Monthly Customer Service Update

Connections

March 2022 Issue: 

Hydraulic Pump Air Release Process for 5215 Series

394-02 Doosan Codes P1825-P1198-P1197-P0428 No Code Description
Hydrostat Drive Surge
LPG Ultrasonic – Level Indicator-Signal
Parts News
Software News
Technical Training

What's New?

Launch of our new Aftermarket Distribution Center

We are excited to inform you that we successfully launched our new Aftermarket
Distribution Center on February 22, 2022. The team worked overtime and
weekends all January and February to move into the new distribution center while
fulfilling orders in parallel out of the old distribution center. We heavily focused on
not missing a beat on your emergency orders and were able to substantially
reduce the backlog on stock orders within 10 days after launch. We apologize for
any inconvenience and delays this may have caused to your business. We are
confident that we now have the proper footprint and facility for years to come to
serve your parts needs as efficiently as possible.

KION Aftermarket Distribution Center 

410 Tradeport Drive, Suite 300
Summerville, SC 29486

Hydraulic Pump Air Release Process for 5215 Series

Steps to take after replacement of the hydraulic pump, or after pump suction circuit
and filter maintenance:

It’s necessary to release the air inside the pump and suction hose line,
otherwise, the pump may be damaged due to wear without oil inside the
pump.
Connect the factory compressed air source to the pressure reducer (usually
the workshop already has), you will need to make an adapter to screw into
the tank air breather port (the thread is G ¾”).
Adjust the pressure reducer to increase the pressure from 0 to 0.5bar, and
then remove the plug of the M1 port of the pump. Take a container at the M1
port to get oil flows out.
Only push the lift button to run the motor(about 1500-2000rpm) and keep
running until the oil flows out without air bubbles inside, which means the
pump has sucked oil from the tank successfully, then screw in the M1 plug.
Push the lift button, wait for a few seconds and you will see the fork lifting,
which means the pump starts successfully.

394-02 Doosan Codes P1825-P1198-P1197-P0428 No

Code Description

Early 394-02 Doosan Diesels do not have an electric fuel pump. The above codes
are like VW Code P0087, referencing low fuel rail pressure. There is not enough
fuel being supplied to the fuel rail. Newer 394-02 trucks with the Doosan are now
fitted with electric fuel pumps as standard. If you experience the above codes, the
solution is to add the electric fuel pump to the fuel system.

Order part numbers 3945709502 Fuel Pump Kit and 3943812623 Wiring Harness.

The installation instructions can be found in LSG, Service Jobs, Install Fuel Pump.

*To complete the process an update to the ECU Software is required, This
task can be carried out using LSG –Doosan-Updates

When bleeding the fuel system after the installation, the following process must be
carried out. Attach a clamp to the overpressure bypass. Item 3 in the photo. Turn
on the ignition for 30 seconds, perform this task 3 times. When you hear a change
in tone of the fuel pump start the engine. Let it run for 30 seconds then remove the
clamp.

Hydrostat Drive Surge

The following advice is based on the experience we have had regarding the
problem “surging driving behavior”. Most surges happen at low rpm , start of the
rotation.

The hydraulic transmission consists of complex components which must work

together with other systems (for example the combustion engine). Therefore,
troubleshooting in one case or another can be difficult at times. Accuracy of the
description is very important.

Before carrying out any troubleshooting of hydraulic components, please check

that this surging behavior doesn’t come from the engine!

*Important things to note before you start the troubleshooting procedure

Do we have an engine issue? An engine with poor performance can result in

a hydrostat surge or loss of travel speed.
Is the surge at start of wheel rotation or at cruising speed?
Is the surge in one direction or both directions?
When the surge appears, is the hydraulic oil hot or cold?

These are very important questions that will put you on a path to troubleshooting
success. Hydrostat pressure testing procedures can be found in all Linde Service
Manuals. Before carrying out any pressure testing, connect to the LHC and check
for error codes associated with the drive system. If any codes are found these
issues must be corrected before carrying out hydrostat troubleshooting. Electrical
components, as well as drive pedal mechanical linkages, must also be inspected
for wear. It is important that the drive parameters do not exceed the calibrated
threshold. These values can all be checked using LSG Diagnostic Software.

Observe all safety requests as noted in the LSG Service Manual

LPG Ultrasonic – Level Indicator-Signal

Parts Information

Baoli Seat Part Numbers

 Universal Mounting Brackets

Software Updates
1. SerDia2010 Annual Maintenance Fee:

A yearly renewal fee of $375.00 will be charged for each active SerDia Deutz
license. This billing will take place on June 15th every calendar year (June 15,
2022, June 15, 2023, June 15, 2024, and so on). For billing purposes, an annual
SerDia license contract has been created to keep a record of all charges. It is
important that you continue to keep accurate records on the number of
SerDia2010 licenses you have at your location.

You can disregard this message if you do not have any active SerDia licenses. 

2. LSG Error Message „Workflow not found“ :

The above message indicates that the diagnosis data or Linde Runtime has
corrupted data.

Possible solutions:

1. Delete the runtime "C:\Linde_MH\Diagnostics\Runtime" folder and replace it

with the folder of a working installation (pay attention to the correct version of the
two LSGs, they need to have the same versions. App version and Data version).

2. If the above doesn't help the same can be tried with the diagnosis "data" folder
in "C:\Linde_MH\Diagnostics\", also here the LSG needs to have the same data
and app version.

3. A clean reinstallation of LSG, starting with the latest full installer version 7.19.0
U218.

Also, please check all security settings are set. This type of issue is mostly due to
security software or third-party software blocking the correct installation.

For questions or concerns reference service software please contact our Service
Software Team at service.software.na@kiongroup.com.   

Technical Training

“Statistics suggest 40% of new hires are lost within a year, and 75% of them cite
lack of training” – Modern Materials Handling.

The very first Technical Training course was held in the brand new KION North
America Training facility in early January and went exceptionally well! The new
facility provides a world-class training environment for technicians to not only learn
the relevant system knowledge for servicing KION North America products but
also provide for the seamless integration of classroom and hands-on training
experience.

KION North America Customer Service Technical Training department Instructor

Jonathan Williams conducted the Basic IC and Electric Truck Troubleshooting
Procedures factory service course to a full class of our dealer technicians. Dealers
taking part included IPW Lift Techs, Wolter, Shoppas Material Handling LTD,
Shoppas Mid America LLC, Advanced Material Handling Systems, Homestead
Materials Handling, Mullen Industrial Forklifts, and Forklifts of Toledo.
 Upcoming Factory Training for April

Basic IC and Electric Truck Troubleshooting Procedures

April 5-8
Complete Your Registration

Service Software Management - Webinar 

April 12
No registration is required. An announcement with the link will be sent out
two weeks in advance.

Parts Technical Support - Webinar 

April 14
No registration is required. An announcement with the link will be sent out
two weeks in advance.

Linde Series 1202: IC Truck

March 22-24
Complete Your Registration

The 2022 Customer Service Technical Training Catalog is always available for
download from the KION Community Portal in the Libraries/Customer
Service/Technical Training/2022 Technical Training Catalog and Forms area. Many
of the scheduled courses are now filling up. Contact KION North America
Technical Training Manager Bob Menges for assistance in planning out your
training.

View All Upcoming Training Courses

Contact Us
KION North America Corporation, 410 Tradeport Drive, Suite 300, Summerville, South Carolina 29486,
USA, +1 843 875 8000
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