Doosan D20S-5 Operation & Maintenance Manual
  1. Manuals
  2. Brands
  3. Doosan Manuals
  4. Lifting Systems
  5. D20S-5
  6. Operation & maintenance manual

Doosan D20S-5 Operation & Maintenance Manual

Forklifts
Hide thumbs Also See for D20S-5:
Table of Contents

Advertisement

Quick Links

Download this manual
SB2349E04
Operation &
Maintenance Manual
FORKLIFTS
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
G20P-5 Plus, G25P-5 Plus,
G30P-5 Plus, G33P-5 Plus, G35C-5 Plus
GC20P-5, GC25P-5, GC30P-5, GC33P-5
Original Instruction
1105

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the D20S-5 and is the answer not in the manual?

Questions and answers

Related Manuals for Doosan D20S-5

Summary of Contents for Doosan D20S-5

  • Page 1 SB2349E04 Operation & Maintenance Manual FORKLIFTS 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 G20P-5 Plus, G25P-5 Plus, G30P-5 Plus, G33P-5 Plus, G35C-5 Plus GC20P-5, GC25P-5, GC30P-5, GC33P-5 Original Instruction 1105...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Information Section Maintenance Section Foreword ............... 2 Inspection, Maintenance and Repair of Lift Truck Forks ..............167 Tire Inflation Information ........171 Torque Specifications ........172 Safety Section Cooling System Specifications ......174 Fuel Specifications ..........176 Important Safety Information ........

  • Page 4: Information Section

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

  • Page 5: Maintenance Intervals

    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 &...

  • Page 6: Safety Section

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

  • Page 7: Safety

    Service Warning outside in U.S.A., operate this lift truck in accordance with local regulations. DOOSAN lift trucks are manufactured according to the regulations and standards laid down in EU Machinery Directive 98/37/EC and EMC directive 2004/108/EC. Please refer to the Directives 89/655/EC and 89/391/EC and its amendments for the safe use of DOOSAN lift trucks.

  • Page 8: General Warning To Operator

    Safety Section 5. Travel with load as low as possible and tilted General Warning to Operator back. If load interferes with visibility, travel with load trailing. 6. On grade operations travel with load up grade. 7. Watch out for pedestrians and obstructions. Check overhead clearances.

  • Page 9: Pressure Warning

    Safety Section Pressure Warning No Standing On Fork Warning No Standing Under Fork Warning WARNING Contents under pressure may be hot. Allow to WARNING cool before opening. Do not stand or ride on the forks. Do not stand or ride on a load or pallet on the forks. Do not stand or walk under the forks.

  • Page 10: Moving Fan Warning

    Safety Section Overhead Guard Must Be In Place Moving Fan Warning Warning WARNING WARNING To avoid personal injury, stay clear of moving fan. Operation without this device in place may be hazardous. This guard conforms A.N.S.I.B56.1 and F.E.M.Section IV. This design has been tested with an impact of appropriate valve.

  • Page 11: Parking Brake

    Safety Section Parking brake Pull the lever BACK to engage the parking brake. Push the lever FORWARD to release the parking brake. Applying the parking brake puts the transmission in NEUTRAL. The parking brake must be applied when leaving the lift truck and when starting the engine.

  • Page 12: General Hazard Information

    Safety Section General Hazard Information 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.

  • Page 13: Operation Information

    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-...

  • Page 14: Operating The Lift Truck

    Safety Section Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck equipped) and all other devices are working properly. Always keep the lift truck under control. Check proper operation mast Obey all traffic rules and warning signs. attachments.

  • Page 15: Lift Truck Parking

    Safety Section Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers.

  • Page 16: Maintenance Information

    To avoid possible weakening of the Falling Objects The maximum air pressure must be below 205 kPa Protective Structure (FOPS), consult a DOOSAN (30 psi) for cleaning purposes. dealer before altering, by adding weight to, welding on, or cutting or drilling holes into the structure.

  • Page 17: Burn Prevention

    Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant Coolant mixtures are flammable. At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to Fuel leaked or spilled onto hot surfaces or electrical heaters or the engine contain hot water or steam.
  • Page 18 Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your DOOSAN dealer for repair or replacement. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks.

  • Page 19: Operator Restraint System(If Equipped)

    If a label is on a part misused equipment. that is replaced, make sure a new label is installed on the replaced part. See you DOOSAN Lift Truck Stand behind the tread and use a self-attaching dealer for new labels.

  • Page 20: Seat Adjustment

    Safety Section If Optional Suspension Seat (weight adjusting type) Equipped Forward and Backward Adjustment The seat can be adjusted by pushing the lever on the right side of seat. The “Survive in tipover” warning is located on the overhead guard. It shows the proper use of the Forward and Ba operator restraint system.
  • Page 21 On visual inspection, fastenings must be intact, otherwise, contact the safety manager. WARNING Your DOOSAN truck comes equipped with a DOOSAN operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DOOSAN operator restraint system.
  • Page 22 Safety Section WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 3. In the event of a tipover, the seat and restraint system should be inspected for damage and replaced, if necessary. NOTE: Operator restraints shall be examined at the regular truck service intervals.

  • Page 23: Avoiding Lift Truck Tipover

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

  • Page 24: Lift Truck Stability Base

    CG moves forward of the front axle, the lift truck forklifts sold by DOOSAN shall not be removed, will tip forward. If the CG moves outside of the line altered or replaced without DOOSAN’s approval. on either side of the stability base, the lift truck will tip to the side.

  • Page 25: Safety Rules

    Safety Section Safety Rules Do not operate a lift truck unless you are in the operator’s seat. Keep hands and feet inside the operator’s compartment. Do not put any part of Only properly trained and authorized personnel the body outside of the operator’s compartment. should operate forklift trucks.
  • Page 26 Safety Section Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the Do not let other people ride on the truck. rated capacity shown on the capacity plate. Lift trucks are designed to carry loads, not people. Do not add extra counterweight to the truck.
  • Page 27 Safety Section Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward. load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards. cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
  • Page 28 Safety Section Do not stack or turn on ramps. Do not drive in forward direction when loads restrict Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
  • Page 29 Safety Section Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and Never overtake other vehicles.
  • Page 30 Safety Section Do not operate forklifts near flammable or An unloaded forklift may be easier to tip over than a combustible materials. loaded truck. avoid discoloration, deformation When traveling without a load, the risk of lateral combustion of materials (such as lumber, veneer overturn is greater.

  • Page 31: How To Survive In A Tipover

    Safety Section How to Survive in a Tipover WARNING In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided. Brace your feet and keep them within the operator’s compartment.

  • Page 32: General Section

    7-11, Hwasu-dong, Dong-gu, Incheon, Korea 401-010 Authorized Representative, Compiler of Technical File According to 2006/42/EC and Keeper of Technical File According to 2000/14/EC Doosan Infracore Europe S.A., Mr. K. S. Yoon 1A Rue Achille Degrace 7080 Frameries, Belgium herewith declare...

