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Operation Section

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G643E Electronic Controlled LP Engines (If Equipped)

General Description

The MI-04 is a closed loop system utilizing a catalytic

muffler to reduce the emission level in the exhaust gas.

In order to obtain maximum effect from the catalyst, an

accurate control of the air fuel ratio is required. A small

engine control module (SECM) uses a heated exhaust

gas oxygen sensor (HEGO) in the exhaust system to

monitor exhaust gas content.

The SECM makes any necessary corrections to the air

fuel ratio by controlling the inlet fuel pressure to the

air/fuel mixer by modulating the fuel trim valve (FTV)

connected to the regulator. Reducing the fuel pressure

leans the air/fuel mixture and increasing the fuel

pressure enriches the air/fuel mixture. To calculate any

necessary corrections to the air fuel ratio, the SECM

uses a number of different sensors to gain information

about the engines performance. Engine speed is

monitored by the SECM through a variable reluctance

(VR) sensor. Intake manifold air temperature and

absolute pressure is monitored with a (TMAP) sensor.

The MI-04 is a drive by wire (DBW) system connecting

the accelerator pedal to the electronic throttle through

the electrical harness, mechanical cables are not used.

A throttle position sensor (TPS) monitors throttle position

in relation to the accelerator pedal position sensor (APP)

feedback. Even engine coolant temperature and

adequate oil pressure is monitored by the SECM. The

SECM controller has full adaptive learning capabilities,

allowing it to adapt control function as operating

conditions change. Factors such as ambient

temperature, fuel variations, ignition component wear,

clogged air filter, and other operating variables are

compensated.

Key switch

Foot Pedal

Fuel Filter

Fault Light

LP Fuel Line

Main
PWR

Fuel Lock

FuelTrim Valve

Air Cleaner

Vacuum
Line

Mixer

Coolant Line

TPS
TMAP

Oxygen Sensor

Converter

Coolant Temperature Sensor

Catalytic

Muffler

Ignition Coil

APP

SECM

MI-04 System

DBW Throttle

Содержание D35S-2

Страница 1: ...al LIFT TRUCKS D35S 2 D40S 2 D45S 2 D50C 2 G35S 2 G40S 2 G45S 2 G50C 2 D40SC 2 D45SC 2 D50SC 2 G40SC 2 G45SC 2 G50SC 2 D35S 2 D40S 2 D45S 2 D50C 2 D40SC 2 D45SC 2 D50SC 2 G35S 2 G40S 2 G45S 2 G50C 2 T...

Страница 2: ...by the machine operator and by all personnel who will come into contact with it The following warning is provided pursuant to California Health Safety Code Sections 25247 5 et seq WARNING California...

Страница 3: ...ting the Engine 67 Lift Truck Operation 86 Auto Shift Controller ASC 200 If Equipped 88 Operating Techniques 91 Parking the Lift Truck 95 Lift Fork Adjustment 96 Storage Information 97 Transportation...

Страница 4: ...y be replaced with another DOOSAN operator restraint system Photographs or illustrations guide the operator through correct procedures of checking operation and maintenance of the DOOSAN operator rest...

Страница 5: ...rform 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...

Страница 6: ...this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The message that appears under the warning explaining the hazard can be either written or pictorially presented O...

Страница 7: ...n of the lift truck to be alert and to avoid actions or conditions which can result in an accident Do not operate a lift truck if in need of repair defective or in any way unsafe Report all defects an...

Страница 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...

Страница 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...

Страница 10: ...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 di...

Страница 11: ...atically applied 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 tru...

Страница 12: ...nd fully supported by the carriage and the load backrest extension if equipped Do not raise loads any higher than necessary and never raise a load higher than 1830 mm 72 in with the overhead guard rem...

Страница 13: ...ther than original 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 befo...

Страница 14: ...operation Report 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 20: ...adjusting set the seat to make sure it is properly locked DO NOT adjust the seat while the truck is in motion WARNING Do NOT place your hand or fingers under the seat Injury may occur as the seat susp...

