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D35C-5
Doosan D35C-5 User Manual
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Maintenance Section
-220-
Inspect Electrical System
(G420F(E)/G424F(E)/G424I(E)
/G430FE Engine Only)
1.
Check for loose, dirt
y or damaged connec
tors
and wires on the harness
including: Fuel
lock-off, TM
AP sen
sor, O2 se
nsor, Ele
ctronic
throttle, Cont
rol Relays, Fuel Trim Valve,
Foot
Pedal, and c
rank sensor.
2.
Repair and/or replace as necess
ary.
221
223
Table of Contents
Table of Contents
3
Information Section
4
Foreword
4
Literature Information
4
Environment Management
5
Maintenance Intervals
5
Safety Section
6
Important Safety Information
6
Safety
7
Warning Signs and Labels
7
General Warning to Operator
8
Hand Placement Warning
9
No Standing on Fork Warning
9
No Standing under Fork Warning
9
Pressure Warning
9
Moving Fan Warning
10
No Riders Warning
10
Parking Brake
11
All Maintenance and Repair, Except Every
12
General Hazard Information
12
Before Starting the Lift Truck
13
Mounting and Dismounting
13
Operation Information
13
Before Operating the Lift Truck
14
Operating the Lift Truck
14
Starting the Lift Truck
14
Lift Truck Parking
15
Crushing or Cutting Prevention
16
Fluid Penetration
16
Maintenance Information
16
Pressure Air
16
Burn Prevention
17
Fire or Explosion Prevention
17
Operator Restraint System(if Equipped)
19
Seat Adjustment
20
Avoiding Lift Truck Tipover
23
Lift Truck Stability
23
Stability and Center of Gravity
23
Lift Truck Stability Base
24
Safety Rules
25
How to Survive in a Tipover
31
General Section
32
Declaration of Conformity
32
Specifications
33
Noise and Vibration
49
Capacity Chart (Without Sideshifter Pneumatic)
50
Capacity Chart (with Sideshifter Pneumatic)
54
Capacity Chart (Without Sideshifter Cushion)
58
Capacity Chart (with Sideshifter Cushion)
62
Serial Number
66
Attachment Abbreviations (Includes Special Forks)
68
Operator's Warning and Identification Plate
69
If Convenience Package Equipped
69
Mast Abbreviations
69
Operator's Warning Plate
69
Operation Section
70
Operator's Station and Monitoring Systems
70
Engine Compartment
73
Seat Switch System (if Equipped)
74
Tilt Steering Column
75
Lift Truck Controls
76
Accelerator Pedal
76
Direction Control Lever
76
Service Brake Pedal
76
Transmission Inching Control Pedal
76
Lift Control
77
Parking Brake Lever
77
Sideshift Attachment (if Equipped)
77
Tilt Control
77
Refueling
78
Changing Lp Tanks
79
Before Starting the Engine
81
Walk - Around Inspection
81
Starting the Engine
83
Diesel Engine
84
Lp Engine
84
Starting a Cold Diesel Engine
84
Starting a Warm Diesel Engine
84
Dual Fuel System
86
Changing from Gasoline to Lp – Gas
86
After Starting the Engine
88
Lift Truck Operation
89
Basic Troubleshooting (Gasoline)
100
Blink Code Function
142
Malfunction Indicator Lamp (Mil) Operation
143
Mono-Ped Control System (Option)
152
Auto Shift Controller ASC-100 (if Equipped)
153
Direction Inhibit Point
153
Product Description
153
Automatic Mode (Direction Inhibit Mode)
154
Diagnostics Features
154
Display for Operator
154
Display for Troubleshooting
154
Manual Mode (Fail-Safe Mode)
155
Finger Tip (Option)
156
Function of Knobs
156
Lift Control Knob
156
Tilt Control Knob
156
Emergency Switch
157
Sideshift Attachment Control
157
Warning Lamp
157
Adjustment of Armrest
159
