Doosan D35S-5 Operation & Maintenance Manual Download | Manualshive

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Operation Section

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Auto Shift Controller ASC - 200 (If Equipped)

Product Description

The Autoshift controller is an electrical control system,
specially designed for use on forklift trucks with internal
combustion engines.
Its primary purpose is to prevent the operator from
operating the truck outside of the design parameters,
e.g. selecting the reverse gear when traveling in excess
of 6.0 km/h ( 3.73mph ) in a forward direction, and vice
versa.

The Autoshift controller is mounted on a convenient
position away from excessive heat sources and retrofits
into the truck’s electrical system. An inductive speed
sensor is mounted on the transmission case where it will
pick up a pulse from a gear tooth pattern. This pulse is
used to monitor the truck in motion and its travel speed.
To enable the system to change gears smoothly, the
shift points for offset speed are adjustable.

An operator no longer has to change gears with his
hands, therefore he can be more productive.

The Autoshift controller prevents strain and abuse to the
transmission by changing gears up and down
automatically. It also prevents damage to the half shaft,
excessive tire wear and heat to the transmission.

Features

1. 2 - speed auto shift control

2. Prevent downshifting at high speed

3. Inhibit selecting direction at high speed outside of

the design parameters.

Adjustments

SW1

( Low-High Shift Point )

SW2

( Direction Inhibit Point )

NOTCH

Vehicle Speed

NOTCH

Vehicle Speed

0

2.5 km/h (1.55 mph)

0

3.3 km/h (2.05 mph)

1

3.0 km/h (1.86 mph)

1

3.6 km/h (2.24 mph)

2

3.5 km/h (2.17 mph)

2

3.9 km/h (2.42 mph)

3

4.0 km/h (2.49 mph)

3

4.2 km/h (2.61 mph)

4

4.5 km/h (2.80 mph)

4

4.5 km/h (2.80 mph)

5

5.0 km/h (3.11 mph)

5

4.8 km/h (2.98 mph)

6

5.5 km/h (3.42 mph)

6

5.1 km/h (3.17 mph)

7

6.0 km/h (3.73 mph)

7

5.4 km/h (3.36 mph)

8

6.5 km/h (4.04 mph)

8

5.7 km/h (3.54 mph)

9

7.0 km/h (4.35 mph)

9

6.0 km/h (3.73 mph)

Adjustment Switch

Low-High Shift Point (SW1)

ASC-500 allows you to set the 2 speed Auto Gear Shift
Point, the maximum travel speed at which the Auto Shift
Controller up-shift or down-shift the transmission
automatically according to the vehicle speed. For
adjustment of 2 speed Auto Gear Shift speed, the SW1
switch is used on the printed circuit board.
For example if SW1 put to 5

th

notch, the 2 Speed Auto

Gear Shift speed will be 5.0 km/h(3.11 mph), which is
factory setting value as a default.

Direction Inhibit Point (SW2)

Auto Shift allows you to set the Direction Inhibit Speed,
the maximum travel speed at which the transmission
can be reversed. For adjustment of direction inhibit
speed, the SW2 switch is used on the printed circuit
board.
For example SW2 is put to 7

rd

notch, the Direction Inhibit

Speed will be 5.4 km/h (3.36 mph), which is factory
setting value as a default.

https://www.forkliftpdfmanuals.com/

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Summary of Contents for D35S-5

Page 1: ...Operation Maintenance Manual LIFT TRUCKS D35S 5 D40S 5 D45S 5 D50C 5 D55C 5 G35S 5 G40S 5 G45S 5 G50C 5 G55C 5 D40SC 5 D45SC 5 D50SC 5 D55SC 5 G40SC 5 G45SC 5 G50SC 5 G55SC 5 0705 https www forkliftpdfmanuals com ...

Page 2: ...https www forkliftpdfmanuals com ...

Page 3: ...72 Lift Truck Operation 108 Mono Ped Control System Option 110 Auto Shift Controller ASC 200 If Equipped 111 Operating Techniques 114 Parking the Lift Truck 118 Lift Fork Adjustment 119 Storage Information 120 Transportation Hints 121 Towing Information 122 Maintenance Section Inspection Maintenance and Repair of Lift Truck Forks 123 Tire Inflation Information 127 Torque Specifications 128 Cooling...

Page 4: ...ith 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 Drivi...

Page 5: ... 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 ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by...

Page 6: ...ert 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 se...

Page 7: ...t 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 Warning Signs and Labels There are several specific safety signs on your lift truck Their exact loc...

Page 8: ...d 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 han...

Page 9: ...reach through the mast or permit others to do so Located on the mast No Standing On Forks Warning No Standing Under Forks Warning 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 Located on the lift cylinder Load Backrest Must Be In Place Warning WARNING Operation without this device in place may be hazardous Locat...

Page 10: ...impact of appropriate value Located on the Overhead Guard Brake Pedal Adjustment Warning WARNING Improper adjustment could result in injury or death It has to be adjusted by drawing dimension on free condition For safe don t unfasten clevis and nut It has to be adjusted by trained personnel SHOE Type Only Located inside Brake pedal box OCDB Type Only Located inside Brake pedal box https www forkli...

Page 11: ...d Alarm will sound if parking brake is not applied 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 No Riders Warning WARNING To avoid personal ...

Page 12: ...ted 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...

Page 13: ...nal DOOSAN spare parts waive any liability by DOOSAN Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully Clean your shoes and wipe your hands before mounting Face the lift truck when mounting and dismounting Use both hands face the lift truck when mounting and dismounting Use the handgrips for mounting and dismounting Do not try to climb on or off the lift tr...

Page 14: ...t 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 Operating the Lift Truck Always keep the lift truck under control Obey all traffic rules and warning signs...

Page 15: ...he Operation Section of this manual 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 If trailer is not coupled to tractor make sure the trailer landi...

Page 16: ...es 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 o...

Page 17: ... lubricants and some coolant mixtures are flammable Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling area Do not smoke in areas where batteries are charged or where flammable materials are stored Batteries in series can be located in separate compartments When using jumper cables always connect positive cable to posit...

Page 18: ...ds 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 blo...

Page 19: ...ry 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 WARNING Tipover can occur if the truck is improperly operated In the event of a tipover injury or death could result The Survive in tipover warning is located on the overhead guard It shows the proper use of the oper...

Page 20: ...t is properly locked Do not adjust the seat while the truck is in motion Weight adjustment Pull the weight adjustment lever upwards and move right or left side Adjust to driver s weight in 7 steps 50 110 kg NOTICE Do not place your hand or fingers under the seat Injury may occur as the seat moves up and down Backrest Inclination The backrest angle can be adjusted by using the lever on the left sid...

Page 21: ...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 3 In the event of a tipover the seat and restraint system should be inspected for damage and replaced if necessary NOTE Operator restraints shall be examined at the regular truck service intervals It is recomme...

Page 22: ...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 to release the belt The belt will automatically retract when released Hold the plate of the belt and allow the belt to slowly retract https www forkliftpdfmanuals c...

Page 23: ...t When the lift truck picks up a load the truck and load have a new combined CG Stability and Center of Gravity The stability of the lift truck is determined by the location of its CG or if the truck is loaded the combined CG of the truck and load The lift truck has moving parts and therefore has a CG that moves The CG moves forward or backward as the mast is tilted forward or backward The CG move...

Page 24: ...achment to the CG of the load The location of the CG in the vertical direction is the same as the horizontal dimension Remember that unless otherwise indicated the capacity load shown on the nameplate is for a standard lift truck with standard backrest forks and mast and having no special purpose attachment In addition the capacity load assumes that the load center is no further from the top of th...

Page 25: ...s and read all warning signs 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 the body outside of the operator s compartment Never put any part of body into the mast structure or between the mast and the truck Do not start stop turn or change direction suddenly or at high speed Sudden movement can cause t...

Page 26: ...er size pallet Position the forks as wide as possible under the load Position loads evenly on the forks for proper balance Do not lift a load with one fork Do not overload Always handle loads within the rated capacity shown on the capacity plate Do not add extra counterweight to the truck An overload can cause the truck to roll over and cause injury to personnel and damage to the lift truck Do not...

Page 27: ... when stacking Travel with the load tilted back and the forks as low as possible This will increase stability to the truck and load and permit better visibility for you Do not 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 Do not jump off if your truck starts to tip over Stay in your seat to survive Go up ram...

Page 28: ...ns or obstructions in your path of travel An operator must be in full control of his lift truck at all times 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 an...

Page 29: ...spilt fuel and do not forget to close the fuel tank before restarting the engine Park your lift truck in authorized areas only Fully lower the forks to the floor put direction lever in NEUTRAL position engage the parking brake and turn the key to the OFF position Remove the key and put blocks behind the wheels to prevent the truck from rolling Shut off your forklift truck when leaving it unattende...

Page 30: ...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 Always use operator restraint system DON T jump Hold on tight Brace your feet and keep them within the operator s compartment https www forkliftpdfmanuals com ...

Page 31: ...Safety Section 29 Lean away from the direction of fall Lean forward https www forkliftpdfmanuals com ...

Page 32: ...4 25 25 Speed lift loaded unloaded mm s 520 540 520 540 26 lowering loaded unloaded mm s 480 450 480 450 28 Drawbar pull at 1 6 km h loaded kg 3300 3300 30 Gradeability at 1 6 km h loaded 38 35 WEIGHT 32 Total weight unloaded kg 5790 6180 33 Axle load with loaded front rear kg 8215 1075 8980 1200 34 without loaded front rear kg 2685 3105 2660 3520 CHASSIS 35 number of front rear 2 2 2 2 36 Tires s...

Page 33: ...0 25 480 450 490 450 490 450 26 3400 3500 3600 28 32 30 28 30 6550 7050 7390 32 9800 1250 10680 1370 11370 1520 33 2810 3740 2890 4160 2800 4590 34 2 2 2 2 2 2 35 300x15 18 300x15 18 300x15 18 36 7 50x16 12 7 50x16 12 7 50x16 12 7 00x12 12 7 00x12 14 7 00x12 14 37 2100 2100 2100 38 1153 1115 1153 1115 1153 1115 39 160 160 160 40 205 205 205 41 shoe disc shoe disc shoe disc 42 ratchet ratchet ratch...

Page 34: ...24 25 25 Speed lift loaded unloaded mm s 520 540 520 540 26 lowering loaded unloaded mm s 480 450 480 450 28 Drawbar pull at 1 6 km h loaded kg 3300 3300 30 Gradeability at 1 6 km h loaded 36 33 WEIGHT 32 Total weight unloaded kg 5790 6180 33 Axle load with loaded front rear kg 8805 985 9540 1140 34 without loaded front rear kg 2685 3105 2660 3520 CHASSIS 35 number of front rear 2 2 2 2 36 Tires s...

Page 35: ...24 25 24 25 24 520 540 470 540 25 480 450 490 450 26 3400 3500 28 31 28 30 6550 7050 32 10340 1210 11200 1350 33 2810 3740 2890 4160 34 2 2 2 2 35 300x15 18 300x15 18 36 7 50x16 12 7 50x16 12 7 00x12 12 7 00x12 14 37 2100 2100 38 1153 1115 1153 1115 39 160 160 40 205 205 41 shoe disc shoe disc 42 ratchet ratchet 43 24 75 24 75 45 DOOSAN DB58S DOOSAN DB58S 49 92 2200 92 2200 50 33 1600 33 1600 51 4...

Page 36: ... lift loaded unloaded mm s 500 540 500 540 26 lowering loaded unloaded mm s 480 450 480 450 28 Drawbar pull at 1 6 km h loaded kg 3355 3430 30 Gradeability at 1 6 km h loaded 36 33 5 WEIGHT 32 Total weight unloaded kg 5790 6180 33 Axle load with loaded front rear kg 8215 1075 8980 1200 34 without loaded front rear kg 2685 3105 2660 3520 CHASSIS 35 number of front rear 2 2 2 2 36 Tires size front s...

Page 37: ...50 490 450 490 450 26 3410 3410 3600 28 30 7 30 7 28 30 6550 7050 7390 32 9800 1250 10680 1370 11370 1520 33 2810 3740 2890 4160 2800 4590 34 2 2 2 2 2 2 35 300x15 18 300x15 18 300x15 18 36 7 50x16 12 7 50x16 12 7 50x16 12 7 00x12 12 7 00x12 14 7 00x12 14 37 2100 2100 2100 38 1153 1115 1153 1115 1153 1115 39 160 160 160 40 205 205 205 41 shoe disc shoe disc shoe disc 42 ratchet ratchet ratchet 43 ...