Страница 21: ...e belt cannot be inserted into the buckle properly replace the seat belt assembly 2 Belt Maintenance Every 500 service hours Check that the belt fastening works properly and that winding device is fre...

Страница 22: ...t Fasten the Seat Belt 1 Grip the plate connector of the belt and pull the belt from the retractor Then insert the plate into the slot of the buckle until a snap is heard Pull on the belt to confirm i...

Страница 23: ...de 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 its CG o...

Страница 24: ...face of an attachment to the CG of the load The location of the CG in the vertical direction is the same as the horizontal dimension Remember that unless otherwise indicated the capacity load shown o...

Страница 25: ...and think safety Do not compromise safety Follow all safety rules and read all warning signs Do not operate a lift truck unless you are in the operator s seat Keep arms legs and head inside the confin...

Страница 26: ...oss both forks Always use the proper size pallet Position the forks as wide as possible under the load Position loads evenly on the forks for proper balance Do not lift a load with one fork Do not ove...

Страница 27: ...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...

Страница 28: ...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...

Страница 29: ...ueling Smoking and handling of naked flames during refueling are strictly prohibited This prohibition also applies during the changing of the LPG liquefied propane gas tank Mop up spilt fuel and do no...

Страница 30: ...the event of a tipover the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided Always use operator restraint s...

Страница 31: ...Safety Section 29 Lean away from the direction of fall Lean forward...

Страница 32: ...0 500 540 520 540 500 540 520 540 500 540 26 Speeds lowering loaded unloaded mm s 480 450 480 450 480 450 28 Drawbar pull at 1 6 km h loaded kg 3300 3355 3300 3430 3400 3410 30 Gradeability at 1 6 km...

Страница 33: ...450 26 3300 3430 3300 3410 3400 3400 28 36 33 5 33 31 32 29 4 30 31 5840 6560 6560 32 8930 910 9860 1200 10380 1180 33 2810 3030 2725 3835 2725 3830 34 2 2 2 2 2 2 35 8 25X15 14 300X15 18 300X15 18 3...

Страница 34: ...ERFORMANCE 24 traveling loaded unloaded km h 21 22 20 21 25 lifting loaded unloaded mm s 500 540 500 540 26 Speeds lowering loaded unloaded mm s 480 450 480 450 28 Drawbar pull at 1 6 km h loaded kg 3...

Страница 35: ...561 571 22 20 21 20 21 24 500 540 500 540 25 480 450 480 450 26 3410 3410 28 30 7 30 7 30 6560 7035 32 9860 1200 10585 1450 33 2725 3835 2660 4375 34 2 2 2 2 35 300X15 18 300X15 18 36 7 00X12 12 7 00X...

Страница 36: ...24 25 24 25 25 lifting loaded unloaded mm s 520 540 520 540 520 540 26 Speeds lowering loaded unloaded mm s 480 450 480 450 480 450 28 Drawbar pull at 1 6 km h loaded kg 3300 3300 3400 30 Gradeabilit...

Страница 37: ...510 540 25 480 450 480 450 490 450 490 450 26 3300 3300 3400 3500 28 36 33 32 30 30 31 5840 6170 6560 7035 32 8930 910 9620 1050 10380 1180 10585 1450 33 2810 3030 2730 3440 2725 3830 2660 4375 34 2...

Страница 38: ...86 5 81 82 108 D35 40 45S 2 D40 45 50SC 2 D50C 2 TIERIIE G W OCabin 81 7 83 7 78 3 77 4 107 G35 40 45S 2 G50C 2 G40 45 50SC 2 W OCabin NON CERT 84 9 87 5 85 85 108 G35 40 45S 2 G50C 2 TIERIIE G W OCa...

Страница 39: ...General Section 37 Capacity Chart...

Страница 40: ...General Section 38 Capacity Chart...