Forward and Backward Adjustment
159
Up and down Adjustment
159
Operating Techniques
160
Inching into Loads
160
Lifting the Load
160
Traveling with the Load
161
Lifting Drums or Round Objects
163
Operating in Hot Weather
163
Parking the Lift Truck
164
If Parking Brake Alarm Equipped
164
Lift Fork Adjustment
165
Hook-On Type Fork
165
Storage Information
166
Before Storage
166
Long Time Storage
166
Transportation Hints
167
Lift Truck Shipping
167
Towing Information
168
Maintenance Section
169
Inspection, Maintenance and Repair of Lift Truck Forks
169
Environment Protection
169
Bent or Twisted Forks
170
Causes of Fork Failure
170
Improper Modification or Repair
170
Daily Inspection
171
First Installation
171
Fork Inspection
171
Maintenance and Repair
172
Tire Inflation Information
173
Tire Shipping Pressure
173
Torque Specifications
174
Cooling System Specifications
176
Coolant Information
176
Coolant Water
177
Make Proper Antifreeze Additions
177
Fuel Specifications
178
Additional Technical Fuel Requirements
178
Bio-Diesel Fuels
178
General Fuel Information
178
Drive Axle Oil
180
Engine Oil (Deo and Eo)
180
Hydraulic Oil (HYDO)
180
Lubricant Information
180
Brake Fluid
181
Lubricating Grease (Mpgm)
181
Oil Cooled Disc Brake Only
181
Transmission Oil
181
Lubricant Viscosities and Refill Capacities
182
Maintenance Intervals
183
Default Chapter
187
When Required
187
Fuel Tank Filter Cap and Screen (if Equipped) - Clean
187
Seat, Hood Latch & Support Cylinder - Check, Lubricate
187
Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset
188
Priming the Fuel System(Diesel Engine Only)
189
Water Seperator (Diesel Engine Only) - Check, Drain
191
Carriage Roller Extrusion - Adjust
193
Check Inflation and Damage
193
Tires and Wheels (D, G-Series) - Inspect, Check
193
Every 10 Service Hours or Daily
194
Inspect Engine for Fluid Leaks
194
Gasoline and Lp Engines
194
Engine Oil Level - Check
194
Diesel Engines
194
Coolant Level - Check
195
Air Cleaner Indicator-Check
196
Inspect Foot Pedal Operation (G420F(E)/G424F(E)/G424I(E) /G430FE Only)
196
Inspect Engine for Exhaust Leaks
196
Walk-Around Inspection - Inspect
196
Mast Channels - Lubricate
197
Transmission Oil Level - Check
198
Parking Brake - Inspect
198
Inspection from Operator's Seat, Engine off
198
Inspection from Operator's Seat, Engine on
198
First 50 - 100 Service Hours or a Week
200
Engine Oil & Filter (Diesel Engine Only) - Change
200
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
201
Drive Axle Oil - Change
203
Parking Brake - Test, Adjust
203
Parking Brake Testing
203
Parking Brake Adjusting
204
First 250 Service Hours or a Month
205
Hydraulic Return Filter - Change
205
Every 250 Service Hours or Monthly
206
Air Intake System - Check, Clean
206
Precleaner (if Equipped)
206
Servicing Filter Element
206
Cleaning Primary Filter Elements
207
Brake Oil Level - Check
208
Hydraulic Oil Level - Check
208
Drive Axle Oil Level - Check
209
Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate
209
Steering Mechanism - Check, Lubricate
209
Battery Terminal - Clean, Inspect
210
Engine Oil & Filter (LP & Gasoline Engine Only) - Change
210
Gasoline, Lp Engine Crankcase
210
G424F(E) Lp and Duel Fuel Engines
211
PCV Valve System - Inspect, Clean
211
G424I(E) Lp and Duel Fuel Engines
212
G430Fe Lp Engine
212
Wheel Bolts & Nuts - Inspect
213
Inspect Tightness (GC - Series)