Page 38: ...ed lift loaded unloaded mm s 500 540 500 540 26 lowering loaded unloaded mm s 480 450 480 450 28 Drawbar pull at 1 6 km h loaded kg 3430 3410 30 Gradeability at 1 6 km h loaded 33 5 31 WEIGHT 32 Total weight unloaded kg 5790 6180 33 Axle load with loaded front rear kg 8805 985 9540 1140 34 without loaded front rear kg 2685 3105 2660 3520 CHASSIS 35 number of front rear 2 2 2 2 36 Tires size front ...

Page 39: ...5 20 5 24 500 540 490 540 25 480 450 490 450 26 3400 3400 28 30 28 30 6550 7050 32 10340 1210 11200 1350 33 2810 3740 2890 4160 34 2 2 2 2 35 300x15 18 300x15 18 36 7 50x16 12 7 50x16 12 7 00x12 12 7 00x12 14 37 2100 2100 38 1153 1115 1153 1115 39 160 160 40 205 205 41 shoe disc shoe disc 42 ratchet ratchet 43 12 75 12 75 45 G643 E G643 E 49 69 93 2450 69 93 2450 50 294 217 1600 294 217 1600 51 4 ...

Page 40: ...5 TIER IIE G W OCabin 82 1 84 1 78 5 77 8 107 G35 40 45S 5 G50 55C 5 G40 45 50 55SC 5 W OCabin NON CERT 84 9 87 5 85 85 107 G35 40 45S 5 G50 55C 5 TIER IIIE G W OCabin 81 5 83 4 76 5 75 1 106 Vibration weighted overall value Unit m sec2 Measuring place Model Seat Steering Wheel Floor Plate D35 40 45S 5 D40 45 50 55SC 5 D50 55C 5 TIER IIE G 0 1 0 3 0 1 G35 40 45S 5 G50 55C 5 G40 45 50 55SC 5 NON CE...

Page 41: ...General Section 39 Capacity Chart D G 35S 5 D G 40S 5 D G 45S 5 https www forkliftpdfmanuals com ...

Page 42: ...General Section 40 Capacity Chart D G 35S 5 D G 40S 5 D G 45S 5 https www forkliftpdfmanuals com ...

Page 43: ...General Section 41 Capacity Chart with Side Shifter D G 35S 5 D G 40S 5 D G 45S 5 https www forkliftpdfmanuals com ...

Page 44: ...General Section 42 Capacity Chart with Side Shifter D G 35S 5 D G 40S 5 D G 45S 5 https www forkliftpdfmanuals com ...

Page 45: ...General Section 43 Capacity Chart D G 40SC 5 D G 45SC 5 D G 50SC 5 https www forkliftpdfmanuals com ...

Page 46: ...General Section 44 Capacity Chart D G 40SC 5 D G 45SC 5 D G 50SC 5 https www forkliftpdfmanuals com ...

Page 47: ...General Section 45 Capacity Chart with Side Shifter D G 40SC 5 D G 45SC 5 D G 50SC 5 D G 40SC 5 D G 45SC 5 D G 50SC 5 https www forkliftpdfmanuals com ...

Page 48: ...General Section 46 Capacity Chart with Side Shifter D G 40SC 5 D G 45SC 5 D G 50SC 5 https www forkliftpdfmanuals com ...

Page 49: ...General Section 47 Capacity Chart D G 50C 2 D G 50C 5 https www forkliftpdfmanuals com ...

Page 50: ...General Section 48 Capacity Chart with Side Shifter D G 50C 2 D G 50C 5 https www forkliftpdfmanuals com ...

Page 51: ...General Section 49 Capacity Chart with Side Shifter SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT DOUBLE TIRE DOUBLE TIRE STD FFL FFT D G 55C 5 https www forkliftpdfmanuals com ...

Page 52: ...General Section 50 Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT DOUBLE TIRE DOUBLE TIRE STD FFL FFT D G 55C 5 https www forkliftpdfmanuals com ...

Page 53: ...General Section 51 Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT DOUBLE TIRE DOUBLE TIRE STD FFL FFT D G 55SC 5 https www forkliftpdfmanuals com ...

Page 54: ...General Section 52 Capacity Chart with Side Shifter SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT DOUBLE TIRE DOUBLE TIRE STD FFL FFT D G 55SC 5 https www forkliftpdfmanuals com ...

Page 55: ...uck Serial Number ______________________________ 5 8 liter Diesel Engine TIER II Serial Number ______________________________ 4 3 liter GM Vortec Engine Serial Number G643 ______________________________ 4 3 liter GM Vortec Engine Serial Number G643E ______________________________ Transmission Serial Number ______________________________ https www forkliftpdfmanuals com ...

Page 56: ...General Section 54 DRIVE AXLE Serial Number ______________________________ Side Shifter Serial Number If Equipped ______________________________ https www forkliftpdfmanuals com ...

Page 57: ... the load center is 600 mm 24in from both the vertical and horizontal faces of the forks Before attempting to lift any load ensure that the weight and load center combination is within the capacity of the lift truck as shown on the capacity rating plate To determine the load center measure the distance from the face of the carriage to the gravitational center of the load The rated capacity on the ...

Page 58: ...tandard carriage and forks are used Attachment Abbreviations Includes Special Forks SC 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 Conta...

Page 59: ...tions 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 24V LPG 12V https www forkliftpdfmanuals com ...

Page 60: ... approximately 106 C 223 F on all engines LED Type Gage If both tenth ninth flash out of phase while operating the lift truck overheating is indicated Park the lift truck and stop the engine Chack the cooling system for a malfunction Both tenth ninth will flash out of phase when the coolant temperature reaches approximately 106 223 on all engine 7 Transmission Oil Temperature Gauge Indicates trans...

Page 61: ...sition Refill the proper brake fluid oil if its light is ON WARNING Frequent rapid starts at 2nd speed can be the cause of overheating at torque converter With this operating condition the pointer can sometimes exceed the green band If this situation occurs from time to time please avoid this operating condition to protect the transmission and increase the work efficiency That is start the truck a...

Page 62: ...l Disconnect Switch If Equipped 1 ON Connects the battery for electrical power to all electrical circuits 2 OFF Disconnects the battery from all electrical circuits Seat NOTE Seat arrangements may vary Basic operation will be similar Seat adjustment should be checked at the beginning of each shift and when operators change Lock the seat into position before operating to prevent an unexpected seat ...

Page 63: ... that will sound if the parking brake is not applied when leaving the machine NOTICE 1 Prior to operating the lift truck be sure to understand and check the SEAT SWITCH SYSTEM 2 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 in the selected direction If you lift yours hips of...

Page 64: ...wise for LOW speed range 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 clutch pack pressure and applies the service brakes to stop and hold the lift truck NOTE The purpose of the inching control pedal is to provide precise inchi...

Page 65: ... lever BACK to engage the parking brake Push the lever FORWARD to release the parking brake Lift Control NOTE 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 w...

Page 66: ...stop 3 Mast Tilt Back Pull the lever BACK smoothly to tilt the mast backward Sideshift Attachment Control If Equipped 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 https www forkl...

Page 67: ... 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 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 Remove the filte...

Page 68: ...eas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to indoor locations Stop the engine and get off the lift truck during refueling The careless handling of LP containers can result in a serious accident Use extreme care when transporting containers to prevent damage to them 1 Park the lift truck on level ground with the parking brake applied t...

Page 69: ...terioration damage or missing flexible seals 11 Position the replacement tank so that the locating pin dowel is in place WARNING The LP tank must not extend past the counterweight 12 Clamp the tank securely 13 Connect the fuel supply line 14 Open the fuel valve by slowly turning the valve counterclockwise If the fuel valve is opened too quickly a back pressure check valve will shut off the fuel su...

Page 70: ... indicator lights or gauges 3 Test the horn and other safety devices for proper operation 4 Inspect the mast and lift chains for wear broken links pins and loose rollers 5 Inspect the carriage forks or attachments for wear damage and loose or missing bolts 6 Inspect the tires and wheels for cuts gouges foreign objects inflation pressure and loose or missing bolts 7 Inspect the overhead guard for d...

Page 71: ...fill the radiator at the top tank 13 Observe the fuel level gauge after starting the truck Add fuel if necessary 14 In case of LPG truck if needed change LPG Fuel Tank as the procedure of changing LP tanks in Refueling Section 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 m...

Page 72: ... come ON The preheat indicator 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 indicator light goes OFF turn the key to the START position with the accelerator pedal fully depressed 3 Release the key when the engine starts and release the accelerator pedal to a low idle position...

Page 73: ...accelerator pedal slightly during cranking 4 Allow the engine to warm up slowly 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 damage to the altern...

Page 74: ...ON with the engine running 3 The G643E engine MIL Malfunction Indicator Light 3 will not come ON with engine running unless the fault or faults are stored in the memory of the engine control module ECM Stop the engine and check the electric engine control system if the light comes ON Refer G643E Engine of thissection 4 Observe the diesel fuel level gauge 4 for fuel level in the tank Diesel Engine ...

Page 75: ...hes 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 MI 07 is a drive by wire DBW system con...

Page 76: ...the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle position in relation to the accelerator pedal position sensor APP feedback Even engine coolant temperature and adequate oil pressure is monitored by the SECM The SECM controller has full adaptive learning capabilities allowing it to adapt control function as operating conditions change Factors su...

Page 77: ...alve Excess flow valve closed Reset excess flow valve z Close liquid valve z Wait for a click sound z Slowly open liquid valve Plugged fuel line Remove obstruction from the fuel line z Close liquid fuel valve z Using caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Broken Fuse SECM Re...

Page 78: ...tion disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and or collapsed hose Pressure regulator converter malfunction Test ...

Page 79: ...l line z Slowly open liquid fuel valve Leak test Pressure regulator freezes Check level in cooling system z Must be full check coolant strength z 35F minimum Check coolant hoses z Watch for kinks and or pinched hoses z Verify one pressure hose and one return hose Fuel Lock off malfunction Repair replace Fuel Lock off z See Engine Service Manual Incorrect idle speed or ignition problem See Advanced...

Page 80: ...Accelerate Hesitation During Acceleration Engine Mechanical See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet z Fill fuel container z Do not exceed 80 of liquid capacity Excess flow valve closed Reset excess flow valve z Close liquid valve z Wait for a click sound z Slowly open liquid valve Clogged fuel filter Repair replace as required z See Maintenance Section LP...

Page 81: ...acuum leak Check for vacuum leaks z Between mixer and throttle body z Between throttle body and intake manifold z Between intake manifold and cylinder head Air Fuel Mixer malfunction Check mixer z See Engine Service Manual Engine Stalls Engine Mechanical See Engine Manufacturers Service Manual Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify ...

Page 82: ...caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve Leak test Air filter clogged Check air filter z Clean replace as required Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and...

Page 83: ...l pressure too high Test pressure regulator operation z See Engine Service Manual Faulty FTV G643E only Check FTV for housing cracks or obstructions z See Advanced Diagnostics FTV operation z 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 Excessive Fuel Con...

Page 84: ...ve Unstable Idle RPM You can adjust idle screw Idle Screw turn to rich side turn in screw Forklift have Poor High Speed Performance you can adjust power valve power valve turn to rich side Power valve marked R and L R is rich side and L is lean side L R https www forkliftpdfmanuals com ...

Page 85: ...hen the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 0 5 seconds between digits and a long pause 1 2 seconds between fault codes A code 12 is displayed at the beginning of the code list EXAMPLE A code 26 has been detected ETCSticking and the engine has shutdown and the MIL has remained ON When the codes are displayed the MIL will flash one time 1 pause t...

Page 86: ...hree 3 times within five 5 seconds to enable the display codes feature of the SECM Simply turn the key OFF to exit display mode The code list will continue to repeat until the key is turned OFF An automatic code display feature is activated if a foot pedal fault condition exists This feature enables the service technician to view the fault codes by turning the key to the ON position if a foot peda...

Page 87: ...the system Possible ECT short to GND check ECT signal wiring Check regulator for coolant leaks 22 ThrottleSensorInputLo TPS1 signal disconnected or open circuit Expected faults when ETC connector is unplugged CODES 22 24 Disable Throttle Check throttle connector connection and TPS1 sensor for an open circuit 23 ThrottleSensorInputHi TPS1 sensor failure or shorted circuit Disable Throttle Check thr...