Страница 41: ...General Section 39 Capacity Chart with Side Shifter...

Страница 42: ...General Section 40 Capacity Chart with Side Shifter...

Страница 43: ...General Section 41 Capacity Chart...

Страница 44: ...General Section 42 Capacity Chart...

Страница 45: ...General Section 43 Capacity Chart with Side Shifter...

Страница 46: ...General Section 44 Capacity Chart with Side Shifter...

Страница 47: ...General Section 45 Capacity Chart D G 50C 2...

Страница 48: ...General Section 46 Capacity Chart with Side Shifter D G 50C 2...

Страница 49: ..._________________________ 5 8 liter Diesel Engine TIER I Serial Number ______________________________ 5 8 liter Diesel Engine TIER II Serial Number ______________________________ 4 3 liter GM Vortec E...

Страница 50: ...General Section 48 DRIVE AXLE Serial Number ______________________________ Side Shifter Serial Number If Equipped ______________________________...

Страница 51: ...ck can lift 1200kg 2640lb if the load center is 600 mm 24in from both the vertical and horizontal faces of the forks Before attempting to lift any load ensure that the weight and load center combinati...

Страница 52: ...cation plate 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 ty...

Страница 53: ...he 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 t...

Страница 54: ...end of the green band when the coolant temperature reaches 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...

Страница 55: ...n push down switch to the first step The front and rear floodlights are ON when push down switch to the second step 18 Brake Fluid Oil Light If Equipped The light is ON when the brake fluid oil of bra...

Страница 56: ...the latch and raising the hood and seat assembly NOTE Unlock latch before pulling if key equipped 2 The hood and seat assembly is held up by a support cylinder Make certain the air cylinder is operati...

Страница 57: ...knob 1 Electrical 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 arr...

Страница 58: ...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...

Страница 59: ...the lever clockwise 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...

Страница 60: ...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...

Страница 61: ...ing action will 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 t...

Страница 62: ...laden air and to prevent condensation In the cold weather the moisture condensation can cause rust in the fuel system and hard starting due to its freezing Do not fill the tank to the top Fuel expands...

Страница 63: ...not smoke in refueling areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to indoor locations Stop the engine and get off the lift truck durin...

Страница 64: ...plings for deterioration damage or missing flexible seals 11 Position the replacement tank so that the locating pin dowel is in place WARNING The LP Gas tank must not extend past the counterweight 12...

Страница 65: ...ator 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 atta...

Страница 66: ...is empty also 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...

Страница 67: ...cator light will 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 W...

Страница 68: ...step 2 and depress the 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 vap...

Страница 69: ...e 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 con...

Страница 70: ...engines performance Engine speed is monitored by the SECM through a variable reluctance VR sensor Intake manifold air temperature and absolute pressure is monitored with a TMAP sensor The MI 04 is a d...

Страница 71: ...n liquid valve 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...

Страница 72: ...e 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 Faulty vapor connection be...

Страница 73: ...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 fo...

Страница 74: ...stics Will Not Accelerate Hesitatio n 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...

Страница 75: ...vice 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 Chec...

Страница 76: ...alve 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 Check...

Страница 77: ...lator malfunction fuel pressure too high Test pressure regulator operation z See G643E Engine Service Manual Faulty FTV Check FTV for housing cracks or obstructions z See Advanced Diagnostics FTV oper...

Страница 78: ...es are two digit codes When the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 5 seconds between digits and a long pause 1 2 seconds between fault codes A cod...

Страница 79: ...he foot pedal three 3 times within five 5 seconds to enable the display codes feature of the SECM Simply turn the key OFF to exit display mode The code list will continue to repeat until the key is tu...

Страница 80: ...nd for leaks in 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 ET...

Страница 81: ...ansient manuevers 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...

Страница 82: ...P PIN 2 to SECM 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 I...

Страница 83: ...ge measured above 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...

Страница 84: ...ditional ETC faults 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 malfun...

