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Doosan D20S-5 Forklift Pneumatic Tire Lift Truck 2000 Hours / 1 Year

The Doosan D20S-5 Forklift Pneumatic Tire Lift Truck 2000 Hours / 1 Year procedure inspects your engine for fluid leaks, engine oil level, coolant level and also checks the air cleaner indicator. This form helps in ensuring your forklifts maintains its quality performance.

MaintainX

04/26/2021

Doosan D20S-5 Forklift Pneumatic Tire Lift Truck 2000 Hours / 1 Year

Engine Valve Lash (Diesel Engine Only) – Check, Adjust

See topic “Engine valve Lash (Diesel Engine Only) – Check, Adjust”. In First 250 Service hours.

Steer Wheel Bearings - Reassemble

Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL and the engine stopped.

NOTE: The procedure is shown on a GC-Series lift truck. It is the same for D, G-Series lift trucks.

Lift the steer wheels off the ground. Place stands or blocking under the frame and steer axle to support the lift truck.

Remove the hub cap which is pressed into the wheel hub.

Straighten the lock washer tangs.

Remove the lock nut, lock washer and flat washer. Remove the outer wheel bearing.

Remove the wheel assembly. Examine the seal for damage and wear. Replace the seal if necessary.

Remove the inner bearing. Clean and lubricate the steering knuckle. Reassemble both the inner and outer bearing cones.

Install the inner bearing. Lubricate the seal and install the wheel assembly on the knuckle.

Install the outer wheel bearing and the out washer. Install a new lock washer and fit the locknut.

Tighten the locknut to 135 N•m (100 lb•ft), while turning wheel hub to seat the bearing.

Loosen the locknut. Retorque it to 50 ± 5N•m (37 ± 4 lb•ft). Bend the lock washer tang to secure locknut.

Install the hub cap.

Raise the lift truck and remove the blocking. Lower the lift truck to the ground.

Drive Wheel Bearing (Power Shaft and Drive Wheel) – Reassemble

Consult your DOOSAN lift truck dealer for the proper wheel bearing reassembling procedure.

Packing of bearings and adjustment procedure must be made by a trained mechanic or dealer personnel.

Pack power shaft bearings (1) and spindle bearings (2). Pack ring gear (3) to the depth of the teeth.

D, G-Series Lift Trucks

Torque for single or dual wheel mounting nuts (1) is 644 ± 34 N•m (470 ± 25 lb•ft).

Tighten wheel bearing nut (3) to 135 N•m (100 lb•ft) while the wheel is turned in both directions. Loosen the nut completely and tighten nut again to 50 ± 5 N•m (37 ± 4 lb•ft). Bend the lock washer tab into a groove of the nut.

Torque for bolts (4) that hold cover to drive axle housing is 55 ± 10 N•m (40 ± 7 lb•ft).

Apply Loctite No.242 to threads of spindle bolts (5).Torque for spindle bolts is 115 ± 14 N•m (85 ± 10 lb•ft).

GC-Series Lift Trucks.

Torque for wheel bolts (1) is 270 ± 25 N•m (200 ± 20 lb•ft).

Tighten wheel bearing nut (2) 135 N•m (100 lb•ft) while the wheel is turned in both directions. Loosen the nut completely and tighten nut again to 50 ±5 N•m (37 ± 4 lb•ft). Bend the lock washer tab into a groove of the nut.

Apply Loctite No. 242 to threads of spindle bolts (4). Torque for spindle bolts is 115 ± 14 N•m (85 ± 10 lb•ft).

Cooling System – Clean, Change

WARNING:At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury.

Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand.

Remove the filler cap slowly to relieve pressure.

Coolant is included 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 brake engaged, the transmission in NEUTRAL and the engine stopped and cool.

Turn the radiator cap slowly to relieve the pressure, and then remove the cap.

Remove the drain plug or water hose on engine block.

4TNE98 3.3L Diesel Engine

4TNV98 3.3L Diesel Engine

G420F(E) 2.0L LPG/Gasoline Engine

G424F(E) 2.4L LPG/Gasoline Engine

G424I(E) 2.4L LPG/Gasoline Engine

G430FE 3.0L LPG Engine

Open the radiator drain valve. Allow the coolant to drain into a suitable container. Drain the recovery bottle.