Page 88: ...s It is not system trouble If the fault really sets then the engine will shut down 28 ETCSpringTestFailed Upon initial key up the internal throttle return spring has become weak Power Limit Perform throttle spring test by cycling the ignition key and re check for fault 29 ETCDriverFault Throttle driver over current or driver signals shorted Disable Throttle Check ETC driver wiring for a shorted ci...

Page 89: ... PIN 4 SIGNAL TMAP PIN 1 to SECM PIN 1 GND TMAP PIN 3 to SECM PIN 18 XDCR 5VDC To check the IAT sensor of the TMAP disconnect the TMAP connector and measure the IAT resistance See the IAT table in Chapter 6 0 42 EST1Low Coil driver signal low or under current Stored Fault Code MIL Only Check coil driver wiring and connector for shorts SECM PIN 7 EST1 to COIL PIN A Verify GND on COIL PIN B Verify G...

Page 90: ...e 15 9 VDC Stored Fault Code MIL Only Check battery and charging system voltage Check battery voltage during starting and with the engine running Check voltage regulator alternator and charging system Check battery and wiring for overheating and damage Measure battery power at the SECM with a multimeter 55 XDRPSensorInputLow 5VDC Transducer power supplied by the SECM to the sensors is below 4 60VD...

Page 91: ...ults z Check for ETC Sticking or other ETC faults z Verify if the lift truck was motored down a steep grade 61 Pedal1SensorInputLo APP1 signal disconnected open circuit or sensor malfunction Expected faults when APP connector is unplugged CODES 61 66 MIN Power Limit Check foot pedal connector 62 Pedal1SensorInputHi APP1 sensor failure or shorted circuit MIN Power limit Check foot pedal connector 6...

Page 92: ...nction Improper APP2 reading may be due to dirt or oxidation on the sensor traces Stored Fault Code MIL Only Check foot pedal connector 68 Pedal2SensorRangeHi APP2 potentiometer malfunction Improper APP2 reading may be due to dirt or oxidation on the sensor traces Stored Fault Code MIL Only Check foot pedal connector 69 Pedal1ToPedal2Difference Measured APP2 pedal position signal is different than...

Page 93: ...heck balance line vacuum hose connection at the regulator z Check N CA55 500 TR mixer for heavy end build up and operation see mixer section z Check N2001 secondary for operation or low primary pressure see N2001 Regulator section 73 AFRTrimValveUpperDC FTV duty cycle at high rich limit Expected fault when FTV connector is unplugged G643E only Stored Fault Code MIL Disable Adaptive learns Engine m...

Page 94: ...arns Note If LP fuel in LP tank is not enough this fault code can be set If LP tank is frozen this fault code can be set too It is not system trouble Check the FTV for proper operation z Check FTV Hose Connections 77 OxygenSensorInputHigh O2 sensor SECM driver signal is shorted to power G643E only Stored Fault Code MIL Disable Adapts Check if O2 sensor is shorted to 5VDC or Battery AFRTrimValveLow...

Page 95: ...een fault codes A code 12 is displayed at the end of the code list EXAMPLE A 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 ...

Page 96: ... Shutdown 3 CheckEngineLight 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 B1 to ECT Pin 1 SECM System GND Pin A16 B17 Check regulator for coolant leaks 171 ECT_IR_Fault Engine coolant temperature not changing as expected None Check for coolant system...

Page 97: ...il Check throttle connector connection and TPS2 sensor for an open circuit or short to GND SECM Pin B4 signal to ETC Pin 5 SECM Pin B1 sensor GND to ETC Pin 2 SECM system GND Pin A16 B17 231 23 TPS1RangeHigh TPS1 sensor voltage out of range high normally set if the TPS1 signal has shorted to power or the ground for the sensor has opened TurnOnMil Check throttle connector and TPS1 sensor wiring for...

Page 98: ... Learned WOT end of TPS2 sensor range higher than expected None N A 271 TPS1AdaptHiMin Learned WOT end of TPS1 sensor range lower than expected None N A 272 TPS2AdaptHiMin Learned WOT end of TPS2 sensor range lower than expected None N A 281 TPS1AdaptLoMax Learned closed throttle end of TPS1 sensor range higher than expected None N A 282 TPS2AdaptLoMax Learned closed throttle end of TPS2 sensor ra...

Page 99: ...nd or the circuit has opened to the SECM 1 TurnOnMil 2 CutThrottle 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 4kΩ 8 2kΩ TMAP Pin 3 power to ...

Page 100: ...pected None Check that TMAP sensor is mounted properly Possible defective TMAP sensor 371 37 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 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 ...

Page 101: ... 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 Check for debris or obstructions inside the throttle body Perform the throttle test using the Service Tool and re check for fault Ch...

Page 102: ...wiring for a shorted circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Perform the throttle test using the Service Tool and re check for fault Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0Ω 521 52 LowOilPressureFault Low engine oil pressure 1 TurnOnMil 2 DelayedE...

Page 103: ...er SECM Pin B24 5 Vdc to SECM Pin B1 XDRG 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 561 56 SensVoltRangeHigh Sensor reference voltage XDRP too high 1 TurnOnMil 2 EngineShutdown Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 XDRP 5 Vdc to TMAP Pin 1 XDRG GND V...

Page 104: ...pened or sensor has failed TurnOnMil Check foot pedal connector Check APP2 signal at SECM PIN B16 621 62 APP1RangeHigh APP1 sensor voltage out of range high normally set if the APP1 signal has shorted to power or the ground for the sensor has opened 1 TurnOnMil 2 CheckEngine Light Check foot pedal connector Check APP1 signal at SECM PIN B7 622 66 APP2RangeHigh APP2 sensor voltage out of range high...

Page 105: ... 711 71 LSDFault_Dither1 Dither Valve 1 Fault signal has opened or shorted to ground or power or defective dither 1 valve TurnOnMil Check FTV1 for an open wire or FTV connector being disconnected FTV1 Pin 1 signal to SECM Pin A1 FTV1 Pin 2 power to SECM DRVP Pin A23 Check FTV1 for an open coil by disconnecting the FTV connector and measuring the resistance 26Ω 2Ω 712 LSDFault_Dither2 Dither Valve ...

Page 106: ... or defective MIL lamp None Check MIL lamp for an open wire or short to GND 721 72 GasFuelAdaptRangeLo In LPG mode system had to adapt rich more than expected TurnOnMil Check for vacuum leaks Check fuel trim valves e g leaking valve or hose Check for missing orifice s 731 73 GasFuelAdaptRangeHi In LPG mode system had to adapt lean more than expected TurnOnMil Check fuel trim valves e g plugged val...

Page 107: ...rify O2 sensor heater circuit is operating by measuring heater resistance 2 1Ω 0 4Ω O2 Pin 2 HEATER GND to Pin 1 HEATER PWR 743 Reserved 751 GasO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on LPG 1 TurnOnMil 2 DisableGas O2Ctrl Check for vacuum leaks Check fuel trim valves e g leaking valve or hose Check for missing orifice s 752 GasPostO2FailedLean Pre catalyst O2 sensor ...

Page 108: ...atRangeLow Post catalyst O2 sensor voltage out of range low sensor signal shorted to ground 1 TurnOnMil 2 Disable LPG Post catalyst O2Ctrl Check if O2 installed after the catalyst sensor is shorted to GND or sensor GND O2 signal Pin 3 to SECM Pin B19 Possible sources SECM DRVG GND Pins A16 B17 and SECM XDRG sensor GND Pin B1 921 O2RangeHigh Pre catalyst O2 sensor voltage out of range high sensor s...

Page 109: ...S Pin 1 SECM sensor GND Pin B1 to FTS Pin 2 933 TransOilTemp Excessive transmission oil temperature 1 TurnOnMil 2 Delayed EngineShutdown Refer to drivetrain manufacturer s transmission service procedures 991 ServiceFault1 Service Interval 1 has been reached None Perform service procedure related to Service Interval 1 determined by OEM 992 ServiceFault2 Service Interval 2 has been reached None Perf...

Page 110: ...er 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 Stop the loaded lift truck completely before...

Page 111: ...ring the lift truck to a smooth stop Inching NOTE The purpose of the inching pedal is to provide precise lift truck inching control at very slow travel speed and high engine rpm This is used for fast hydraulic lift during load approach pick up or load positioning 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 tran...

Page 112: ...e to truck instability and a tip over A steering knob is intended for slow travel maneuverability ONLY 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 direct...

Page 113: ...direction at high speed outside of the design parameters Adjustments SW1 Low High Shift Point SW2 Direction Inhibit Point NOTCH Vehicle Speed NOTCH Vehicle Speed 0 2 5 km h 1 55 mph 0 3 3 km h 2 05 mph 1 3 0 km h 1 86 mph 1 3 6 km h 2 24 mph 2 3 5 km h 2 17 mph 2 3 9 km h 2 42 mph 3 4 0 km h 2 49 mph 3 4 2 km h 2 61 mph 4 4 5 km h 2 80 mph 4 4 5 km h 2 80 mph 5 5 0 km h 3 11 mph 5 4 8 km h 2 98 mp...

Page 114: ...eselected modes automatic mode and manual mode Automatic Mode is selected in factory setting controller as a default Manual Mode Fail Safe Mode is selected to operate the truck manually in case of emergency Automatic mode Direction Inhibit 1 Start the engine with the direction control lever in NEUTRAL and the parking brake engaged 2 Press down on the service brake pedal disengage the parking brake...

Page 115: ...d ratio control so that the appropriate gear may be engaged in every situation NOTICE Two Speed Auto Shift Control function can be accomplished only when the direction control lever is placed in the high speed 2ndgear position Manual Mode Fail Safe mode In case that the controller is broken down or you don t want to use the functions of the Auto Shift Controller you can select Manual Mode In Manua...

Page 116: ...its Typical Example 2 Move the lift truck FORWARD until the load touches the carriage Lifting the Load 1 Lift the load carefully and tilt the mast back a short distance Typical Example 2 Tilt the mast further back to cradle the load Typical Example 3 Operate the lift truck in reverse until the load is clear of the other material 4 Lower the cradled load to the travel position NOTE Lift and tilt sp...

Page 117: ...and downgrades Typical Example 2 For better vision travel in reverse with bulky loads Unloading Typical Example 1 Move the lift truck into the unloading position Typical Example 2 Tilt the mast FORWARD only when directly over the unloading area WARNING Do not tilt the mast forward with the load unless directly over the unloading area even if the power is off https www forkliftpdfmanuals com ...

Page 118: ...carriage and forks to the travel position or to the park position Turning 1 When turning sharp corners keep close to the inside corner Begin the turn when the inside drive wheel meets the corner 2 In narrow aisles keep away from the stockpile when turning into the aisle Allow for counterweight swing https www forkliftpdfmanuals com ...

Page 119: ...eep 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 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 t...

Page 120: ...e 4 Lower the forks to the ground WARNING Blocking the wheels will prevent unexpected lift truck movement which could cause personal injury 5 Turn the key in the ignition switch to the OFF position and remove the key NOTE If a LP equipped lift truck is stopped or parked for an indefinite or prolonged period of time close the fuel shutoff valve on the LP tank Run the engine until fuel in the line r...

Page 121: ...e 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 WARNING Make sure the forks are locked before carrying a load https www ...

Page 122: ...he 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 z Apply antirust to the exposed parts which tend to rust z Cover components such as the breather and air cleaner which may be caught with humidity z The machine should be operated at least once a week Fill the cooling syst...

Page 123: ...n the lift truck on the truck bed or the rail car Apply the parking brake and place the transmission control in NEUTRAL Turn the ignition switch to the OFF position and remove the key If LP equipped shut off the LP fuel tank Block the wheels and secure the lift truck with tiedowns Machine Lifting and Tiedown Information NOTICE Improper lifting or tiedowns can allow load to shift and cause injury a...

Page 124: ...ble 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 dista...

Page 125: ...reater 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 z A fork rated at 1500 pounds at 24 inch load center will be stamped 1500X24 z A fork rated at 2000 kg at 600 mm load center will be stamped 2000X600 The manufacturer identification and yea...

Page 126: ...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 z Repetitive Overloading Repetitive cycling of load...

Page 127: ...t Installation 1 Inspect forks to ensure they are the correct size for the truck on which they will be used Make sure they are the correct length and type for the loads to be handled If the forks have been previously used perform the 12 Month Inspection If the forks are rusted see Maintenance and Repair 2 Make sure fork blades are level to each other within acceptable tolerances See Forks Step 4 i...

Page 128: ...ne 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 z Repair or replace the positioning locks on hook type forks z Repair or replace most fork retention devices used with other fork types 4 A fork should be load tested before being returned to service...