Страница 85: ...2 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 68 Pedal2SensorRangeHi APP2 potentiometer m...

Страница 86: ...nifold leaks z Check 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 lo...

Страница 87: ...Adaptive learns Note If LP Gas 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...

Страница 88: ...ion control lever in the NEUTRAL center position and apply the parking brake before dismounting the lift truck 5 Release the service brake 6 Push down on the accelerator pedal to obtain the desired tr...

Страница 89: ...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...

Страница 90: ...ibit 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...

Страница 91: ...rated in two preselected 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...

Страница 92: ...by its own speed ratio control so that the appropriate gear may be engaged in every situation NOTICE Two Speed Auto Shift Control function can be accomplished only when the direction control lever is...

Страница 93: ...rt as load permits Typical Example 2 Move the lift truck FORWARD until the load touches the carriage Lifting the Load 1 Lift the load carefully and tilt the mast back a short distance Typical Example...

Страница 94: ...ll on upgrades 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...

Страница 95: ...le 4 Lower the 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 t...

Страница 96: ...n hot weather Keep the following points in mind when you operate the lift truck in hot weather 1 Check the radiator Clogging can cause overheating Clean them out regularly with a blast of compressed a...

Страница 97: ...he parking brake 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...

Страница 98: ...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...

Страница 99: ...er z 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 z Apply...

Страница 100: ...uck Position 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...

Страница 101: ...as low as possible on the lift truck that is being towed Quick lift truck movement could overload the tow line or bar and cause it to break Gradual and smooth lift truck movement will work better Norm...

Страница 102: ...s 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...

Страница 103: ...d 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 failur...

Страница 104: ...the 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...

Страница 105: ...ith a carbon stone to remove minor surface cracks or defects Polish the inside radius of the heel section to increase the fatigue life of the fork Always grind or polish in the direction of the blade...

Страница 106: ...re cold inflation 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...

Страница 107: ...h 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 m1 lb in 16 mm 625 in 4 5 0 5 40 5 13 5 mm 531 in 3 0 0 5 25...

Страница 108: ...t in personal injury Original fasteners removed from the lift truck should be saved for reassembly whenever possible If new fasteners are needed they must be of the same size and grade as the ones tha...

Страница 109: ...shipped to an area with freezing temperatures the cooling system must be protected to the lowest expected outside ambient temperature The engine cooling system is normally protected to 28 C 20 F with...

Страница 110: ...r use it mixed with antifreeze of different brand DOOSAN recommends that the coolant mix contain 50 commercially available automotive antifreeze or equivalent and acceptable water to maintain and adeq...

Страница 111: ...nance costs and reduced engine service life Crude oil is used to describe oils fuels that are not refined and are in the original state as when pumped from the ground Certain types of crude oils can b...

Страница 112: ...request fuel sulfur content information from your fuel supplier Fuel sulfur content can change with each bulk delivery LP Gas Specifications LP Gas is Liquefied Petroleum Gas The exact composition of...

Страница 113: ...mmendations For fuel sulfur effects the Infrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil The sulfur products formation depe...

Страница 114: ...al requirements 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 recommenda...

Страница 115: ...r antifoam antirust and antioxidation additives for heavy duty use as stated by the oil supplier ISO viscosity grade of 32 would normally be selected The following products are authorized for use Supp...

Страница 116: ...sc 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 prop...

Страница 117: ...el Check 139 Drive Axle Oil Level Check 139 Mast Carriage Lift Chains Attachments Check Lubricate 140 Carriage Side Rollers Lubricate 141 Steering Mechanism Check Lubricate 141 Battery Terminal Clean...

Страница 118: ...ock off Operation LP Gas Engine Only 158 Every 2000 Service Hours or Yearly Steer Wheel Bearings Reassemble 159 Cooling System Clean Change 161 Fork Inspect 162 Every 2500 Service Hours or 15 Months H...