  • Page 33: Specifications

    General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN D20S-5 D25S-5 MODEL (YANMAR,TIER2) (YANMAR,TIER2) CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas diesel diesel OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven)
  • Page 34 General Section DOOSAN DOOSAN DOOSAN D30S-5 D33S-5 D35C-5 (YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2) 3000 3250 3500 diesel diesel diesel rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197 1255 2165 2165...
  • Page 35 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN D20S-5 D25S-5 MODEL (YANMAR,TIER3) (YANMAR,TIER3) CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas diesel diesel OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven)
  • Page 36 General Section DOOSAN DOOSAN DOOSAN D30S-5 D33S-5 D35C-5 (YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3) 3000 3250 3500 diesel diesel diesel rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197 1255 2165 2165...
  • Page 37 General Section Specifications CHARACTERISTICS MANUFACTURER MODEL CAPACITY at rated load center LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load LIFT WITH STD TWO-STAGE MAST free lift FORK CARRIAGE ISO class...
  • Page 38 General Section DOOSAN DOOSAN DOOSAN G20E-5 G25E-5 G30E-5 2000 2500 3000 rider-seated rider-seated rider-seated 3230 3230 3230 40x100x1050 40x100x1050 45x125x1050 275x1035 275x1035 286x1044 6/10 6/10 6/10 2530 2595 2700 1170 1170 1197 2175 2175 2165 4490 4490 4490 2183 2183...
  • Page 39 General Section Specifications CHARACTERISTICS MANUFACTURER MODEL CAPACITY at rated load center LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load LIFT WITH STD TWO-STAGE MAST free lift FORK CARRIAGE ISO class...
  • Page 40 General Section DOOSAN DOOSAN DOOSAN G20E-5 G25E-5 G30E-5 2000 2500 3000 LP/Gas LP/Gas LP/Gas rider-seated rider-seated rider-seated 3230 3230 3230 40x100x1050 40x100x1050 45x125x1050 275x1035 275x1035 286x1044 6/10 6/10 6/10 2530 2595 2700 1170 1170 1197 2175 2175 2165 4490 4490...
  • Page 41 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN MODEL G20P-5 G25P-5 CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS...
  • Page 42 General Section DOOSAN DOOSAN DOOSAN G30P-5 G33P-5 G35C-5 3000 3250 3500 rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197 1255 2165 2165 2165 4490 4490 4260 2183 2183...
  • Page 43 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN DOOSAN MODEL G20P-5 Plus G25P-5 Plus CAPACITY at rated load center 2000 2500 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear...
  • Page 44 General Section DOOSAN DOOSAN DOOSAN G30P-5 Plus G33P-5 Plus G35C-5 Plus 3000 3250 3500 rider-seated rider-seated rider-seated 3230 3230 3000 45x125x1050 45x125x1050 45x125x1050 286x1044 286x1044 286x1044 6/10 6/10 6/10 2700 2730 2765 1197 1197 1255 2165 2165 2165 4490 4490...
  • Page 45 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN MODEL GC20E-5 CAPACITY at rated load center 2000 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load...
  • Page 46 General Section DOOSAN DOOSAN DOOSAN GC25E-5 GC30E-5 GC33E-5 2500 3000 3000(6500LBS) rider-seated rider-seated rider-seated 3230 3230 3230 40x100x1050 45x125x1050 45x125x1050 297x905 282x954 282x954 2268 2333 2368 1110 1110 1110 2130 2130 2130 4480 4480 4480 2150 2150 2150 1038 1038...
  • Page 47 General Section Specifications CHARACTERISTICS MANUFACTURER DOOSAN MODEL GC20P-5 CAPACITY at rated load center 2000 LOAD CENTER distance POWER TYPE electric, diesel, gas, LPG-gas OPERATOR TYPE stand-on, ride-seated rider-seated TIRES C=cushion, P=pneumatic WHEELS(x=driven) number of front/rear DIMENSIONS maximum fork height with rated load...
  • Page 48 General Section DOOSAN DOOSAN DOOSAN GC25P-5 GC30P-5 GC33P-5 2500 3000 3000(6500LBS) rider-seated rider-seated rider-seated 3230 3230 3230 40x100x1050 45x125x1050 45x125x1050 297x905 282x954 282x954 2268 2333 2368 1110 1110 1110 2130 2130 2130 4480 4480 4480 2150 2150 2150 1038 1038...

  • Page 49: Noise And Vibration

    2000/14/EC Model Guaranteed Sound (m/s dB(A) dB(A) Mean Uncertainty TIER - II (B3.3 E/G) D20S-5,D25S-5,D30S-5, D33S-5, D35C-5 (W/O Cabin) TIER - III (4TNE98 E/G) D20S-5,D25S-5,D30S-5, (W/O Cabin) TIER - III (4TNE98 E/G) D33S-5, D35C-5 (W/O Cabin) TIER - III (G420F(E) E/G)

  • Page 50: Capacity Chart (Without Sideshifter Pneumatic)

    General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -48-...
  • Page 51 General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -49-...
  • Page 52 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -50-...
  • Page 53 General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -51-...

  • Page 54: Capacity Chart (With Sideshifter Pneumatic)

    General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -52-...
  • Page 55 General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE MODEL STD, FFL -53-...
  • Page 56 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -54-...
  • Page 57 General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE MODEL STD, FFL -55-...

  • Page 58: Capacity Chart (Without Sideshifter Cushion)

    General Section Capacity Chart (Without Sideshifter cushion) NARROW TIRE MODEL STD, FFL -56-...
  • Page 59 General Section Capacity Chart (Without Sideshifter cushion) NARROW TIRE MODEL STD, FFL -57-...
  • Page 60 General Section Capacity Chart (Without Sideshifter cushion) WIDE TIRE MODEL STD, FFL -58-...
  • Page 61 General Section Capacity Chart (Without Sideshifter cushion) WIDE TIRE MODEL STD, FFL -59-...

  • Page 62: Capacity Chart (With Sideshifter Cushion)

    General Section Capacity Chart (With Sideshifter cushion) NARROW TIRE MODEL STD, FFL -60-...
  • Page 63 General Section Capacity Chart (With Sideshifter cushion) NARROW TIRE MODEL STD, FFL -61-...
  • Page 64 General Section Capacity Chart (With Sideshifter cushion) WIDE TIRE MODEL STD, FFL -62-...
  • Page 65 General Section Capacity Chart (With Sideshifter cushion) WIDE TIRE MODEL STD, FFL -63-...

  • Page 66: Serial Number

    General Section Serial Number Serial Number Locations For quick reference, record your lift truck's serial numbers in the spaces provided below the photographs. 2.0 liter Spark-Ignition Engine Serial Number (G420F(E)) •_____________________________ Lift Truck Serial Number •_____________________________ 2.4 liter Spark-Ignition Engine Serial Number (G424F(E)) •_____________________________ 3.3 liter Diesel Engine (4TNV98) Serial Number...
  • Page 67 General Section Typical Example 3.0 liter Spark-Ignition Engine Serial Number Side Shifter Serial Number (If Equipped) (G430FE) •_____________________________ •_____________________________ Power Shift Transmission Serial Number •_____________________________ Drive Axle Serial Number •_____________________________ -65-...

  • Page 68: Attachment Abbreviations (Includes Special Forks)

    General Section Attachment Abbreviations (Includes Special Forks) -Special Carriage-increased width, height or outreach -Shaft-type Sideshift Carriage -Hook-type Sideshift Carriage (ITA) -Counterweight -Special Forks -Swing Shift, Sideshift -Ram or Boom DBCBH -Double Cube Block Handler -Hydraulic Fork Positioner -Crane Arm or Crane Boom -Tire Handler -Container Handler -Load Push-Pull Device...

  • Page 69: Operator's Warning And Identification Plate

    General Section Operator's Warning and Identification Plate Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES. DO NOT exceed capacity as equipped load ratings. Operator's Warning Plate Identification, Lift Capacity and Attachment Plate Located on the right side of the operator's seat. Located on the cowl to the right side of the steering column.

  • Page 70: Operation Section

    Operation Section Operator’s Station and Monitoring Systems Instrument Panel Your lift truck may not have the same indicator or warning lights as shown in the illustrations. Due to the various options available, typical instrument panels are shown. However, the symbols on the indicators and lights on your panel identify what those particular items are. Also, the symbol for each of the items is identified and an explanation of their function and location is described on the following pages.
  • Page 71 Operation Section 1. Engine Oil Pressure Indicator Light - 7. Transmission Oil Temperature Gauge (Except for G430FE) Indicates insufficient - Indicates transmission oil temperature. If engine oil pressure. The light will come on both tenth & ninth flash out of phase while when the ignition switch is turned to the operating the lift truck, excessive transmission oil ON position.
  • Page 72 Operation Section 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. 15. Low Level Light of LP GAS – Indicates the low Level of LP GAS (LP or DUAL only) 16.

  • Page 73: Engine Compartment

    Operation Section Electrical Disconnect Switch (If Engine Compartment Equipped) 1. The engine compartment is accessible by pulling the latch (GC Series), or pushing down the lever 1. ON - Connects the battery for electrical located at cowl (G.D Series) and raising the hood power to all electrical circuits.

  • Page 74: Seat Switch System (If Equipped)

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

  • Page 75: Tilt Steering Column

    Operation Section Tilt Steering Column WARNING When closing the engine hood, be careful not to pinch your hand. Circuit Breaker To adjust the steering column, push down the knob(1), and move the steering column to the desired position, then release the knob(1). Circuit Breaker -Protects...