Page 129: ...n shipping pressures Shipping Pressure Size Ply Rating or Strength Index kPa psi 7 00X12 Steer 12 860 125 8 25X15 Drive 14 825 120 300X15 Drive 18 785 115 7 50X16 Drive dual 12 760 110 1 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 operating conditions Pressure...

Page 130: ... mm 625 in 7 5 0 5 65 5 13 5 mm 531 in 4 5 0 5 40 5 8 mm 312 in 0 9 0 2 8 2 Reassembly Or Retightening Torque Clamp Width N m 1 lb in 16 mm 625 in 4 5 0 5 40 5 13 5 mm 531 in 3 0 0 5 25 5 8 mm 312 in 0 7 0 2 6 2 1 1 Newton meter N m is approximately the same as 0 1 kg m Torque for Standard Bolts Nuts and Taperlock Studs NOTICE The two charts below give general torques for bolts nuts and taperlock ...

Page 131: ...njury 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 re...

Page 132: ...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 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 ...

Page 133: ...with antifreeze of different brand DOOSAN recommends that the coolant mix contain 50 commercially available automotive antifreeze or equivalent and acceptable water to maintain and adequate water pump cavitation temperature for efficient water pump performance Premix coolant solution to provide protection to the lowest expected outside ambient temperature Pure undiluted antifreeze will freeze at 2...

Page 134: ...NES Specifications Requirements Aromatics ASTD1319 35 Max Ash ASTMD482 0 02 WeightMax CetaneNumber ASTMD613 35Min for45 Max 40Min forDIEngines CloudPoint ASTMD97 NotAboveLowestExpected AmbientTemperature GravityAPI ASTMD287 30Min and45Max PourPoint ASTMD97 6 C 10 F Below AmbientMin Sulfur ASTMD2788 D3605orD1552 0 5 Max SeeSulfurTopic Viscosity Kinematic 38 C 100 F ASTMD445 20 0cStMax 1 4cStMin Wat...

Page 135: ...ferent refineries HD5 is recommended for DOOSAN forklift trucks Remember LP is heavier than air and will sink to the lowest spot possible Avoid areas near floor drains or lubrication pits where escaped fuel may collect Composition of HD5 Propane C3H8 90 0 Propylene up to 5 Butane C4H10 2 0 iso Butane 1 5 Methane CH4 1 5 Total 100 https www forkliftpdfmanuals com ...

Page 136: ... Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil The sulfur products formation depends on the fuel sulfur content oil formulation crankcase blowby engine operating conditions and ambient temperature Hydraulic Oil HYDO The following commercial classifications can be used in the hydraulic system z ISO 6743 4 HM z AFNOR NFE 48 603 H...

Page 137: ...for disk materials and or excessive gear wear Select the oil that meets the following specification z GM DEXRON III z FORD MERCON V Drive Axle Oil NOTE Failure to follow the recommendation will cause shortened life due to excessive gear wear Shoe Brake Select oil that meets below specifications z API GL 5 z MIL L 2105 C D Gear Oil offers maximum protection against the scoring and pitting of gear t...

Page 138: ...ust and antioxidation additives for heavy duty use as stated by the oil supplier ISO viscosity grade of 32 would normally be selected The following products are authorized for use Supplier Product Name TOTAL AZOLLAZS SHELL TELLUS MOBIL DTE20S CALTEX RANDO HD ESS NOTO H CASTROL HYSPIN AWS Lubricating Grease MPGM Use Multipurpose Molybdenum Grease MPGM for all lubrication points If MPGM grease can n...

Page 139: ... Brake OCDB UTTO UTTO 20 80 4 176 ISO VG32 20 30 4 86 ISO VG46 10 40 14 104 Brake Reservoir Only for OCDB ISO 6743 4HM ISO VG68 0 50 32 122 The SAE grade number indicates the viscosity of oil A proper SAE grade number should be selected according to ambient temperature Refill Capacities Refill Capacities Approximate Compartment or System Liters U S Gal Engine Crankcase w Filter LP 4 3 1 1 Engine C...

Page 140: ...th Hydraulic Return Filter Change 159 Every 250 Service Hours or Monthly Air Intake System Check Clean 160 Brake Oil Level Check 161 Hydraulic Oil Level Check 163 Drive Axle Oil Level Check 163 Mast Carriage Lift Chains Attachments Check Lubricate 164 Carriage Side Rollers Lubricate 165 Steering Mechanism Check Lubricate 165 Battery Terminal Clean Inspect 166 Engine Oil Filter Change 166 Wheel Bol...

Page 141: ...ting Fuel Lock off Operation LP Engine Only 182 Every 2000 Service Hours or Yearly Steer Wheel Bearings Reassemble 183 Cooling System Clean Change 184 Fork Inspect 185 Every 2500 Service Hours or 15 Months Hydraulic Oil Check Clean Change 187 Inspect Battery System 187 Checking the TMAP Sensor LP Engine Only 188 Inspect for Intake Leaks LP Engine Only 188 Replace PCV Valve and breather element Cha...

Page 142: ...pped Lubricate 170 O Checking the TMAP Sensor LP Engine Only 188 O Circuit Breaker 146 O Circulation Pump Belt OCDB LP Engine Only If Eguipped Check Adjust 171 O Coolant Level Check Clean 149 O Cooling System Clean Change 184 O Crosshead Rollers Inspect 170 O Disassembly 181 O Drive Axle Oil Check Clean Change 156 O Drive Axle Oil Strainer OCDB Only Check Clean Change 171 O Drive Axle Oil Shoe Bra...

Page 143: ...ge Pins Lubricate 168 O Mast Carriage Lift Chains Attachments Check Lubricate 164 O Overhead Guard Inspect 173 O Parking Brake Test Adjust 157 171 O O Priming the Fuel System Diesel Engine Only 144 O Replace LP Fuel Filter Element LP Engine Only 181 O Replace Oxygen Sensor G643E Engine Only 188 O Replace PCV Valve and breather element Change LP Engine Only 188 O Replace Spark Plugs LP Engine Only ...

Page 144: ...ional time for the engine to cool before measuring valve clearance NOTICE Measure the valve lash with the engine stopped To obtain an accurate measurement allow at least 20 minutes for the engine cylinder head and block to cool Set the clearance to the nominal appropriate clearance given in the Valve Clearance Setting chart shown below Valve Clearances Engine Valve Clearance Exhaust Valves 40mm 16...

Page 145: ...sual inspection of the fuel system Leaks will cause the solution to bubble 5 Repair any leaks before continuing 6 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 and housing Repeat leak inspection as listed above 7 Repair any ...

Page 146: ...mpletely remove an air 4 Tighten air bleed nut 2 5 Make sure to check leakage of injection pump filter after operating feed pump many times Seat Hood Latch 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 ce...

Page 147: ...he fuses are located under the air cleaner Fuse Protects an electrical circuit from an overload Opens filament separates if an overload occurs Fuse Box Open Typical Example Diesel Gas Fuse Box Close Typical Example Fuses are identified as follows 1 Horn 10 A 2 Head Lamp Clearance Lamp Tail Lamp 15 A 3 Lamp Relay Coil Fwd Rev Solenoid Rear Lamp Relay Back up Lamp Alarm 15 A 4 Instrument Panel Hour ...

Page 148: ...p or light Fuse Relay LP Engine Only Circuit Breaker 1 Raise the hood and seat assembly Make sure the support cylinder securely holds the hood open Typical Example Diesel Engine Truck Typical Example LP Engine Truck 2 The main circuit breaker is located on the rear of the support for the controls NOTE To reset circuit breakers push in on the button The button should stay in if the breaker is reset...

Page 149: ... 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 Do not reinflate a 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 necessa...

Page 150: ...ple lift models the bottom of the inner mast must be flush with the bottom of the stationary mast 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 unit mm STD mast FF mast FFT mast 7 43 43 https www forkliftpdfmanuals com ...

Page 151: ...he support cylinder securely holds the hood open 2 Maintain oil level between the MAX and MIN marks on the dipstick Coolant Level Check Clean Check Coolant Level WARNING At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand Re...

Page 152: ...cal Example Diesel Engine Truck Typical Example LP Engine Truck 1 Observe the air cleaner service indicator 2 Service the air cleaner when the RED band in the service indicator lock 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 frequent...

Page 153: ...the ground 5 Inspect the operator s 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 Typical Example TIER II Diesel Engine Truck Typical Example LP Engine Truck 8 Inspect the cooling system for leaks worn hoses and debris buildup 9 Inspect engine compartment for oil coolan...

Page 154: ...d parking brake applied and the transmission controls in NEUTRAL 3 With the 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 Open the access door in floor plate 6 Remove the dipstick filter cap Observe the oil level 7 Maintain the oil level between the Min a...

Page 155: ...ed 2 Raise rear of lift truck off ground and block securely WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Typical Example 3 Remove the crankcase drain plug and allow oil to drain into a suitable container Clean and install drain plug Typical Example 4 Remove and discard oil filter element 5 Wipe sealing surface of oil filter element mou...

Page 156: ...d 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 Remove the drain plug spring and strainer Allow the oil to drain NOTICE Careless disposal of waste oil can harm the environment and can be dangerous to persons Always dispose of waste oil to...

Page 157: ... Install the dipstick filter cap 9 Start the engine 10 With the service brake applied and engine at low idle shift the transmission to forward and reverse to fill the clutches 11 Shift the transmission into NEUTRAL Apply the parking brake 12 Remove the dipstick filter cap 13 Maintain the oil level between the Min and Max marks on the dipstick filter cap When the oil temperature is 40 C approximate...

Page 158: ...nt fresh oil through the fill opening until it reaches the bottom of the oil level plug opening See the section Lubricant Specification Drive Axle Oil and Refill Capacity 7 Clean and reinstall the oil level plug and fill plug with breather 8 Remove the blocks from under the carriage Lower the carriage 9 Operate the lift truck for a few minutes Check oil level again See topic Drive Axle Oil Check i...

Page 159: ...e grade The parking brake needs adjusting if it does not hold the lift truck on the grade 6 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 To prevent personal injury the operator MUST be ready to use the serv...

Page 160: ... 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 To Adjust Park the lift truck level wi...

Page 161: ... skin Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped 1 Raise the hood and seat assembly Loosen the bolts of the hydraulic tank cover and remove the hydraulic tank cover with filter assembly 2 Remove filter assembly from the hydraulic tank cover 3 Install new filter assembly in the hydraulic tank cover 4 Inspect cover gasket for...

Page 162: ...gine Truck 1 Check the precleaner bowl for dirt build up If the dirt is up to the line remove the precleaner bowl and empty it Periodically wash the cover and bowl in water Servicing Filter Element NOTICE Never service precleaner with the engine running Typical Example Diesel Engine Truck Typical Example LP Engine Truck Service the air cleaner when the red target in the service indicator stays loc...

Page 163: ...air cleaner housing 5 Check the air cleaner housing for loose latches 6 Reset the air cleaner service indicator 7 Install the air filter element 8 Install the cover and tighten the cover latches 9 Start the engine and observe the position of the indicator If the indicator shows RED after the installation of the primary element install another clean or a new element or replace the secondary element...

Page 164: ...le cleaning used elements The primary element should be replaced after a year s service or after cleaning no more than 6 times 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 280 kPa 40 psi Maximum Pressure Direct water on the inside and outside of the element along the lengt...

Page 165: ...the air lift cylinder securely holds the hood open 3 Remove the dipstick filter cap Maintain the oil level to the FULL mark on the breather dip stick Drive Axle Oil Level Check WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Park the lift truck on a level surface Apply the parking brake The engine is at the low idle Place the directional ...

Page 166: ...epair 2 Inspect for 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 4 Brush a film of oil on all links of the chain 5 Raise and lower the carriage a few times to work lubricant into the chain links NOTICE Lubricate chains more frequently than normal in applications whe...

Page 167: ...sher Carriage Side Rollers Lubricate D35 40S 5 D40 45SC 5 G35 40S 5 G45 50SC 5 D45S 5 D50SC 5 D50C 5 G45S 5 G50SC 5 Lubricate 2 side roller fittings one on each side of the carriage Steering Mechanism Check Lubricate 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 rig...

Page 168: ...il Filter Diesel Engine Only Change in First 50 100 Service Hours 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 WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to con...

Page 169: ...as of wheels or ball faces of wheel nuts Be sure mounting faces of hub wheel nuts and flat mounting surfaces are clean Tighten wheel nuts again after 24 hours of operation NOTE Always tighten wheel lug nuts in a sequence opposite 180 each other If equipped with dual wheels follow the same nut tightening sequence for both wheels Steer Wheels Install steer wheel Put two nuts opposite 180 each other ...