Страница 119: ...r Change 142 148 O O Engine Oil Oil Filter Diesel E G Only Change 129 O Engine Oil Level Clean Check 125 O Engine Valve Lash Diesel E G Only Check Adjust 118 O Forks Inspect 162 O Fuel Filter Change 1...

Страница 120: ...rns Allow additional time for the engine to cool before measuring valve clearance NOTICE Measure the valve lash with the engine stopped To obtain an accurate measurement allow at least 20 minutes for...

Страница 121: ...en perform 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 fue...

Страница 122: ...ertical until completely 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 Lubri...

Страница 123: ...over from the fuse box The fuses are located under the cowl Fuse Protects an electrical circuit from an overload Opens filament separates if an overload occurs Fuse Box Open Typical Example Fuse Box C...

Страница 124: ...n 24V 55W 2 Bulb back up 24V 10W 3 Bulb turn signal 24V 25W 4 Bulb stop tail 24V 25 10W LP Gas Engine 1 Bulb head lamp halogen 12V 35W 2 Bulb back up 12V 8W 3 Bulb turn signal 12V 23W 4 Bulb stop tail...

Страница 125: ...rims the assemblies could burst with explosive force and cause serious physical injury or death Follow carefully the specific information provided by your tire servicing man or dealer Check Inflation...

Страница 126: ...attempt to rework weld heat or braze any rim components Carriage Roller Extrusion Check Adjust 1 Set the mast vertical 2 Lower the carriage completely 3 On full free lift and full free triple lift mo...

Страница 127: ...y Make certain the 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 t...

Страница 128: ...Indicator Typical Example Diesel Engine Truck Typical Example LP GasEngine Truck 1 Observe the air cleaner service indicator 2 Service the air cleaner when the RED band in the service indicator lock i...

Страница 129: ...lift chains for wear broken links pins and loose rollers 3 Inspect the hydraulic system for leaks worn hoses or damaged lines 4 Look for transmission and differential leaks on the lift truck and on t...

Страница 130: ...onents can cause personal injury Do not allow hot oil or components to contact skin 1 Start and operate the lift truck until the engine reaches normal operating temperature 2 Park the lift truck level...

Страница 131: ...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 Typical Example...

Страница 132: ...NING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL...

Страница 133: ...fill Capacities 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...

Страница 134: ...rains Remove the drain plug 3 Allow the oil to drain completely out Discard the oil according to local regulations 4 Clean and reinstall the drain plug 5 Remove the oil level plug 6 Add sufficient fre...

Страница 135: ...all the dip stick filter cap Parking Brake Test Adjust NOTE Be sure area around the lift truck is clear of personnel and obstructions 1 Drive the lift truck with a capacity load forward up a 15 inclin...

Страница 136: ...th the forks lowered transmission in NEUTRAL the engine stopped and the wheels securely blocked 1 Release the parking brake 2 Turn the adjustment knob clockwise to tighten the brake 3 Test the parking...

Страница 137: ...nents to contact 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 h...

Страница 138: ...Truck Typical Example LP Gas Engine 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 w...

Страница 139: ...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 Check the air cleaner housing for loose l...

Страница 140: ...hand to use while 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 ins...

Страница 141: ...mbly Make sure 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...

Страница 142: ...te a need for repair 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...

Страница 143: ...or inserting washer Carriage Side Rollers Lubricate D35 40S 2 D40 45SC 2 G35 40S 2 G45 50SC 2 D45S 2 D50SC 2 D50C 2 G45S 2 G50SC 2 Lubricate 2 side roller fittings one on each side of the carriage Ste...

Страница 144: ...topic Engine Oil Filter Diesel Engine Only Change in First 50 100 Service Hours LP Gas Engine Crankcase 1 Operate lift truck a few minutes to warm oil Park the lift truck with the forks lowered parki...

Страница 145: ...ubricate 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...

Страница 146: ...under 110N of force 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 bra...

Страница 147: ...d To adjust back 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 ha...

