Doosan GC15S-5 Operation & Maintenance Manual Download

Page: 107 / 151

Maintenance section

105

Maintenance Intervals

NOTICE

All maintenance and repair, except every 10
service hours or daily, on the lift truck must be
performed by qualified and authorized personnel
only.

NOTICE

Careless disposal of waste oil can harm the
environment and can be dangerous to persons.
Always dispose of waste oil to an authorized
personnel only.

When Required

Operator's Seat, Hood Latch and Support Cylinder -
Check, Lubricate................................................... 107

Fuses & Relay Change ........................................ 107

Tire and Wheels - Inspect, Check ....................... 108

Test Fuel System for Leaks ................................. 109

Wheel Bolts - Inspect ........................................... 110

Carriage Roller Extrusion – Adjust ...................... 110

Every 10 Service Hours or Daily

Walk-Around Inspection – Inspect....................... 111

Inspect Engine for Fluid Leaks ............................ 112

Engine Oil Level – Check..................................... 112

Coolant Level - Check.......................................... 112

Air Intake System - Check ................................... 113

Mast Channels - Lubricate................................... 114

Transmission Oil Level - Check........................... 114

First 50-100 Service Hours or a Week

Parking Brake - Test, Adjust ................................ 115

Transmission Oil & Strainer - Change, Clean .... 115

Drive Axle Oil - Change........................................ 116

First 250 Service Hours or a Month

Hydraulic Return Filter - Change......................... 118

Every 250 Service Hours or Monthly

Air Intake System - Check, Clean ....................... 119

Hydraulic Oil Level - Check.................................. 121

Drive Axle Oil Level - Check ................................ 121

Mast, Carriage, Lift Chains & Attachments - Inspect,
Lubricate................................................................ 122

Steering Mechanism - Check, Lubricate ............. 122

Battery Terminal - Clean, Inspect ........................ 123

Brake Oil Level - Check........................................ 123

Engine Oil Filter - Change.................................... 124

Every 500 Service Hours or 3 Months

Belts - Check, Adjust ............................................ 125

Tilt Cylinders - Check, Adjust, Lubricate ............. 125

Mast Hinge Pin - Lubricate................................... 126

Crosshead Roller - Inspect................................... 126

Inching & Braking Control Shaft - Lubricate........ 127

Horn & Lights (If Equipped) - Check.................... 127

Overhead Guard - Inspect.................................... 127

Inspect Vacuum Lines and Fittings (G420F(E)
Engine Only).......................................................... 128

Fuel Trim Valve(FTV) Inspection (G420F(E) Engine
Only) ...................................................................... 128

Inspect Electrical System (G420F(E) Engine Only)

............................................................................... 128

Every 1000 Service Hours or 6 Months

Hydraulic Return Filter, Breather & Strainer - Check,
Change .................................................................. 129

Lift Chains - Test, Check, Adjust ......................... 130

Transmission Oil & Strainer - Clean, Change..... 132

Inspect Coolant Hoses (LP, Dual Fuel Engines
Only) ...................................................................... 133

LP Regulator/Converter Inspection (LP, Dual Fuel
Engine Only).......................................................... 133

Fuel Lines & Fittings - Check............................... 133

Inspect Mixer Assembly (G420F(E) Engine Only)

............................................................................... 133

Inspect Throttle Assembly (G420F(E) Engine Only)

............................................................................... 133

Every 1500 Service Hours or 9 Months

Drive Axle Oil (Shoe Brake) - Change................. 134

Inspect Ignition System (LP-Gas, Gasoline & Dual
Fuel Engines Only) ............................................... 134

Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
Engine Only).......................................................... 134

Fuel Filter (LP - Gas Engine Only) ...................... 135

Testing Fuel Lock-off Operation (LP-Gas Engine
Only) ...................................................................... 135

Every 2000 Service Hours or Yearly

Steer Wheel Bearings - Repack .......................... 136

Cooling System – Clean, Change ....................... 137

Fork - Inspect ........................................................ 139

Summary of Contents for GC15S-5

Page 1: ...SB2354E00 Operation Maintenance Manual LIFT TRUCKS GC15S 5 GC18S 5 GC20SC 5 0703...