  • Page 76: Lift Truck Controls

    Operation Section Lift Truck Controls Direction Control Lever Service Brake Pedal Push DOWN on the brake pedal to slow 1. Forward - Push the lever forward for or stop the lift truck. FORWARD direction travel. RELEASE the brake pedal to allow the lift 2.

  • Page 77: Parking Brake Lever

    Operation Section Parking Brake Lever Tilt Control Pull the lever BACK to engage the parking brake. 1. Mast Tilt Forward - Push the lever FORWARD smoothly to tilt the mast forward. Push the lever FORWARD to release the parking brake. 2.

  • Page 78: Refueling

    Operation Section Refueling Gasoline or Diesel Engine Equipped WARNING Explosive fumes present during refueling. Do not smoke in refueling areas. Lift truck should be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors. Stop the engine and get off the lift truck during 1.

  • Page 79: Changing Lp Tanks

    Operation Section Changing LP Tanks WARNING Only trained, authorized personnel should fill or exchange LP tanks. Personnel engaged in filling of LP containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves. Do not refuel or store LP powered lift trucks near any underground entrance, elevator shafts or any other place where LP could collect in a pocket...
  • Page 80 Operation Section NOTICE If the location pin (dowel) is missing or broken, be sure the pin is replaced. 11. Position the replacement tank so that the locating pin (dowel) is in place. WARNING The LP tank must not extend past the 6.

  • Page 81: Before Starting The Engine

    Operation Section Before Starting the Engine Walk - Around Inspection Make a thorough walk - around inspection before mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or coolant leaks. Check condition of tires, mast, carriage, forks or attachments.
  • Page 82 Operation Section 11. Measure the engine crankcase oil level with the 13. Observe the fuel level gauge after starting the dip stick. Maintain the oil level between the truck. Add fuel if necessary. MAX. and MIN., (or FULL and ADD) notches on the dip stick.

  • Page 83: Starting The Engine

    Operation Section Starting the Engine Prestart Conditions Gasoline Engine NOTE: The engine will not start unless the transmission directional control lever is in NOTICE the NEUTRAL position. Do not leave the key in ON position when engine is not running. Do not engage the starter more than 10 seconds at any one time.

  • Page 84: Diesel Engine

    Operation Section LP Engine Diesel Engine Starting a Cold Diesel Engine WARNING 1. Turn the key to the ON position. The start pre LP fuel is flammable and can cause personal heat light will come ON. The preheat light will injury.
  • Page 85 : 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. -83-...

  • Page 86: Dual Fuel System

    Operation Section Dual Fuel System Changing From Gasoline to LP – 4. Open the fuel valve, on the LP tank, by slowly turning the valve counterclockwise. 5. Turn the ignition switch key to the OFF position NOTE: The Underwriter’s Laboratory (U.L.) and then to the START position to start the requires that the gasoline tank must be at...
  • Page 87 Operation Section 3. Move lever (1) from the LPG (3) POSITION to the OFF (2) position. Allow the engine to run until the fuel in the line runs out and engine stops. 4. Move lever (1) from the LPG (3) position to the GAS (4) position.

  • Page 88: After Starting The Engine

    Operation Section After Starting the Engine The diesel engine water in fuel filter indicator light(4), will not come ON with the engine Observe all indicator lights and gauges frequently running, unless water in fuel filter exceeds during operation, to make sure all systems are 100cc.

  • Page 89: Lift Truck Operation

    Operation Section Lift Truck Operation Power Shift Transmission/ Drive axle WARNING A lift truck with the engine running but without an operator can move slowly (creep) if the 1. Start the engine. See topic “Starting the Engine”. transmission is engaged. This could result in personal injury.
  • Page 90 Operation Section Inching 7. To change the lift truck direction of travel, release the accelerator pedal. NOTE: The purpose of the inching pedal is to 8. Push down on the service brake pedal to provide precise lift truck inching control at reduce the lift truck speed as necessary.
  • Page 91 Operation Section Electronic Controlled Spark-Ignition Engines G420FE Engine and G424FE Engine and G424IE Engine EMS (Engine management system) of G420FE required. A small engine control module (SECM) engine and G424FE engine and G424IE engine is uses two heated exhaust gas oxygen sensors a closed loop system utilizing a 3-way catalytic (HEGO) in the exhaust system to monitor exhaust muffler to reduce the emission level in the exhaust...
  • Page 92 Operation Section G420F Engine and G424F Engine and G424I Engine EMS (Engine management system) of G420F engine and G424F engine and G424I engine is an open loop LP system and/or closed loop gasoline system. 3-way catalytic muffler is not used for this system. LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM.
  • Page 93 Operation Section Basic Troubleshooting(LP) The MI-07 systems are equipped with built-in fault basic checks that should be made before referring diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
  • Page 94 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Difficult to Start Fill fuel container Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for a “click”...
  • Page 95 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Will Not Run Fill fuel container Continuously Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for a “click”...
  • Page 96 Operation Section Problem Probable Cause Corrective Action Clogged fuel filter Repair/replace as required Will Not See Maintenance Accelerate/Hesita Section, LP Fuel Filter replacement tion During Faulty vapor connection between Check connection Acceleration pressure regulator/converter Verify no holes in hose and the mixer Clamps must be tight Look for kinked, pinched and/or collapsed hose...
  • Page 97 Operation Section Problem Probable Cause Corrective Action Fuel Lock-off malfunction Repair/replace Fuel Lock-off Engine Stalls See Engine Service Manual Faulty vapor connection between Check connection pressure regulator/converter Verify no holes in hose and the mixer Clamps must be tight Look kinked, pinched and/or...
  • Page 98 Operation Section Problem Probable Cause Corrective Action Incorrect Idle speed control See Advanced Diagnostics & See Engine Rough Idle Service Manual Incorrect timing or spark control Engine Mechanical See Engine Service Manual Incorrect Idle speed control See Advanced Diagnostics & See Engine High Idle Speed Service Manual Throttle sticking...
  • Page 99 Operation Section Problem Probable Cause Corrective Action Air/Fuel Mixer malfunction Check mixer Excessive Fuel See Engine Service Manual Consumption/LP Air filter clogged Check air filter Clean/replace as required G Exhaust Smell Vacuum leak Check system vacuum hoses from regulator to FTV and mixer Repair/replace as necessary Pressure regulator malfunction/fuel Test pressure regulator operation...

  • Page 100: Basic Troubleshooting (Gasoline)