Page 170: ...orce NOTICE Failure to loosen the alternator mounting bolt will cause excessive stress and break the alternator mounting gear 3 To adjust the alternator drive belt loosen adjusting bracket bolt Move the alternator in or out as required Tighten bolts 4 To adjust fan belt loosen idler pulley mounting bolt Move idler pulley in or out as required Tighten idler pulley mounting bolt 5 Lower the hood and...

Page 171: ... tilt spacers must be added or removed Typical Example 1 Check to make sure the tilt cylinders extend and retract evenly 2 If one cylinder continues to move after the other cylinder has stopped in full forward or backward tilt an adjustment must be made to one cylinder Typical Example 3 To adjust the cylinder rod extension move the spacer to the rear and loosen the pinch bolt on the clevis 4 Turn ...

Page 172: ...gh enough to gain access to the side thrust rollers on the back side of the carriage Block the carriage in this position 2 Lubricate 2 side thrust roller fittings one on each side of the mast 3 Raise the carriage remove the blocking Lower the carriage to the floor Carriage Sideshifter If Equipped Lubricate 1 Lubricate 4 6 fittings The forks may have to be moved to gain access to all of the fitting...

Page 173: ...r the hood and seat assembly Drive Axle Oil Strainer OCDB Only Check Clean Change WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Park the lift truck on a level surface Apply the parking brake Place the directional control level in NEUTRAL and stop the engine 1 Remove drain plug Allow the oil to drain into a suitable container Clean the m...

Page 174: ...ine if horn is operational 2 Check and replace all defective gauges 3 Check all lights such as warning directional backup driving and flood lights for correct operation Replace all burned out bulbs Have repairs made if needed Inspect Vacuum Lines and Fittings LP Engine only 1 Visually inspect vacuum lines and fittings for physical damage such as brittleness cracks and kinks Repair replace as requi...

Page 175: ...gized replace the FTV Inspect Electrical System LP 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 Distributor sensor 2 Repair and or replace as necessary Overhead Guard Inspect 1 Check tightness of overhead guard mounting bolts at 95 N m 70 lb ft 2 Che...

Page 176: ... the filter with a feed pump Air Intake System Change Changing Primary Element See topic Air Intake System Check Clean in Every 250 Service Hours or Monthly Changing Secondary Element Replace the secondary element after the primary element has been cleaned three times or yearly 1 Remove the primary air cleaner element See topic Servicing Filter Element Clean the inside of the air cleaner housing a...

Page 177: ...service manual if maintenance is required NOTE For pressure testing and internal inspection of the pressure regulator converter refer to the pressure regulator converter section of the service manual Fuel Lines Fittings Check Visually inspect fuel lines and fittings for physical damage Replace as required Inspect Mixer Assembly LP Engine Only Refer to the LP mixer section of the engine service man...

Page 178: ...ler 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 pin is extended beyond its connecting corresponding link it should be suspected of being broken inside of its link hole Lift chains are required to check for wear about every 1 000 service hours or 6 months Chain wear test is a measurement ...

Page 179: ... 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 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 pr...

Page 180: ...f 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 Mast Chain Adjustment FF FFT Mast Typical example for FF mast Typical example for FFT mast Make sure that mast height is correct If correct adjust chain for equal tension If not adjust mast chain for correct mast height by adjusting ...

Page 181: ... Section 179 Universal Joint Inspect 1 Inspect for loose retaining bolts Check for worn or damaged bearings 2 Have worn or damaged bearings replaced Tighten the bolts if necessary https www forkliftpdfmanuals com ...

Page 182: ...air and or replace 4 Remove distributor cap and perform visual inspection Replace cap and rotor if corrosion is found on the contacts 5 Inspect the ignition coil for cracks and heat deterioration Visually inspect the coil heat sink fins If any fins are broken replace as required Replace Spark Plugs LP Engine Only 1 Disconnect Battery Cables 2 Using a gentle twisting motion remove the high voltage ...

Page 183: ...nly Disassembly 1 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 2 Replace the filter element 7 3 Check bottom cover O ring seal 6 for damage Replace if necessary 4 Re assemble the filter assembly aligning the scribe lines on the top and bottom covers 5 Install the cover retaining screws tightening the screws in an opposite sequence across the cover 6 Open the fuel v...

Page 184: ...ne should run out of fuel and stop within a short period of time 5 Turn the ignition key switch off and re connect the fuel lock off connector NOTE The length of time the engine runs on trapped fuel vapor increases with any increase in distance between the fuel lock off and the pressure regulator converter 1 LP fuel lock off 2 LP regulator converter 2 1 https www forkliftpdfmanuals com ...

Page 185: ...Remove the wheel assembly Examine the seal for damage and wear Replace the seal if necessary WARNING Deflate tire before removing wheel nuts at tire change 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 and install the wheel assembly on the knuckle 8 Install the outer wheel bearing...

Page 186: ...to drain Drain the recovery bottle 4 Close radiator drain valve and install block drain plug Fill the cooling system with 1 kg 2 lb sodium bisulphate per 40 liters 10 gallons of water Most commercial cooling system cleaners can be used 5 Start and run the engine for 30 minutes 6 Stop the engine and drain the cleaning solution 7 Flush the system with clean water until draining water is clear 8 Clos...

Page 187: ...ithdrawn from service if angle C exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees as may be found in some special application forks 3 Check the straightness of the upper face of blade D and the front face of shank E with a straight edge The fork should be withdrawn from service if the deviation from straightness exceeds 0 5 percent of the length of...

Page 188: ...iding 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 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...

Page 189: ...in plug Allow the oil to drain Clean and install the plug 2 Raise the hood and seat assembly 3 Remove dipstick filter cap Fill the hydraulic tank See Refill Capacities Install the breather dipstick 4 Lower the hood and seat assembly 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...

Page 190: ...ect for Intake Leaks LP Engine Only 1 Visually inspect the intake manifold throttle assembly 4 and manifold adapters 3 for looseness and leaks Repair as necessary Replace PCV Valve and breather element Change LP Engine Only 1 Loosen the hose clamps and remove the PCV valve 2 Assemble new PCV valve and hose 3 Tighten the hose clamps Replace Oxygen Sensor G643E Engine Only Exhaust Tube Muffler Ass y...

Page 191: ...nt 174 Changing Secondary Element 174 Chassis Pivot Eyebolts 169 Check Coolant Level 149 Check for Equal Tension 177 Check Inflation and Damage 147 Checking Element 162 Checking Service Indicator 150 Checking the TMAP Sensor LP Engine Only 188 Circuit Breaker 60 146 Circulation Pump Belt OCDB LP Engine Only If Eguipped Check Adjust 171 Cleaning Primary Filter Elements 162 Coolant Information 130 C...

Page 192: ...87 Hydraulic Oil HYDO 134 Hydraulic Oil Level Check 163 Hydraulic Return Filter Change 159 177 I Identification Lift Capacity and Attachment Plate 55 If Optional Suspension Seat weight adjusting type Equipped 18 Important Safety Information 4 Improper Modification or Repair 124 Inching Brake Control shaft Lubricate 172 Inching into Loads 114 Inching 109 Index 189 Inspect Mixer Assembly LP Engine O...

Page 193: ...Operator s Warning Plate 55 Overhead Guard Inspect 173 Overhead Guard Must Be In Place Warning 8 Overloading 124 P Parking Brake Test Adjust 157 172 Parking Brake Adjusting 157 Parking Brake Lever 63 Parking Brake Testing 157 Parking brake 9 Parking the Lift Truck 118 Power Shift Transaxle 108 Precleaner If Equipped 160 Pressure Air 14 Pressure Warning 7 Prestart Conditions 70 Priming the Fuel Sys...

Page 194: ...ations 128 Torques for Bolts and Nuts With Standard Threads 128 Torques for Taperlock Studs 129 Towing Information 122 Training Required to Operate or Service Warning 5 Transmission Inching Control Pedal 62 Transmission Oil TDTO 135 Transmission Oil Level Check 152 Transmission Oil Oil Filter Strainer Clean Change 154 Transmission Oil Oil Filter Strainer Clean Change 176 Transmission Speed Range L...

Page 195: ...SB2357E00 Operation Maintenance Manual LIFT TRUCKS GC35S 5 GC40S 5 GC45S 5 GC50C 5 GC55C 5 0706 https www forkliftpdfmanuals com ...

Page 196: ...https www forkliftpdfmanuals com ...

Page 197: ...efore Starting the Engine 50 Starting the Engine 52 After Starting the Engine 54 Lift Truck Operation 78 Mono Ped Control System Option 80 Auto Shift Controller ASC 200 If Equipped 81 Operating Techniques 84 Parking the Lift Truck 88 Lift Fork Adjustment 89 Storage Information 90 Transportation Hints 91 Towing Information 92 Maintenance Section Inspection Maintenance and Repair of Lift Truck Forks...

Page 198: ...ith 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 Drivi...

Page 199: ... 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 ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by...

Page 200: ...ert 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 se...

Page 201: ...t 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 Warning Signs and Labels There are several specific safety signs on your lift truck Their exact loc...

Page 202: ...d 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 han...

Page 203: ...reach through the mast or permit others to do so Located on the mast No Standing On Forks Warning No Standing Under Forks Warning 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 Located on the lift cylinder Load Backrest Must Be In Place Warning WARNING Operation without this device in place may be hazardous Locat...

Page 204: ...as been tested with an impact of appropriate value Located on the Overhead Guard Brake Pedal Adjustment Warning WARNING Improper adjustment could result in injury or death It has to be adjusted by drawing dimension on free condition For safe don t unfasten clevis and nut It has to be adjusted by trained personnel OCDB Type Only Located inside Brake pedal box https www forkliftpdfmanuals com ...

Page 205: ...d Alarm will sound if parking brake is not applied 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 No Riders Warning WARNING To avoid personal ...

Page 206: ...ted 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...

Page 207: ...nal DOOSAN spare parts waive any liability by DOOSAN Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully Clean your shoes and wipe your hands before mounting Face the lift truck when mounting and dismounting Use both hands face the lift truck when mounting and dismounting Use the handgrips for mounting and dismounting Do not try to climb on or off the lift tr...

Page 208: ...t 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 Operating the Lift Truck Always keep the lift truck under control Obey all traffic rules and warning signs...

Page 209: ...he Operation Section of this manual 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 If trailer is not coupled to tractor make sure the trailer landi...

Page 210: ...es 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 o...

Page 211: ... lubricants and some coolant mixtures are flammable Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling area Do not smoke in areas where batteries are charged or where flammable materials are stored Batteries in series can be located in separate compartments When using jumper cables always connect positive cable to posit...

Page 212: ...ds 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 blo...

Page 213: ...ry 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 WARNING Tipover can occur if the truck is improperly operated In the event of a tipover injury or death could result The Survive in tipover warning is located on the overhead guard It shows the proper use of the oper...

Page 214: ...t is properly locked Do not adjust the seat while the truck is in motion Weight adjustment Pull the weight adjustment lever upwards and move right or left side Adjust to driver s weight in 7 steps 50 110 kg NOTICE Do not place your hand or fingers under the seat Injury may occur as the seat moves up and down Backrest Inclination The backrest angle can be adjusted by using the lever on the left sid...

Page 215: ...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 3 In the event of a tipover the seat and restraint system should be inspected for damage and replaced if necessary NOTE Operator restraints shall be examined at the regular truck service intervals It is recomme...

Page 216: ...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 to release the belt The belt will automatically retract when released Hold the plate of the belt and allow the belt to slowly retract https www forkliftpdfmanuals c...

Page 217: ...t When the lift truck picks up a load the truck and load have a new combined CG Stability and Center of Gravity The stability of the lift truck is determined by the location of its CG or if the truck is loaded the combined CG of the truck and load The lift truck has moving parts and therefore has a CG that moves The CG moves forward or backward as the mast is tilted forward or backward The CG move...

Page 218: ...achment to the CG of the load The location of the CG in the vertical direction is the same as the horizontal dimension Remember that unless otherwise indicated the capacity load shown on the nameplate is for a standard lift truck with standard backrest forks and mast and having no special purpose attachment In addition the capacity load assumes that the load center is no further from the top of th...

Page 219: ...s and read all warning signs 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 the body outside of the operator s compartment Never put any part of body into the mast structure or between the mast and the truck Do not start stop turn or change direction suddenly or at high speed Sudden movement can cause t...

