orifice s Fault actions shown are default values specified by the OEM 113 Operation Section GasPostO2FailedRich Pre catalyst O2 sensor indicates extended rich operation on LPG Table 2 Diagnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION 1 TurnOnMil 2 DisableGasPost O2Ctrl CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 772 e g faults pertaining to FTVs Pre Cat O2 Post Cat O2 sensor Look for leaks in exhaust catalytic converter HEGO sensors repair leak
101. an expected GasO2NotActive Pre catalyst O2 sensor inactive on LPG open 2 sensor signal or heater leads defective 2 sensor GasPostO2NotActive Post catalyst O2 sensor inactive on LPG open O2 sensor signal or heater leads defective O2 sensor GasCatlnactive None 1 TumOnMil 2 DisableGas O2Ctrl 3 Disable GasPost O2Ctrl 1 TurnOnMil 2 DisableGasPost O2Ctrl None Check that Pre catalyst O2 sensor connections are OK 2 signal Pin 3 to SECM Pin B13 O2 Pin 2 HEATER GND to SECM DRVG GNG Pins A16 B17 2 Pin 1 HEATER PWR to SECM DRVP 12V Pin A23 Verify O2 sensor heater circuit is operating by measuring heater resistance 2 10 0 40 2 Pin 2 HEATER GND to Pin 1 HEATER 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 2 Pin 1 HEATER PWR to Post O2 Heater Relay Relay pin 87 This relay only turns on after engine has been running for some time and SECM has calculated that water condensation in exhaust has been removed by exhaust heat Post O2 Heater Relay has SECM 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 N A GasO2FailedLe
102. an often be avoided by recognizing potentially hazardous situations before an accident occurs person must be alert to potential 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 proced
103. 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 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 Causes of Fork Failure Improper Modification or Repair Fork failure can occur as a result of a field modification 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
104. and the engine stops 2 Turn off the ignition switch 3 Scribe a line across the filter housing covers which will be used for alignment purposes when re installing the filter cover 1 screws 4 Remove the cover retaining screws 1 Fuel Filter LP Engine Only Disassembly 1 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 2 Replace the filter element 7 Check bottom cover O ring seal 6 for damage Replace if necessary Re assemble the filter assembly aligning the scribe lines on the top and bottom covers Install the cover retaining screws tightening the screws in an opposite sequence across the cover Open the fuel valve by slowly turning the valve counterclockwise Crank the engine several revolutions to open the fuel lock off NOT START THE ENGINE Turn the ignition key switch to the off position Check the filter housing fuel lines and fittings for leaks Repair as necessary Testing Fuel Lock off Operation LP Engine Only Start engine Locate the electrical connector for the fuel lock Disconnect the electrical connector The engine should run out of fuel and stop within a short period of time Turn the ignition key switch off and re connect 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 conve
105. are authorized for use Supplier Product Name TOTAL AZOLLAZS SHELL TELLUS MOBIL DTE20S CALTEX RANDO HD ESS NOTO H CASTROL HYSPIN AWS 142 Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities LUBRICANT VISCOSITIES FOR AMBIENT OUTSIDE TEMPERATURES Compartment F orSystem Viscosities Min Max Min Max G420F E SAE10W30 20 40 4 104 Engine un Crankcase Gasoline and LP m m API SJ G424F E Engine Crankcase Gasoline and LP 20 20 22 sove fe API SJ E Engine Crankcase Diesel API CH4 ACEA E5 Power Shift Transmission amp Drive Axle Housing API CD TO 2 Hydraulic and Power Steering System ISO 6743 4 HM Brake Reservoir Only for OCDB ISO 6743 4HM The SAE grade number indicates the viscosity of oil A proper SAE grade number should be selected according to ambient temperature 143 Refill Capacities REFILL CAPACITIES APPROXIMATE Compartment or System Liters U S Gal Engine Crankcase w Filter 4 2 1 11 G420F amp G420F E 2 0 liter Gasoline amp LP Engine Crankcase w Filter od amp G424F E 2 4 liter 1 19 Ec cM CREE 4TNV98 Diesel Engine Crankcase w Filter Cooling System w Coolant Recovery uus 85 225 G420F amp G420F E 2 0 liter Gasoline amp LP Cooling System w Coolant Recovery Bottle 2 38 G424F amp 424F E 2 4
106. 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 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 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 ho
107. arge the battery If the light turns on with the engine running check the alternator charging system for a malfunction Light The light will come 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 2 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 3 Diesel Engine Start Preheat Indicator 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 Indicator Light Indicates when the engine is running there is water in the fuel filter exceeds 100cc 4 Diesel Engine Water in Fuel Filter 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 with the engine running park the lift truck and stop the engine Drain some fuel and any water until clean fuel flows from the filter which approximately takes 5 to 6 seconds 5 Fuel Level Gauge Indicates fuel level Gas Diesel or Dual Fuel Trucks Only 6 Engine Coolant Temperature Gauge 9 Indicat
108. art and run the engine for 30 minutes 6 Stop the engine and drain the cleaning solution into a suitable container 7 Flush the system with clean water until draining water is clear 8 Close the drain valve and install the block drain plug Fill coolant to top of the filler neck 9 Start and run the engine to stabilize the coolant level See topic Coolant Level Check in Every 10 Service hours or Daily 198 Forks Inspect IAOMO941 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 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 Qualifications IAOMOSS 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 9
109. asket contacts the base tighten it 3 4 of a turn more Do not over tighten Raise the lift truck remove the blocking and lower the lift truck Fillthe crankcase See Refill Capacities Start the engine and allow the oil to fill the filter and passages Check for oil leaks 13 Stop the engine and measure the oil level Maintain the oil level to the FULL mark on the dip stick 14 Close hood and seat assembly 172 PCV Valve System Inspect Clean G420F E Gasoline LP and Dual Fuel Engines 1 Loosen the hose clamps and remove the PCV valve 2 Shake the PCV valve If it rattles reinstall it If it does not rattle replace it 3 Tighten the hose clamps Wheel Bolts amp Nuts Inspect Inspect Tightness D G Series Steer Wheels ILO1012P Typical Example 1 Inspect tightness of wheel bolts in a sequence opposite each other 110 Nem 75 Ib ft Drive Wheels ILO1013P Typical Example 2 Inspect tightness of wheel nuts in a sequence opposite each other to 610 Nem 450 Ib ft 173 Maintenance Section Inspect Tightness GC Series Drive Wheels ILOMO17P Typical Example 1 Inspect tightness of wheel bolts in a sequence opposite each other to 245 Nem 180 Ib ft Maintenance Section Governor Lever and Engine Speed Control Diesel Engine Only Check Adjust 4TNV98 Diesel Engine Only The governor lever and engine speed control
110. ast Abbreviations STD Standard Mast single inner member low free lift Full Free Lift Mast single inner member with high free lift duplex cylinder Triple Lift Mast two inner members with either low full free lift characteristics Quadruple Quad Mast with three inner members FF FFT QUAD NOTE When only a mast type is listed on the identification plate a standard carriage and forks are used Operation Section Operator s Station and Monitoring Systems Instrument Panel Your lift truck may not have the same indicator or warning lights as shown in the illustrations Due to the various options available typical instrument panels are shown However the symbols on the indicators and lights on your panel identify what those particular items are Also the symbol for each of the items is identified and an explanation of their function and location is described on the following pages Diesel 12V 63 Operation Section 1 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 f The light should go off after the engine is started indicating the alternator is producing sufficient voltage to ch
111. ast backward 1 Sideshift Left Push the lever FORWARD to shift the carriage to the left 2 Sideshift Hold When the lever is released it will return to the HOLD or center position Sideshifting action will stop 3 Sideshift Right Pull the lever BACK to shift the carriage to the right Refueling Gasoline or Diesel Engine Equipped A WARNING Explosive fumes be present during refueling Do not smoke in refueling areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to those indoors Stop the engine and get off the lift truck during refueling 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 71 Operation Section 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 2 Open the filter cap 3 Fill the
112. at step 2 5 If engine coolant is cold engine speed could be higher than normal low idle speed Don t drive forklift until engine speed becomes normal low idle speed 77 Operation Section Diesel Engine Starting a Cold Diesel Engine 1 Turn the key to the ON position The start pre heat light will come ON The preheat light will stay ON approximately seven seconds depending on the surrounding air temperature NOTICE Do not engage the starter for more than 10 seconds 2 When the preheat light goes OFF turn the key to the START position with the accelerator pedal pressed 3 Release the key when the engine starts and release the accelerator pedal to a low idle position 4 f the engine stalls or does not start turn the key to the OFF position then repeat steps 1 thru 3 Starting a Warm Diesel Engine 1 Turn the key to the ON position and then to START position without waiting for the preheat light to go OFF At the same time press the accelerator 2 Release the key when the engine starts and release the accelerator pedal to a low idle position Operation Section Starting From a 12 Volt External Source 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 NOTICE Do not reverse battery cables It can cause dam
113. ation of 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 Water Content Limits PPM Chlorides CI Sulfates SO Total hardness 80mg l Total solids 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 138 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 5096 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 Use a greater concentration above 50 of commercially available automotive antifreeze only as needed for anticipated outside ambient temperatures Do not exceed the recommendation
114. attachment to the floor shut OFF the engine remove the key chock the tires terminate the inspection tag the lift truck Do Not Operate and immediately report the failure of the parking brake to hold the lift truck 160 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 Filter Diesel Engine Only Change The engine oil in a new engine becomes contaminated from the initial break in of internal parts It is very important that the initial oil and filter change is performed as scheduled NOTE The oil drain plug may be in another location if an optional oil pan is used Drain the engine oil as follows 1 Make sure the engine is level 2 Start the engine and bring it up to operating temperature 3 Stop the engine 4 Remove one of the oil filler caps Figure 5 1 1 to vent the engine crankcase and allow the engine oil to drain more easily 5 Position a container under the engine to collect waste oll Figure 5 1 161 6 Remove the oil drain plug Figure 5 2 1 from the engine oil pan Allow oil to drain After all oil has been drained from the engine reinstall the oil drain plug Figure 5 2 1 and tighten to 139 8 47 0 ftelb 53 9 63 7 Nem 5 5 6 5 kgfem 8 Dispose of used oil properly
115. attery from all electrical circuits N The engine compartment is accessible by pulling the latch GC Series or pushing down the lever located at cowl G D Series and raising the hood and seat assembly Note Unlock latch before pulling if key equipped The hood and seat assembly is held up by a support cylinder Make certain the air cylinder is operating properly and securely hold the hood up before doing anything engine compartment Operation Section Seat Switch System If Equipped 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 IS NOT AUTOMATICALLY APPLIED 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 mac
116. 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 and 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 50 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 ILOS006P 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 wears 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 cor
117. ble for most temperatures Use NLGI No 1 or No 0 grade for extremely low temperature Transmission Oil NOTICE This oil is 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 in transmissions Multi grade oils which use high molecular weight polymers as 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 The API CD TO 2 specification or MIL L 2104D E or F oil could be used Oil Cooled Disc Brake Only Use heavy duty hydraulic brake fluid certified by oil supplier to meet the latest version of following classifications e ISO 6743 4 HM AFNOR 48 603 HM e DIN 51524 TEIL 2 H LP HAGGLUNDS DENISON HFO HF2 CINCINNATI P68 69 70 Viscosity ISO VG32 Brake reservoir 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 grade of 32 would normally be selected The following products
118. ck Inflation and Damage 154 Check Operation RR m 177 Checking Service 157 Checking the TMAP Sensor G420F E G424F E Engine Only uu uman 203 Circuit Breaker 68 150 Cleaning Primary Filter Elements 168 Coolant Information 137 Coolant Level 156 Coolant Water asas sassa 138 Cooling System Clean 197 Cooling System Specifications 137 Crankcase Breather System 4TNV98 Diesel Engine Only IDSB6GGL _ uu uuu uuu 193 Crosshead Rollers 177 Crushing or Cutting Prevention 14 Cylinder Rod Extension Adjust 177 D D G Series Lift Trucks 196 Daily Inspection 132 Diagnostics Features 119 Diesel Engine 77 Diesel Engines qm 155 Diesel Specifications 139 Direction Control Lever 69 Direction Inhibit Point
119. container empt Engine Cranking dd but Will Not Start Fill fuel container e Do not exceed 80 of liquid capacity Liquid valve closed Slowly open liquid valve Excess flow valve closed Reset excess flow valve e Close liquid valve e Waitfor 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 Clogged fuel filter Replace Fuse for SECM e See Maintenance Section Fuses replacement Repair replace as required e See Maintenance Section LP Fuel Filter replacement Faulty vapor connection between Check connection the pressure regulator converter and the mixer e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose Fuel Lock off malfunction Pressure malfunction Repair replace Fuel Lock off e See Engine Service Manual regulator converter Test pressure regulator converter operation e See Engine Service Manual Incorrect air fuel or ignition spark See Advanced Diagnostics control No VR Sensor Signal Verify the VR signal is present e See Advanced Diagnostics Operation Section Problem Probable Cause Corrective Action Fuel container almost empt