    Operation Section Basic Troubleshooting (Gasoline) Problem Probable Cause Corrective Action Fuel tank empty Fill fuel container Engine Cranking The tank should be at least ¼ full to but Will Not Start properly prime the fuel pump. Fuel select switch is not on GAS (Gas) Clogged fuel filter Repair/replace as required...
  • Page 101 Operation Section Problem Probable Cause Corrective Action Fuel tank almost empty Fuel Pump Cavitations Difficult to Start The tank should be at least ¼ full to (Gas) properly prime the fuel pump Fuel select switch is not on GAS Clogged fuel filter Repair/replace as required See Maintenance section, Primary and Secondary Fuel Filter replacement...
  • Page 102 Operation Section Problem Probable Cause Corrective Action Electric Fuel Pump malfunction Check electrical connection Will Not Run (GAS) Check Relay and fuse Turn key ON Continuously and verify pump is operating See Engine Service Manual (Gas) Pressure regulator malfunction Test pressure regulator operation See Engine Service Manual Fuel Injector malfunction Test Injector operation...
  • Page 103 Operation Section Problem Probable Cause Corrective Action Throttle butterfly valve not opening See Advanced Diagnostics Will Not or sticking Accelerate/Hesita Foot Pedal signal incorrect or tion During intermittent Acceleration or Incorrect air/fuel or ignition control Engine Stalls (Gas) Engine Mechanical See Engine Service Manual Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
  • Page 104 Operation Section Problem Probable Cause Corrective Action Incorrect Idle speed control Advanced Diagnostics & Engine Rough Idle (Gas) Service Manual Incorrect timing or spark control Engine Mechanical See Engine Service Manual Incorrect Idle speed control Advanced Diagnostics & Engine High Idle Speed Service Manual (Gas) Throttle sticking...
  • Page 105 Operation Section Problem Probable Cause Corrective Action Isolate the gasoline system by Verify LPG cylinder is full and valve is open. Poor High Speed running the lift truck on LPG If the problem does not exist in LPG mode Performance proceed with the corrective action steps below.
  • Page 106 Operation Section Advanced Diagnostics Displaying Fault Codes (DFC) from SECM Memory MI-07 systems are equipped with built-in fault diagnostics. Detected system faults To enter code display mode you must turn OFF the displayed by the Malfunction Indicator Lamp (MIL) ignition key. Now turn ON the key but do not start as Diagnostic Fault Codes (DFC) or flash codes, the engine.
  • Page 107 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK NONE None, used as end of the fault list Signifies the end of one pass NONE identification through the fault list (1) TurnOnMil Check INJ1 wiring for an open circuit Inj1Open...
  • Page 108 Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check coolant system for radiator blockage, proper coolant level and for ECTOverTempFault leaks in the system. Engine coolant temperature is (1) TurnOnMil Possible ECT short to GND, check ECT high.
  • Page 109 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 out of TPS1 sensor for an open circuit or short to (1) TurnOnMil range low, normally set if the (2) CutThrottle...
  • Page 110 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TPS2AdaptHiMin Learned WOT end of TPS2 None sensor range lower than expected TPS1AdaptLoMax Learned closed throttle end None of TPS1 sensor range higher than expected TPS2AdaptLoMax Learned closed throttle end of...
  • Page 111 Operation Section Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 (signal) MAPRangeLow TMAP Pin 1 to SECM Pin B1 (sensor GND) Manifold Absolute Pressure TMAP Pin 3 to SECM Pin B24 (XDRP +5 sensor input is low, normally Vdc) set if the TMAP pressure...
  • Page 112 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK MAPTimeRangeHigh Check TMAP connector and MAP signal wiring for a shorted circuit Manifold Absolute Pressure Sensor Input is High, normally TMAP Pin 4 to SECM Pin B18 (signal) TMAP Pin 1 to SECM Pin B1 (sensor GND) set if the TMAP pressure TMAP Pin 3 to SECM Pin B24 (XDRP +5 Vdc)
  • Page 113 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check TMAP connector and IAT signal wiring IATRangeHigh for a shorted circuit TMAP Pin 2 to SECM Pin B12 (signal) Intake Air Temperature TMAP Pin 1 to SECM Pin B1 (sensor GND) Sensor Input is High normally TurnOnMil...
  • Page 114 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A6 (EST4) to OEM ignition EST4_Open system. See application manual. EST4 output open, possibly Verify GND on ignition module TurnOnMil...
  • Page 115 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK EST2_Short EST2 output shorted high or low, EST2 signal shorted to None ground or power or defective spark module EST3_Short EST3 output shorted high or low, EST3 signal shorted to None ground or power or defective...
  • Page 116 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK EST7_Short EST7 output shorted high or low, EST7 signal shorted to None ground or power or defective spark module EST8_Short EST8 output shorted high or None low, EST8 signal shorted to ground or power or defective...
  • Page 117 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check ETC driver wiring for a shorted circuit SECM Pin A17 to ETC + Pin 1 HbridgeFault_ETC SECM Pin A18 to ETC - Pin 4 Electronic Throttle Control Perform the throttle test using the Service Driver has failed.
  • Page 118 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 XDRP +5 Vdc to TMAP Pin 1 XDRG GND Verify transducer power at the (1) TurnOnMil SECM with a multimeter...
  • Page 119 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION FIRST PROBABLE FAULT FAULT ACTION * CHECK APP2RangeLow APP2 sensor voltage out of range Check foot pedal connector low, normally set if the APP2 signal TurnOnMil Check APP2 signal at SECM PIN •...
  • Page 120 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK (1) TurnOnMil Check FTV1 for an open wire or FTV connector (2) Disable LSDFault_Dither1 being disconnected GasO2 Ctrl Dither Valve 1 Fault, signal FTV1 Pin 1 (signal) to SECM Pin A1 has opened or shorted to FTV1 Pin 2 (power) to SECM (DRVP) Pin A23...
  • Page 121 Operation Section LSDFault_MIL Malfunction Indicator Lamp Fault, signal has opened or None None shorted to ground or power or defective MIL lamp (1) TurnOnMil (2) Disable GasFuelAdaptRangeLo Check for vacuum leaks. GasO2 Ctrl In LPG mode, system had to Check fuel trim valves, e.g. leaking valve or (3) Disable (72) adapt rich more than...
  • Page 122 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Check dual dither valves, e.g. plugged valve or (1) TurnOnMil hose. GasFuelAdaptRangeHi (2) Disable Check for plugged orifice(s). In LPG mode, system had GasO2 Ctrl (73) to adapt lean more than...
  • Page 123 Operation Section Correct other faults that may contribute to 752 (e.g. faults pertaining to dither valves, Pre-Cat GasPostO2FailedLean (1) TurnOnMil O2, Post Cat O2 sensor) Pre-catalyst O2 sensor (2) DisableGasPost Check for vacuum leaks indicates extended lean O2Ctrl Check for leaks in exhaust, catalytic converter, operation on LPG (Certified Units Only) HEGO sensors;...
  • Page 124 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 772 (1) TurnOnMil (e.g. faults pertaining to FTVs, Pre-Cat O2, GasPostO2FailedRich (2) DisableGasPost Post Cat O2 sensor) Pre-catalyst O2 sensor O2Ctrl Look for leaks in exhaust, catalytic converter,...
  • Page 125 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 852 (e.g. faults pertaining to Injectors, MAP, IAT, (1) TurnOnMil LiqPostO2FailedLean Pre-Cat O2, Post Cat O2 sensor) (2) DisableLiqPost Pre-catalyst O2 sensor Look for leaks in exhaust, catalytic converter,...
  • Page 126 Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TransOilTemp (1) TurnOnMil Refer to drivetrain manufacturer’s Excessive transmission oil (2) DelayedEngine transmission service procedures. temperature Shutdown Perform service procedure related to ServiceFault1 None Service Interval 1...
  • Page 127 Operation Section Electronic Controlled Spark-Ignition Engines G430FE Engine The primary components of the fuel system are the fuel supply, direct electronic pressure regulator (DEPR), fuel mixer, electronic throttle control (ETC) device, 2-Stage convertor, engine control module (ECM), and a catalytic converter. The system operates on a slightly positive fuel pressure. Primary fuel pressure can be measured at the LD 2-Stage convertor.
  • Page 128 Operation Section EMS schematic of G430FE LP engine -126-...
  • Page 129 Operation Section Basic Troubleshooting(LP) The G430FE fuel systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) and are covered in the Advanced Diagnostics section. Items such as fuel level, plugged fuel lines, clogged fuel filters and malfunctioning pressure regulators may not set a fault code by the Engine Control Module (ECM).
  • Page 130 Operation Section INTERMITTENT Checks Action DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code (DTC). Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables Preliminary Checks with this condition may result in the replacement of good parts.
  • Page 131 Operation Section NO START Checks Action DEFINITION: The engine cranks OK but does not start. Preliminary Checks None Use the DST to : • Check for proper communication with both the ECM • Check all system fuses engine fuse holder. Refer to Engine Controls Schematics. ECM Checks •...
  • Page 132 Operation Section NO START Checks Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel system. Check for the following: • Vacuum leaks. • Improper valve timing. Engine Mechanical Checks • Low compression. •...
  • Page 133 Operation Section HARD START Checks Action DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. Preliminary Checks Make sure the vehicle’s operator is using the correct starting procedure. •...
  • Page 134 Operation Section HARD START Checks Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system. Check for the following: • Vacuum leaks • Improper valve timing Engine Mechanical • Low compression Checks •...
  • Page 135 Operation Section CUTS OUT, MISSES Checks Action DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
  • Page 136 Operation Section HESITATION, SAG, STUMBLE Checks Action DEFINITION: The engine has a momentary lack of response when putting it under load. The condition can occur at any engine speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks None •...
  • Page 137 Operation Section BACKFIRE Checks Action DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Checks None Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire.
  • Page 138 Operation Section LACK OF POWER, SLUGGISHNESS, OR SPONGINESS Checks Action DEFINITION: The engine delivers less than expected power. • Refer to the LPG Fuel system OBD System Check. • Compare the customer’s vehicle with a similar unit to verify customer has an actual problem.
  • Page 139 Operation Section ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action DEFINITION: The engine runs unevenly at idle. If severe enough, the engine may shake. Preliminary Checks None. Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance: • Check for silicone contamination from fuel or improperly used sealant. If contaminated, the sensor may have a white powdery coating result in a high but false signal voltage (rich exhaust indication).
  • Page 140 Operation Section ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action Check the engine for: • Broken motor mounts. • Improper valve timing. • Low compression. Engine Mechanical Check • Improper valve clearance. • Worn rocker arms. • Broken or weak valve springs. •...
  • Page 141 Operation Section Advanced Diagnostics The Fuel system has built-in diagnostics for system trouble shooting. The system has a dash mounted malfunction indicator lamp (MIL) that provides indications of engine or fuel system related problem. Most engine control system related problems that affect emissions or driveability of the vehicle will set a (DTC) diagnostic trouble code and illuminate the MIL.