Page 2: ......

Page 3: ...ing the Engine 53 Lift Truck Operation 81 Operating Techniques 83 Parking the Lift Truck 87 Lift Fork Adjustment 88 Storage Information 89 Transportation Hints 90 Towing Information 91 Maintenance Sec...

Page 4: ...laced with another DOOSAN operator restraint system Photographs or illustrations guide the operator through correct procedures of checking operation and maintenance of the DOOSAN operator restraint sy...

Page 5: ...service on items at multiples of the original requirement For example at Every 500 Service Hours or 3 Months also service those items listed under Every 250 Service Hours or Monthly and Every 10 Servi...

Page 6: ...fety alert symbol is as follows Attention Become Alert Your Safety is involved The message that appears under the warning explaining the hazard can be either written or pictorially presented Operation...

Page 7: ...familiar with the proper operation of the lift truck to be alert and to avoid actions or conditions which can result in an accident Do not operate a lift truck if in need of repair defective or in an...

Page 8: ...travel with load trailing 6 On grade operations travel with load up grade 7 Watch out for pedestrians and obstructions Check overhead clearances 8 Do not permit riders on forks or machine at any time...

Page 9: ...ouch lean on or 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...

Page 10: ...value Located on the Overhead Guard No Riders Warning WARNING To avoid personal injury allow no riders A lift truck is designed for only one operator and no riders Located beside the operator s statio...

Page 11: ...ll sound WARNING When leaving machine apply parking brake Parking brake is not automatically applied Alarm will sound if parking brake is not applied WARNING Correct adjustment is necessary to provide...

Page 12: ...ility of falling objects from any adjacent storage or work area Make sure the load is stable and fully supported by the carriage and the load backrest extension if equipped Do not raise loads any high...

Page 13: ...nance wrong repairs or the use of other than original DOOSAN spare parts waive any liability by DOOSAN Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully Clean...

Page 14: ...uck 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 cons...

Page 15: ...Techniques in the 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...

Page 16: ...moving fan blades They will throw or cut any object or tool that falls or is pushed into them Do not use a kinked or frayed wire rope cable Wear gloves when handling the wire rope cable Retainer pins...

Page 17: ...fuels most lubricants and some coolant mixtures are flammable Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling area Do...

Page 18: ...se your bare hand to check for leaks Use a board or cardboard to check for leaks See Fluid Penetration in the Safety Section for more details Tighten all connections to the recommended torque Replace...

Page 19: ...he assemblies could burst with explosive force and cause serious personal injury or death Follow carefully the specific information provided by your tire or rim servicing personnel or dealer Operator...

Page 20: ...tment Move the lever slide the seat to the desired position and release the lever Adjust the seat before operating the lift truck After adjusting set the seat to make sure it is properly locked Do not...

Page 21: ...to make sure it is properly locked Do not adjust the seat while the truck is in motion Weight adjustment Pull the weight adjustment lever upwards and move right or left side Adjust to driver s weight...

Page 22: ...DOOSAN truck comes equipped with a DOOSAN operator restraint system Should it become necessary to replace the seat for any reason it should only be replaced with another DOOSAN operator restraint syst...

Page 23: ...he belt is designed to automatically adjust to your size and movement A quick pull on the belt will confirm that the automatic adjuster will hold the belt position in the event of an accident Release...

Page 24: ...nt outside of the object 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...

Page 25: ...e of an attachment to the CG of the load The location of the CG in the vertical direction is the same as the horizontal dimension Remember that unless otherwise indicated the capacity load shown on th...

Page 26: ...all safety rules 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 outs...

Page 27: ...ays use the proper size pallet Position the forks as wide as possible under the load Position loads evenly on the forks for proper balance Do not lift a load with one fork Do not overload Always handl...

Page 28: ...r falling loads when stacking Travel with the load tilted back and the forks as low as possible This will increase stability to the truck and load and permit better visibility for you Do not elevate t...

Page 29: ...for other persons 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 Operat...