120. cs 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 conditions 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 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 a 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 b
121. cting the Fuel Pump connector and measuring the resistance 26Q 3Q Check for 12V to fuel pump Check fuel lock off valve for an open wire or connector being disconnected or signal shorted to GND Lock off Pin B signal from SECM Pin A11 Lock off Pin A power from main relay 1 Pin A23 Check lock off valve for an open coil by disconnecting the lock off valve connector and measuring the resistance 260 3Q Check for 12V to lock off valve LSDFault_MIL Malfunction Indicator Lamp Fault signal has opened or shorted to ground or power or defective MIL lamp GasFuelAdaptRangeLo In LPG mode system had to adapt rich more than expected GasDesEquivLo In LPG mode system had to adapt rich more than expected Fault actions shown are default values specified by the OEM 1 TurnOnMil 2 Disable GasO2 Ctrl 3 Disable GasPost O2Ctrl 112 None Check for vacuum leaks Check fuel trim valves e g leaking valve or hose Check for missing orifice s Table 2 Diagnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION Operation Section CORRECTIVE ACTION FIRST CHECK GasFuelAdaptRangeHi In LPG mode system had to adapt lean more than expected 1 TumOnMil 2 Disable GasO2 Ctrl 3 Disable GasPost O2Ctrl Check dual dither valves e g plugged valve or hose Check for plugged orifice s GasDesEquivHi In LPG mode system had to adapt rich more th
122. d lift chains for wear broken links pins and loose rollers 3 Inspect the hydraulic system for leaks worn hoses or damaged lines 4 Look for transmission and drive axle leaks on the lift truck and on the ground 5 Inspect the operators compartment for loose items and cleanliness 6 Inspect the instrument panel for broken gauges and indicator lights 7 Test the horn and other safety devices for proper operation Maintenance Section 8 Inspect the cooling system for leaks worn hoses and debris buildup 9 Inspect engine compartment for oil coolant and fuel leaks 10 Inspect the forks e Visually inspect forks for cracks especially in the heel section around the mounting brackets and all weld areas e Inspect for broken or jagged fork tips bent or twisted blades and shanks e 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 e Remove all defective forks from service 158 Mast Channels Lubricate ILOMO19P A 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 WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 1 Start
123. diaphragm opens a passage that allows crankcase fumes to be routed to the intake manifold To inspect the diaphragm and spring Figure5 19 3 1 Remove the bolts retaining the diaphragm cover Figure5 19 4 193 Maintenance Section Figure5 19 2 Remove the diaphragm cover spring diaphragm plate Figure5 19 5 diaphragm 3 Inspect the diaphragm for tears Inspect the spring for distortion Replace components if necessary 4 Reinstall the diaphragm diaphragm plate spring and diaphragm cover Tighten the diaphragm bolts to specified torque Failure of the diaphragm and or spring will cause the loss of pressure control and allow an excessive amount of crankcase fumes to be routed to the intake manifold This could result in excessive deposits in the intake system high engine exhaust smoke levels excessive engine oil consumption and or engine run on due to the burning of the engine oil Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Engine Valve Lash Diesel Engine Only Check Adjust See topic Engine valve Lash Diesel Engine Only Check Adjust In First 250 Service hours 194 Steer Wheel Bearings Reassemble Park the lift truck level with the forks lowered parking brake engaged
124. djust 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 IC100086 19 Safety Section Seat Belt The Operator Restraint System Prevents the operator from jumping from the operators compartment in the event of a forward or side tipover The system is designed to keep the operator on the seat and in the operators compartment in the event of a tipover Inspection INSQUATS 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 16900009 2 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 the 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 rea
125. e spark module TurnOnMIil Check coil driver wiring and connector for open circuit SECM Pin A6 ESTA to OEM ignition system See application manual Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details EST5 Open EST5 output open possibly open EST5 signal or defective spark module EST6 Open EST6 output open possibly open 5 6 signal or defective spark module EST7 Open EST7 output open possibly open EST7 signal or defective spark module EST8 Open 5 8 output open possibly ue open ESTS signal or defective Nong spark module EST1_Short EST1 output shorted high or 431 low EST1 signal shorted to None N A ground or power or defective spark module Fault actions shown are default values specified by the OEM 106 Table 2 Diagnostic Fault Codes Flash Codes cont d DFC 432 PROBABLE FAULT EST2 Short EST2 output shorted high or low EST2 signal shorted to ground or power or defective spark module FAULT ACTION None Operation Section CORRECTIVE ACTION FIRST CHECK N A 433 EST3 Short 5 output shorted high or low EST3 signal shorted to ground or power or defective spark module None N A 434 435 EST4 Short EST4 output shorted high or low EST4 signal shorted to ground or power or defective
126. e Wheel Reassemble ILOMO37I Consult your DOOSAN lift truck dealer for the proper wheel bearing reassembling procedure Packing of bearings and adjustment procedure must be made by a trained mechanic or dealer personnel Pack power shaft bearings 1 and spindle bearings 2 Pack ring gear 3 to the depth of the teeth D G Series Lift Trucks ILOMO3B8I Torque for single or dual wheel mounting nuts 1 is 644 34 Nem 470 x 25 Ib ft Torque for adapter assembly bolts 2 is 285 13 Nem 210 10 Ib ft Tighten wheel bearing nut 3 to 135 Nem 100 Ib ft while the wheel is turned in both directions Loosen the nut completely and tighten nut again to 50 5 Nem 37 4 Ib ft Bend the lock washer tab into a groove of the nut Torque for bolts 4 that hold cover to drive axle housing is 55 10 Nem 40 7 Ib ft Apply Loctite No 242 to threads of spindle bolts 5 Torque for spindle bolts is 115 14 Nem 85 10 Ib ft 196 GC Series Lift Trucks ILOMO389I Torque for wheel bolts 1 is 270 25 Nem 200 20 Ib ft Tighten wheel bearing nut 2 135 Nem 100 Ib ft while the wheel is turned in both directions Loosen the nut completely and tighten nut again to 50 5 Nem 37 4 Ib ft Bend the lock washer tab into groove of the nut Torque for bolts 3 that hold cover to drive axle housing is 55 10 Nem 40 7 Ib ft Apply Loctite No 242 to threads of spindle bolts 4 Torqu
127. e 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 1 Malfunction Indicator Lamp MIL for Engine control system 99 Operation Section 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 Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK NONE Signifies the end of one pass through the fault list Inj1Open Gasoline Injector 1 open circuit broken injector 1 wire or defective injector NONE 1 TurnOnMil 2 Disable LiquidO2Ctrl 3 Delayed EngineShutdown None used as end of the fault list identification Check INJ1 wiring for an open circuit SECM Signal A5 to Injector 1 Pin A Switched 12V to Injector 1 Pin B Check Injecto
128. e details Tighten all connections to the recommended torque Replace if any of the following conditions are found 16 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 or 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 IlAOYO12I Do not approach a warm tire closer than the outside 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 ti
129. e engine running but without an operator can move slowly creep if the transmission is engaged This could result in personal injury Always place the transmission control lever in the NEUTRAL center position and apply the parking brake before dismounting the lift truck 5 Release the service brake 6 Push down on the accelerator pedal to obtain the desired travel speed Release the pedal to decrease travel speed WARNING Sudden reversal of a loaded lift truck traveling forward can cause the load to fall 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 NOTE Where conditions permit directional changes can be made under full power at speeds up to 6 km h 3 73 mph A speed of 6 km h 3 73 mph is a fast walk Directional shift changes at speeds above 6 km h 3 73 mph are considered abusive Bring the lift truck to a complete stop where load stability or other factors prevent safe operation under full power shifts Operation Section Inching 7 To change the lift truck direction of travel release the accelerator pedal NOTE The purpose of the inching pedal is to 8 Push down on the service brake pedal to provide precise lift truck inching control at reduce the lift truck speed as necessary very slow travel speed and high engine rpm This is used for fast hydraulic lift during load approach pick up o
130. e for spindle bolts is 115 14 Nem 85 10 lbeft Cooling System Clean Change WARNING At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly to relieve pressure Coolant is included antifreeze for forbidding corrosion Avoid contact with the skin and eyes to prevent personal injury Use all cleaning solution with care The Lift truck must be level the forks lowered the parking brake engaged the transmission in NEUTRAL and the engine stopped and cool 1 Turn the radiator cap slowly to relieve the pressure and then remove the cap 2 Remove the drain plug or water hose on engine block 4 98 3 3L Diesel Engine 197 Maintenance Section G424F E 2 4L LPG Gasoline Engine 3 Open the radiator drain valve Allow the coolant to drain into a suitable container Drain the recovery bottle Maintenance Section NOTICE Hold the drain port when the radiator drain valve is turned because the tank and the drain port are separated 4 After draining the coolant completely close the radiator drain valve and the block drain plug fill the engine and the radiator full with a radiator cleaner and clean the engine and the radiator 5 St
131. e regulator malfunction Test pressure regulator operation e Engine Service Manual Clogged fuel filter Repair replace as required e See Maintenance section Primary and Secondary Fuel Filter replacement Pressure regulator malfunction Test pressure regulator operation e Engine Service Manual Fuel Injector malfunction Test Injector operation e See Engine Service Manual Vacuum leak 96 Check for vacuum leaks e Between mixer and throttle body e Between throttle body intake manifold e Between intake manifold and cylinder head Operation Section Problem Rough Idle Gas High Idle Speed Gas Probable Cause Incorrect Idle speed control Incorrect timing or spark control Engine Mechanical Incorrect Idle speed control Throttle sticking Foot pedal pedal signal sticking or incorrect 97 Corrective Action See Advanced Diagnostics amp Engine Service Manual See Engine Service Manual See Advanced Diagnostics amp Engine Service Manual Check pedal return spring travel for binding See Advanced Diagnostics Operation Section Problem Poor High Speed Performance Gas Probable Cause Isolate the gasoline system by running the lift truck on LPG Corrective Action Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the
132. e tension from the lift chains 2 Loosen nut 3 and adjust nut 4 to make inner mast rail flush with outer mast rail bottom 3 Make adjustment anchor nuts 3 4 for equal chain tension 4 Raise the inner mast 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 3 4 after the adjustment is completed Maintenance Section Universal Joint Inspect ILO1051P Check for worn or damaged bearings Have worn or damaged bearings replaced Check for loose retaining bolts and nuts Tighten the bolts and nuts if necessary 188 Air Intake System Change Changing Primary Element See topic Air Intake System Check Clean in Every 250 Service Hours or Monthly Changing Secondary Element 1 Remove the primary air cleaner element See topic Servicing Filter Element Clean the inside of the air cleaner housing and cover Q IB1O4008 te Remove the secondary element Inspect the gasket between the air cleaner housing and the engine inlet Replace the gasket if it is damaged NOTICE Always replace the secondary element Do not attempt to reuse it by cleaning 3 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
133. ee topic Refill Capacities Install the dipstick filter assembly 4 Start the engine and operate the hydraulic controls and the steering system through a few cycles to fill the lines Look for oil leaks 5 Stop the engine and check the oil level With all cylinders retracted maintain the oil level to the FULL mark on the dipstick filter cap assembly 201 Maintenance Section Replace Oxygen Sensor G420F E G424F E Engine Only G420F E Engine When indicated by MIL replace oxygen seasor on the exhaust manifold and oxygen sensor on muffler assembly 1 Stop engine and wait until the exhaust pipe and exhaust pipe is cooled Disconnect the electrical connector of oxygen sensor Remove oxygen sensor 202 4 Assemble new oxygen sensor Tightening torque 45 Nem 32 5 Ib ft 5 Connect the electrical connector of oxygen sensor A WARNING When assembling the filters check the arrow mark on the filter surface The arrow mark position is same as fuel flow direction Replace Spark Plugs G420F E Engine Only Disconnect Battery Cables N Remove the ignition wiring harness Remove the ignition coil assy Remove spark plugs o Gap the new spark plugs to the proper specifications G420F E Engine 0 7 0 8 mm o Apply anti seize compound to the spark plug threads and install G420F E Engine 25 Nem 18 Ib ft A WARNING DO NOT OVERTI
134. efore operating to prevent an unexpected seat change 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 68 Tilt Steering Column the the To adjust the steering column push down knob 1 and move the steering column to desired position then release the knob 1 Fuel Selector Switch G420F E G424F E Dual Fuel Only 1 LPG This position supplies electrical power to the LP fuelock solenoid when the ignition switch is in the ON or the START position With the LP fuel tank valve open LP can then flow the tank through the converter to the carburetor C 2 OFF This position shuts off all fuel supply to the carburetor injector 3 GAS This position supplies electrical power to gasoline fuel pump and injector This will allow gasoline fuel to flow from the tank through the fuel filter and fuel pump to the injector 9 Lift Truck Controls 1 Forward Push the lever forward for FORWARD direction travel 2 Neutral Move the lever to center position for NEUTRAL 3 Reverse Pull the lever back for REVERSE direction travel Transmission Inching Control Pedal 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 clutc