Page 220: ...er size pallet Position the forks as wide as possible under the load Position loads evenly on the forks for proper balance Do not lift a load with one fork Do not overload Always handle loads within the rated capacity shown on the capacity plate Do not add extra counterweight to the truck An overload can cause the truck to roll over and cause injury to personnel and damage to the lift truck Do not...

Page 221: ... when stacking Travel with the load tilted back and the forks as low as possible This will increase stability to the truck and load and permit better visibility for you Do not 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 Do not jump off if your truck starts to tip over Stay in your seat to survive Go up ram...

Page 222: ...ns or obstructions in your path of travel An operator must be in full control of his lift truck at all times 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 an...

Page 223: ...spilt fuel and do not forget to close the fuel tank before restarting the engine Park your lift truck in authorized areas only Fully lower the forks to the floor put direction lever in NEUTRAL position engage the parking brake and turn the key to the OFF position Remove the key and put blocks behind the wheels to prevent the truck from rolling Shut off your forklift truck when leaving it unattende...

Page 224: ...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 Always use operator restraint system DON T jump Hold on tight Brace your feet and keep them within the operator s compartment https www forkliftpdfmanuals com ...

Page 225: ...Safety Section 29 Lean away from the direction of fall Lean forward https www forkliftpdfmanuals com ...

Page 226: ...FORMANCE 23 travel loaded unloaded km hr 15 15 15 15 24 SPEED lift loaded unloaded mm s 500 550 480 550 25 lowering loaded unloaded mm s 530 450 500 450 27 GRADEABILITY at 1 6km hr loaded unloaded 27 24 WEIGHT 28 TOTAL WEIGHT at unloaded kg 5470 5850 29 at loaded front rear kg 7970 1000 8690 1160 30 AXLE LOAD at unloaded front rear kg 2230 3240 2130 3720 CHASSIS 31 number of front rear 2 2 2 2 32 ...

Page 227: ...15 23 480 500 450 500 450 500 24 500 440 480 440 480 440 25 23 22 21 27 6500 6990 7340 28 9775 1225 10630 1360 11330 1510 29 2495 4005 2520 4470 2400 4940 30 2 2 2 2 2 2 31 22X12X16 22X12X16 22X12X16 32 18X8X12 1 18X8X12 1 18X8X12 1 33 1790 1790 1790 34 1116 1044 1116 1044 1116 1044 35 130 130 130 36 130 130 130 37 foot hyd foot hyd foot hyd 38 hand mech hand mech hand mech 39 12 12 12 40 GM 4 3 V...

Page 228: ...odel AS3713 prEN12053 Drive By LiftingMode GuaranteedSound PowerLevel LWA bynewdirective 2000 14 EC GC35 40 45S 5 GC50 55C 5 TIER IIIE G W O Cabin 81 5 83 4 76 5 75 1 106 107 Vibration weighted overall value Unit m sec2 Measuring place Model Seat Steering Wheel Floor Plate GC35 40 45S 5 GC50 55C 5 TIER IIIE G 0 97 0 82 0 25 https www forkliftpdfmanuals com ...

Page 229: ...General Section 33 Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT GC35S 5 GC40S 5 GC45S 5 https www forkliftpdfmanuals com ...

Page 230: ...General Section 34 Capacity Chart with Side Shifter SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT GC35S 5 GC40S 5 GC45S 5 https www forkliftpdfmanuals com ...

Page 231: ...General Section 35 Capacity Chart SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT GC50C 5 GC55C 5 https www forkliftpdfmanuals com ...

Page 232: ...General Section 36 Capacity Chart with Side Shifter SINGLE TIRE SINGLE TIRE MODEL STD FFL FFT GC50C 5 GC55C 5 https www forkliftpdfmanuals com ...

Page 233: ...graphs Lift Truck Serial Number ______________________________ 4 3 liter GM Vortec Engine Serial Number G643E ______________________________ Transmission Serial Number ______________________________ DRIVE AXLE Serial Number ______________________________ Side Shifter Serial Number If Equipped ______________________________ https www forkliftpdfmanuals com ...

Page 234: ... the load center is 600 mm 24in from both the vertical and horizontal faces of the forks Before attempting to lift any load ensure that the weight and load center combination is within the capacity of the lift truck as shown on the capacity rating plate To determine the load center measure the distance from the face of the carriage to the gravitational center of the load The rated capacity on the ...

Page 235: ...tandard carriage and forks are used Attachment Abbreviations Includes Special Forks SC 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 Conta...

Page 236: ...ustrations 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 LPG 12V https www forkliftpdfmanuals com ...

Page 237: ...nes LED Type Gage If both tenth ninth flash out of phase while operating the lift truck overheating is indicated Park the lift truck and stop the engine Chack the cooling system for a malfunction Both tenth ninth will flash out of phase when the coolant temperature reaches approximately 106 223 on all engine 7 Transmission Oil Temperature Gauge Indicates transmission oil temperature If the pointer...

Page 238: ...sition Refill the proper brake fluid oil if its light is ON WARNING Frequent rapid starts at 2nd speed can be the cause of overheating at torque converter With this operating condition the pointer can sometimes exceed the green band If this situation occurs from time to time please avoid this operating condition to protect the transmission and increase the work efficiency That is start the truck a...

Page 239: ...h If Equipped 1 ON Connects the battery for electrical power to all electrical circuits 2 OFF Disconnects the battery from all electrical circuits Seat NOTE Seat arrangements may vary Basic operation will be similar Seat adjustment should be checked at the beginning of each shift and when operators change Lock the seat into position before operating to prevent an unexpected seat change Adjust seat...

Page 240: ... that will sound if the parking brake is not applied when leaving the machine NOTICE 1 Prior to operating the lift truck be sure to understand and check the SEAT SWITCH SYSTEM 2 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 in the selected direction If you lift yours hips of...

Page 241: ...wise for LOW speed range 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 clutch pack pressure and applies the service brakes to stop and hold the lift truck NOTE The purpose of the inching control pedal is to provide precise inchi...

Page 242: ... lever BACK to engage the parking brake Push the lever FORWARD to release the parking brake Lift Control NOTE 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 w...

Page 243: ...stop 3 Mast Tilt Back Pull the lever BACK smoothly to tilt the mast backward Sideshift Attachment Control If Equipped 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 https www forkl...

Page 244: ...ng areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to indoor locations Stop the engine and get off the lift truck during refueling The careless handling of LP containers can result in a serious accident Use extreme care when transporting containers to prevent damage to them 1 Park the lift truck on level ground with the parking brake appl...

Page 245: ...terioration damage or missing flexible seals 11 Position the replacement tank so that the locating pin dowel is in place WARNING The LP tank must not extend past the counterweight 12 Clamp the tank securely 13 Connect the fuel supply line 14 Open the fuel valve by slowly turning the valve counterclockwise If the fuel valve is opened too quickly a back pressure check valve will shut off the fuel su...

Page 246: ... for broken or damaged indicator lights or gauges 3 Test the horn and other safety devices for proper operation 4 Inspect the mast and lift chains for wear broken links pins and loose rollers 5 Inspect the carriage forks or attachments for wear damage and loose or missing bolts 6 Inspect the tires and wheels for cuts gouges foreign objects inflation pressure and loose or missing bolts 7 Inspect th...

Page 247: ...rk If the recovery bottle is empty also fill the radiator at the top tank 13 In case of LPG truck if needed change LPG Fuel Tank as the procedure of changing LP tanks in Refueling Section 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 sh...

Page 248: ...rting turn the disconnect switch to the OFF open position LP Engine WARNING LP fuel is flammable and can cause personal injury Inspect LP fuel lines and fitting for leaks Inspect tank for secure mounting 1 Open the tank fuel valve by slowly turning the valve counterclockwise Observe the LP gauge if equipped 2 Turn the engine ignition switch to the START postion Release it when the engine starts 3 ...

Page 249: ...attery and well clear of fuel system components NOTICE Do not reverse battery cables It can cause damage to the alternator Always connect the external power source cables in parallel with the lift truck battery cables POSITIVE to POSITIVE and NEGATIVE to NEGATIVE Attach ground cable last remove first All lift trucks equipped with DOOSAN built internal combustion engines are NEGATIVE ground https w...

Page 250: ...r is not charging if the light comes ON with the engine running 3 The G643E engine MIL Malfunction Indicator Light 3 will not come ON with engine running unless the fault or faults are stored in the memory of the engine control module ECM Stop the engine and check the electric engine control system if the light comes ON Refer G643E Engine of thissection 4 The engine coolant temperature gauge point...

Page 251: ...hes 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 MI 07 is a drive by wire DBW system con...

Page 252: ...alve Excess flow valve closed Reset excess flow valve z Close liquid valve z Wait for a click sound z Slowly open liquid valve Plugged fuel line Remove obstruction from the fuel line z Close liquid fuel valve z Using caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Broken Fuse SECM Re...

Page 253: ...tion disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and or collapsed hose Pressure regulator converter malfunction Test ...

Page 254: ...l line z Slowly open liquid fuel valve Leak test Pressure regulator freezes Check level in cooling system z Must be full check coolant strength z 35F minimum Check coolant hoses z Watch for kinks and or pinched hoses z Verify one pressure hose and one return hose Fuel Lock off malfunction Repair replace Fuel Lock off z See Engine Service Manual Incorrect idle speed or ignition problem See Advanced...

Page 255: ...Accelerate Hesitation During Acceleration Engine Mechanical See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet z Fill fuel container z Do not exceed 80 of liquid capacity Excess flow valve closed Reset excess flow valve z Close liquid valve z Wait for a click sound z Slowly open liquid valve Clogged fuel filter Repair replace as required z See Maintenance Section LP...

Page 256: ...acuum leak Check for vacuum leaks z Between mixer and throttle body z Between throttle body and intake manifold z Between intake manifold and cylinder head Air Fuel Mixer malfunction Check mixer z See Engine Service Manual Engine Stalls Engine Mechanical See Engine Manufacturers Service Manual Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify ...

Page 257: ...caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve Leak test Air filter clogged Check air filter z Clean replace as required Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and...

Page 258: ...l pressure too high Test pressure regulator operation z See Engine Service Manual Faulty FTV G643E only Check FTV for housing cracks or obstructions z See Advanced Diagnostics FTV operation z 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 Excessive Fuel Con...

Page 259: ...ween fault codes A code 12 is displayed at the end of the code list EXAMPLE A 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...

Page 260: ... Shutdown 3 CheckEngineLight 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 B1 to ECT Pin 1 SECM System GND Pin A16 B17 Check regulator for coolant leaks 171 ECT_IR_Fault Engine coolant temperature not changing as expected None Check for coolant system...

Page 261: ...il Check throttle connector connection and TPS2 sensor for an open circuit or short to GND SECM Pin B4 signal to ETC Pin 5 SECM Pin B1 sensor GND to ETC Pin 2 SECM system GND Pin A16 B17 231 23 TPS1RangeHigh TPS1 sensor voltage out of range high normally set if the TPS1 signal has shorted to power or the ground for the sensor has opened TurnOnMil Check throttle connector and TPS1 sensor wiring for...

Page 262: ... Learned WOT end of TPS2 sensor range higher than expected None N A 271 TPS1AdaptHiMin Learned WOT end of TPS1 sensor range lower than expected None N A 272 TPS2AdaptHiMin Learned WOT end of TPS2 sensor range lower than expected None N A 281 TPS1AdaptLoMax Learned closed throttle end of TPS1 sensor range higher than expected None N A 282 TPS2AdaptLoMax Learned closed throttle end of TPS2 sensor ra...

Page 263: ...nd or the circuit has opened to the SECM 1 TurnOnMil 2 CutThrottle 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 4kΩ 8 2kΩ TMAP Pin 3 power to ...

Page 264: ...pected None Check that TMAP sensor is mounted properly Possible defective TMAP sensor 371 37 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 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 ...

Page 265: ... 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 Check for debris or obstructions inside the throttle body Perform the throttle test using the Service Tool and re check for fault Ch...

Page 266: ...wiring for a shorted circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Perform the throttle test using the Service Tool and re check for fault Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0Ω 521 52 LowOilPressureFault Low engine oil pressure 1 TurnOnMil 2 DelayedE...

Page 267: ...er SECM Pin B24 5 Vdc to SECM Pin B1 XDRG 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 561 56 SensVoltRangeHigh Sensor reference voltage XDRP too high 1 TurnOnMil 2 EngineShutdown Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 XDRP 5 Vdc to TMAP Pin 1 XDRG GND V...