Page 30: ...as tank Mop up spilt fuel and do not forget to close the fuel tank before restarting the engine Park your lift truck in authorized areas only Fully lower the forks to the floor put direction lever in...

Page 31: ...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 ti...

Page 32: ...Safety Section 30 Lean away from the direction of fall Lean forward...

Page 33: ...d unloaded mph 11 3 11 6 11 3 11 6 11 3 11 6 kph 18 0 18 5 18 0 18 5 18 0 18 5 25 lift loaded unloaded fpm 118 1 128 118 1 128 118 1 128 mm s 600 650 600 650 600 650 26 lowering loaded unloaded fpm 98...

Page 34: ...General Section 32...

Page 35: ...33 Noise and Vibration Sound Pressure Level at Operator s ear Leq according to EN12053 Guaranteed Sound Whole body Vibration Level according to EN13059 m s 2 Model dB A Mean Uncertainty GC15 18S 5 GC2...

Page 36: ...tographs Lift Truck Serial Number ______________________________ 2 0 liter Spark Ignition Engine Serial Number G420F E ______________________________ 2 3 liter Diesel Engine Serial Number ____________...

Page 37: ...e lift truck can lift 1500kg 3300lb if the load center is 500 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...

Page 38: ...eplate a standard 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 Sid...

Page 39: ...the illustrations Due to the various options available typical instrument panels are shown However the symbols on the indicators and lights on your panel identify what those particular items are Also...

Page 40: ...cates coolant temperature If both tenth ninth flash out of phase while operating the lift truck overheating is indicated Park the lift truck and stop the engine Check the cooling system for a malfunct...

Page 41: ...LP GAS Indicates the low Level of LP GAS LP or DUAL only 16 Directional Turning Indicator Light 17 Front and Rear Floodlishts Switch The front floodright is ON when push down switch to the first step...

Page 42: ...ck with an alarm 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...

Page 43: ...he hood and seat assembly is held up by a support cylinder Make certain the air cylinder is operating properly and will hold the hood up before doing anything in the engine compartment Circuit Breaker...

Page 44: ...he seat into position before operating to prevent an unexpected seat change Adjust seat to allow full brake pedal travel with operator s back against seat back NOTE The seat can only be correctly adju...

Page 45: ...l 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 pre...

Page 46: ...e Lever Pull the 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 a...

Page 47: ...tion will stop 3 Mast Tilt Forward Push the lever FORWARD smoothly to tilt the mast forward Sideshift Attachment Control If Equipped 1 Sideshift Left Push the lever FOR WARD to shift the carriage to t...

Page 48: ...ot smoke in refueling areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to indoor locations Stop the engine and get off the lift truck during...

Page 49: ...couplings for deter ioration damage or missing flexible seals 11 Position the replacement tank so that the locating pin dowel is in place The LP Gas tank must not extend past the counterweight 12 Cla...

Page 50: ...ems and cleanliness 2 Inspect the instrument panel for broken or damaged indicator lights or gauges 3 Test the horn and other safety devices for proper operation 4 Inspect the mast and lift chains for...

Page 51: ...rk If the recovery bottle is empty also fill the radiator at the top tank 13 Observe the fuel level gauge after starting the truck Add fuel if necessary WARNING Personal injury may occur from accident...

Page 52: ...ot engage the starter more than 10 seconds at any one time 1 Don t press accelerator pedal and turn the ignition switch to the START position 2 Once the engine starts release the ignition switch 3 If...

Page 53: ...a Cold Diesel Engine 1 Turn the key to the ON position The start preheat light will come ON The preheat light will stay ON approximately seven seconds depending on the surrounding air temperature NOTI...

Page 54: ...w the battery and well clear of fuel system components Typical Example NOTICE Do not reverse battery cables It can cause damage to the alternator Always connect the external power source cables in par...

Page 55: ...MIL Malfunction Indicator Light 3 will not come ON with the 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 e...

Page 56: ...e 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 0...

Page 57: ...this system LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM Manifold pressure from the TMAP rpm from the crank position sensor and throttle positi...

Page 58: ...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 cauti...

Page 59: ...e 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 C...

Page 60: ...Re connect fuel 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...