135. en 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 load 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 Be sure operating surface can safely support machine 11 Operate machine and attachments only from operator s position 12 Do not handle unstable or loosely stacked loads 13 Use minimum tilt when picking up or depositing a load 14 Use extreme care when handling long high or wide loads 15 Forks should be completely under load and spread apart as far as load permits 16 Machine should be equipped with overhead guard or equivalent protection Where load requires it use a load backrest extension Use extreme caution if operating without these devices 17 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 18 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 bef
136. eneral torques for bolts nuts and taperlock studs of SAE Grade 5 or better quality Torques for Bolts and Nuts with Standard Threads Thread Size Standard Nut and Bolt Torque 9 3 18 5 45 7 33 5 70 15 50 11 100 15 75 11 150 20 110 15 150 18 2 0 37 420 60 640 75 820 110 1000 130 1180 150 1480 200 4 Newton meter is approximately the same as 0 1 kg m Maintenance Section Torques for Taperlock Studs mr 8 3 652 17 5 35 5 45 10 65 10 110 20 170 30 260 40 400 60 500 700 650 80 6 2 750 90 870 100 14 Newton meter is approximately the same as 0 1 kgem Torque 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 136 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 This chart gives standard torques for bolts and nuts with Grade 8 8 NOTE Metric hardware must be replaced with metric hardware Check parts book Thread Size Metric M6 Standard Torque 12 4 25 xy
137. er the first 50 hours 162 Transmission Oil Oil Filter amp Strainer 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 brake engaged direction control lever in NEUTRAL and the engine stopped ILOM034P 1 Remove drain plug 1 Allow the oil to drain into a suitable container Clean the magnetic drain plug Check O ring seal and replace if necessary Remove the spring and the strainer am i a Wash the strainer assembly clean nonflammable solvent and dry it Install the strainer assembly Maintenance Section 12 Maintain the oil level between the Min and Max marks on the dip stick filter cap When the oil temperature is 40 approximately the cold side mark on the dipstick is applicable When the oil temperature is 80 approximately the hot side mark on the dipstick is applicable 13 Check for oil leaks at the filters and drain plug 14 Stop the engine Install the floor mat and floor ES plate ILO1045P 3 Remove the floor mat and the floor plate Remove and discard the oil filter 4 Wipe off the filter base Make certain that all of the old seal is removed 5 Apply a small amount of clean oil on the seal of the new filter 6 Install the filter by hand When the filter contacts the base tighten an additional 3 4 turn
138. er and bowl in water Servicing Filter Element NOTICE Never service filter with the engine running Service the air cleaner when the red target in the service indicator stays locked in the visible position with the engine stopped 167 1 To service the air cleaner raise the hood and seat assembly Make certain the support cylinder securely holds the hood open Loosen the cover latches and remove the cover 101007 21 Rotate the element slightly to separate it from its base and remove it from the air cleaner housing Clean and inspect the element or replace with a new element See topic Cleaning Primary Filter Element 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 necessary to prevent leakage NOTICE Do not allow dirty air to enter the intake hose when cleaning the inside of the air cleaner housing Check the air cleaner housing for loose latches Reset the air cleaner service indicator Install the air filter element Install the cover and tighten the cover latches 2 Start the engine 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 1
139. erator s Seat Engine ON PARKING BRAKE SWITCH 1 With the parking brake engaged the direction control lever in NEUTRAL and the engine running shift the direction control lever to FORWARD The lift truck should not move forward or feel like it wants to move forward even when the engine is accelerated briefly Repeat this procedure in REVERSE Report truck movement or tendency to move under power with the parking brake engaged Maintenance Section PARKING BRAKE NOTE The parking brake is required to be adjusted to hold the lift truck with capacity load on a 15 grade If there is a 15 grade in your workplace engage a capacity load and drive over to the grade If the maximum grade in your workplace is less than 15 or if the maximum load carried by the lift truck is less than the lift truck s load capacity pick up the maximum load and drive to the steepest grade in your workplace 1 Raise the forks or load engaging attachment about 30 cm 12 in from the floor 2 Drive forward up the grade or in reverse down the grade and stop the lift truck with the service brakes 3 Engage the parking brake and release the service brakes 4 If the lift truck moves down the grade control its speed with the service brakes release the parking brake and return directly to the inspection area 5 Park the lift truck engage the parking brake shift the direction control lever to NEUTRAL lower the forks or load engaging
140. ermined by OEM ServiceFault2 Service Interval 2 has been reached ServiceFault3 Service Interval 3 has been reached None Perform service procedure related to Service Interval 2 determined by OEM Perform service procedure related to Service Interval 3 determined by OEM ServiceFault4 Service Interval 4 has been reached replace HEGO sensors ServiceFault5 Service Interval 5 has been reached replace timing belt TumOnMil 116 Replace Pre catalyst HEGO sensor Replace Post catalyst HEGO sensor TurnOnMil Replace engine timing belt Fault actions shown are default values specified by the OEM Operation Section Mono Ped Control System Option Forward Push the left side 2 of the pedal for FORWARD direction travel Neutral The lift truck should not move when the Mono Ped pedal is released Reverse Push the right side 1 of the pedal a for REVERSE direction travel The MONO PED pedal controls the speed and direction of the lift truck Pushing on the right side of the pedal 1 causes the lift truck to move in REVERSE The optional reverse lights and optional back up alarm will be ON in the REVERSE position Pushing on the left side of the pedal 2 causes the lift truck to move in FORWARD The speed of the truck increases as the pedal is depressed 117 Operation Section Auto Shift Controller ASC 100 If Equipped Product Description The Autoshift controller is
141. es 9 Look for transmission and drive axle leaks on the truck and on the ground 10 Inspect the engine compartment for oil coolant and fuel leaks 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 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 75 Operation Section 13 Observe the fuel level gauge after starting the truck Add fuel if necessary WARNING Personal injury may occur from accidents caused by improper seat adjustment Always adjust the operator s seat before starting the lift truck engine Seat adjustment must be done at the beginning of each shift and when operators change 14 To position the seat PUSH the lever away from the seat track and move the seat forward or backward to a comfortable position Operation Section Starting the Engine Prestart Conditions NOTE The engine will not start unless the transmission directional control lever is in the NEUTRAL position 1 Engage the parking brake if not already engaged Place the transmission directional control lever in the NEUTRAL position 2 Lift trucks equipped with electrical disconnect switches the engine will not start unless
142. es coolant temperature If both tenth amp ninth flash out of phase while operating the lift truck overheating is indicated Park the lift truck and stop the engine Check the cooling system for a malfunction Both tenth amp ninth will flash out of phase when the coolant temperature reaches approximately 106 C 223 F on all engines 64 7 Transmission Oil Temperature Gauge Indicates transmission oil temperature If both tenth amp ninth flash out of phase while operating the lift truck excessive transmission oil temperature is indicated Park the lift truck and stop the engine 8 G420F E G424F E Malfunction Indicator Lamp MIL G420F E and G424F E engine control systems are equipped with built in fault diagnostics Deteted 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 module ECM Once a fault occurs the MIL will illuminate and remain ON This signals the operator that a faults has been detected by the SECM Engine 9 Seat Equipment Indicates when the seat belt dose not fastened by operator The light will come on when the ignition switch is turned to the o
143. esita proceed with the corrective action steps tion During below Acceleration If the problem also exists LPG mode then Engine Stalls the root cause is most likely to be Gas something other than the fuel system e See Advanced Diagnostics Fuel tank almost empty Fuel Pump Cavitations e The tank should be at least 1 4 full to properly prime the fuel pump Clogged fuel filter Repair replace as required e See Maintenance section Primary and Secondary Fuel Filter replacement Pressure regulator malfunction Fuel Injector malfunction 95 Test pressure regulator operation e Engine Service Manual Test Injector operation Operation Section Problem Will Not Accelerate Hesita tion During Acceleration or Engine Stalls Gas Rough Idle Gas Probable Cause Throttle butterfly valve not opening or sticking Foot Pedal signal incorrect or intermittent Incorrect air fuel or ignition control Engine Mechanical Isolate the gasoline system by running the lift truck on LPG Corrective Action See Advanced Diagnostics See Engine Service Manual Verify LPG oylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in LPG mode then the root cause is most likely to something other than the fuel system e Advanced Diagnostics amp Service Manual Pressur
144. for Fluid Leaks 155 Inspect Foot Pedal Operation G420F E G424F E t 157 Inspect for Intake Leaks G420F E G424F E Engine Only 203 Inspect Ignition System LP Gasoline amp Dual Fuel Engines Only 191 Inspect Mixer Assembly G420F E G424F E Engine Only u uy 189 Inspect Throttle Assembly G420F E G424F E E giNe 189 Inspect Tightness D G Series 173 Inspect Tightness GC Series 173 Inspect Vacuum Lines and Fittings G420F E G424F E Engine Only 181 Inspection from Operator s Seat Engine OFF 159 Inspection from Operator s Seat Engine ON 159 Inspection Maintenance and Repair of Lift Truck FOKS NR 130 Instrument Panel 63 L Lift Chain Adjustment 186 Lift Chain Wear Test 186 Lift Chains Test Check Adjust 186 206 70 Lift Fork Adjustment 126 Lift Truck Controls 69 Lift Truck Operation 82 Lift Truck 13 Lift Truck
145. for Taperlock Studs 136 Towing Information 129 Traing Required Operate Service Warning 5 Transmission Inching Control Pedal 69 Transmission Oil Filter Change 178 Transmission Oil Level Check 159 Transmission MM 142 Transmission Oil Oil Filter amp Strainer Check Clean Change 162 186 Transportation Hints 128 Traveling With the 122 123 U Universal Joint Inspect 188 122 Walk Around Inspection Inspect 157 Walk Around Inspection 74 Warning Signs and Labels 17 Warning Signs and 5 Water Separator 4TNV98 Diesel Engine Only i D 184 Water Seperator Diesel Engine Only Check T 152 Wheel Bolts amp Nuts Inspect 173 When Required 148 208
146. from liquid outlet e Fill fuel container e Donot exceed 80 of liquid capacity Excess flow valve closed Clogged fuel filter Plugged fuel line Reset excess flow valve e Close liquid valve e Wait for a click sound Slowly open liquid valve Repair replace as required e See Maintenance Section LP Fuel Filter replacement Remove obstruction from the fuel line Close liquid fuel valve e Using caution disconnect the fuel line Some propane may escape e Clear obstruction with compressed air Re connect fuel line e Slowly open liquid fuel valve amp Leak test Pressure regulator freezes Fuel Lock off malfunction 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 Repair replace Fuel Lock off e See Engine Service Manual Incorrect problem idle speed or ignition See Advanced Diagnostics Engine Mechanical See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet e Fill fuel container e Donot exceed 80 of liquid capacity Excess flow valve closed 88 Reset excess flow valve e Close liquid valve e Wait for a click sound Slowly open liquid valve Operation Section Problem Will Not Accelerate Hesita tion During Acceleration Engine Stalls Probable Cause Clogged fuel filter Correc
147. fuel tank slowly Close the filter cap If spillage occurs wipe off excess fuel and was down area with water 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 This will help prevent water or sediment being pumped from the storage tank into the lift truck fuel tank Operation Section Changing LP Tanks WARNING Only trained authorized personnel should fill or exchange LP tanks Personnel engaged in filling of LP containers should wear protective clothing such as face shield long sleeves and gauntlet gloves Do not refuel or store LP powered lift trucks near any underground entrance elevator shafts or any other place where LP could collect in a pocket causing a potentially dangerous condition 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 be present during refueling Do not smoke in refueling areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to 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 transpor
148. g Service Indicator 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 Close hood and seat assembly Inspect Foot Pedal Operation G420F E G424F E Only 1 Verify foot pedal travel is smooth without sticking WARNING When the acceleration pedal harness 15 connected or disconnected should be worked key OFF condition If not occured malfunction can cause the personal injury Inspect Engine for Exhaust Leaks 1 Start the engine and allow it to reach operating temperatures Perform visual inspection of exhaust system Repair any all leaks found 157 Maintenance Section 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 1 Inspect the tires and wheels for cuts gouges foreign objects inflation pressure and loose or missing bolts 2 Inspect the mast an
149. ge 185 0 Inching amp Braking Control Shaft_ Lubricate 180 Jo inspectBattery System 20 Pr L jo Inspect Coolant Hoses LP Dual Fuel Engine Only 389 0 Inspect Electrical System G420F EVG424F E Engine Ony L 381 10 j InpectEngmeforExhaustLeaks 1 P P P L j Inspect Engine for Fluid Leaks ts P jo y Inspect Foot Pedal Operation G420F EVG424F E Only L 3 P lo j Inspect for Intake Leaks G420F EVG424F E Engine Only 1 j P P P lol 50 100 Service Hours or a Week o Ren gt a o gt o 2 o o e x gt c o g 2 42 e t cl o gt x oj e 3 2 2 I o g 2 0 olo olo i x gt c o o e o RS e D A c o e gt o When Required b 2000 Service Hours or a Yearly SES ERRATA 2500 Service Hours or15 Months d 3000 Service Hours or18 Months 146 Maintenance Section Quick Reference to Maintenance Schedule Reference to Maintenance Schedule FIRST ITEMS SERVICES Inspect Ignition System LP Gasoline amp Dual Fuel Engines pf