  • Page 142: Blink Code Function

    Operation Section BLINK CODE FUNCTION Although the DST is considered a required tool to access the DTC codes, codes may be retrieved without a laptop computer using the blink code function. To enable this function follow the steps below: • Jump pins 1 and 4 at the DLC connector (see illustration below) •...

  • Page 143: Malfunction Indicator Lamp (Mil) Operation

    Operation Section Malfunction Indicator Lamp (MIL) Operation How does my MIL work? The emissions control system utilizes a MIL to warn the operator or technician of a possible issue with the engine or emissions control system. The system will keep the MIL illuminated for the entire key cycle in which the trouble code was set.
  • Page 144 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (1 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 11: Intake cam / distributor position error DTC 268: Injector 3 coil shorted 520800 DTC 16: Crank and/or cam could not synchronize during DTC 270: Injector 4 open or short to ground...
  • Page 145 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (2 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 601: Microprocessor failure - FLASH DTC 1175: MegaJector voltage supply low 520260 DTC 1176: MegaJector internal actuator fault DTC 604: Microprocessor failure - RAM 520260...
  • Page 146 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (3 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 1546: AUX analog Pull-Up/Down 3 low voltage DTC 1662: PWM6 short to power 520221 DTC 1547: AUX analog Pull-Up/Down 4 high voltage DTC 1663: PWM7 open / ground short...
  • Page 147 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (4 of 4) DTC Set 2 Description SPN-2 FMI-2 DTC 2618: Tach output ground short DTC 2619: Tach output short to power DTC 8901: UEGO microprocessor internal fault 3221 DTC 8902: UEGO heater supply high voltage 3222...
  • Page 148 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (1 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 1561: AUX analog Pull-Down 2 high voltage DTC 107: MAP voltage low DTC 1561: AUX analog Pull-Down 3 high voltage DTC 108: MAP pressure high DTC 1561: AUX analog Pull-Down 2 low voltage DTC 2229: BP pressure high...
  • Page 149 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (2 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 16: Crank and/or cam could not synchronize du DTC 1661: PWM6 open / ground short DTC 1629: J1939 TSC1 message receipt loss DTC 1664: PWM7 short to power DTC 1626: CAN-J1939 Tx fault...
  • Page 150 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (3 of 4) DTC Set 2 DTC Set 2 Description Description SPN-2 FMI-2 SPN-2 FMI-2 DTC 304: Cylinder 4 emissions/catalyst damaging m DTC 175: Adaptive-learn gasoline bank2 low 1326 520201 DTC 1315: Cylinder 5 misfire detected DTC 1161: Adaptive-learn LPG high...
  • Page 151 Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (4 of 4) DTC Set 2 Description SPN-2 FMI-2 DTC 188: Gaseous fuel temperature sender high vol 520240 DTC 187: Gaseous fuel temperature sender low volta 520240 DTC 331: Knock2 excessive or erratic signal 520241 DTC 332: Knock2 sensor open or not present 520241...

  • Page 152: Mono-Ped Control System (Option)

    Operation Section Mono-Ped Control System (Option) Forward-Push the left side (2) of the pedal for FORWARD direction travel. Neutral-The lift truck should not move when the Mono-Ped pedal is released.. Reverse-Push the right side (1) of the pedal for REVERSE direction travel. The MONO-PED pedal controls the speed and direction of the lift truck.

  • Page 153: Auto Shift Controller Asc-100 (If Equipped)

    Operation Section Auto Shift Controller ASC-100 (If Equipped) Product Description Adjustments The Autoshift controller is an electrical control system, specially designed for use on forklift trucks (Direction Inhibit Point) with internal combustion engines. NOTCH Vehicle Speed Its primary purpose is to prevent the operator from 3.3 km/h ( 2.05 mph ) driving the truck outside of the design parameters, 3.6 km/h ( 2.24 mph )

  • Page 154: Diagnostics Features

    Operation Section Diagnostics Features Operation ASC-100 has an internal indicator on the right side This system can basically operate in 2 pre-selected of the controller for displaying the selected gear modes. and the abnormal condition. Automatic mode (Direction Inhibit mode): Selected as factory-setting.

  • Page 155: Manual Mode (Fail-Safe Mode)

    Operation Section Manual Mode (Fail-Safe mode) The system still allows movement of the vehicle in case of controller breakdown by selecting the manual mode with the Fail-Safe mode Switch in the controller. WARNING manual mode, direction inhibition function can not be operated normally. The sudden reversal of a loaded lift truck traveling forward can cause the load to fall or the lift truck to tip.

  • Page 156: Finger Tip (Option)

    Operation Section Finger Tip (Option) Tilt Control knob Function of Knobs If finger tip control option is equipped, the hall-effect type electric knobs replace conventional control valve levers. Lift Control knob Tilt Forward - Push the knob forward smoothly to tilt the lift forks forward. Hold - Release the tilt knob.

  • Page 157: Sideshift Attachment Control

    Operation Section Sideshift Attachment Control Warning Lamp Sideshift Left - Push the knob forward The state of the finger tip system can be checked smoothly to shift the carriage to the left. by the external warning lamp blinking.. Sideshift Hold - Release the sideshift Blinking Lamp State attachment knob.
  • Page 158 Operation Section Auto Tilt Leveling Switch [Aux2] Optional Selector Switch for SAFETY Operating a Rotating Cramp Attachment In case of auto tilt leveling, push this button. Pushing button makes auto tilt leveling function on and off alternately. When the function is on, the mast stops at a vertical position while tilting forward and backward.

  • Page 159: Adjustment Of Armrest

    Operation Section Adjustment of Armrest Up and Down Adjustment By using 2 knobs, adjust the position of the armrest To move the armrest down, turn the knob(2) to give the operator the best comfortable position of counterclockwise arm. knob #1 - Forward and backward adjustment knob #2 - Up and down adjustment.

  • Page 160: Operating Techniques

    Operation Section Operating Techniques Inching into Loads Lifting the Load 1. Lift the load carefully and tilt the mast back a short distance. Typical Example 1. Move the lift truck slowly FORWARD into position and engage the load. The lift truck Typical Example should be square with load, forks spaced evenly between pallet stringers and as far apart...

  • Page 161: Traveling With The Load

    Operation Section Traveling With the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. Typical Example 1. Move the lift truck into the unloading position. Typical Example 1. Travel with the load uphill on upgrades and downgrades.
  • Page 162 Operation Section Turning 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. Typical Example 4.

  • Page 163: Lifting Drums Or Round Objects

    Operation Section Lifting Drums or Round Objects Operating in hot weather Keep the following points in mind when you operate the lift truck in hot weather. 1. Check the radiator. Clogging can cause overheating. Clean them out regularly with a blast of compressed air, also, check for leakage of water.

  • Page 164: Parking The Lift Truck

    Operation Section Parking the Lift Truck 5. Turn the key in the ignition switch to the OFF position and remove the key. NOTE: Park the lift truck level with the fork lowered and the mast tilted forward until the fork touches the floor.

  • Page 165: Lift Fork Adjustment

    Operation Section Lift Fork Adjustment WARNING When adjusting the fork spread, be careful not to pinch your hand between forks and the carriage slot. Hook-on type Fork 1. Move up the hook pin to the free position. 2. Raise the hook pin in each fork to side the fork on the carriage bar.