Page 61: ...ostics Will Not Accelerate Hesita tion 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...

Page 62: ...Service Manual Vacuum 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...

Page 63: ...l 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 Leak test Air filter clogged Che...

Page 64: ...ator malfunction fuel pressure too high Test pressure regulator operation z See Engine Service Manual Faulty FTV Check FTV for housing cracks or obstructions z See Advanced Diagnostics FTV operation z...

Page 65: ...d 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 fla...

Page 66: ...ken injector 3 wire or defective injector TurnOnMil Check INJ3 wiring for an open circuit SECM Signal A4 to Injector 3 Pin A Switched 12V to Injector 3 Pin B Check Injector 3 Resistance 12 to14 ohms c...

Page 67: ...rankshaft sensor leads or defective CAM sensor None Check CAM sensor connections SECM SIGNAL Pin B10 to CAM sensor Pin 2 SECM Sensor GND Pin B1 to CAM sensor Pin 3 Switched 12V to CAM sensor Pin 1 Che...

Page 68: ...in 6 SECM Pin B1 sensor GND to ETC Pin 2 232 TPS2RangeHigh TPS2 sensor voltage out of range high normally set if the TPS2 signal has shorted to power or the ground for the sensor has opened TurnOnMil...

Page 69: ...pened to the SECM None 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...

Page 70: ...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 P...

Page 71: ...d connector for open circuit SECM Pin A9 EST1 to OEM ignition system See application note Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connecto...

Page 72: ...or defective spark module None N A 426 EST6_Open EST6 output open possibly open EST6 signal or defective spark module None N A 427 EST7_Open EST7 output open possibly open EST7 signal or defective sp...

Page 73: ...EST3 to ignition module Pin D 4 pin connector Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific...

Page 74: ...Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS Pin 1 DRIVER to...

Page 75: ...Check engine oil level Check electrical connection to the oil pressure switch SECM Pin B9 to Oil Pressure Switch 531 53 SysVoltRangeLow System voltage too low TurnOnMil Check battery voltage Perform...

Page 76: ...G GND Verify transducer power to the foot pedal with a multimeter 571 57 HardOverspeed Engine speed has exceeded the third level 3 of 3 of overspeed protection 1 TurnOnMil 2 HardRevLimit Usually assoc...

Page 77: ...nd check APP1 signal at SECM Pin B7 632 67 APP2AdaptLoMin Learned idle end of APP2 sensor range lower than expected None Check APP connector and pins for corrosion Cycle the pedal several times and ch...

Page 78: ...Fault signal has opened or shorted to ground or power or defective check engine lamp None Check Check Engine Lamp for an open wire or shorted to GND 715 LSDFault_CrankDisable Crank Disable Fault signa...

Page 79: ...ns on after engine has been running for some time and SECM has calculated that water condensation in exhaust has been removed by exhaust heat Post O2 Heater Relay has SECM DRVP 12V applied to the rela...

Page 80: ...B13 O2 Pin 2 HEATER GND to SECM DRVG GNG Pins A16 B17 O2 Pin 1 HEATER PWR to SECM DRVP 12V PIN A23 Verify O2 sensor heater circuit is operating by measuring heater resistance 2 1 0 4 O2 Pin 2 HEATER G...

Page 81: ...of range low sensor signal shorted to ground 1 TurnOnMil 2 Disable asoline Post catalyst O2Ctrl 3 Disable LPG Post catalyst O2Ctrl Check if O2 installed after the catalyst sensor is shorted to GND or...

Page 82: ...edEngine Shutdown Refer to drivetrain manufacturer s transmission service procedures 994 ServiceFault4 Service Interval 4 has been reached replace HEGO sensors TurnOnMil Replace Pre catalyst HEGO sens...

Page 83: ...n 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...

Page 84: ...ake pedal and bring 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...

Page 85: ...and as far apart as load permits 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 2 Tilt the mast fu...

Page 86: ...th the load uphill on upgrades and downgrades 2 For better vision travel in reverse with bulky loads Unloading 1 Move the lift truck into the unloading position 2 Tilt the mast FORWARD only when direc...