150. ge height is correct If correct adjust the chain for equal tension If not adjust the chain for correct carriage height by adjusting anchor nuts 1 2 NOTE See the previous section Carriage Roller Extrusion in When Required for proper height of carriage 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 Loosen nut 1 and adjust nut 2 to get proper distance from bottom of inner upright to the bottom of carriage bearing IABO4083 IB20642P Typical example for carriage chain of FF FFT mast 3 Make adjustment anchor nut 1 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 1 2 after the adjustment is completed Maintenance Section Mast Chain Adjustment FF FFT Mast Typical example for FF mast 1820644P Typical example for 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 3 4 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 th
151. h 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 Operation Section Service Brake Pedal 4 RELEASE the brake pedal to allow the lift truck to move Push DOWN on the brake pedal to slow or stop the lift truck Accelerator Pedal Push DOWN on the pedal to increase engine rpm speed RELEASE the pedal to decrease engine rpm speed Operation Section Parking Brake Lever I Pull the lever BACK to engage the parking brake Push the lever FORWARD to release the parking brake To prevent a sudden change of position of the load operate all lift tilt and attachment controls smoothly 1 Lower Position Push the lever FORWARD smoothly to lower the load 2 Hold Position When the lever is released it will return to the HOLD or center position Lifting or lowering action will stop 3 Lift Position Pull the lever BACK smoothly to lift the load 70 Tilt Control 1 Mast Tilt Forward Push the lever FORWARD smoothly to tilt the mast forward 2 Mast Hold When the lever is released it will return to the HOLD or center position Tilting action will stop 3 Mast Tilt Back Pull the lever BACK smoothly to tilt the m
152. he 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 monoxide can cause serious injury or health problems including death and avoid unnecessary Exhaust from all combustion engines idling of the engine If nausea dizziness or headaches are experienced stop the truck and seek fresh air Safety Section How to Survive in a Tipover WARNING In the event of a tipover the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided ed 5 IM CASE OF TIFOVER 41 FASTEN SEAT BELT Always use operator restraint system ese IRIE OF TIPOVER CASE TIPOVER DON T JUMP Don t jump HOLD ON TIGHT Hold on tight IN CABE OF TIPOVER BRACE FEET Brace your feet and keep them within the operators compartment SARA IN CASE OF TIPOVER LEAN AWAY Lean away from the direction of fall m d AS iN CASE OF TIPOVER LEAN FORWARD Lean forward 29 Safety Section General Section
153. hine 67 NOTICE lift truck be sure to Prior to operating the the SEAT SWITCH understand and check SYSTEM While in normal operation and on level ground select a direction with the derectional lever and with the park brake released You will note that the truck will move slowly 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 truck to coast but not automatically stop To restore the lift truck to normal operation while sitting in the operators 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 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 Operation Section A WARNING When closing the engine hood be careful not to pinch your hand Circuit Breaker Circuit Breaker Protects the main electrical circuits To reset the circuit breaker push the button in Located in the engine compartment e Seat NOTE Seatarrangements 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 b
154. his lift truck at all times 26 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 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 will 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 27 Park your lift truck in authorized areas only Fully lower the forks to t
155. hut off the LP fuel tank Block the wheels and secure the lift truck with tiedowns 128 Machine Lifting and Tiedown Information NOTICE Improper lifting or tiedowns can allow load to shift and cause injury and or damage 1 Weight and instructions given herein apply to lift trucks as manufactured by DOOSAN 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 Towing Information 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 haul 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 D
156. ide load IKOO0381 is Tilt the 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 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 13 Safety Section Loading or Unloading Trucks Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose Be certain truck or trailer brakes are applied and wheel chocks in place or be certain unit is locked to the loading dock before entering ont
157. ified by the National Lubricating Grease Institute NLGI based on ASTM D217 68 Worked Penetration characteristics which are given a defined consistency number Engine Oil DEO and EO The following oil specifications provide guidelines for the selection of commercial products e Gasoline LP Engine API SJ or higher e Diesel Engine CH4 ACEA E5 NOTICE Failure to follow the oil recommendations can cause shortened engine lift 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 blow by engine operating conditions and ambient temperature Maintenance Section Hydraulic Oil HYDO The following commercial classifications can be used in the hydraulic system e 150 6743 4 48 603 e DIN 51524 TEIL 2 H LP e HAGGLUNDS DENISON HFO HF2 e 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 I
158. ift truck 1 Release the parking brake NOTICE Release the parking brake to prevent excessive wear and damage to the parking brake system Check that the service brake pedal is released Key switch is in the OFF position Direction control lever is in neutral Fasten the tow bar to the lift truck Ue XO uM Remove the wheel blocks Tow the lift truck slowly Do not tow any faster than 2 km h 1 2 mph WARNING sure all necessary repairs 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 repair 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 k
159. ift truck is shown on the capacity nameplate riveted to the truck lt 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 22 Remember that unless otherwise indicated the capacity load shown on the nameplate is for 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 f the load is not uniform the heaviest portion should be placed closer to the 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 DOOSAN assumes no responsibility for lift trucks placed in service without a valid DOOSAN Nameplate If necessary to change your specification contact your DOOSAN lift tr
160. igure5 16 5 to the left Figure5 16 10 and remove the cup Figure5 16 6 If equipped disconnect the sensor wire Figure5 16 7 from the cup before removing the cup Carefully hold the cup to prevent fuel from spilling If you spill any fuel clean up the spill completely 184 10 11 12 13 14 15 Remove the float ring Figure5 16 8 from the cup Pour the contaminants into the container and dispose of it properly Clean the element Figure5 16 9 and inside cup Replace the element if it is damaged Install the element and O ring in the bracket Position the float ring in the cup Check the condition of the cup O ring Replace if necessary Install the cup to the bracket by tightening the retaining ring to the right Figure5 16 6 to a torque of 11 15 ftelb 15 20 Nem 1 5 2 0kgf m Close the drain cock Reconnect the sensor wire if equipped Open the fuel cock Figure5 16 3 Prime the fuel system See topic Priming the Fuel System in When required Check for leaks Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Hydraulic Return Filter Breather amp Strainer Check Change A WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contac
161. ing corresponding link it should be suspected of being broken inside of its link hole Lift chains are required to check for wear 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 IB2O639P Typical example 2 Measure precisely ten links of chain distance at the center of pins in millimeter 3 Calculate chain wear 4 lf the chain wears rate is 2 or more replace the lift chain Chain wear rate 96 C u s Pitch X 10 Chain Pitch 19 05mm 0 75in x 100 186 Check for Equal Tension Lift the carriage 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 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 IB20641F 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 Make sure that carria
162. ion GC33E 5 GC33P 5 STD FFL WIDE TIRE A 2030 3950mm MAST 4350mm 5 C 4960mm MAST A 3900mm MFH MAST B 4290mm MAST C 4730mm MFH MAST D 5560mm MFH MAST E 6010mm MFH MAST 54 Capacity Chart With Sideshifter cushion MODEL GC20E 5 GC20P 5 STD FFL nonce BsBHEBSEE A 2030 3950mm MAST B 4350mm MAST C 4960mm MAST NARROW TIRE soc z A 3900mm MAST B 4290 MAST C 4730mm MAST D 5560mm MFH MAST E 6010mm MFH MAST General Section Te N O LO N o GC30E 5 GC30P 5 2030 3950mm MAST B 4350mm MAST C 4960mm MAST BEBHEZBH 2030 3850mm MAST B 4350mm MAST C 4960mm MAST 55 3900mm MFH MAST 4290mm MAST C 4730mm MAST D 5560mm MFH MAST E 8010mm MAST 3900mm MAST B 4290mm MAST C 4750 MAST D 5560mm MAST E 6010mm MAST General Section Capacity Chart With Sideshifter cushion MODEL GC33E 5 GC33P 5 STD FFL B 4350mm MAST C 4960mm MAST A 2030 3950 MFH MAST NARROW TIRE 3900mm MFH MAST 4290mm MAST C 4730mm MAST D 5560mm MAST E 6010mm MAST 56
163. ipe up any spills and properly dispose of fuel 6 NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear To prime the fuel system on engines not equipped with an electric fuel system 1 Place an approved container under the air bleed port 2 Loosen the air bleed port Figure 2 1 2 or 3 turns 3 Operate the fuel priming pump Figure 2 2 until the fuel coming out of the air bleed port is free of bubbles 4 Tighten the air bleed port 5 Wipe up any spills and properly dispose of fuel 6 NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear 151 Maintenance Section Water Seperator Diesel Engine Only Check Drain 4TNV98 Diesel Engine Only Drain the fuel filter water separator whenever there are contaminants such as water collected in the bottom of the cup NEVER wait until the scheduled periodic maintenance if contaminants are discovered The cup of the separator is made from semi transparent material In the cup is a red colored float ring The float ring will rise to the surface of the water to show how much needs to be drained Also some optional fuel filter water separators are equipped with a sensor to detect the amount of contaminants Th
164. ire supplier NOTE Fill tires to the recommended pressures listed 35 kPa 5 psi Tires can be filled with nitrogen Tire Inflation Pressures Adjustment Tire inflation in a warm shop area 18 to 21 C 65 to 70 F will be underinflated if the machine works in freezing temperatures Low pressure shortens the life of a tire Torque Specifications Metric Hardware Most of the nuts bolts studs and threaded holes in your lift truck are metric In this manual we provide specifications in both metric and U S customary measurement Always replace metric hardware with metric hardware See the parts books for proper replacement NOTE For proper fit use only metric tools on metric hardware Non metric tools might slip and cause injury Torque for Standard Hose Clamps Worm Drive NOTICE The chart below 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 7 5 0 5 13 5 mm 531 in 4 5 0 5 8 mm 312 in 0 9 02 8 2 Reassembly or Retightening Clamp Width Torque On Existing Hose 16 mm 625 4 5 0 5 13 5 mm 531 3 0 0 5 8mm 312in 0 7 02 14 Newton meter Nem is approximately the same as 0 1 kgem Maintenance Section Torque for Standard Bolts Nuts and Taperlock Studs NOTICE The two charts below give g
165. irection Inhibit mode e Start the engine See topic Starting the engine e Push down on the service brake pedal to hold the lift truck until ready to move it e Release the parking brake e Check diagnostics display on controller See Diagnostics Features NOTICE The parking brake must be released before the direction control lever can be used e The gear direction is selected with the direction control lever In automatic mode if the turbine speed in a for ward direction is higher than direction inhibit speed though the reverse gear is selected by operator the direction of travel will not be changed until the speed is reduced sufficiently by pushing down on the service brake pedal A WARNING When you want to change the direction of travel you must push down on the service brake pedal to reduce the travel speed In automatic mode the lift truck s stopping distance may be longer than in manual mode BE CAUTIOUS e When the directional change is completed continue to push down on the accelerator pedal to obtain the desired travel speed Operation Section Manual Mode Fail Safe mode The system still alows movement of the vehicle in case of controller breakdown by selecting the manual mode with the Fail Safe mode Switch in the controller A WARNING the manual mode direction inhibition function can not be operated normally The sudden reversal of a loaded lift truck traveling forward
166. ired A small Ignition Switch Fuel Select CAM Sensor SECM 48 Coolant Temp Pre CAT Q2 Sensor Post CAT 02 Sensor Catalytic Muffler Crankshaft Sensor Oil Pressure Switch Ignition Coil Packs engine control module SECM uses two heated exhaust gas oxygen sensors HEGO in the exhaust system to monitor exhaust gas content One is installed in front of the catalytic muffler and one is installed after the catalytic muffler Dual Dither CA100 Mixer Fuel Lackoff N 2007 Regulator Bosch Electronic Throttle E Tm oan Transmission Oil Temp Switch Fuel Injectors Gasoline Manifold Pressure Temperature Sensor EMS schematic of G420FE Dual fuel 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 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
167. is sensor sends a signal to an indicator to alert the operator Drain the fuel filter water separator as follows 1 Position an approved container under the fuel filter water separator Figure 5 7 1 to collect the contaminants Figure 5 7 2 Close Figure 5 7 2 the fuel cock Figure 5 7 3 3 Loosen the drain cock Figure 5 7 4 at the bottom of the fuel filter water separator Drain any water collected inside 4 Hand tighten the drain cock A WARNING If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 5 Open the fuel cock Figure 5 7 3 6 Be sure to prime the diesel fuel system when you are finished See topic Priming the Fuel System When required 7 Check for leaks 4 98 Diesel Engine Only NEVER wait until the scheduled periodic maintenance if the fuel filter indicator comes on The fuel filter water separator contains a sensor to detect the amount of water and contaminants This sensor sends a signal to an indicator to alert the operator Drain the fuel filter water separator as follows 1 Position an approved container under the fuel filler
