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D35C-5 FDA04
Doosan D35C-5 FDA04 User Manual
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M
ai
ntenanc
e S
ecti
on
-256-
Every
8000 Ser
vic
e Hour
s or
48 Mont
hs
You m
u
st read an
d u
nd
er
stand
t
he war
ni
ngs
and ins
tr
u
cti
ons c
ontai
ne
d i
n the
Saf
ety s
ec
ti
on of
thi
s m
an
ual
,
befo
re per
f
or
min
g any
ope
ration
or
m
ain
ten
ance pr
oce
dur
es
.
Timing
Belt (G42
4P(
E) LP, Dual
Fuel
E
ngi
ne O
nly) -
Cha
nge
See
the
“
S
ervi
ce
m
an
ual
” for
the
pr
ocedur
e
a
nd
spec
i
fi
cati
on.
257
259
Table of Contents
Table of Contents
3
Information Section
4
Foreword
4
Safety Section
6
Important Safety Information
6
Safety
7
Warning Signs and Labels
7
Parking Brake
11
All Maintenance and Repair, Except Every
12
General Hazard Information
12
Operation Information
13
Maintenance Information
16
Burn Prevention
17
Fire or Explosion Prevention
17
Operator Restraint System (if Equipped)
19
Avoiding Lift Truck Tipover
23
Safety Rules
25
How to Survive in a Tipover
31
General Section
32
Declaration of Conformity
32
Specifications
33
Noise and Vibration
47
Capacity Chart (Without Sideshifter Pneumatic)
48
Capacity Chart (with Sideshifter Pneumatic)
52
Capacity Chart (Without Sideshifter Cushion)
56
Capacity Chart (with Sideshifter Cushion)
60
Serial Number
64
Operator's Warning and Identification Plate
67
Operator's Station and Monitoring Systems
68
Seat Switch System (if Equipped)
83
Lift Truck Controls
85
Refueling
87
Before Starting the Engine
90
Starting the Engine
92
Dual Fuel System
95
Lift Truck Operation
98
Mono-Ped Control System (Option)
168
Auto Shift Controller ASC-100 (if Equipped)
169
Finger Tip (Option)
172
Operating Techniques
176
Parking the Lift Truck
180
Lift Fork Adjustment
181
Storage Information
182
Transportation Hints
183
Towing Information
185
Maintenance Section
186
Inspection, Maintenance and Repair of Lift Truck Forks
186
Tire Inflation Information
190
Torque Specifications
191
Cooling System Specifications
193
Fuel Specifications
195
Lubricant Information
197
Lubricant Viscosities and Refill Capacities
199
Maintenance Intervals
200
Fuel Tank Filter Cap and Screen (if Equipped) - Clean
205
Seat, Hood Latch & Support Cylinder - Check, Lubricate
205
When Required
205
Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset
206
Battery Terminal - Clean, Inspect
207
Priming the Fuel System(Diesel Engine Only)
208
Water Separator (Diesel Engine Only) - Check, Drain
209
Carriage Roller Extrusion - Adjust
210
Tires and Wheels (D, G-Series) - Inspect, Check
210
Engine Oil Level - Check
211
Every 10 Service Hours or Daily
211
Inspect Engine for Fluid Leaks
211
Coolant Level - Check
212
Air Cleaner Indicator - Check
213
Inspect Engine for Exhaust Leaks
213
Inspect Foot Pedal Operation (G424I(E) /G430FE/G424P(E) Only)
213
Walk- Around Inspection - Inspect
213
Mast Channels - Lubricate
214
Parking Brake - Inspect
215
Transmission Oil Level - Check
215
Brake Oil Level - Check
216
Drive Axle Oil Level - Check
216
Hydraulic Oil Level - Check
217
Engine Oil & Filter (Diesel Engine Only) - Change
218
First 50 - 100 Service Hours or a Week
218
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
219
Drive Axle Oil - Change
221