Page 87: ...arriage 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 n...

Page 88: ...Hot Weather Keep the following points in mind when you operate the lift truck in hot weather 1 Check the radiator Clogging can cause the overheating Clean them out regularly with a blast of compresse...

Page 89: ...erous condition 2 Place the transmission controls in NEUTRAL 3 Engage the parking brake 4 Lower the forks to the ground WARNING Blocking the wheels will prevent unexpected lift truck movement which co...

Page 90: ...position 2 Raise the hook pin in each fork to side the fork on the carriage bar 3 Adjust the forks in the position most appropriate for the load and as wide as possible for load stability 4 When adjus...

Page 91: ...Dismount the battery from the machine Even though the machine is parked indoors if the place is hot or humid the battery should be kept in a dry cool place Charge the battery once a month Apply antiru...

Page 92: ...sition the lift truck on the truck bed or the rail car Apply the parking brake and place the directional control lever in NEUTRAL Turn the ignition switch to the OFF position and remove the key If LP...

Page 93: ...e as low as possible on the lift truck that is being towed Quick lift truck movement could overload the tow line or bar and cause it to break Gradual and smooth lift truck movement will better Normall...

Page 94: ...equal to or greater than the Standard or rated Capacity of the lift truck The individual load rating in most cases will be stamped on the fork in a readily visible area This is generally on the top or...

Page 95: ...load bearing cross section of the remaining metal is decreased in size until it becomes insufficient to support the load and complete failure occurs Fatigue failure is the most common mode of fork fai...

Page 96: ...e forks First Installation 1 Inspect forks to ensure they are the correct size for the truck on which they will be used Make sure they are the correct length and type for the loads to be handled If th...

Page 97: ...carbon stone to remove minor surface cracks or defects Polish the inside radius of the heel section to increase the fatigue life of the fork Always grind or polish in the direction of the blade and s...

Page 98: ...N m 1 lb in 16 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...

Page 99: ...en result in personal injury Original fasteners removed from the lift truck should be saved for reassembly whenever possible If new fasteners are needed they must be of the same size and grade as the...

Page 100: ...and can result in radiator tube blockage overheating and or water pump seal damage If the machine is to be stored in or shipped to an area with freezing temperatures the cooling system must be protec...

Page 101: ...tal solids 20 340 maximum PH 5 5 to 9 0 ppm parts per million Using water that meets the minimum acceptable water requirement may not prevent drop out of these chemical compounds totally but should mi...

Page 102: ...parts of the country and different refineries HD5 is recommended for DOOSAN forklift trucks Remember LP Gas is heavier than air and will sink to the lowest spot possible Avoid areas near floor drains...

Page 103: ...ysis 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 crankc...

Page 104: ...ife due to material incompatibility inadequate friction al requirements for disk materials and or excessive gear wear The API CD TO 2 specification or MIL L 2104D or E oil could be used Drive Axle Oil...

Page 105: ...P68 69 70 Viscosity ISO VG10 ISO Viscosity Grade of 10 would normally be selected The following products are authorized for use Supplier Product Name TOTAL AZOLLAZS10 AGIP ACER10 BP ENERGOLHP10 HLP10...

Page 106: ...SAE 80W90 20 50 4 122 SEA 10W 20 22 4 72 Drive Axle Housing Disc Brake OCDB API CD TO 2 SAE 30 10 50 50 122 Shoe Brake DOT3 DOT4 SAE J1703f 30 50 22 122 Brake Reservoir Disc Brake OCDB ISO 6743 4 HM I...

Page 107: ...spect Lubricate 122 Steering Mechanism Check Lubricate 122 Battery Terminal Clean Inspect 123 Brake Oil Level Check 123 Engine Oil Filter Change 124 Every 500 Service Hours or 3 Months Belts Check Adj...

Page 108: ...nsor G420F E Engine Only 142 Checking the TMAP Sensor G420F E Engine Only 143 Inspect for Intake Leaks G420F E Engine Only 143 Replace Spark Plugs G420F E Engine Only 144 Every 3000 Service Hours or 1...