168. just 1 Setthe 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 11 exlrusian 2 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 STDmast FFmast FFTmast L 09 _ Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Inspect Engine for Fluid Leaks Gasoline and LP Engines 1 Start the engine and allow it to reach dperating temperatures 2 Turn the engine off Inspect the entire 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 1 Maintain oil level between the MAX and MIN marks on the dipstick Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Diesel Engines 1 Maintain oil level between the MAX and MIN marks on the dipstick 155 Maintenance Section Coolant Level Check WARNING At operating temperature the engine coolant is hot and under pres
169. k in accordance with local regulations DOOSAN lift trucks are manufactured according to the regulations and standards laid down 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
170. l See Advanced Diagnostics Engine Mechanical See Engine Service Manual Isolate the gasoline system by Verify LPG cylinder is full and valve is open Will Not Run Continuously Gas running the lift truck on LPG If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in LPG mode then the root cause is most likely to something other than the fuel system e See Advanced Diagnostics Fuel tank almost empty Fuel Pump Cavitations e The tank should be at least 74 full to properly prime the fuel pump Clogged fuel filter Repair replace as required e See Maintenance section Primary and Secondary Fuel Filter replacement 94 Operation Section Problem Probable Cause Corrective Action Electric Fuel Pump malfunction Check electrical connection Will Not Run GAS e Check Relay and fuse Turn key ON Continuously and verify pump is operating Gas e See Engine Service Manual Pressure regulator malfunction Test pressure regulator operation e Engine Service Manual Fuel Injector malfunction Test Injector operation e See Engine Service Manual Incorrect idle speed or ignition See Advanced Diagnostics problem Engine Mechanical See Engine Service Manual Isolate the gasoline system by Verify LPG cylinder is full and valve is open Will Not running the lift truck on LPG If the problem does not exist in LPG mode Accelerate H
171. late shaft for bearing wear e Check the ETC driver wiring for an open circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 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 0 4 0Q Check the ETC driver wiring for an open circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Check the ETC internal motor drive by Arl signals nave failed open or 2 CutThrottle disconnecting the throttle connector and become disconnected I measuring the motor drive resistance at electronic throttle or SECM is the throttle defective TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 00 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 the drive mechanism is damaged or 1 TurnOnMil 21 the return spring has lost tension 2 EngineShutdown eO rotte spring es oy Cy m 28 the throttle willa liheest and the ignition key and re check for fault 3 CutThrottle set the fault NOTE The throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly Fault actions shown are default values specified by the OEM 108 Operation Section Table 2 Diagnostic Fault Codes Flash Codes cont d PROBABLE FA
172. le 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 24 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 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
173. le 1 Travel with the load uphill on upgrades and downgrades iACY 0311 Typical Example 2 For better vision travel in reverse with bulky loads 122 Unloading M lAQO0421 Typical Example 1 Move the lift truck into the unloading position 110000301 Typical Example 2 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 Turning WOOO gt Typical Example 3 Deposit the load and BACK away carefully to disengage the forks 1 When turning sharp corners keep close to the inside corner Begin the turn when the inside drive wheel meets the corner IACYOQASI Typical Example 4 Lower the carriage and forks to the travel position or to the park position 2 n narrow aisles keep away from the stockpile when turning into the aisle Allow for counter weight swing 123 Operation Section Lifting Drums or Round Objects IAOO0481 1 Block drums or round objects Tilt the mast FORWARD and slide the fork tips along the floor to get under the load IAOO0491 2 Before lifting tilt the mast BACK slightly until the load is cradled on the forks 124 Operating in hot weather Keep the following points in mind when you operate
174. linders and hoses If Parking Brake Alarm Equipped A WARNING When leaving machine apply parking brake Parking brake is not automatically applied Alarm will sound if parking brake is not applied Operation Section Lift Fork Adjustment A WARNING When adjusting the fork spread be careful not to pinch your hand between forks and the carriage slot Hook on type Fork 1 Move up the hook pin to the free position 2 Raise the hook pin in each fork to side the fork on the carriage bar 3 Adjust the forks in the position most appropriate for the load and as wide as possible for load stability 4 When adjusting the forks make sure that the weight of the load is centered on the truck 5 After adjustment set the fork locks to keep the forks in place A WARNING Make sure the forks are locked before carrying a load 126 Storage Information Before Storage Before storing your lift truck clean and inspect as the following procedures e Wipe away grease oil etc adhering to the body of the truck with waste cloth and use water if needed e 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
175. liter Cooling System w Coolant Recovery Bottle 4TNV98 amp 4TNE98 Diesel F uel TANK 012 5155 51 13 74 Gasoline or Diesel Fuel Tank an GC Series 40 10 56 Gasoline Powershift Transmission Drive Axle Maintenance Section Maintenance Intervals NOTICE All maintenance and repair except Every 10 Service Hours or Daily on the lift truck 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 authorized personnel only When Required Fuel Tank Filter Cap and Screen If Equipped Clean 148 Seat Hood Latch amp Support Cylinder Check Able d eiii MM es 148 Fuses Bulbs Circuit Breaker amp Relay Change Reset 149 Priming the Fuel System Diesel Engine Only 150 Water Seperator Diesel Engine Only Check Drain Tires and Wheels D G Series Inspect Check 154 Carriage Roller Extrusion Adjust 154 Every 10 Service Hours or Daily Inspect Engine for Fluid Leaks 155 Engine Oil Level 155 Coolant Level Check 156 Air Cleaner Indicator Check 157 Inspect Foot Pedal Operation G420F E G424F E e 157 Inspec
176. m a walk around inspection daily and at the start of each shift Refer 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 be obtained with the operators back against the seat back 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 Operate the lift truck and controls only from the operator s station Safety Section 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 IAOY O10 Do not start the engine or move any of the controls if there is a DO NOT OPERATE or similar warning tag a
177. n of this manual before performing any operation or maintenance procedures Fuel Tank Filter Cap and Screen If Equipped Clean Park the lift truck with the forks lowered parking brake applied transmission in neutral and the engine stopped Remove the filter cap assembly Clean in clean nonflammable solvent m Dry cap assembly gt Install filter assembly WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause fire 4 Drain moisture and sediment from fuel tank as required by prevailing conditions Seat Hood Latch amp Support Cylinder Check Lubricate 1 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 2 Push the lever down to raise the hood and seat assembly Make certain the support cylinder will hold the hood open Note Unlock latch before pulling it if key equipped Typical Example 3 Lightly oil the hood latch mechanism and the rod for the hood support cylinder 148 Fuses Bulbs Circuit Breaker amp Relay Change Reset Fuses NOTE If a fuse filament separates use only the same type and size fuses for replacement If the filament in a new fuse separates have the circuits and instruments checked NOTICE Always replace fuses with ones of the correct ampere rating Typical
178. n position The light should go off after engine is started Belt Warning Light If 10 Service hour Meter 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 11 Parking indicator light The light will come ON when the parking lever is applied 12 Front Floodlights Push down on the switch 14 to the first step to turn the front floodlights on Front and Rear Floodlights Push down on the switch 14 to the second step to turn both the front and rear floodlights on The floodlights are optional 13 Transmission Neutral Position Light Indicates the neutral position of transmission 14 Front and Rear Floodlights Switch The front floodright is ON when push down switch to the first step The front and rear floodlights are ON when push down switch to the second step Operation Section 15 Low Level Light of LP GAS Indicates the low Level of LP GAS LP or DUAL only v 16 Directional Turning Indicator Light 17 Horn Switch Push on the horn button to sound the horn 65 Operation Section Electrical Disconnect Switch If Equipped 1 ON Connects the battery for electrical power to all electrical circuits 2 OFF Disconnects the b
179. 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 Engine Valve Lash Diesel Engine Only Check Adjust NOTICE The valve clearances are to be adjusted at the times of the following situations e When 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 WARNING 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 to cool the engine cylinder head and block temperature Set the clearance to the nominal appropriate clearance given in the Valve Clearance Setting shown below Valve Clearances Engine Valve Clearance 3 3 liter Exhaust Valves 0 2 mm 0 08 in 4TNV98 amp Intake Val 2 0 08 4TNE98 Diesel ntake Valves 0 2 in Refer to the Service Manual for the complete valve adjustment procedure In regards to G420F E G424F E Engines valve adjustment is not necessary because of automatic adjusting system
180. ng brake Push the lever FORWARD to release the parking brake 00 Applying the parking brake puts the transmission in NEUTRAL The parking brake must be applied when leaving the lift truck and when starting the engine If the operator leaves the seat without applying the parking brake an audible alarm will sound 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 0101 Attach a Do Not Operate or 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 t
181. ngine Only u u 202 Replace PCV Valve and breather element Change LP Gasoline and Dual Fuel Engines 203 Replace Spark Plugs G420F E Engine Only 202 Replace Spark Plugs G424F E LP Dual Fuel eio 191 S Safety DNE 23 IGIGLY M 2 5 Seat ACIUSIHOEL uu uu 18 Seat Switch System If Equipped 67 68 Seat Hood Latch amp Support Cylinder Check LuDri68 e 148 Serial Number Locations 59 Serial Number 59 Service Brake Pedal 69 Servicing Filter 167 Sideshift Attachment If Equipped 70 Specifications 30 32 34 36 38 40 Stability and Center of Gravity 21 Starting a Cold Diesel Engine 77 207 Index Section Starting a Warm Diesel Engine 77 Starting From a 12 Volt External Source 78 Starting the Engine 76 Starting the Lift truck 12 Steer Suspension
182. ngine Only The governor lever and engine speed control accelerator lever pedal etc of the machine are connected together by an accelerator cable or rod If the cable becomes stretched or the connections loosen the governor lever may not respond to change of engine speed control position This may make operation of the machine unsafe Check the cable periodically and adjust if necessary Consult your authorized Yanmar industrial engine dealer or distributor for the adjustment procedure NEVER force the accelerator cable or pedal to move This may deform the governor lever or stretch the cable and cause irregular operation of the engine speed control Checking and adjusting the governor lever 1 Check that the governor lever Figure 5 12 1 makes uniform contact with the low idle Figure 5 12 2 and high idle Figure 5 12 3 speed limit screws when the engine speed control is in the high idle speed or low idle speed position 2 If the governor lever does not make contact with the high idle or low idle speed limit screw adjust the accelerator cable 3 3 In some engine speed control applications loosen the accelerator cable locknut and adjust the cable so the governor lever makes proper contact with the high low idle speed limit Screw DOO TOGA Figure 5 12 175 Maintenance Section Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and i
183. nning 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 G420F E G424F E Engines of this section 81 Operation Section The diesel engine water in fuel filter indicator light 4 will not come ON with the engine running unless water in fuel filter exceeds 100cc Stop the engine immediately and drain the water if the light comes ON Observe the fuel level gauge 5 for fuel level in the tank The engine coolant temperature gauge pointer 6 will be in the green band with the engine running unless the coolant temperature is excessive The transmission oil temperature gauge pointer 7 will be in the green band with the engine running unless the oil temperature is excessive 8 Observe the hour meter 8 to make sure it is operating properly Operation Section Lift Truck Operation Power Shift Transmission Drive axle 1 Start the engine See topic Starting the Engine 2 Push down on the service brake pedal to hold the lift truck until ready to move it 3 Release the parking brake NOTE The parking brake must be released before the directional control can be used 4 Select the direction of travel by pushing the directional lever FORWARD for forward direction or by pulling the lever BACK for reverse direction 82 WARNING A lift truck with th
184. nows 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 fork rated at 1500 pounds at 24 inch load center will be stamped 1500x24 fork rated at 2000 kg at 600 mm load center will be stamped 2000x600 The manufacturer identification and year and date of manufacture are also usually shown 130 Some countries have standards or regulations which apply specifically to the inspection and repair of forks 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
185. nstructions contained in the Safety section of this manual before performing any operation or maintenance procedures Belts Check Adjust Mast Hinge Pin Lubricate E z D gt om ILOMO29I Typical Example Typical Example 1 Check the condition and adjustment of the belt 1 Lower the forks and tilt the mast forward Correct adjustment allows 10 3 8 inch deflection under 110 N 25 Ib of force 2 Lubricate the two fittings for the mast hinge pins one on each side of the mast Tilt Cylinders Check Adjust Lubricate Chassis Pivot Eyebolts Lubricate lt 1 A m NOTICE Failure to loosen the alternator mounting bolt 2 will cause excessive stress and break the alternator mounting ear Typical Example 2 adjust the alternator drive belt loosen adjusting bracket bolt 1 and mounting bolt 2 Move the alternator in or out as required 15 Tighten bolts 1 and 2 2 Lubricate two fittings for the pivot eyebolts one on each tilt cylinder 1 Remove lloor plates GC series only 3 Check the pivot eye pins for loose retainer bolts and wear 176 Mast P ivot Eyes Lubricate Typical Example 1 Lubricate two fittings for the mast pivot eyes one on each side of the pin 2 Check the pivot eye pins for loose retainer bolts and wear Cylinder Rod Extension Adjust NOTE The following desc