  • Page 166: Storage Information

    Operation Section Storage Information Before Storage To Operate the Lift Truck after a Long Time Storage Before storing your lift truck, clean and inspect as the following procedures. Remove covers and antirust from each of the components and exposed parts. Wipe away grease, oil, etc.

  • Page 167: Transportation Hints

    Check the state and local laws governing weight, width and length of a load. Contact your DOOSAN Lift Truck dealer for shipping instructions for your lift truck. Always block the trailer or the rail car wheels before loading the lift truck.

  • Page 168: Towing Information

    Operation Section Towing Information Consult your DOOSAN Lift Tuck dealer for towing a WARNING disabled lift truck. Personal injury or death could result when towing a disabled lift truck incorrectly. Block the lift truck wheels to prevent movement before releasing the brakes. The lift truck can roll free if it is not blocked.

  • Page 169: Maintenance Section

    Maintenance Section Inspection, Maintenance and Repair of Lift Truck Forks The following section gives practical guidelines for Some countries have standards or regulations inspection, maintenance and repair of lift truck forks. which apply specifically to the inspection and repair It also provides general information on the design of forks.

  • Page 170: Causes Of Fork Failure

    Maintenance Section Causes of Fork Failure Repetitive Overloading Repetitive cycling of loads which exceeds the Improper Modification or Repair fatigue strength of the material can lead to fatigue Fork failure can occur as a result of a field failure. The overload could be caused by loads in modification involving welding, flame cutting or excess of the rated fork capacity and by use of the other similar processes which affect the heat...

  • Page 171: Daily Inspection

    Maintenance Section Fork Inspection First Installation 1. Inspect forks to ensure they are the correct size for the truck on which they will be used. Make sure they are the correct length and type for the loads to be handled. If the forks have been previously used, perform the “12 Month Inspection”.

  • Page 172: Maintenance And Repair

    Maintenance Section 12 Months Inspection With the fork restrained in the same manner as its mounting on the lift truck, apply the test load Forks should be inspected, at a minimum, every 12 twice, gradually and without shock. Maintain the months.

  • Page 173: Tire Inflation Information

    Maintenance Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures. Shipping Pressure Ply Rating or Size Strength Index 6.5X10 7.0X15 28X9-15 Standard tire, ply rating and inflation pressures. The operating inflation pressure is based on the weight of a ready - to - work machine without attachments, at rated payload, and in average...

  • Page 174: Torque Specifications

    Maintenance Section Torque Specifications Metric Hardware Torque for Standard Bolts, Nuts, and Taperlock Studs Most of the nuts, bolts, studs, and threaded holes in your lift truck are metric. In this manual we provide specifications in both metric and U.S. customary measurement.
  • Page 175 Maintenance Section Torque for Metric Fasteners Torques for Taperlock Studs Thread Size Standard Taperlock Stud Torque NOTICE Inch N•m lb•ft Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or 8 ± 3 6 ± 2 incorrect fasteners will cause lift truck damage or 5/16 17 ±...

  • Page 176: Cooling System Specifications

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

  • Page 177: Coolant Water

    DOOSAN recommends that the coolant mix contain 50% commercially available automotive antifreeze, DOOSAN prefers the use of distilled water or or equivalent and acceptable water to maintain and deionized water to reduce the potential and severity adequate water pump cavitation temperature for of chemical insolubility.

  • Page 178: Fuel Specifications

    Less than 0.05% is preferred. diesel fuels. For electronically controlled engines, for example Doosan approves the use of bio-diesel fuels that do 4TNV98-ZSDF, it is mandatory to use fuel that not exceed a blend of 5% (by volume) of FAME does not contain 0.1 % or more sulfur content.
  • Page 179 LP varies slightly between different parts of the country and different refineries. HD5 or HD10 is recommended for DOOSAN forklift trucks. Precautions and concerns regarding the use of bio- fuels: Composition of HD5 Propane (C 90.0 %...

  • Page 180: Engine Oil (Deo And Eo)

    Failure to follow the oil recommendations can cause suction line clamps, purge and refill the system. shortened engine lift due to carbon deposits or Consult your DOOSAN Lift Truck dealer for purging excessive wear. instructions. Consult the EMA Lubricating Oils Data Book for a Drive Axle Oil listing of oil brands.

  • Page 181: Lubricating Grease (Mpgm)

    Use heavy duty hydraulic brake fluid certified by oil Shortened engine life will result. supplier to meet the latest version of following classifications. NOTE: Multi-grade oils blended DOOSAN for use in transmissions. • ISO 6743/4 Multi-grade oils which use high molecular • AFNOR NFE 48-603 weight polymers viscosity index •...

  • Page 182: Lubricant Viscosities And Refill Capacities

    Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities LUBRICANT VISCOSITIES REFILL CAPACITIES - (APPROXIMATE) FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment or System Liters U.S Gal. Compartment °C °F Engine Crankcase w/Filter or System Viscosities G420F & G420FE 2.0 liter 1.11 G420F(E) Gasoline &...

  • Page 183: Maintenance Intervals

    Maintenance Section Maintenance Intervals First 50 - 100 Service Hours or a Week NOTICE Engine Oil & Filter (Diesel Engine Only) - Change Never exceed the Maintenance Intervals specified ................198 in the manual. Defects and/or damage to the Transmission Oil, Oil Filter & Strainer - Check, important functional components may be resulted Clean, Change ..........
  • Page 184 Maintenance Section Engine Oil & Filter (Diesel Engine Only) - Change Every 2500 Service Hours or 15 Months ................222 Water Separator (4TNV98 Diesel Engine Only) - Hydraulic Oil - Check, Clean, Change ....241 Clean ..............223 Inspect Battery System ........241 Replace Oxygen Sensor (G420F(E) /G424F(E) /G424I(E) /G430FE Engine Only) ......
  • Page 185 Maintenance Section FIRST Quick Reference to Maintenance Schedule EVERY ITEMS SERVICES PAGE Air Cleaner Indicator Check Air Intake System Change Air Intake System Check, Clean Battery Terminal Clean, Inspect Belts Check, Adjust Brake Oil Level Check Carriage Roller Extrusion Adjust Checking the TMAP Sensor (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) Coolant Level...
  • Page 186 Maintenance Section FIRST Quick Reference to Maintenance Schedule EVERY ITEMS SERVICES PAGE Inspect for Intake Leaks (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) Inspect Ignition System (LP, Gasoline & Dual Fuel Engines Only) Inspect Mixer Assembly (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) Inspect Throttle Assembly (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) Inspect Tightness (GC - Series) Inspect Vacuum Lines and Fittings (G420F(E)/G424F(E)/G424I(E) Engine Only)

  • Page 187: When Required

    Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Fuel Tank Filter Cap and Screen Seat, Hood Latch & Support (If Equipped) - Clean Cylinder - Check, Lubricate Park the lift truck with the forks lowered, parking brake applied, transmission in neutral and the...

  • Page 188: Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset

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

  • Page 189: Priming The Fuel System(Diesel Engine Only)

    Maintenance Section Priming the Fuel System(Diesel Circuit Breaker Engine Only) 4TNV98 Diesel Engine Only The fuel system needs to be primed under certain conditions. Before starting the engine for the first time After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as 1.
  • Page 190 Maintenance Section 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. To prime the fuel system on engines not equipped with an electric fuel system: 1.

  • Page 191: Water Seperator (Diesel Engine Only) - Check, Drain

    Maintenance Section Water Seperator (Diesel Engine WARNING Only) - Check, Drain If the fuel filter/water separator is positioned higher than the fuel level in the fuel tank, water 4TNV98 Diesel Engine Only may not drip out when the fuel filter/water separator drain cock is opened.
  • Page 192 Maintenance Section Test Fuel System for Leaks(LP and Dual Fuel 4TNE98 Diesel Engine Only Engines Only) NEVER wait until scheduled periodic maintenance if the fuel filter indicator comes on. The fuel filter / water separator contains a sensor to detect the amount of water and contaminants. This sensor sends a signal to an indicator to alert the operator.

  • Page 193: Tires And Wheels (D, G-Series) - Inspect, Check

    Maintenance Section Tires and Wheels (D, G-Series) - Carriage Roller Extrusion – Adjust Inspect, Check 1. Set the mast vertical. WARNING 2. Lower the carriage completely. Servicing and changing tires and rims can be dangerous and should be done only by trained 3.