Parking Brake - Test, Adjust
221
Engine Oil & Filter (LP & Gasoline Engine Only) - Change
223
Every 250 Service Hours or Monthly
223
Air Intake System - Check, Clean
224
Every 500 Service Hours or 3 Months
224
Belts - Check, Adjust
226
Mast Hinge Pin - Lubricate
227
Tilt Cylinders - Check, Adjust, Lubricate
227
Crosshead Rollers - Inspect
228
Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate
228
Horn and Lights (if Equipped) - Check
229
Inching & Braking Control Shaft - Lubricate
229
Parking Brake - Test, Adjust
229
Transmission Oil Filter - Change
229
Drive Axle Oil & Strainer - Change, Clean
230
Overhead Guard - Inspect
230
Steer Suspension - Inspect
231
Steering Mechanism - Check, Lubricate
231
Wheel Bolts & Nuts - Inspect
232
Fuel Trim Valve(FTV) Inspection (G424I(E) Engine Only)
233
Inspect Electrical System (G424I(E) /G430FE/G424P(E) Engine Only)
233
Inspect Vacuum Lines and Fittings (G424I(E) Engine Only)
233
Engine Oil & Filter (Diesel Engine Only) - Change
234
Fuel Filter (Diesel Engine Only) - Change
234
PCV Valve System - Inspect, Clean
235
Governor Lever and Engine Speed Control (Diesel Engine Only) - Check, Adjust
236
Every 1000 Service Hours or 6 Months
237
Hydraulic Return Filter, Breather & Strainer - Check, Change
237
Lift Chains - Test, Check, Adjust
238
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
238
Air Intake System - Change
240
Universal Joint - Inspect
240
Fuel Lines & Fittings - Check
241
Inspect Coolant Hoses (LP, Dual Fuel Engine Only)
241
LP Regulator/Converter Inspection (LP, Dual Fuel Engine Only)
241
Engine Valve Lash (Diesel Engine Only) - Check, Adjust
242
Inspect Mixer Assembly (G424I(E) /G430FE/G424P(E) Engine Only)
242
Inspect Throttle Assembly (G424I(E) /G430FE/G424P(E) Engine Only)
242
Every 1500 Service Hours or 9 Months
243
Inspect Ignition System (LP, Gasoline & Dual Fuel Engines Only)
243
Replace Spark Plugs (G430FE / G424P(E) Engine Only)
243
Fuel Filter (LP Engine Only)
244
Replace LP Fuel Filter Element (LP, Dual Fuel Engine Only)
244
Testing Fuel Lock-Off Operation (LP Engine Only)
244
Fuel Injectors (Diesel Engine Only) - Inspect, Clean, Test
245
Engine Valve Lash (Diesel Engine Only) - Check, Adjust
246
Every 2000 Service Hours or Yearly
246
Steer Wheel Bearings - Reassemble
246
Drive Wheel Bearing (Power Shaft and Drive Wheel) - Apply Grease and Reassemble
248
Cooling System - Clean, Change
250
Forks - Inspect
252
Every 2500 Service Hours or 15 Months
254
Hydraulic Oil - Check, Clean, Change
254
Inspect Battery System
254
Replace Oxygen Sensor (G424I(E) /G430FE/G424P(E) Engine Only)
255
Replace Spark Plugs (G424I(E) Engine Only)
256
Checking the TMAP Sensor (G424I(E) /G430FE/G424P(E) Engine Only)
257
Inspect for Intake Leaks (G424I(E) /G430FE/G424P(E) Engine Only)
257
Replace PCV Valve and Breather Element - Change (LP, Gasoline and Dual Fuel Engines)
257
Every 8000 Service Hours or 48 Months
258
Timing Belt (G424P(E) LP, Dual Fuel Engine Only) - Change
258
Environment Protection
259
Environment Protection Section
259
Index
260
4
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Doosan D35C-5 FDA04 Specifications
General
Brand
Doosan
Model
D35C-5 FDA04
Category
Forklifts
Language
English
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