186. o not allow riders on the 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 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 truck 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 129 Operation Section Consult your DOOSAN Lift Tuck dealer for towing a disabled l
187. o trucks or trailers If trailer is not coupled to tractor make sure the trailer landing gear is properly secured in place On 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 Parkthe 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 if equipped 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 Place the transmission controls in neutral Engage the parking brake Stop the engine 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
188. 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 2 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 3 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 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 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 in accordance with the manufacturer s recommendations Most repairs or modifications should be done
189. or an open ECT circuit SEOM Signal Pin B15 to ECT Pin 3 SECM Sensor GND Pin B1 to ECT Pin 1 Fault actions shown are default values specified by the OEM 100 PROBABLE FAULT ECTOverTempFault Engine coolant temperature is high The sensor has measured an excessive coolant temperature typically due to the engine overheating ECT IR Fault Engine coolant temperature not changing as expected Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION 1 TurnOnMil 2 DelayedEngine Shutdown TurnOnMil Operation Section CORRECTIVE ACTION FIRST CHECK Check coolant system for radiator blockage proper coolant level and for leaks in the system Possible ECT short to GND check ECT signal wiring SECM Signal Pin B15 to ECT Pin 3 SECM Sensor GND Pin 1 to ECT Pin 1 SECM System GND Pin A16 B17 Check regulator for coolant leaks Check for coolant system problems e g defective or stuck thermostat FuelSelectConflict Conflict in fuel select signals normally set if both of the fuel select signals are shorted to ground CamEdgesFault No CAM signal when engine is known to be rotating broken crankshaft sensor leads or defective CAM sensor 1 TurnOnMil 2 Delayed EngineShutdown Check fuel select switch connection for a short to GND SECM SIGNAL Pin A12 SECM SIGNAL Pin A15 SECM Sensor GND Pin B1 Check CAM sensor connections SECM SIGNAL Pin B10 to CAM sen
190. ore opening IAOY0031 Located on the radiator top tank by the radiator cap Hand Placement Warning No hands Do not place hands in this area Do not touch lean on or reach through the mast or permit others to do so ILO2003P Located on the mast Safety Section No Standing On Fork Warning No Standing Under Fork 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 AG 0051 Located on the lift cylinder Load Backrest Must Be In Place Warning WARNING Operation without this device in place may be hazardous ILOS004P 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 I B56 1 and F E M Section IV This design has been tested with an impact of appropriate valve ILOS005P Located on the Overhead Guard No Riders Warning WARNING To avoid personal injury allow no riders lift truck is designed for only one operator and no riders iIOYO0O8 Located beside the operator s station STD or on front of the hood Convenience Package Moving Fan Warning A WARNING To avoid personal injury stay clear of moving fan 0091 Located inside the engine compartment cover Parking brake Pull the lever BACK to engage the parki
191. osition is used by the SEOM to calculate load Feedback from the electronic throttle is still provided to the SECM by the throttle position sensors TPS Ignition Fial bicini E Fuel Select e Swrlrki Coil Packs Sanm CAI Miner E a E 2 H ugilalar CAN k Coolant F ae 2 Sensor Aver Election Catalytic Muffler C rankashaft M Presaire Transmissor Temp Swich ual Injectors Maminti Pressiee Tamparature Sensor EMS schematic of G420F Dual Fuel engine 85 Operation Section Basic Troubleshooting LP The 07 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 ltems 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 Fuel
192. out of TPS1 sensor for an open circuit or short to range low normally set if the 1 TurnOnMil GND TPS1 signal has shorted to 2 CutThrottle SECM Pin B23 signal to ETC Pin 6 ground circuit has opened or SECM Pin B1 sensor GND to E TC Pin 2 sensor has failed SECM system GND Pin 16 17 TPS2RangeLow Check throttle connector connection and 52 sensor voltage out of 52 sensor for an open circuit or short to range low normally set if the 1 TurnOnMil GND 52 signal has shorted to 2 CutThrottle SECM Pin B4 signal to ETC Pin 5 ground circuit has opened or SECM Pin B1 sensor GND to ETC Pin 2 sensor has failed SECM system GND Pin 16 17 TPS1RangeHigh TPS1 sensor voltage out of Check throttle connector and TPS1 sensor range high normally set if the 1 TurnOnMil wiring for a shorted circuit TPS1 signal has shorted to 2 CutThrottle SECM Pin B23 signal to ETC Pin 6 power or the ground for the SECM Pin B1 sensor GND to ETC Pin 2 sensor has opened TPS2RangeHigh TPS2 sensor voltage out of Check throttle connector and TPS1 sensor range high normally set if the 1 TurnOnMil wiring for a shorted circuit TPS2 signal has shorted to 2 CutThrottle SECM Pin B4 signal to ETC Pin 5 power or the ground for the SECM pin B1 sensor GND to ETC Pin 2 sensor has opened TPS1AdaptLoMin Learned closed throttle end of TPS1 sensor range lower than expected TPS2AdaptLoMin Learned closed throttle end of TPS2 sensor range lower
193. r 1 Resistance 12 to14 ohms cold Inj2Open Gasoline Injector 2 open circuit broken injector 2 wire or defective injector 1 TurnOnMil 2 Disable LiquidO2Ctrl 3 Delayed EngineShutdown Check INJ2 wiring for an open circuit SECM Signal A8 to Injector 2 Pin A Switched 12V to Injector 2 Pin B Check Injector 2 Resistance 12 to14 ohms cold Inj3Open Gasoline Injector 3 open circuit broken injector 3 wire or defective injector InjdOpen Gasoline Injector 4 open circuit broken injector 4 wire or defective injector ECTRangeLow Coolant Sensor failure or shorted to GND ECTRangeHigh Coolant sensor disconnected or open circuit 151 15 1 TurnOnMil 2 Disable LiquidO2Ctrl 3 Delayed EngineShutdown 1 TurnOnMil 2 Disable LiquidO2Ctrl 3 Delayed EngineShutdown 1 TurnOnMil 2 DelayedEngine Shutdown 1 TurnOnMil 2 DelayedEngine Shutdown Check INJ3 wiring for an open circuit SECM Signal A4 to Injector 3 Pin A Switched 12V to Injector 3 Pin B Check Injector 3 Resistance 12 to14 ohms cold Check INJ4 wiring for an open circuit SECM Signal A7 to Injector 4 Pin A Switched 12V to Injector 4 Pin B Check Injector 4 Resistance 12 to 14 ohms cold Check ECT sensor connector and wiring for a short to GND SECM Signal Pin B15 To ECT Pin 3 SECM Sensor GND Pin B1 to ECT Pin 1 SECM System GND Pin A16 B17 Check if ECT sensor connector is disconnected or f
194. r load positioning 1 To inch creep in either direction slowly push down on the inching pedal This will start to apply the service brakes and allow the transmission clutch discs to slip 2 Vary the position of the 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 9 Move the directional lever to the desired the service brakes fully to stop and hold the lift direction of travel Slowly push down on the truck This will provide full engine power for fast accelerator pedal as the lift truck changes hydraulic lift direction 10 When the direction change is completed continue to push down on the accelerator pedal WARNING Do not use inching pedal instead of brake pedal It will give wearing to transmission clutch disc 11 To stop the lift truck when traveling in either direction release the accelerator pedal 12 Push down on the service brake pedal and bring the lift truck to a smooth stop 83 Operation Section Electronic Controlled Spark Ignition Engines G420FE Engine and G424FE Engine EMS Engine management system of G420FE engine and G424FE engine is a closed loop system utilizing 3 way 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 requ
195. reather amp Strainer Check Change 185 Transmission Oil Oil Filter amp Strainer Check Clean Change TE 186 Lift Chains Test Check Adjust 186 Universal Joint Inspect 188 Air Intake System Change 188 Inspect Coolant Hoses LP Dual Fuel Engine Only u u eera 189 LP Regulator Converter Inspection LP Dual Fuel Engine ONIY E 189 Fuel Lines amp Fittings Check 189 Inspect Mixer Assembly G420F E G424F E Engine ONIY Mir 189 Inspect Throttle Assembly G420F E G424F E Engine OMY 189 Engine Valve Lash Diesel Engine Only Check PRONG CUR 190 Every 1500 Service Hours 9 Months Inspect Ignition System LP Gasoline amp Dual Fuel Engines Only uuu uuu u uuu uta 191 Replace Spark Plugs G424F E LP Dual Fuel Engine Only uuu 191 Replace LP Fuel Filter Element LP Dual Fuel Engine uuu u sn u Susanna s 192 Fuel Filter LP Engine Only 192 Testing Fuel Lock off Operation LP Engine Only 192 Fuel Injectors Diesel Engine Only Inspect Clean TeSt 193 Crankcase Breather System 4 98 Diesel Engine Only 193 Every 2000 Service Hours
196. res Hydraulic Return Filter Change WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped 1 Loosen the bolts of the hydraulic tank top plate assembly bk LIINC amp k CES IB60M10P Filter 2 Remove the return filter from tank top plate assembly 3 Change the return filter 4 Install the tank top plate assembly and fasten the bolts 5 Start the engine and operate the hydraulic controls and the steering system through a few cycles to fill the lines Look for oil leaks 6 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 166 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 Precleaner If Equipped NOTICE Never service precleaner with the engine running ww 2 Sak m OW I a 1 4 ac ILOMO42P F 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 cov
197. res 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 17 Safety Section 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 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 effec
198. responding 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 change 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 11 Safety Section Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully Clean your shoes and wipe your hands before mounting Use both hands and 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 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 Perfor
199. ription is for forward tilt For cylinder rod back tilt the collar should be stationary by the tilt eye If it is not the O ring inside the collar may need to be replaced To adjust back tilt spacers must be added or removed ILOMO31P Typical Example 1 Check to make sure the tilt cylinders extend and retract evenly 2 lfone cylinder continues to move after the other cylinder has stopped in full forward or backward adjustnent must be made to one cylinder 177 Maintenance Section 4 ILOM031P Typical Example 3 To adjust the cylinder rod extension move the spacer to the rear and loosen the pinch bolt on the clevis Turn the cylinder rod in or out of the clevis to obtain the proper adjustment Turning the rod into the clevis shortens the stroke Turning the rod out of the clevis lengthens the stroke Tighten the pinch bolts to a torque of 95 15 Name 70 10 abaft Check the cylinder rods again for even travel Crosshead Rollers Inspect Check Operation 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 ILOMO33P Typical Example 2 Check for damaged crosshead rollers guards and retainer rings Maintenance Section Transmission Oil Filter Change WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin
200. rom 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 139 Maintenance Section 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 DISEL ENGINES Specifications Aromatics AST D1319 3596 Max Ash ASTM D482 0 02 Weight Max Cetane Number 35Min for 45 max ASTM D613 40 Min for DI Engines Not Above L tE ted Could Point ASTM D287 01006 0 5 Expecte Ambient Temperature Gravity API ASTM D287 30 Min and 45 Max Pour Point ASTM D97 ifa ED M Sulfur ASTM D2788 D3605 or D1552
201. rter 1 LP fuel lock off 2 Regulator Converter 3 Fuel Trim valve FTV Fuel Injectors Diesel Engine Only Inspect Clean Test A WARNING HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar industrial engine dealer or distributor repair the damage Failure to comply could result in death or serious injury Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance The EPA ARB requires that the fuel injectors are inspected cleaned and tested every 1500 hours See Testing of Fuel Injectors on Service Manual Crankcase Breather System 4TNV98 Diesel Engine Only Inspect Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine The EPA ARB requires that the crankcase breather system is inspected every 1500 hours 4TNV98 engines use a crankcase breather system that has spring backed diaphragm 5 19 1 in the valve cover Figure5 19 2 When the crankcase pressure reaches a predetermined value the
202. ruck Keep the lift truck especially the deck and steps free of foreign material such as debris oil tools and other items which are not 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 10 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
203. s Check all sensor connections see fault 742 corrective actions LiqFuelAdaptRangeHi In Gasoline mode system had to adapt lean more than expected 1 TumOnMil 2 Disable LiquidO2 Ctrl 8 Disable LiqPost O2Ctrl Check for vacuum leaks Low gasoline fuel pressure perform gasoline pressure test Injector problems e g plugged defective injector LiqDesEquivHi None N A LiqFuelAdaptRangeLow In Gasoline mode system had to adapt rich more than expected LiqDesEquivLo 1 TurnOnMil 2 Disable LiquidO2 Ctrl 3 Disable LiqPost O2Ctrl Low gasoline fuel pressure perform gasoline pressure test Injector problems e g leaking defective injector N A LiqO2NotActive Pre catalyst O2 sensor inactive on gasoline open O2 sensor signal or heater leads defective O2 sensor 1 TurnOnMil 2 DisableLiquid O2Ctrl Check that Pre catalyst O2 sensor connections are OK 2 signal Pin 3 to SECM Pin B13 O2 Pin 2 HEATER GND to SECM DRVG GNG Pins A16 B17 O2 Pin 1 HEATER PWR to SECM DRVP 12V PIN A23 Verify O2 sensor heater circuit is operating by measuring heater resistance 2 1Q 0 40 O2 Pin 2 HEATER GND to Pin 1 HEATER PWR LiqPostO2NotActive Post catalyst O2 sensor inactive on gasoline open O2 sensor signal or heater leads defective O2 sensor LiqCatlnactive 1 TurnOnMil 2 DisableLiqPost O2Ctrl None Check that Post catalyst O2 sensor connec
204. s 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 increases 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 40 antifreeze and 60 water 50 antifreeze and 50 water 60 antifreeze and 40 water 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 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 f