213
Governor Lever and Engine Speed Control (Diesel Engine Only) - Check ,Adjust
214
Every 500 Service Hours or 3 Months
216
Belts - Check, Adjust
216
Mast Hinge Pin - Lubricate
216
Tilt Cylinders - Check, Adjust, Lubricate
216
Chassis Pivot Eyebolts-Lubricate
216
Crosshead Rollers - Inspect
217
Mast Pivot Eyes-Lubricate
217
Transmission Oil Filter - Change
218
Overhead Guard - Inspect
218
Drive Axle Oil & Strainer - Change, Clean
219
Steer Suspension - Inspect
220
Parking Brake - Test, Adjust
220
Inching & Braking Control Shaft - Lubricate
220
Horn and Lights (if Equipped) - Check
220
Inspect Vacuum Lines and Fittings (G420F(E)/G424F(E)/G424I(E) Engine Only)
221
Fuel Trim Valve(FTV) Inspection (G420F(E)/G424F(E)/G424I(E) Engine Only)
221
Inspect Electrical System (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only)
222
Fuel Filter (Diesel Engine Only) - Change
223
Engine Oil & Filter (Diesel Engine Only) - Change
224
Water Separator (4TNV98 Diesel Engine Only) - Clean
225
Every 1000 Service Hours or 6 Months
226
Hydraulic Return Filter, Breather & Strainer - Check, Change
226
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
227
Lift Chains - Test, Check, Adjust
227
Check for Equal Tension
227
Lift Chain Wear Test
227
Lift Chain Adjustment
227
Universal Joint - Inspect
229
Air Intake System - Change
229
Inspect Coolant Hoses (LP, Dual Fuel Engine Only)
230
LP Regulator/Converter Inspection (LP, Dual Fuel Engine Only)
230
Fuel Lines & Fittings - Check
230
Inspect Mixer Assembly (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only)
231
Inspect Throttle Assembly (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only)
231
Engine Valve Lash (Diesel Engine Only) - Check, Adjust
231
Every 1500 Service Hours or 9 Months
232
Inspect Ignition System (LP, Gasoline & Dual Fuel Engines Only)
232
Replace Spark Plugs (G424F(E) LP, Dual Fuel Engine / G430FE Engine Only)
233
Replace LP Fuel Filter Element (LP, Dual Fuel Engine Only)
234
Fuel Filter (LP Engine Only)
234
Testing Fuel Lock-Off Operation (LP Engine Only)
234
Fuel Injectors (Diesel Engine Only) - Inspect, Clean, Test
235
Crankcase Breather System (4TNV98 Diesel Engine Only) - Inspect
235
Every 2000 Service Hours or Yearly
236
Engine Valve Lash (Diesel Engine Only) - Check, Adjust
236
Steer Wheel Bearings - Reassemble
236
Drive Wheel Bearing (Power Shaft and Drive Wheel) - Reassemble
238
Gc-Series Lift Trucks
238
D, G-Series Lift Trucks
238
Cooling System - Clean, Change
239
Forks - Inspect
241
Every 2500 Service Hours or 15 Months
243
Hydraulic Oil - Check, Clean, Change
243
Inspect Battery System
243
G420F(E) Engine
244
Replace Oxygen Sensor (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only)
244
G424I(E) Engine
244
Replace Spark Plugs (G420F(E)/G424I(E) Engine Only)
245
Checking the TMAP Sensor (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only)
246
Inspect for Intake Leaks (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only)
246
Every 3000 Service Hours or 18 Months
248
Timing Belt [G420F(E)/G424F(E) LP, Gasoline, Dual Fuel Engine Only] - Change
248
Index Section
249
Index
249
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Doosan D35C-5 Specifications
General
Brand
Doosan
Model
D35C-5
Category
Lifting Systems
Language
English
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