NOTICE: Hold the drain port when the radiator drain valve is turned because the tank and the drain port are separated.

After draining the coolant completely, close the radiator drain valve and the block drain plug, fill the engine and the radiator full with a radiator cleaner, and clean the engine and the radiator.

Start and run the engine for 30 minutes.

Stop the engine and drain the cleaning solution into a suitable container.

Flush the system with clean water, until draining water is clear.

Close the drain valve and install the block drain plug. Fill coolant to top of the filler neck.

Start and run the engine to stabilize the coolant level. See topic, “Coolant Level – Check” in “Every 10 Service hours or Daily”.

NOTICE Inject the coolant additionally into below specific port of G424I(E) engine besides the radiator if needs more coolant while clean & change the cooling system.

Remove the indicated coolant hose above picture and then, add the coolant to hose as much as needed.

Forks – Inspect

Forks should be inspected, at a minimum, every 12 months. If the truck is being used in a multi-shift or heavy duty operation, they should be checked every six months.

Inspect the forks carefully for cracks. Special attention should be given to the heel section (A), all weld areas and mounting brackets (B). Inspect the top and bottom hooks on forks used on hook type carriages and tubes on shaft mounted forks.

Forks with cracks should be removed from service.

"Wet Test" magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results. Portable equipment is usually recommended so it can be moved to the lift truck.

Inspectors should be trained and qualified in accordance with The American Society for Non Destructive Testing, Level II Qualifications.

Check the angle between the upper face of the blade and the front face of the shank.

The 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.

Check the straightness of the upper face of blade (D) and the front face of shank (E) with a straight edge.

The fork should be withdrawn from service if the deviation from straightness exceeds 0.5 percent of the length of the blade and/or the height of the shank respectively 5 mm/1000 mm (0.18"/36").

Check the difference in height of one fork tip to the other when mounted on the fork carrier. A difference in fork tip height can result in uneven support of the load and cause problems with entering loads.

The maximum recommended difference in fork tip elevation (F) is 6.5 mm (0.25") for pallet forks and 3 mm (0.125") for fully tapered forks.

The maximum allowable difference in fork tip elevation between the two or more forks is 3 percent of blade length (L).

Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DOOSAN Lift Truck Dealer for further information.

Check the fork blade (J) and shank (H) for wear with special attention to the heel (G). The fork should be withdrawn from service if the thickness is reduced to 90 percent or less of the original thickness.

Fork blade length may also be reduced by wear, especially on tapered forks and platens. Remove the forks from service when the blade length is no longer adequate for the intended loads.

Check the fork mountings (K) for wear, crushing and other local deformation, which can cause excessive side to side wobble of the forks.

Excessive clearance on hook type forks may allow them to fall from the carrier. Forks which show visible signs of such damage should be removed from service.

Check the positioning lock and other fork retention devices to make sure they are in place and working.

Hook type forks use a spring loaded pin (M), located in the top hook, to engage notches in the top carriage bar to hold the fork in place.

When adjusting the fork spacing, the forks are prevented 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 place of the stop blocks in some cases.Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork.

They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage.

Check fork markings (N) for legibility. Renew markings as required to retain legibility.

a. Lift the mast and operate the tilt control lever, until the top surface of the forks is parallel with the floor. Place two straight bars that are the same width as the carriage, across the forks as shown.

b. Measure the distance from the bottom of each end of the two bars to the floor. The forks must be parallel within 3 mm (.12 in) for Full Tapered and Polished (FTP) forks, all other forks 6.4 mm (.25 in), for their complete length.

c. Put one fork, one third from the tip, under a fixture that will not move. Then operate the tilt control with caution until the rear of the truck lifts just off the floor. Follow the same procedure with the second fork. Repeat Step

Source: Doosan

Please note that any procedure, checklist, or other document available in the MaintainX Procedure Hub is provided for general education and information only and does not constitute legal, medical, or financial advice. MaintainX makes the materials available AS IS and AS PROVIDED, without warranties of any kind. By downloading or using any such materials, you assume the risk that they may not be appropriate for your specific situation and agree that you are solely responsible for any such use, including compliance with applicable law and with meeting any conditions of product warranties.

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