Page 268: ...ened or sensor has failed TurnOnMil Check foot pedal connector Check APP2 signal at SECM PIN B16 621 62 APP1RangeHigh APP1 sensor voltage out of range high normally set if the APP1 signal has shorted to power or the ground for the sensor has opened 1 TurnOnMil 2 CheckEngine Light Check foot pedal connector Check APP1 signal at SECM PIN B7 622 66 APP2RangeHigh APP2 sensor voltage out of range high ...

Page 269: ... 711 71 LSDFault_Dither1 Dither Valve 1 Fault signal has opened or shorted to ground or power or defective dither 1 valve TurnOnMil Check FTV1 for an open wire or FTV connector being disconnected FTV1 Pin 1 signal to SECM Pin A1 FTV1 Pin 2 power to SECM DRVP Pin A23 Check FTV1 for an open coil by disconnecting the FTV connector and measuring the resistance 26Ω 2Ω 712 LSDFault_Dither2 Dither Valve ...

Page 270: ... or defective MIL lamp None Check MIL lamp for an open wire or short to GND 721 72 GasFuelAdaptRangeLo In LPG mode system had to adapt rich more than expected TurnOnMil Check for vacuum leaks Check fuel trim valves e g leaking valve or hose Check for missing orifice s 731 73 GasFuelAdaptRangeHi In LPG mode system had to adapt lean more than expected TurnOnMil Check fuel trim valves e g plugged val...

Page 271: ...ify O2 sensor heater circuit is operating by measuring heater resistance 2 1Ω 0 4Ω O2 Pin 2 HEATER GND to Pin 1 HEATER PWR 743 Reserved 751 GasO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on LPG 1 TurnOnMil 2 DisableGas O2Ctrl Check for vacuum leaks Check fuel trim valves e g leaking valve or hose Check for missing orifice s 752 GasPostO2FailedLean Pre catalyst O2 sensor i...

Page 272: ...atRangeLow Post catalyst O2 sensor voltage out of range low sensor signal shorted to ground 1 TurnOnMil 2 Disable LPG Post catalyst O2Ctrl Check if O2 installed after the catalyst sensor is shorted to GND or sensor GND O2 signal Pin 3 to SECM Pin B19 Possible sources SECM DRVG GND Pins A16 B17 and SECM XDRG sensor GND Pin B1 921 O2RangeHigh Pre catalyst O2 sensor voltage out of range high sensor s...

Page 273: ... Pin 1 SECM sensor GND Pin B1 to FTS Pin 2 933 TransOilTemp Excessive transmission oil temperature 1 TurnOnMil 2 Delayed EngineShutdown Refer to drivetrain manufacturer s transmission service procedures 991 ServiceFault1 Service Interval 1 has been reached None Perform service procedure related to Service Interval 1 determined by OEM 992 ServiceFault2 Service Interval 2 has been reached None Perfo...

Page 274: ...er 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 Stop the loaded lift truck completely before...

Page 275: ...ring the lift truck to a smooth stop Inching NOTE The purpose of the inching pedal is to provide precise lift truck inching control at very slow travel speed and high engine rpm This is used for fast hydraulic lift during load approach pick up or load positioning 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 tran...

Page 276: ...e to truck instability and a tip over A steering knob is intended for slow travel maneuverability ONLY 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 direct...

Page 277: ...direction at high speed outside of the design parameters Adjustments SW1 Low High Shift Point SW2 Direction Inhibit Point NOTCH Vehicle Speed NOTCH Vehicle Speed 0 2 5 km h 1 55 mph 0 3 3 km h 2 05 mph 1 3 0 km h 1 86 mph 1 3 6 km h 2 24 mph 2 3 5 km h 2 17 mph 2 3 9 km h 2 42 mph 3 4 0 km h 2 49 mph 3 4 2 km h 2 61 mph 4 4 5 km h 2 80 mph 4 4 5 km h 2 80 mph 5 5 0 km h 3 11 mph 5 4 8 km h 2 98 mp...

Page 278: ...eselected modes automatic mode and manual mode Automatic Mode is selected in factory setting controller as a default Manual Mode Fail Safe Mode is selected to operate the truck manually in case of emergency Automatic mode Direction Inhibit 1 Start the engine with the direction control lever in NEUTRAL and the parking brake engaged 2 Press down on the service brake pedal disengage the parking brake...

Page 279: ... ratio control so that the appropriate gear may be engaged in every situation NOTICE Two Speed Auto Shift Control function can be accomplished only when the direction control lever is placed in the high speed 2ndgear position Manual Mode Fail Safe mode In case that the controller is broken down or you don t want to use the functions of the Auto Shift Controller you can select Manual Mode In Manual...

Page 280: ...its Typical Example 2 Move the lift truck FORWARD until the load touches the carriage Lifting the Load 1 Lift the load carefully and tilt the mast back a short distance Typical Example 2 Tilt the mast further back to cradle the load Typical Example 3 Operate the lift truck in reverse until the load is clear of the other material 4 Lower the cradled load to the travel position NOTE Lift and tilt sp...

Page 281: ...and downgrades Typical Example 2 For better vision travel in reverse with bulky loads Unloading Typical Example 1 Move the lift truck into the unloading position Typical Example 2 Tilt the mast FORWARD only when directly over the unloading area WARNING Do not tilt the mast forward with the load unless directly over the unloading area even if the power is off https www forkliftpdfmanuals com ...

Page 282: ...carriage and forks to the travel position or to the park position Turning 1 When turning sharp corners keep close to the inside corner Begin the turn when the inside drive wheel meets the corner 2 In narrow aisles keep away from the stockpile when turning into the aisle Allow for counterweight swing https www forkliftpdfmanuals com ...

Page 283: ...ep 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 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 te...

Page 284: ... 4 Lower the forks to the ground WARNING Blocking the wheels will prevent unexpected lift truck movement which could cause personal injury 5 Turn the key in the ignition switch to the OFF position and remove the key NOTE If a LP equipped lift truck is stopped or parked for an indefinite or prolonged period of time close the fuel shutoff valve on the LP tank Run the engine until fuel in the line ru...

Page 285: ... 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 WARNING Make sure the forks are locked before carrying a load https www f...

Page 286: ...e 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 z Apply antirust to the exposed parts which tend to rust z Cover components such as the breather and air cleaner which may be caught with humidity z The machine should be operated at least once a week Fill the cooling syste...

Page 287: ...n the lift truck on the truck bed or the rail car Apply the parking brake and place the transmission control in NEUTRAL Turn the ignition switch to the OFF position and remove the key If LP equipped shut off the LP fuel tank Block the wheels and secure the lift truck with tiedowns Machine Lifting and Tiedown Information NOTICE Improper lifting or tiedowns can allow load to shift and cause injury a...

Page 288: ...le 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 distan...

Page 289: ...eater 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 z A fork rated at 1500 pounds at 24 inch load center will be stamped 1500X24 z A fork rated at 2000 kg at 600 mm load center will be stamped 2000X600 The manufacturer identification and year...

Page 290: ...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 z Repetitive Overloading Repetitive cycling of load...

Page 291: ... Installation 1 Inspect forks to ensure they are the correct size for the truck on which they will be used Make sure they are the correct length and type for the loads to be handled If the forks have been previously used perform the 12 Month Inspection If the forks are rusted see Maintenance and Repair 2 Make sure fork blades are level to each other within acceptable tolerances See Forks Step 4 in...

Page 292: ...ne 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 z Repair or replace the positioning locks on hook type forks z Repair or replace most fork retention devices used with other fork types 4 A fork should be load tested before being returned to service...

Page 293: ...n shipping pressures Shipping Pressure Size Ply Rating or Strength Index kPa psi 7 00X12 Steer 12 860 125 8 25X15 Drive 14 825 120 300X15 Drive 18 785 115 7 50X16 Drive dual 12 760 110 1 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 operating conditions Pressure...

Page 294: ...mm 625 in 7 5 0 5 65 5 13 5 mm 531 in 4 5 0 5 40 5 8 mm 312 in 0 9 0 2 8 2 Reassembly Or Retightening Torque Clamp Width N m 1 lb in 16 mm 625 in 4 5 0 5 40 5 13 5 mm 531 in 3 0 0 5 25 5 8 mm 312 in 0 7 0 2 6 2 1 1 Newton meter N m is approximately the same as 0 1 kg m Torque for Standard Bolts Nuts and Taperlock Studs NOTICE The two charts below give general torques for bolts nuts and taperlock s...

Page 295: ...jury 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 rep...

Page 296: ...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 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 ...

Page 297: ...with antifreeze of different brand DOOSAN recommends that the coolant mix contain 50 commercially available automotive antifreeze or equivalent and acceptable water to maintain and adequate water pump cavitation temperature for efficient water pump performance Premix coolant solution to provide protection to the lowest expected outside ambient temperature Pure undiluted antifreeze will freeze at 2...

Page 298: ...ated wear to the fuel system parts Drain the water and sediment from main fuel storage tank before it is refilled This will help prevent water and or sediment from being pumped from the fuel storage tank into the engine fuel tank LP Specifications LP is Liquefied Petroleum Gas The exact composition of LP varies slightly between different parts of the country and different refineries HD5 is recomme...

Page 299: ...procedure can be used to evaluate the residual neutralization properties of an engine oil The sulfur products formation depends on the fuel sulfur content oil formulation crankcase blowby engine operating conditions and ambient temperature Hydraulic Oil HYDO The following commercial classifications can be used in the hydraulic system z ISO 6743 4 HM z AFNOR NFE 48 603 HM z DIN 51524 TEIL 2 H LP z ...

Page 300: ...sal Transmission Tractor Oil UTTO The following UTTO products are authorized for use Supplier Product Name TOTAL TRANSMISSION MP MOBIL MOBILFLUID 424 Brake Fluid Oil Cooled Disc Brake Only Use heavy duty hydraulic brake fluid certified by oil supplier to meet the latest version of following classifications z ISO 6743 4 HM z AFNOR NFE 48 603 HM z DIN 51524 TEIL 2 H LP z HAGGLUNDS DENISON HFO HF2 z ...

Page 301: ...2 122 Drive Axle Housing Disc Brake OCDB UTTO UTTO 20 80 4 176 ISO VG32 20 30 4 86 ISO VG46 10 40 14 104 Brake Reservoir Only for OCDB ISO 6743 4HM ISO VG68 0 50 32 122 The SAE grade number indicates the viscosity of oil A proper SAE grade number should be selected according to ambient temperature Refill Capacities Refill Capacities Approximate Compartment or System Liters U S Gal Engine Crankcase...

Page 302: ... 250 Service Hours or Monthly Air Intake System Check Clean 125 Hydraulic Oil Level Check 127 Drive Axle Oil Level Check 127 Brake Oil Level Check 127 Mast Carriage Lift Chains Attachments Check Lubricate 128 Carriage Side Rollers Lubricate 129 Steering Mechanism Check Lubricate 129 Battery Terminal Clean Inspect 130 Engine Oil Filter Change 130 Wheel Bolts and Nuts Inspect 131 Every 500 Service H...

Page 303: ...ting Fuel Lock off Operation LP Engine Only 144 Every 2000 Service Hours or Yearly Steer Wheel Bearings Reassemble 145 Cooling System Clean Change 146 Fork Inspect 147 Every 2500 Service Hours or 15 Months Hydraulic Oil Check Clean Change 149 Inspect Battery System 149 Checking the TMAP Sensor LP Engine Only 150 Inspect for Intake Leaks LP Engine Only 150 Replace PCV Valve and breather element Cha...

Page 304: ...If Equipped Lubricate 134 O Checking the TMAP Sensor LP Engine Only 150 O Circuit Breaker 112 O Circulation Pump Belt OCDB LP Engine Only If Eguipped Check Adjust 134 O Coolant Level Check Clean 115 O Cooling System Clean Change 146 O Crosshead Rollers Inspect 133 O Disassembly 143 O Drive Axle Oil Check Clean Change 121 O Drive Axle Oil Strainer OCDB Only Check Clean Change 135 O Drive Axle Oil S...

Page 305: ...ricate 132 O Mast Carriage Lift Chains Attachments Check Lubricate 128 O Overhead Guard Inspect 137 O Parking Brake Test Adjust 122 134 O O Replace LP Fuel Filter Element LP Engine Only 143 O Replace Oxygen Sensor G643E Engine Only 150 O Replace PCV Valve and breather element Change LP Engine Only 150 O Replace Spark Plugs LP Engine Only 142 O Seat Hood Latch Support Cylinder Check Lubricate 110 O...