205. s accomplished on each machine with a factory adjusted controller e The SW2 is for adjustment of optimal direction inhibit speed e Factory setting value is 5 1 km h 3 17 mph e SW1 is not used MIT IE NNI CM OC von Adjustment Switch Diagnostics Features ASC 100 has an internal indicator on the right side of the controller for displaying the selected gear and the abnormal condition Below is a description applicable for many ASC 100 implementations Display for Operator This information is given during normal operating when something special happens For example on ASC 100 s with the speed sensor one of the indicators is used to indicate a sensor problem Display Description Remark Automatic operation NENNEN P Speed sensor open Flashing Controller fault Flashing 6 Forward Sol Short Flashing Reverse Sol Short Flashing Display for Troubleshooting This information is input signal for diagnostics This test is used to verify an operation of direction control lever Display Description Automatic operation Forward s w input Lever input test Reverse s w input Lever input test 119 Operation Section Operation This system can basically operate in 2 pre selected modes e Automatic mode Direction Inhibit mode Selected as factory setting e Manual mode Fail Safe mode manual operation in emergency Automatic mode D
206. s 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 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 tires for proper inflation See Tire Inflation Pressures To inflate tires always use a clip on chuck with a minimum 60 cm 24 inches length of hose to an in line valve and gauge Always stand behind the tread of the tire NOT in front of the rim not re inflate tire that has been run while flat or underinflated without first checking to make sure the locking ring on 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 154 Carriage Roller Extrusion Ad
207. s properly mounted to manifold Check coil driver wiring and connector for open circuit SECM Pin 9 EST1 to OEM ignition system See application note Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details EST2 Open EST2 output open possibly open EST2 signal or defective spark module TurnOnMil Check coil driver wiring and connector for open circuit SECM Pin A10 EST2 to OEM ignition system See application note Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details EST3 Open 5 output open possibly open ESTS signal or defective spark module TurnOnMil 105 Check coil driver wiring and connector for open circuit SECM Pin EST3 to OEM ignition system See application note Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details Fault actions shown default values specified by the OEM Operation Section Table 2 Diagnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK EST4 Open EST4 output open possibly open ESTA signal or defectiv
208. s 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 amount of forward or backward tilt tire pressure dynamic forces created when the lift truck is accelerated braked or turned condition and grade of surfaces on which the lift truck is operated CG mad E Combined GG y truck INSO0261 These same factors are also important for unloaded lift trucks They tip over sideways easier than a loaded lift truck carrying its load in the lowered position Safety Section Lift Truck Stability Base GG Truck will tip over INSOOSTI 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 will 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 INSOUZBI The capacity load of the l
209. signal TurnOnMil Check APP2 signal at SECM PIN has shorted to ground circuit has B16 opened or sensor has failed APP1RangeHigh 621 APP1 sensor voltage out of range ent Check foot pedal connector 62 high normally set if the APP1 signal Check APP1 signal at SECM PIN has shorted to power or the ground B7 for the sensor has opened APP2RangeHigh 622 APP2 sensor voltage out of range Check foot pedal connector 66 high normally set if the 2 signal TurnOnMil Check APP2 signal at SECM PIN has shorted to power or the ground B16 for the sensor has opened Check APP connector and pins for 631 APP1AdaptLoMin corrosion 63 Learned idle end of APP1 sensor TurnOnMil Cycle the pedal several times and range lower than expected check APP1 signal at SECM Pin B7 Check APP connector and pins for 632 APP2AdaptLoMin corrosion 67 Learned idle end of APP2 sensor TurnOnMil Cycle the pedal several times and range lower than expected check APP2 signal at SECM Pin B16 641 APP1AdaptHiMax 2 connector and pins for Learned full pedal end of APP1 TurnOnMil 64 I Cycle the pedal several times and sensor range higher than expected check APP signal SECM Pin B7 ec connector and pins for 60 iiem Jerem of APP2 TurnOnMil 1 sensor range higher than expected check APP2 signal at SECM Pin B16 na Check APP connector and pins for APP1 AdaptHiMin 651 Learned full pedal end of APP1 TurnOnMil 4 5 sensor range lower than expected hes 22
210. son it should only be replaced with another DOOSAN operator restraint system Safety Section 3 In the event of a tipover the seat and restraint system should be inspected for damage and replaced if necessary NOTE Operator restraints shall be examined at the regular truck service intervals lt is recommended that they be replaced if any of the following conditions are found e Cut or frayed strap e Worn or damaged hardware including anchor points Buckle or retractor malfunction Loose 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 Pull on the belt to confirm it is latched 2 Make sure the belt is not twisted 20 WARNING If you fasten the belt across your abdomen the belt may injure your abdomen in an accident 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 Release the Seat Belt Push the button of the buckle
211. sor Pin 2 SECM Sensor GND Pin B1 to CAM sensor Pin 3 Switched 12V to CAM sensor Pin 1 Check for defective CAM sensor CamSyncFault Loss of synchronization on the CAM sensor normally due to noise on the signal or an intermittent connection on the CAM sensor CrankEdgesFault No crankshaft signal when engine is known to be rotating broken crankshaft sensor leads or defective crank sensor Check CAM sensor connections SECM SIGNAL Pin B10 to CAM sensor Pin 2 SECM Sensor GND Pin B1 to CAM sensor Pin 3 Switched 12V to CAM sensor Pin 1 Check for defective CAM sensor Check Crankshaft sensor connections SECM SIGNAL Pin B5 to Crank sensor Pin 3 SECM Sensor GND PIN B1 to Crank sensor Pin 2 Switched 12V to Crank sensor Pin 1 Check for defective Crank sensor CrankSyncFault Loss of synchronization on the crankshaft sensor normally due to noise on the signal or an intermittent connection on the crankshaft sensor Fault actions shown are default values specified by the OEM 101 Check Crankshaft sensor connections SECM SIGNAL Pin B5 to Crank sensor Pin 3 SECM Sensor GND Pin B1 to Crank sensor Pin 2 Switched 12V to Crank sensor Pin 1 Check for defective Crank sensor Operation Section Table 2 MI 07 Diagnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK TPS1RangeLow Check throttle connector connection and TPS1 sensor voltage
212. spark module EST5 Short EST5 output shorted high or low EST5 signal shorted to ground or power or defective spark module None None N A N A 436 EST6 Short EST6 output shorted high or low EST6 signal shorted to ground or power or defective spark module None N A Fault actions shown are default values specified by the OEM 107 Operation Section Table 2 Diagnostic Fault Codes Flash Codes cont d PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK EST7_Short EST7 output shorted high or low EST signal shorted to ground or power or defective spark module EST8 Short EST8 output shorted high or low EST8 signal shorted to ground or power or defective spark module ETC_ Sticking Electronic Throttle Control is sticking This can occur if the throttle plate butterfly valve inside the throttle bore is sticking The plate sticking can be due to some type of obstruction a loose throttle plate or worn components shaft bearings NOTE The throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly 1 TurnOnMil 2 EngineShutdown 3 CutThrottle ETC Open Fault Electronic Throttle Control Driver has failed normally set if driver 1 TumOnMil Check for debris or obstructions inside the throttle body Perform the throttle test using the Service Tool and re check for fault e Check throttle p
213. spect 173 Inspect Tightness GC Series 173 Governor Lever and Engine Speed Control Diesel Engine Only Check Adjust 174 Every 500 Service Hours or 3 Months Belts Check Adjust 176 Mast Hinge Pin Lubricate 176 Tilt Cylinders Check Adjust Lubricate 176 Crosshead Rollers Inspect 177 Transmission Oil Filter Change 178 Overhead Guard 178 Drive Axle Oil amp Strainer Change Clean 179 Steer Suspension 180 Parking Brake Test 180 Inching amp Braking Control Shaft Lubricate 180 Horn and Lights If Equipped Check 180 Inspect Vacuum Lines and Fittings G420F E G424F E Engine Only 181 Fuel Trim Valve FTV Inspection G420F E G424F E Engine Only 181 Inspect Electrical System G420F E G424F E r n 181 Fuel Filter Diesel Engine Only Change 182 Engine Oil amp Filter Diesel Engine Only Change 183 Water Separator 4TNV98 Diesel Engine Only 184 Every 1000 Service Hours or 6 Months Hydraulic Return Filter B
214. st O2 sensor voltage out of range low sensor signal shorted to ground O2 PostCatRangeLow Post catalyst O2 sensor voltage out of range low sensor signal shorted to ground 1 TurnOnMil 2 DisableLiqPost O2Ctrl 1 TurnOnMil 2 DisableLiquid O2Ctrl 1 TurnOnMil 2 DisableLiq PostO2Ctrl Correct other faults that may contribute to 852 e g faults pertaining to Injectors MAP IAT Pre Cat O2 Post Cat O2 sensor Look for leaks in exhaust catalytic converter HEGO sensors repair leaks Check all sensor connections see fault 842 corrective actions High gasoline fuel pressure perform gasoline pressure test Injector problems e g leaking defective injector Correct other faults that may contribute to 872 e g faults pertaining to Injectors MAP IAT Pre Cat O2 Post Cat O2 sensor Look for leaks in exhaust catalytic converter HEGO sensors repair leaks Check all sensor connections see fault 842 corrective actions O2RangeHigh Pre catalyst O2 sensor voltage out of range high sensor signal shorted to power O2 PostCatRangeHigh Post catalyst O2 sensor voltage out of range low sensor signal shorted to ground 1 TurnOnMil 2 DisableLiquid O2Ctrl 3 DisableGas O2Ctrl 1 TurnOnMil 2 Disable asoline Post catalyst O2Ctrl 3 Disable LPG Post catalyst O2Ctrl Check if O2 sensor installed before catalyst is shorted to 5Vdc or battery 2 signal Pin 3 to SECM Pin B13 SECM
215. stics amp See Engine oug e Incorrect timing or spark control service Manual Engine Mechanical See Engine Service Manual Incorrect Idle speed control High Idle Speed hrote sticking Foot pedal sticking or incorrect pedal signal See Advanced Diagnostics amp See Engine Service Manual Check pedal return spring travel for binding e See Advanced Diagnostics d fuel filt Poor High Speed 9990 497187 Performance Repair replace as required See Maintenance section 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 Air filter clogged Faulty vapor connection between the pressure regulator converter and the mixer Pressure regulator malfunction Check air filter e Clean replace as required Check connection e Verify no holes in hose e Clamps must be tight e for kinked collapsed hose Test pressure regulator operation e See Engine Service Manual pinched and or Air Fuel Mixer malfunction Restricted exhaust system Check mixer e See Engine Service Manual Check exhaust system e Measure exhaust back pressure Incorrect ignition control Incorrect air fuel control Incorrect throttle position See Advanced Diagnostics
216. sty or wet operating conditions more frequent lubrication than 15 specified in the Maintenance Intervals chart might be necessary Perform service 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 Environment Management Note that DOOSAN INFRACORE 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 LIFE CYCLE 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 Safety 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 c
217. sure 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 4TNV98 Diesel Engine 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 coolant at the radiator filter neck Remove the radiator cap Fill radiator to the top of the filter neck Inspect radiator cap Replace if damaged Install the radiator cap 156 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 in 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 Air Cleaner Indicator Check Checkin
218. t Engine for Exhaust Leaks 157 Walk Around Inspection Inspect 157 Mast Channels Lubricate 158 Transmission Oil Level Check 159 Parking Brake 159 First 50 100 Service Hours or a Week Engine Oil amp Filter Diesel Engine Only Change 161 Transmission Oil Oil Filter amp Strainer Check Clean 162 Drive Axle Oil 164 Parking Brake Test Adjust 164 144 First 250 Service Hours or a Month Hydraulic Return Filter Change 166 Every 250 Service Hours or Monthly Air Intake System Check Clean 167 Brake Oil Level 169 Hydraulic Oil Level Check 169 Drive Axle Oil Level Check 170 Mast Carriage Lift Chains amp Attachments Inspect ereite e E 170 Steering Mechanism Check Lubricate 170 Battery Terminal Clean Inspect 171 Engine Oil amp Filter LP amp Gasoline Engine Only Societ 171 PCV Valve System Inspect Clean 172 Wheel Bolts amp Nuts In
219. t 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 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 39 102 F Discard cylinders in a safe place Do not puncture or burn cylinders the reach of Keep ether cylinders out 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 cause fires Contact your DOOSAN dealer for repair or replacement Check lines tubes and hoses carefully Do not use your bare hand to check for leaks Use a board or cardboard to check for leaks See Fluid Penetration in the Safety Section for mor
220. t load equal to the capacity of the truck and 15 grade If the maximum grade in the workplace is less than its capacity use the Parking Brake inspection procedure covered in Inspection from Operator s Seat Engine On in Every 10 Service Hours or Daily section 1 Pick up capacity load and drive over to a 15 grade Drive forward up the 1596 grade Halfway up the grade stop the lift truck with its service brakes Engage the parking brake and the service brake slowly release Engage the parking brake and shift the transmission to NEUTRAL Slowly release the service brakes The parking brake adjustment is proper if it holds the lift truck on the grade The parking brake needs adjusting if it does not hold the lift truck on the grade If the lift truck starts to move in reverse down the grade with the parking brake engaged stop it with the service brakes disengage the parking brake and reverse slowly down the grade controlling your speed with the service brakes WARNING prevent personal injury the operator MUST be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move Parking Brake Adjusting 1 Park the lift truck on a level surface lowered the forks shift the transmission to NEUTRAL and shut OFF the engine and block the wheels securely 2 Chock the lift trucks tires to prevent unintentional movement 3