Страница 148: ...the carriage high 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 t...

Страница 149: ...nut 4 4 Lower 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 ski...

Страница 150: ...hts 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 driving and flood lights fo...

Страница 151: ...V when de energized replace the FTV Inspect Electrical System G643E Engine only 1 Check for loose dirty or damaged connectors and wires on the harness including Fuel lock off TMAP sensor O2 sensor Ele...

Страница 152: ...ne stopped For the complete procedure and specifications for your specific engine see the Service Manual Fuel Filters Change Diesel Engine Park the lift truck with the forks lowered parking brake appl...

Страница 153: ...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 Coolan...

Страница 154: ...ixer and throttle section of the service manual for procedures on removing the mixer and inspecting the throttle plate Hydraulic Return Filter Change See topic Hydraulic Return Filter Change in First...

Страница 155: ...le 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 wear rate Actual m...

Страница 156: ...chain tension If not equal repeat the same procedure as step 1 through step 3 5 Put LOCTITE No 242 Tread lock on the threads of the anchor nuts 1 2 after the adjustment is completed Mast Chain Adjust...

Страница 157: ...enance Section 155 Universal Joint Diesel Engine Only Inspect 1 Inspect for loose retaining bolts Check for worn or damaged bearings 2 Have worn or damaged bearings replaced Tighten the bolts if neces...

Страница 158: ...an 25 kOhms repair and or replace 4 Remove distributor cap and perform visual inspection Replace cap and rotor if corrosion is found on the contacts 5 Inspect the ignition coil for cracks and heat det...

Страница 159: ...lter LP Gas Engine Only Disassembly 1 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 2 Replace the filter element 7 3 Check bottom cover O ring seal 6 for damage Replace...

Страница 160: ...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 fu...

Страница 161: ...ds or blocking under the frame and steer axle to support the lift truck 2 Remove the hub cap Typical Example 3 Remove the cutter pin 4 Remove the castle nut and washer 5 Remove the wheel assembly Exam...

Страница 162: ...cknut to 135 N m 100 lb ft while turning wheel hub to seat the bearing 10 Loosen the locknut Retorque it to 50 5 N m 37 4 lb ft Bend the lockwasher tang to secure locknut 11 Install the hub cap 12 Rai...

Страница 163: ...ow the coolant 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 M...

Страница 164: ...ork 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 C...

Страница 165: ...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...

Страница 166: ...d back all cylinders retracted parking brake engaged 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 Raise the...

Страница 167: ...eplace as necessary 4 Apply a thin coat of an approved silicon lubricant to the TMAP o ring seal 5 Re install the TMAP sensor into the manifold adapter and securely tighten the retaining screw 1 LP fu...

Страница 168: ...643E Engine Only 1 Stop engine and wait until the exhaust pipe and exhaust pipe is cooled 2 Disconnect the electrical connector of oxygen sensor 3 Remove oxygen sensor 4 Assemble new oxygen sensor Tig...

Страница 169: ...Secondary Element 151 Chassis Pivot Eyebolts 145 Check Coolant Level 125 Check for Equal Tension 153 Check Inflation and Damage 123 Checking Element 138 Checking Service Indicator 126 Checking the TMA...

Страница 170: ...eck Clean Change 164 Hydraulic Oil HYDO 111 Hydraulic Oil Level Check 139 Hydraulic Return Filter Change 135 152 Identification Lift Capacity and Attachment Plate 49 If Optional Suspension Seat weight...

Страница 171: ...Operator s Warning and Identification Plate 49 Overhead Guard Inspect 149 Overhead Guard Must Be In Place Warning 8 Overloading 101 P Parking brake 9 Parking Brake Test Adjust 133 147 Parking Brake Le...

Страница 172: ...tandard Hose Clamps Worm Drive 105 Torque Specifications 105 Torques for Bolts and Nuts With Standard Threads 105 Torques for Taperlock Studs 106 Towing Information 99 Training Required to Operate or...

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