SB2349E02

Operation &
Maintenance Manual
LIFT TRUCKS

D20S-5, D25S-5, D30S-5, D33S-5, D35C-5

G20E-5, G25E-5, G30E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5

0712
 

Table of Contents

Table of Contents

Information Section Maintenance Section

Foreword
Fore word ......................................................
....................................................................2
..............2  
Inspection, Maintenance and Repair of Lift Truck
Forks ........................................................
......................................................................
..............130
130
 

Tire Inflation
Inflatio n Information.......................................134
Infor mation.......................................134  

Safety Section Torque Specifications

Specifica tions .............................
...........................................
..............135
135
 

Cooling System Specifications............................

Specificatio ns.............................. 137  

Fuel Specifications...............................................
Specifica tions................................................. 139
Importan t Safety
Important Safe ty Information
Info rmation ....................................4
....................................4
 

Lubricant
Lubric ant Information
Info rmation .........................
............................................
...................141
141
 

Safety
Safe ty .......................................................
.........................................................................5
..................5
 

Lubricant Viscosities
Viscosities and Refill Capacities ......... .........143
143
Warning Signs and Labels ...............................
................................5
.5
 

Maintenance
Maintena nce Intervals
Interval s .......................
..........................................
...................144
144
Parking brake .....................................................9
.....................................................9
 

When Required
Requi red ....................................................
...................................................... 148
General Hazard Information............
Information.................. ............
.........
... 10
 

Every 10 Service Hours or Daily.............

Daily...................
...........
.......
..155
155
Operation Information.............
Information.................. ...........
............
............
........ 11
 

First 50 - 100 Service Hours or a Week..............161

Week..............161
Maintenance Information.............
Information................... ............
............
........ 14
 

First 250 Service Hours or o r a Month............

Month...........................
...166
166
Operator Restraint
Restraint System(If
System(If Equipped)....... 17
 

Every 250 Service Hours or Monthly..............

Monthly...................167
.....167
 

Avoiding Lift Li ft Truck Tipover............

Tipover..............................
...........
..... 21
 

Every 500 Service Hours or 3 Months... Months........ ...........

.........
...176
176
Safety Rules ..................................................
....................................................
.. 23
 

Every 1000 Service Hours Hours or 6 Months ........... ..............

...185
185
How to Survive in a Tipover ............ .................
..........
..........
..... 28
 

Every 1500 Service Hours Hours or 9 Months .......... ..............

....191
191  

Every 2000 Service Hours or Yearly ...... ...........

...........
........
..194
194  

Every 2500 Service Hours Hours or 15 Months .... ..........

........
..201
201  

General Section Every 3000 Service Hours Hours or 18 Months .... ..........
........
..204
204

Specifica tions.........................
Specifications ........................................................
.................................
.. 30  

Noise and Vibration......

Vibration ...........
..........
...........
............
............
...........
...........
.........
... 42  
Index Section
Capacity Chart
Chart (Without Sideshifter
Sideshifter Pneumatic).. 43  

Capacity Chart
Chart (With Sideshifter
Sideshifter Pneumatic)....... 47  

Index ........................................................
......................................................................
..............205
205
Capacity Chart (Without Sideshifter
Sideshifter cushion).......
cushion)....... 51
 

Capacity Chart (With Sideshifter

Sideshifter cushion)
cushion)...... ...........
....... 55  

Serial Number
Numbe r .......................................................
.........................................................
.. 59  

Operator's Warning and and Identification Plate ......... ......... 62

Operation Section

Operator’s Station and Monitoring Monitoring Systems.........

Systems......... 63  

Seat Switch System (If Equipped)..........

Equipped)................ ............
.........
... 67 

Lift Truck Controls ..........

................
...........
..........
...........
............
...........
..........
.......
.. 69 

Refueling
Refuel ing .......................
......................................................
..........................................
........... 71 

Before
Befo re Starting the Engine..................................... 74  

Starting
Startin g the Engine .................................................
................................................. 76 

Dual Fuel System ...........

.................
...........
..........
...........
............
...........
..........
.......
.. 79 

Lift Truck Operation

Opera tion........................
................................................
........................ 82 

Mono-Ped Control System (Option)......... (O ption)...............

...........
..... 117  

Auto Shift Controller ASC-100 ASC-100 (If Equipped)......

Equipped) ...... 118  

Operating
Opera ting Techniques..........................................
Technique s.......................................... 121  

Parking the Lift Truck ...........

................
...........
...........
...........
...........
..........
..... 125  

Lift Fork Adjustment .........................