221. t skin Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped Strainer mam Filter 1 Loosen the bolts of the hydraulic tank top plate assembly 2 Remove the return filter from tank top plate assembly 3 Install new return filter by hand 4 Remove the suction strainer from the tank 5 Install the new strainer by hand 6 Install the tank top plate assembly and fasten the bolts 185 Typical Example 7 Remove and discard the air breather 8 Install a new air breather 9 Start the engine and operate the hydraulic controls and the steering system through a few cycles to fill the lines Look for oil leaks 10 Stop the engine and check the oil level With all cylinders retracted maintain the oil level to the FULL mark on the dipstick filter cap assembly Maintenance Section Transmission Oil Oil Filter amp Strainer Check Clean Change See topic Transmission Oil Oil Filter amp Strainer Check Clean Change in First 50 100 Service Hours Lift Chains Test Check Adjust Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller When the chain bends over the roller the movement of the parts against each other causes wears Inspect to be sure that chain link pins do not extend outside of the link hole If any single link is extended beyond its connect
222. 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 84 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 MPI multi point injection is used for this system Fuel injection pressure and flow rate depend on engine specific fuel injection requirements A variety of regulators and injectors can be used to fit individual needs The gasoline fuel pressure regulator is a one way non return configuration All gasoline specific components are automotive production parts and validated to strict automotive standards Four 4 sequential injection channels are supported Operation Section G420F Engine and G424F Engine EMS Engine management system of G420F engine and G424F engine is an open loop LP system and or closed loop gasoline system 3 way catalytic muffler is not used for this system LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM Manifold pressure from the TMAP rpm from the crank position sensor and throttle p
223. ting containers to prevent damage to them 1 Park the lift truck on level ground with the parking brake applied the transmission in NEUTRAL the forks lowered and the engine running at low idle ILOO018P 2 Close the fuel shut off valve at the LP tank Run the engine until it stops then turn off the ignition switch and the disconnect switch if equipped 3 Disconnect the fuel supply line If Swing out type LP Cradle Equipped 4 Loosen the retaining clamps and remove the tank 5 Check the mounting to be sure the locating pin dowel is not missing or broken If the location dowel is missing or broken be sure the pin is replaced Check to be sure that the LP warning plate is in position on the lift truck and is legible Check to be sure the replacement tank is of the correct type Inspect the replacement tank for damage such as dents scrapes or gouges and for indication of leakage at valves or threaded connections Check for debris in the relief valve for damage to various valves and liquid level gauge Inspect the quick disconnect couplings for deterioration damage or missing flexible seals 73 Operation Section 11 Position the replacement tank so that the locating pin dowel is in place WARNING The tank must not extend past the counterweight 12 Clamp the tank securely 13 Connect the fuel supply line
224. tion Engine Serial Number G420F E 2 4 Number liter Spark Ignition Engine Serial G424F E General Section ILOGO0SP Typical Example Side Shifter Serial Number If Equipped 60 General Section Attachment Abbreviations Includes Special Forks 5 Special Carriage increased width height or outreach SSS Shaft type Sideshift Carriage HSS Hook type Sideshift Carriage ITA CW Counterweight SF Special Forks SWS Swing Shift Sideshift RAM Ram or Boom DBCBH Double Cube Block Handler HFP Hydraulic Fork Positioner CR Crane Arm or Crane Boom TH Tire Handler CTH Container Handler LPP Load Push Pull Device CC Carton Clamp RC Roll Clamp LS Load Stabilizer PWH Pulp Wood Handler SS ST Sideshift Side Tilt Carriage 61 General Section Operator s Warning and Identification Plate Familiarize yourself with the OPERATOR S WARNING PLATE and IDENTIFICATION LIFT CAPACITY and ATTACHMENT PLATES DO NOT exceed capacity as equipped load ratings Operator s Warning Plate Located on the right side of the operator s seat If Convenience Package Equipped Located on the overhead guard 62 Identification Lift Capacity and Attachment Plate lis Located on the cowl to t column he right side of the steering Below are abbreviations that may appear on the IDENTIFICATION LIFT CAPACITY and ATTACHMENT PLATES and their meanings M
225. tions are OK 2 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 only turns on after engine has been running for some time and SECM has calculated that water condensation in exhaust has been removed by exhaust heat Post O2 Heater Relay has SECM 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 N A LiqO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on gasoline 1 TurnOnMil 2 DisableLiquid O2Ctrl 114 Check for vacuum leaks Low gasoline fuel pressure perform gasoline pressure test Injector problems e g plugged defective injector Fault actions shown are default values specified by the OEM PROBABLE FAULT Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION Operation Section CORRECTIVE ACTION FIRST CHECK LiqPostO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on gasoline LiqO2FailedRich Pre catalyst O2 sensor indicates extended rich operation on gasoline LiqPostO2FailedRich Pre catalyst O2 sensor indicates extended rich operation on gasoline O2RangeLow Pre cataly
226. tive Action Repair replace as required e See Maintenance Section LP Fuel Filter replacement Faulty vapor connection between the pressure regulator converter and the mixer Throttle butterfly valve not opening or sticking Foot Pedal intermittent Incorrect air fuel or ignition control signal incorrect or Check connection e Verify no holes in hose e Clamps must be tight e Look for kinked pinched and or collapsed hose See Advanced Diagnostics Engine Mechanical Fuel container almost empty See Engine Service Manual LPG Vapor from liquid outlet e Fil fuel container e not exceed 80 of liquid capacity Excess flow valve closed Clogged fuel filter Plugged fuel line Reset excess flow valve e Close liquid valve e Waitfor a click sound Slowly open liquid valve Repair replace as required e See Maintenance Section LP Fuel Filter replacement 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 Slowly open liquid fuel valve amp Leak test 89 Operation Section Problem Engine Stalls Rough Idle Probable Cause Fuel Lock off malfunction Corrective Action Repair replace Fuel Lock off e Engine Service Manual Faulty vapor connection between the pressure regulator converter and the mixer
227. tive 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 iri tipover decal Bere m aL MEE POET masc r IM GASE OF IBSOOO02 Survive in lipover decal Safety Section Fasten seat belt decal Survive in tipover decal 18900004 Survive tipover warning is located the overhead guard It shows the proper use of the operator restraint system Seat Adjustment IBSO0005 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 WARNING Do not place your hand or fingers under the seat Injury may occur as the seat moves up and down 18 If Optional Suspension Seat weight adjusting type Equipped Forward and Backward Adjustment The seat can be adjusted by pushing the lever on the right side of seat Adjust the seat before operating the lift truck After adjusting set the seat to make sure it 15 properly locked Do not a
228. to release the belt The belt will automatically retract when released Hold the plate of the belt and allow the belt to slowly retract Avoiding Lift Truck Tipover Lift Truck Stability INSOU23I 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 INSOD24I 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 21 Safety Section Stability and Center of Gravity CG load Combined CG C INSOD251 The stability of the lift truck is determined by the location of its or if the truck is loaded the combined CG of the truck and load The lift truck has moving parts and therefore has a that moves The CG moves forward or backward as the mast i
229. ttached to the start switch or controls Before Operating the 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 a 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 l AVE i bhi 4 P IAOYO013I Use special care when operating on grades Do not angle across or turn on grades Do not use lift truck on 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 w
230. uck dealer Safety Rules 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 Safety Section Do not operate a lift truck unless you are in the operators seat Keep hands and feet inside the operators compartment not put any part of the body outside of the operators compartment Never put any part of body into the mast structure or between the mast and the truck 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 23 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 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 peop
231. ues specified by the OEM 103 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 6 TPS1 SIGNAL 0 7 3095 TPS Pin 3 PWR to Pin 6 TPS1 SIGNAL 1 4 Q 3095 Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by 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 2 Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by disconnect ing 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 4 8 2 Operation Section PROBABLE FAULT MAPTimeRangeHigh Manifold Absolute Pressure Sensor Input is High normally set if the TMAP pressure signal wire has become shorted to power shorted to the IAT signal the TMAP has failed or the SECM has failed Table 2 Diagnostic Fault Codes Flash Codes cont d FAULT ACTION TurnOnMil CORRECTIVE ACTI
232. umber of speeds forward reverse 49 s ded system attachment 50 NOISE LEVEL equivelent continuous sound dB A pressure level Leq at operator s ear DI BITA CE prEN 12053 34 DOOSAN DOOSAN G20E 5 G25E 5 G30E 5 2000 2500 500 500 500 LP LP LP rider seated rider seated rider seated p p 2 2 2 2 3230 3230 3230 9 152 152 152 10 I I 11 40x100x1050 40x100x1050 45x125x1050 12 275x1035 275x1035 286x1044 13 6 10 6 10 6 10 14 2530 2595 15 1170 1170 16 2175 2175 17 4490 4490 18 2183 2183 19 1026 1026 20 2220 2265 2365 21 480 480 485 22 2700 2745 2850 23 1970 2000 23a 19 20 19 20 18 19 24 530 600 510 600 500 600 25 510 460 510 460 1440 1415 27 27 22 5 28 29 3570 3940 30 4940 630 5670 770 1730 1840 1660 2280 1800 2580 32 2 2 2 2 2 2 33 7 00x15 12 7 00x15 12 28x9x15 12 34 6 50x10 10 6 50x10 10 6 50x10 10 35 1625 1625 1700 36 975 1000 975 1000 982 1000 37 115 115 38 143 143 39 foot hyd foot hyd foot hyd 40 hand mech hand mech hand mech 41 12 45 12 45 42 G420F E G420F E G420F E 43 39 9 53 5 2500 39 9 53 5 2500 39 9 53 5 2500 44 157 116 1600 157 116 1600 157 116 1600 45 4 4 1975 4 4 1975 46 powershift powershift powershift 47 181 156 195 156 49 35 General Section
233. ure work method or operating technique not specifically recommended by DOOSAN is used you must be sure that it is safe for you and others You should also ensure that the product will not be damaged or made unsafe by the operation lubrication maintenance or repair procedures you choose 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 U S A operate this lift truc
234. val 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 change with each bulk delivery 140 Gasoline Specifications Only unleaded gasoline should be used DOOSAN forklift trucks The gasoline in which methanol is contained is not recommended The gasoline in which ethanol is contained is not recommended either for It is recommended to use gasoline fuel that has octane number 87 to prevent knocking trouble LP Specifications LP is liquefied petroleum gas The exact composition of LP varies slightly between different parts of the country and different refineries HD5 or HD10 is recommended for DOOSAN forklift trucks Composition of HD5 Propane CsHs Propylene Butane C4 Hio iso Butane Methane CH1 WARNING 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 Lubricant Information Lubricant Information Certain abbreviations follow Society of Automotive Engineers SAE J754 nomenclature and some classifications follow SAE J183 abbreviations The MIL specifications are Specifications U S A Military The recommended oil viscosities can be found in the Lubricant Viscosities chart in this publication Grease is class
235. width as the carriage across the forks as shown 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 Put one 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 second 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 Hydraulic Oil Check Clean Inspect Battery System Change 1 Clean battery outer surfaces with a mixture of baking soda and water A WARNING 2 Inspect battery outer surfaces for damage and Hot oil and components can cause personal replace as necessary injury Do not allow hot oil or components to contact skin 3 Remove battery cable and clean repair and or replace as necessary Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped 1 Remove the hydraulic tank drain plug Allow the oil to drain into a suitable container Clean and install the plug 2 Remove the dipstick filter cap assembly 3 Fill the hydraulic tank S
236. y LPG Vapor from liquid outlet e Fil fuel container e Donotexceed 80 of liquid capacity Difficult to Start Excess flow valve closed Reset excess flow valve e Close liquid valve e Waitfor 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 Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve Leak test the pressure regulator converter Verify no holes in hose Clamps must be tight Look for kinked pinched and or collapsed hose Pressure regulator converter Test pressure regulator converter operation malfunction See Engine Service Manual and the mixer Faulty vapor connection between Check connection e e e Fuel container almost empty LPG Vapor from liquid outlet e Fil fuel container e not exceed 80 of liquid capacity 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 87 Operation Section Problem Will Not Run Continuously Will Not Accelerate Hesita tion During Acceleration Probable Cause Fuel container almost empty Corrective Action LPG Vapor
237. your dealer for new labels Traing Required To Operate or Service Warning Located on the right side of the steering wheel 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 Located on the right side of the operator s seat STD Located on the overhead guard If Convenience Package Equipped 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 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 wh

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