  • Page 194: Every 10 Service Hours Or Daily

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

  • Page 195: Coolant Level - Check

    Maintenance Section Coolant Level – Check 3. Start and run the engine to stabilize the coolant level in the filter neck. If low, add coolant until it reaches the top of the filter neck. Install the WARNING radiator cap. Observe coolant level in the expansion bottle.

  • Page 196: Air Cleaner Indicator-Check

    Maintenance Section Air Cleaner Indicator-Check Walk-Around Inspection - Inspect For maximum service life of the lift truck, make a Checking Service Indicator thorough walk-around inspection. Look around and under the truck for such items as loose or missing bolts, debris or dirt buildup, fuel, oil or coolant leaks and cut or gouged tires.

  • Page 197: Mast Channels - Lubricate

    Maintenance Section Mast Channels – Lubricate 8. Inspect the cooling system for leaks, worn hoses and debris buildup. The channels on the roller-type mast require a break-in period. Apply a light film of lubricant on the 9. Inspect engine compartment for oil, coolant and channels where the rollers ride.

  • Page 198: Transmission Oil Level - Check

    Maintenance Section Transmission Oil Level – Check Parking Brake - Inspect Inspection from Operator's Seat, Engine WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Start and operate the lift truck until the engine reaches normal operating temperature.
  • Page 199 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.

  • Page 200: First 50 - 100 Service Hours Or A Week

    Maintenance Section First 50 - 100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Oil & Filter (Diesel Engine 6.

  • Page 201: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

    Maintenance Section Transmission Oil, Oil Filter & WARNING Strainer - Check, Clean, Change NEVER overfill the engine with engine oil. ALWAYS keep the oil level between the upper WARNING and lower lines on the oil cap/dipstick. Hot oil and components can cause personal injury.
  • Page 202 Maintenance Section 12. Maintain the oil level between the Min and Max marks on the dip stick/filter cap. When the oil temperature is 40°C approximately, the cold side mark on the dipstick is applicable. When the oil temperature is 80°C approximately, the hot side mark on the dipstick is applicable.

  • Page 203: Drive Axle Oil - Change

    Maintenance Section Drive Axle Oil - Change Parking Brake - Test, Adjust Park the lift truck on a level surface. Apply the Parking Brake Testing parking brake. Place the directional control lever in NEUTRAL and stop the engine. NOTICE OSHA requires the parking brake to hold the lift truck, with capacity load, on a 15% grade.

  • Page 204: Parking Brake Adjusting

    Maintenance Section WARNING To prevent personal injury, the operator MUST be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move. Parking Brake Adjusting 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.

  • Page 205: First 250 Service Hours Or A Month

    Maintenance Section First 250 Service Hours or a Month You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Return Filter – Change WARNING Hot oil and components can cause personal injury.

  • Page 206: Every 250 Service Hours Or Monthly

    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 1. To service the air cleaner, raise the hood and seat assembly.

  • Page 207: Cleaning Primary Filter Elements

    Maintenance Section Air-205 kPa (30 psi) Maximum Pressure Cleaning Primary Filter Elements WARNING Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

  • Page 208: Brake Oil Level - Check

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

  • Page 209: Drive Axle Oil Level - Check

    Maintenance Section Drive Axle Oil Level - Check 5. Raise and lower the carriage a few times to allow lubricant to enter into the chain links. Park the lift truck on a level surface. Apply the parking brake. The engine at low idle. Place the NOTICE directional control lever in NEUTRAL.

  • Page 210: Battery Terminal - Clean, Inspect

    Maintenance Section Battery Terminal - Clean, Inspect Engine Oil & Filter (LP & Gasoline Engine Only) - Change WARNING Gasoline, LP Engine Crankcase Batteries give off flammable fumes that can explode. 1. Operate lift truck a few minutes to warm oil. Do not smoke when observing the battery Park the lift truck with the forks lowered, parking electrolyte levels.

  • Page 211: G424F(E) Lp And Duel Fuel Engines

    Maintenance Section 7. Before installing a new filter element, apply a PCV Valve System - Inspect, small amount of clean engine oil to the filter Clean element gasket. G420F(E) Gasoline, LP and Dual Fuel 8. Install the new filter element. When the gasket contacts the base, tighten it 3/4 of a turn more.

  • Page 212: G424I(E) Lp And Duel Fuel Engines

    Maintenance Section G424I(E) LP and Duel Fuel Engines G430FE LP Engine 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 -210-...

  • Page 213: Wheel Bolts & Nuts - Inspect

    Maintenance Section Wheel Bolts & Nuts - Inspect Inspect Tightness (GC - Series) Drive Wheels Inspect Tightness (D, G - Series) Steer Wheels Typical Example 1. Inspect tightness of wheel bolts in a sequence Typical Example opposite each other to 245 N•m (180 lb•ft). 1.

  • Page 214: Governor Lever And Engine Speed Control (Diesel Engine Only) - Check ,Adjust

    Maintenance Section Governor Lever and Engine Speed WARNING Control (Diesel Engine Only) - NEVER attempt to adjust the low or high idle Check ,Adjust speed limit screw. This may impair the safety and performance of the machine and shorten its 4TNV98 Diesel Engine Only life.
  • Page 215 Maintenance Section 4TNE98 Diesel Engine Only governor lever engine speed control(accelerator lever, pedal, etc.) 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.

  • Page 216: Every 500 Service Hours Or 3 Months

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

  • Page 217: Crosshead Rollers - Inspect

    Maintenance Section Mast Pivot Eyes-Lubricate Typical Example Typical Example 3. To adjust the cylinder rod extension, move the spacer to the rear and loosen the pinch bolt on 1. Lubricate two fittings for the mast pivot eyes, the clevis. one on each side of the pin. 4.

  • Page 218: Transmission Oil Filter - Change

    Maintenance Section Transmission Oil Filter – Change Overhead Guard – Inspect 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.

  • Page 219: Drive Axle Oil & Strainer - Change, Clean

    Maintenance Section Drive Axle Oil & Strainer - Change, Clean 7. Install the dip stick/filter cap. Park the lift truck level, with the forks lowered, parking brake engaged, transmission in NEUTRAL and engine stopped. 1. Remove drain plug. Allow the oil to drain into a suitable container.

  • Page 220: Steer Suspension - Inspect

    Maintenance Section Steer Suspension – Inspect Inching & Braking Control Shaft - Lubricate 1. Inspect the suspension mounting bolts. Tighten suspension mounting bolts, if necessary, to 240 1. Lubricate three fittings for the inching and brake ± 30 N•m (180 ± 20 lb•ft). pedal control shaft.

  • Page 221: Inspect Vacuum Lines And Fittings (G420F(E)/G424F(E)/G424I(E) Engine Only)

    Maintenance Section Inspect Vacuum Lines and Fittings (G420F(E)/G424F(E)/G424I(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.

  • Page 222: Inspect Electrical System (G420F(E)/G424F(E)/G424I(E) /G430Fe Engine Only)

    Maintenance Section Inspect Electrical System (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) 1. Check for loose, dirty or damaged connectors and wires on the harness including: Fuel lock-off, TMAP sensor, O2 sensor, Electronic throttle, Control Relays, Fuel Trim Valve, Foot Pedal, and crank sensor. 2.

  • Page 223: Fuel Filter (Diesel Engine Only) - Change

    Maintenance Section Fuel Filter (Diesel Engine Only) - 4TNE98 Diesel Engine Only Change Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the 4TNV98 Diesel Engine Only diesel fuel flow. Replace the fuel filter at specified intervals to 1.

  • Page 224: Engine Oil & Filter (Diesel Engine Only) - Change

    Maintenance Section 17. Install the new fuel filter (Figure 5-14, (2)) by turning it to the right (Figure 5-14, (4)) until it contacts the mounting surface. Tighten one additional turn. 18. Open all fuel cocks in the fuel line. 19. Reconnect the fuel filter sensor connector (Figure 5-14, (1)).