...........
............
............
............
............
...... 126  

Storage Information
Informa tion........................
..............................................
...................... 127  

Transportation
Transpo rtation Hints .............................................
............................................. 128  

Towing Information
Infor mation.........................
...............................................
...................... 129

-1-
 

Information Section

Foreword
Literature Information Photographs or illustrations guide the operator
through correct procedures of checking, operation
This manual should be stored in the operator’s and maintenance of the DOOSAN operator
compartment in the literature holder or seat back restraint system.
literature storage area.
SAFE and EFFICIENT OPERATION of a lift truck
This manual contains safety, operation, depends to a great extent on the skill and alertness
transportation, lubrication and maintenance on the part of the operator. To develop this skill the
information. operator should read and understand the Safe
Driving Practices contained in this manual.
Some photographs or illustrations in this publication
show details or attachments that can be different Forklift trucks seldom tipover, but in the rare event
from your lift truck. Guards and covers might have they do, the operator may be pinned to the ground
been removed for illustrativ
illu strative
e purposes. by the lift truck or the overhead guard. This could
result in serious injury or death.
Continuing improvement and advancement of
product design might have caused changes to your Operator training and safety awareness is an
lift truck which are not included in this publication. effective way to prevent accidents, but accidents
Read, study and keep this manual with the lift truck. can still happen. The DOOSAN operator restraint
system can minimize injuries. The DOOSAN
Whenever a question arises regarding
rega rding your lift truck, operator restraint system keeps the operator
or this publication, please consult your DOOSAN substantially within the confines of the operator’s
dealer for the latest available information. compartment and the overhead guard.

This manual contains information necessary for

Safety Safe Operation. Before operating a lift truck, make
sure that the necessary instructions are available
The Safety Section lists basic safety precautions. In and understood.
addition, this section identifies the text and
locations of warning signs and labels used on the
lift truck. Operation
Read and understand the basic precautions listed
in the Safety Section before operating or The Operation Section is a reference for the new
performing lubrication, maintenance and repair on operator and a refresher for the experience
experienced
d one.
this lift truck. This section includes a discussion of gauges,
switches, lift truck controls, attachment controls,
transportation and towing information.
i nformation.
Operator Restraint System (If Equipped) Photographs and illustrations guide the operator
through correct procedures of checking, starting,
This manual contains safety, operation and operating and stopping the lift truck.
tru ck.
maintenance information for the DOOSAN operator Operating techniques outlined in this publication
restraint system. Read, study and keep it handy. are basic. Skill and techniques develop as the
operator gains knowledge of the lift truck and its
capabilities.
WARNING
Your DOOSAN truck comes equipped with an
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DOOSAN
operator restraint system.

-2-
 

Information Section

Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without
specific intervals are listed under “When Required”
topics. Items in the “Maintenance Intervals” chart
are referenced to detailed instructions that follow.

Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.

Under extremely severe, dusty or wet operating

conditions, more frequent lubrication than is
specified in the “Maintenance Intervals” chart might
be necessary.

Perform 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 Service Hours or Daily”.

Environment Management
Note that DOOSAN INFRACORE is ISO 14001
certified which is harmonized with ISO 9001.
Periodic ENVIRONMENTAL AUDITS &
ENVIRONMENTAL PERFORMANCE
EVALUATIONS have been made by internal and
external inspection entities. LIFE-CYCLE
ANALYSIS has also been made through out the
total product life. ENVIRONMENT MANAGEMENT
SYSTEM includes DESIGN FOR ENVIRONMENT
from the initial stage of
o f the design. ENVIRON
ENVIRONMENT
MENT
MANAGEMENT
MANAGEME NT SYSTEM considers environmental
laws & regulations, reduction or elimination of
resource consumption as well as environmental
emission or pollution from industrial activities,
energy saving, environment-friendly product
design(lower noise, vibration, emission, smoke,
heavy metal free, ozone depleting substance free,
etc.), recycling, material cost reduction, and even
environmentally oriented education for the
employee. 

-3-
 

Safety Section

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons
must also have the necessary
n ecessary training, skills and tools before a
attempting
ttempting to perform these functions.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair
re pair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or othe
otherr persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”
as shown below.

WARNING 

The meaning of 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.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure,
pro cedure, work method or operating technique not
no t specifically recommended by DOOSAN is
used, you must be sure that it is safe for you and others. You should also ensure that the product will not be

damaged or made unsafe

un safe by the operation, lubrication, maintenance or repair procedures
p rocedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
a vailable.