Page 109: ...ecessary 2 Pull the latch to raise the hood and seat assembly Make certain the support cylinder will hold the hood open 3 Lightly oil the hood latch mechanism and the rod for the hood support cylinder...

Page 110: ...reaker 1 Raise the hood and seat assembly Make sure the support cylinder securely holds the hood open Typical Example 2 The main circuit breaker is located on the rear of the support for the controls...

Page 111: ...orm a visual 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...

Page 112: ...et the mast vertical 2 Lower the carriage completely 3 On full free lift and full free triple lift models the bottom of the inner mast must be flush with the bottom of the stationary mast 4 Measure th...

Page 113: ...pins and loose rollers 3 Inspect the hydraulic system for leaks worn hoses or damaged lines 4 Look for transmission and differential leaks on the lift truck and on the ground 5 Inspect the operator s...

Page 114: ...e hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury 1 Observe the coolant level with engine...

Page 115: ...c 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 o...

Page 116: ...onents to contact skin 1 Start and operate the lift truck until the engine reaches normal operating temperature 2 Park the lift truck level with the forks lowered parking brake applied and the transmi...

Page 117: ...ately apply the service brakes Have the parking brake adjusted Transmission Oil Strainer Change Clean Power Shift Transaxle PTA18 WARNING Hot oil and components can cause personal injury Do not allow...

Page 118: ...e high enough to access the drain plug and level fill plug 2 Block the bottom of the mast with a block of wood to hold the carriage in the raised position 3 Turn the ignition switch OFF 4 Place an app...

Page 119: ...reinstall the level fill plug 9 Remove the wood blocking and lower the carriage 10 Operate the lift truck for a few minutes and check oil level again See the topic Drive Axle Oil Level Check in Every...

Page 120: ...ilter Change Hot oil and components can cause personal injury Do not allow hot oil or component to con tact skin Park the lift truck level with the forks lowered parking brake engaged transmission in...

Page 121: ...using 3 Clean and inspect the element or replace 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 th...

Page 122: ...05 kPa 30 psi maximum pressure to prevent filter element damage When cleaning with pressure water use 280 kPa 40 psi maximum pressure to prevent fil ter element damage Have spare elements on hand to u...

Page 123: ...ood and seat assembly Make sure the air lift cylinder securely holds the hood open 3 Remove the breather dip stick Maintain the oil level to the FULLmark on the breather dip stick Drive Axle Oil Level...

Page 124: ...ubricant into the chain links NOTICE Lubricate chains more frequently than normal in applications where the lift truck is operating in a atmosphere which could cause corrosion of components or when li...

Page 125: ...ts skin or eyes Always wear protective glasses when working with batteries Typical Example 1 Clean the top of the battery and terminals 2 Check terminals for corrosion Coat terminals with heavy grease...

Page 126: ...scard oil filter element 6 Wipe sealing surface of oil filter element mounting base Make sure all of the old gasket is removed 7 Before installing a new filter element apply a small amount of clean en...

Page 127: ...alternator mounting bolt will cause excessive stress and break the alter nator mounting ear 2 To adjust the alternator drive belt loosen adjusting bracket bolt and mounting bolt Move the alternator i...

Page 128: ...e spacer to the rear and loosen the pinch bolt on the clevis 4 Turn the cylinder rod in or out of the clevis to obtain the proper adjustment Turning the rod into the clevis shortens the stroke Turning...

Page 129: ...100 Service Hours Horn Lights If Equipped Check 1 Press horn button to determine if horn is operational 2 Check and replace all defective gauges 3 Check all lights such as warning directional backup...

Page 130: ...g Replace as necessary 2 To ensure the valve is not leaking a blow by test can be performed 3 With the engine off disconnect the electrical connector to the FTV 4 Disconnect the vacuum lines form the...

Page 131: ...ion in NEUTRAL and the engine stopped 1 Remove and discard the air breather 2 Install a new air breather 3 Loosen the bolts of the hydraulic tank top plate assembly 4 Remove the return filter from tan...

Page 132: ...ension on lift chains 2 Measure precisely ten links of chain distance at the center of pins in millimeter 3 Calculate chain wear rate 4 If the chain wear rate is 2 or more replace the lift chain Chain...