  • Page 225: Water Separator (4Tnv98 Diesel Engine Only) - Clean

    Maintenance Section Water Separator (4TNV98 Diesel 6. Remove the float ring (Figure5-16, (8)) from the cup. Pour the contaminants into the container Engine Only) - Clean and dispose of it properly. 7. Clean the element (Figure5-16, (9)) and inside Periodically clean the fuel filter / water separator cup.

  • Page 226: Every 1000 Service Hours Or 6 Months

    Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Return Filter, Breather & Strainer - Check, Change WARNING Hot oil and components can cause personal injury.

  • Page 227: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

    Maintenance Section Transmission Oil, Oil Filter & Check for Equal Tension Strainer - Check, Clean, Change See topic, “Transmission Oil, Oil Filter & Strainer- Check, Clean, Change” in “First 50 - 100 Service Hours” Lift Chains - Test, Check, Adjust Lift Chain Wear Test Inspect the part of the chain that is normally operated over the cross head roller.
  • Page 228 Maintenance Section Carriage Chain Adjustment Mast Chain Adjustment - FF, FFT Mast Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts (1), (2). NOTE: See the previous section, “Carriage Roller Extrusion”...

  • Page 229: Universal Joint - Inspect

    Maintenance Section Universal Joint – Inspect 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.”...

  • Page 230: Inspect Coolant Hoses (Lp, Dual Fuel Engine Only)

    Maintenance Section Inspect Coolant Hoses Fuel Lines & Fittings - Check (LP, Dual Fuel Engine Only) Visually inspect fuel lines and fittings for physical damage. Replace as required. 1. Visually inspect coolant hoses and clamps. Remember to check the two coolant lines that G420F(E)/G424F(E)/G424I(E) Engine connect to the pressure regulator/converter.

  • Page 231: Inspect Mixer Assembly (G420F(E)/G424F(E)/G424I(E) /G430Fe Engine Only)

    Maintenance Section Inspect Mixer Assembly Engine Valve Lash (Diesel Engine (G420F(E)/G424F(E)/G424I(E) Only) - Check, Adjust /G430FE Engine Only) Refer to the LP mixer section of the engine service NOTICE manual for procedures. The valve clearances are to be adjusted at the times of the following situations.

  • Page 232: Every 1500 Service Hours Or 9 Months

    Maintenance Section Every 1500 Service Hours or 9 Months Inspect Ignition System (LP, Gasoline & Dual Fuel Engines G424I(E) Engine Only) 1. Disconnect Battery Cables. 2. Remove and inspect the spark plugs. Replace as required. 3. Test secondary cables with an Ohmmeter. If the maximum resistance is higher than 25 kOhms, repair and/or replace(G424F(E) engine only).

  • Page 233: Replace Spark Plugs (G424F(E) Lp, Dual Fuel Engine / G430Fe Engine Only)

    Maintenance Section Replace Spark Plugs (G424F(E) LP, Dual Fuel Engine / G430FE Engine Only) 1. Disconnect Battery Cables. 2. Using a gentle twisting motion remove the high voltage cables from the spark plugs. Replace any damaged cables. 3. Remove the spark plugs. 4.

  • Page 234: Replace Lp Fuel Filter Element (Lp, Dual Fuel Engine Only)

    Maintenance Section 3. Check bottom cover O-ring seal (6) for damage. Replace LP Fuel Filter Element Replace if necessary. (LP, Dual Fuel Engine Only) 4. Re-assemble the filter assembly aligning the Park the lift truck in an authorized refueling area scribe lines on the top and bottom covers.

  • Page 235: Fuel Injectors (Diesel Engine Only) - Inspect, Clean, Test

    Maintenance Section Fuel Injectors (Diesel Engine Only) – Inspect, Clean, Test WARNING HIGH-PRESSURE HAZARD! Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury.

  • Page 236: Every 2000 Service Hours Or Yearly

    Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures Engine Valve Lash (Diesel Engine Steer Wheel Bearings - Only) –...
  • Page 237 Maintenance Section 3. Straighten the lock washer tangs. 8. Install the outer wheel bearing and the out washer. Install a new lock washer and fit the locknut. 4. Remove the locknut, lock washer and flat washer. Typical Example Remove the outer wheel bearing. 9.

  • Page 238: Drive Wheel Bearing (Power Shaft And Drive Wheel) - Reassemble

    Drive Wheel) – Reassemble Torque for wheel bolts (1) is 270 ± 25 N•m (200 ± 20 lb•ft). Consult your DOOSAN lift truck dealer for the proper wheel bearing reassembling procedure. Tighten wheel bearing nut (2) 135 N•m (100 lb•ft) Packing of bearings and adjustment procedure while the wheel is turned in both directions.

  • Page 239: Cooling System - Clean, Change

    Maintenance Section Cooling System – Clean, Change WARNING At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand.
  • Page 240 Maintenance Section 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.

  • Page 241: Forks - Inspect

    Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer further 2. Check the angle between the upper face of the information. blade and the front face of the shank. The fork...
  • Page 242 Maintenance Section Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage.

  • Page 243: Every 2500 Service Hours Or 15 Months

    Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Oil - Check, Clean, Inspect Battery System Change 1.

  • Page 244: G420F(E) Engine

    Maintenance Section Replace Oxygen Sensor G430FE Engine (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) G420F(E) Engine G424F(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.

  • Page 245: Replace Spark Plugs (G420F(E)/G424I(E) Engine Only)

    Maintenance Section Replace Spark Plugs (G420F(E)/G424I(E) Engine Only) 1. Disconnect Battery Cables. 2. Remove the ignition wiring harness. 3. Remove the ignition coil assy. 4. Remove spark plugs. 5. Gap the new spark plugs to the proper specifications. G420F(E) Engine : 0.7 ~ 0.8 mm G424I(E) Engine : 0.8 ~ 0.9 mm 6.

  • Page 246: Checking The Tmap Sensor (G420F(E)/G424F(E)/G424I(E) /G430Fe Engine Only)

    Maintenance Section Checking the TMAP Sensor Inspect for Intake Leaks (G420F(E)/G424F(E)/G424I(E) (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) /G430FE Engine Only) 1. Verify that the TMAP sensor (F) is mounted 1. Visually inspect the intake manifold, throttle tightly into the manifold adapter (E), with no assembly (2), and manifold adapters (3), for leakage.
  • Page 247 Maintenance Section G424I(E) Engine G430FE Engine 1. Loosen the hose clamps and remove the PCV valve. 2. Assemble new PCV valve and hose. 3. Tighten the hose clamps -245-...

  • Page 248: Every 3000 Service Hours Or 18 Months

    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”...

  • Page 249: Index

    Index Section Index Capacity Chart (Without Sideshifter cushion) ............. 56,57,58,59 12 Months Inspection ......... 170 Capacity Chart (Without Sideshifter Pneumatic) 4TNE98 Diesel Engine Only ..187,190,213,221 ............. 48,49,50,51 4TNV98 Diesel Engine Only ..187,189,212,221 Carriage Roller Extrusion – Adjust ..... 191 Causes of Fork Failure ........
  • Page 250 Index Section G420F Engine and G424F Engine and G424I Electrical Disconnect Switch (If Equipped) ... 71 Engine ..............90 Electronic Controlled Spark-Ignition Engines ..125 G420F(E) Engine ........230,242 Emergency Switch ..........155 G420F(E) Gasoline, LP and Dual Fuel Engines ..209 EMS schematic of G430FE LP engine ....
  • Page 251 Index Section Inspect Electrical System (G420F(E) /G424F(E) Maintenance Information ........14 /G424I(E) /G430FE Engine Only) ...... 220 Maintenance Intervals ........3,181 Inspect Engine for Exhaust Leaks ...... 194 Maintenance ............3 Make proper antifreeze additions....... 175 Inspect Engine for Fluid Leaks ......192 Malfunction Indicator Lamp (MIL) Operation ..
  • Page 252 Index Section Product Description ........... 151 Fuel Engine Only] - Change ......246 Tire Inflation Information ........171 Tire Inflation Pressures Adjustment ....171 Tire Inflation ............171 Tire Shipping Pressure ........171 Reading Diagnostic Fault Codes......104 Tires and Wheels (D, G-Series) - Inspect, Check191 Refill Capacities ..........

This manual is also suitable for:

D30s-5G20e-5G25e-5D25s-5G30e-5Gc20e-5 ... Show all

Table of Contents

Save PDF