Page 306: ...uing 6 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 and housing Repeat leak inspection as listed above 7 Repair any fuel leaks before continuing WARNING Prior to any service or maintenance activity Test Fuel System for Leak...

Page 307: ...x The fuses are located under the air cleaner Fuse Protects an electrical circuit from an overload Opens filament separates if an overload occurs Fuse Box Open Typical Example Gas Fuse Box Close Typical Example Fuses are identified as follows 1 Horn 10 A 2 Head Lamp Clearance Lamp Tail Lamp 15 A 3 Lamp Relay Coil Fwd Rev Solenoid Rear Lamp Relay Back up Lamp Alarm 15 A 4 Instrument Panel Hour Mete...

Page 308: ... Breaker 1 Raise the hood and seat assembly Make sure the support cylinder securely holds the hood open Typical Example LP Engine Truck 2 The main circuit breaker is located on the rear of the support for the 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 circui...

Page 309: ... 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 Do not reinflate a 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 necessa...

Page 310: ...ple lift models the bottom of the inner mast must be flush with the bottom of the stationary mast 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 unit mm STD mast FF mast FFT mast 7 43 43 https www forkliftpdfmanuals com ...

Page 311: ...he support cylinder securely holds the hood open 2 Maintain oil level between the MAX and MIN marks on the dipstick Coolant Level Check Clean Check Coolant Level WARNING At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand Re...

Page 312: ...ice Indicator Typical Example LP Engine Truck 1 Observe the air cleaner service indicator 2 Service the air cleaner when the RED band in the service indicator lock 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 opera...

Page 313: ...the lift truck and on the ground 5 Inspect the operator s 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 Typical Example LP Engine Truck 8 Inspect the cooling system for leaks worn hoses and debris buildup 9 Inspect engine compartment for oil coolant and fuel leaks 10 In...

Page 314: ...d parking brake applied and the transmission controls in NEUTRAL 3 With the 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 Open the access door in floor plate 6 Remove the dipstick filter cap Observe the oil level 7 Maintain the oil level between the Min a...

Page 315: ...e drain plug spring and strainer Allow the oil to drain NOTICE Careless disposal of waste oil can harm the environment and can be dangerous to persons Always dispose of waste oil to authorized and licensed personnel only 2 Wash the strainer screen spring and drain plug in clean nonflammable solvent Dry and install the strainer spring and drain plug 3 Raise the hood and seat assembly 4 Remove and d...

Page 316: ...everse to fill the clutches 11 Shift the transmission into NEUTRAL Apply the parking brake 12 Remove the dipstick filter cap 13 Maintain the oil level between the Min and Max marks on the dipstick 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 1...

Page 317: ...position 3 Turn the ignition switch OFF Oil Cooled Disc Brake OCDB Type 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 3 Remove the dip stick filter cap Fill the drive axle housing with oil See Lubricant Specification Drive Axle Oil and Refill Capacity 4 Start the lift truck With...

Page 318: ...e grade The parking brake needs adjusting if it does not hold the lift truck on the grade 6 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 To prevent personal injury the operator MUST be ready to use the serv...

Page 319: ... 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 To Adjust Park the lift truck level wi...

Page 320: ... skin Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped 1 Raise the hood and seat assembly Loosen the bolts of the hydraulic tank cover and remove the hydraulic tank cover with filter assembly 2 Remove filter assembly from the hydraulic tank cover 3 Install new filter assembly in the hydraulic tank cover 4 Inspect cover gasket for...

Page 321: ...e with a new element See topic Cleaning Primary Filter Element 4 Clean the inside of air cleaner housing and the cover Inspect all connections between the air cleaner and engine Check intake hose for cracks damage and loose clamps Tighten or replace parts as necessary to prevent leakage NOTICE Do not allow dirty air to enter the intake hose when cleaning the inside of the air cleaner housing 5 Che...

Page 322: ...le cleaning used elements The primary element should be replaced after a year s service or after cleaning no more than 6 times 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 280 kPa 40 psi Maximum Pressure Direct water on the inside and outside of the element along the lengt...

Page 323: ...y holds the hood open 3 Remove the dipstick filter cap Maintain the oil level to the FULL mark on the breather dip stick Drive Axle Oil Level Check WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Park the lift truck on a level surface Apply the parking brake The engine is at the low idle Place the directional control level in NEUTRAL 1 Li...

Page 324: ...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 4 Brush a film of oil on all links of the chain 5 Raise and lower the carriage a few times to work lubricant into the chain links NOTICE Lubricate chains more frequently than normal in applications where the lift truck is operating i...

Page 325: ...ing or inserting washer Carriage Side Rollers Lubricate GC35S 5 GC40S 5 GC45S 5 GC50C 5 GC55C 5 Lubricate 2 side roller fittings one on each side of the carriage Steering Mechanism Check Lubricate 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 t...

Page 326: ...rate 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 WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 3 Remove the crankcase drain plug and allow oil to drain Clean and install drain ...

Page 327: ...d and seat assembly Wheel Bolts and Nuts Inspect Inspect Tightness NOTICE Do not lubricate ball seas of wheels or ball faces of wheel nuts Be sure mounting faces of hub wheel nuts and flat mounting surfaces are clean Tighten wheel nuts again after 24 hours of operation NOTE Always tighten wheel lug nuts in a sequence opposite 180 each other If equipped with dual wheels follow the same nut tighteni...

Page 328: ...orward 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 Typical Example 1 Lubricate two fittings for the pivot eyebolts one on each tilt cylinder 2 Check the pivot eye pins for loose retainer bolts and wear Mast Pivot Eyes Typical Example 1 Lubricate two fittings for the mast pivot eyes one on each side o...

Page 329: ...d 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 When turning for extending rod the overlapped length between clevis s thread and cylinder rod must be minimum 32 mm 5 Tighten the pinch bolts to a torque of 95 15 N m 70 10 lb ft Check the cylinder rods again for even travel Crosshead ...

Page 330: ... to distribute the grease the carriage to the floor Parking Brake Test Adjust See topic Parking Brake Test Adjust in First 50 100 Service Hours Circulation Pump Belt OCDB LP Engine Only If Eguipped Check Adjust 1 Raise the hood and seat assembly 2 Check the condition and adjustment of the belt 1 Correct adjustment allows 10 mm 3 8 inch deflection under 45 N of force 3 To adjust the circulation pum...

Page 331: ...k O ring seal and replace if necessary 2 Install the drain plug 3 Remove strainer assembly 4 Washer the strainer assembly in clean nonflammable solvent and dry it 5 Install the strainer assembly and reconnect the hose and harness 6 Remove the dip stick filter cap Fill the drive axle housing with oil See Lubricant Specification Drive Axle Oil and Refill Capacity 7 Start the lift truck With the engi...

Page 332: ...ixer 5 Vacuum lines 6 Coolant lines 7 LP fuel line Fuel Trim Valve FTV Inspection G643E Engine only 1 Visually inspect the Fuel trim valve 3 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 line from the FTV to the pressure regulator conver...

Page 333: ... bent or cracked sections Have repairs made if needed Steer Suspension Inspect 1 Inspect the suspension mounting bolts Tighten suspension mounting bolts if necessary to 240 30 N m 180 20 lb ft 2 Look for leaks at the power steering hose connections 3 Remove any trash buildup on the suspension or the steer axle https www forkliftpdfmanuals com ...

Page 334: ...he cover Tighten the latches 4 Start the engine and observe the air cleaner service indicator If the indicator shows RED after installing a new secondary element and a cleaned primary outer element replace the cleaned primary filter with a new element 5 Stop the engine Close the hood and seat assembly Inspect Coolant Hoses LP Engines Only 1 Visually inspect coolant hoses and clamps Remember to che...

Page 335: ...Strainer Clean Change See topic Transmission Oil Oil Filter Strainer Clean Change in First 50 100 Service Hours or a Week 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 ex...

Page 336: ...orrect 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 ...

Page 337: ...inner mast to release the 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 ...

Page 338: ...air and or replace 4 Remove distributor cap and perform visual inspection Replace cap and rotor if corrosion is found on the contacts 5 Inspect the ignition coil for cracks and heat deterioration Visually inspect the coil heat sink fins If any fins are broken replace as required Replace Spark Plugs LP Engine Only 1 Disconnect Battery Cables 2 Using a gentle twisting motion remove the high voltage ...

Page 339: ...nly Disassembly 1 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 2 Replace the filter element 7 3 Check bottom cover O ring seal 6 for damage Replace if necessary 4 Re assemble the filter assembly aligning the scribe lines on the top and bottom covers 5 Install the cover retaining screws tightening the screws in an opposite sequence across the cover 6 Open the fuel v...

Page 340: ...ne should run out of fuel and stop within a short period of time 5 Turn the ignition key switch off and re connect the fuel lock off connector NOTE The length of time the engine runs on trapped fuel vapor increases with any increase in distance between the fuel lock off and the pressure regulator converter 1 LP fuel lock off 2 LP regulator converter 2 1 https www forkliftpdfmanuals com ...

Page 341: ...Remove the wheel assembly Examine the seal for damage and wear Replace the seal if necessary WARNING Deflate tire before removing wheel nuts at tire change 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 and install the wheel assembly on the knuckle 8 Install the outer wheel bearing...

Page 342: ...to drain Drain the recovery bottle 4 Close radiator drain valve and install block drain plug Fill the cooling system with 1 kg 2 lb sodium bisulphate per 40 liters 10 gallons of water Most commercial cooling system cleaners can be used 5 Start and run the engine for 30 minutes 6 Stop the engine and drain the cleaning solution 7 Flush the system with clean water until draining water is clear 8 Clos...

Page 343: ...ithdrawn from service if angle C exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees as may be found in some special application forks 3 Check the straightness of the upper face of blade D and the front face of shank E with a straight edge The fork should be withdrawn from service if the deviation from straightness exceeds 0 5 percent of the length of...

Page 344: ...iding 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 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...

Page 345: ...in plug Allow the oil to drain Clean and install the plug 2 Raise the hood and seat assembly 3 Remove dipstick filter cap Fill the hydraulic tank See Refill Capacities Install the breather dipstick 4 Lower the hood and seat assembly 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...

Page 346: ...ect for Intake Leaks LP Engine Only 1 Visually inspect the intake manifold throttle assembly 4 and manifold adapters 3 for looseness and leaks Repair as necessary Replace PCV Valve and breather element Change LP Engine Only 1 Loosen the hose clamps and remove the PCV valve 2 Assemble new PCV valve and hose 3 Tighten the hose clamps Replace Oxygen Sensor G643E Engine Only Exhaust Tube Muffler Ass y...

Page 347: ...ecking Element 126 Checking Service Indicator 116 Checking the TMAP Sensor LP Engine Only 150 Circuit Breaker 43 112 Circulation Pump Belt OCDB LP Engine Only If Eguipped Check Adjust 134 Cleaning Primary Filter Elements 126 Coolant Information 100 Coolant Level Check Clean 115 Coolant Water 101 Cooling System Clean Change 146 Cooling System Specifications 100 Crosshead Rollers Inspect 133 Crushin...

Page 348: ...ct Coolant Hoses LP Engines Only 138 Inspect Electrical System LP Engine only 136 Inspect Engine for Exhaust Leaks 116 Inspect Engine for Fluid Leaks 115 Inspect for Intake Leaks LP Engine Only 150 Inspect Ignition System LP Engine Only 142 Inspect Throttle Assembly LP Engine Only 139 Inspect Tightness 131 Inspect Vacuum Lines and Fittings LP Engine only 136 Inspection Maintenance and Repair of Li...

Page 349: ...48 Replace LP Fuel Filter Element LP Engine Only 143 Replace Oxygen Sensor G643E Engine Only 150 Replace PCV Valve and breather element Change LP Engine Only 150 Replace Spark Plugs LP Engine Only 142 S Safety Rules 23 Safety 2 5 Seat Adjustment 17 Seat Switch System If Equipped 44 Seat 43 Seat Hood Latch Support Cylinder Check Lubricate 110 Serial Number Locations 37 Serial Number 37 Service Brak...

Page 350: ...Transmission Oil Oil Filter Strainer Clean Change 119 139 Transmission Speed Range Lever 45 Transportation Hints 91 Traveling With the Load 85 Turning 86 U Universal Joint Inspect 141 Unloading 85 Vibration weighted overall value 32 W Walk Around Inspection 50 Walk Around Inspection Inspect 117 Warning Signs and Labels 5 17 Water 280 kPa 40 psi Maximum Pressure 126 Weight adjustment 18 Wheel Bolts...

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