Page 133: ...hain of FF FFT mast 3 Make adjustment anchor nut 1 2 for equal chain tension 4 Set the mast vertical and raise the carriage and check equal chain tension If not equal repeat the same procedure as step...

Page 134: ...heck equal chain tension If not equal repeat the same procedure as step 1 through step 3 5 Put LOCTITE No 242 tread lock on the threads of the anchor nuts 3 4 after the adjustment is completed Transmi...

Page 135: ...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...

Page 136: ...ct the ignition coil for cracks and heat deterioration Visually inspect the coil heat sink fins If any fins are broken replace as required G420F E Engine Replace LP Fuel Filter Element LP Gas Dual Fue...

Page 137: ...the ignition key switch to the off position 6 Check the filter housing fuel lines and fittings for leaks Repair as necessary Testing Fuel Lock off Operation LP Gas Engine Only 1 Start engine 2 Locate...

Page 138: ...eel bearing 6 Remove the wheel assembly 7 Examine the seal for damage and wear Replace the seal if necessary 8 Remove the inner bearing 9 Clean and lubricate the steering knuckle 10 Repack the inner a...

Page 139: ...luded antifreeze for forbidding corrosion Avoid contact with the skin and eyes to prevent personal injury Use all cleaning solution with care The Lift truck must be level the forks lowered the parking...

Page 140: ...full with a radiator cleaner and clean the engine and the radiator 5 Start and run the engine for 30 minutes 6 Stop the engine and drain the cleaning solution into a suitable container 7 Flush the sys...

Page 141: ...fork should be withdrawn from service if angle C exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees as may be found in some special application forks 3...

Page 142: ...revented from sliding off the end of the carriage by stop blocks These stop blocks are at both ends of the carriage and in the path of the bottom fork hook The load backrest extension may be used in p...

Page 143: ...transmission in NEUTRAL and the engine stopped 1 Remove the hydraulic tank drain plug Allow the oil to drain Clean and install the plug 2 Remove the breather dip stick 3 Remove the strainer Wash the b...

Page 144: ...e When indicated by MIL replace oxygen seasor on the exhaust manifold and oxygen sensor on muffler assembly 1 Stop engine and wait until the exhaust pipe and exhaust pipe is cooled 2 Disconnect the el...

Page 145: ...sary 4 Apply a thin coat of an approved silicon lubricant to the TMAP o ring seal 5 Re install the TMAP sensor into the manifold adapter and securely tighten the retaining screw Inspect for Intake Lea...

Page 146: ...move the ignition coil assy 4 Remove spark plugs 5 Gap the new spark plugs to the proper specifications G420F E Engine 0 7 0 8 6 Apply anti seize compound to the spark plug threads and install G420F E...

Page 147: ...rocedure and specifications Timing Belt for Counterbalance Shaft Change See the Service Manual for the procedure and specifications Every 4500 Service Hours or two Years Replace Oxygen Sensor 1 Oxygen...

Page 148: ...ing Primary Filter Elements 120 Coolant Information 98 Coolant Level Check 112 Coolant Water 99 Cooling System Clean Change 137 Cooling System Specifications 98 Crosshead Roller Inspect 126 Crushing o...

Page 149: ...Lubricate 127 Inching into Loads 83 Inspect Battery System 142 Inspect Coolant Hoses LP Dual Fuel Engines Only 133 Inspect Electrical System G420F E Engine Only 128 Inspect Engine for Exhaust Leaks 1...

Page 150: ...Guard Inspect 127 Overhead Guard Must Be In Place Warning 8 Overloading 93 P Packing brake 8 Parking Brake Test Adjust 115 127 Parking Brake Lever 44 Parking the Lift Truck 87 Power Shift Transaxle 8...

Page 151: ...Torque for Standard Hose Clamps Worm Drive 96 Torque Specifications 96 Torques for Bolts and Nuts With Standard Threads 96 Torques for Taperlock Studs 97 Towing Information 91 Training Required To Op...

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Doosan GC15S-5, Operation & Maintenance Manual

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