-4-
 

Safety Section

Safety
The safety rules and regulations in this section are Warning Signs and Labels
representative of some, but not all rules and
regulations noted under the Occupational Safety There are several specific safety signs on your lift
and Health Act (OSHA) and are paraphrased truck. Their exact location and description of the
without representation that the OSHA rules and hazard are reviewed in this section. Please take the
regulations have been reproduced
rep roduced verbatim. time to familiar
fa miliarize
ize yourself with these safety signs.
Make sure that you can read all warning and
Please refer to 1910. 178 in Federal Register Vol. instruction labels. Clean or replace these labels if
37, No. 202, the National Fire Protection you cannot read the words or see the pictures.
Association No. 505 (NFPA), American National When cleaning the labels use a cloth, water and
Standard, ANSI B56. 1 Safety Standard for Low lift soap. Do not use solvent, gasoline, etc.
and High Lift Trucks and subsequent revis
revisions
ions for a You must replace a label if it is damaged, missing
complete list of OSHA rules and regulations as to or cannot be read. If a label is on a part that is
the safe operation of powered industrial lift trucks. replaced, make sure a new label is installed on the
Since regulations vary from country to country replaced part. See your dealer for new labels.
outside in U.S.A., operate this lift truck in
accordance with local regulations.
r egulations. Traing Required To Operate or Service
DOOSAN lift trucks are manufactured according to Warning
the regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives
89/655/EC and 89/391/EC and its amendments for
the safe use of DOOSAN lift trucks.

The most effective method of preventing serious

injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation 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 Located on the right side of the steering wheel.
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so.
WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DOOSAN Lift Truck dealers.

This label also provides allowable lift truck capacity

information

-5-
 

Safety Section

General Warning to Operator 5.  Travel with load as low as possible and tilted
back. If load interferes with visibility, 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.

9.  Do not allow anyone to stand or pass under the

elevated portion of any machine.

10. Be sure operating surface can safely support

Located on the right side of the operator's seat machine.
(STD ).
11. Operate machine and attachments only from
operator's position.

12. Do not handle unstable or loosely stacked

loads.

13. Use minimum tilt when picking up or depositing

a load.

14. Use extreme care when handling long, high, or

wide loads.

15. Forks should be completely under load and

spread apart as far as load permits.
Located on the overhead guard (If Convenience
Package Equipped). 16. Machine should be equipped with overhead
guard or equivalent protection. Where load
requires it, use a load backrest extension. Use
WARNING extreme caution if operating without these
devices.
Only trained and authorized personnel may
operate this machine. For safe operation, read 17. Parking - Lower lifting mechanism to floor. Put
and follow the operation and maintenance directional control or shift lever in neutral. Set
Manual furnished with this lift truck and parking/secondary brake. Turn “ON - OFF”
observe the following warnings: switch off. Chock wheels if machine is on incline.
Disconnect battery when storing electric
machines.
1.  Before starting machine. Check all controls and
warning devices for proper operation. 18.
18. Observe safety rules when handling fuel for
engine powered machine and when changing
2.  Refer to machine identification plate for batteries for electric machines.
allowable machine capacity. Do not overload.
Operate machines equipped with attachments
as partially loaded machines when not handling
a load.

3.  Put directional control or shift lever in neutral

before “ON - OFF” switch is turned on.

4.  Start, turn and brake smoothly. Slow down for

turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid running
over loose objects or holes in the roadway
surfaces. Use extreme caution when turning on
inclines.

-6-
 

Safety Section

Pressure Warning No Standing On Fork Warning

WARNING No Standing Under Fork Warning

Contents under pressure may be hot. Allow to WARNING
cool before opening.
Do not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do not
stand or walk under the forks.

Located on the radiator top tank by the radiator

cap.

Hand Placement Warning Located on the lift

li ft cylinder.

WARNING Load Backrest Must Be In Place

Warning

WARNING
Operation without this device in place may be
No hands. Do not place hands in this area. Do hazardous.
not touch, lean on, or reach through the mast or
permit others to do so.

Located on the load

l oad backrest.

Located on the mast.

-7-
 

Safety Section

Overhead Guard Must Be In Place Moving Fan Warning

Warning WARNING
WARNING To avoid personal injury, stay clear of moving
fan.
Operation without this device in place may be
hazardous. This guard conforms to
A.N.S.I.B56.1 and F.E.M.Section IV. This design
has been tested with an impact of appropriate
valve.

Located inside the engine compartment cover.

Located on the Overhead Guard.

No Riders Warning

WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.

Located beside the operator's station (STD) or on

front of the hood (Convenience Package).

-8-
 

Safety Section

Parking brake

Pull the lever BACK to engage the

parking brake.

Push the lever FORWARD to release

the parking brake.

Applying the parking brake puts the transmission in

NEUTRAL. The parking brake must be applied
when leaving the lift truck and when starting the
engine. If the operator leaves the seat without
applying the parking brake, an audible alarm will
sound.

WARNING
When leaving machine apply parking brake!
Parking brake is not automatically 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
truck may creep at engine idle and can cause
damage, injury or death. Always apply the
parking brake when leaving the lift truck. The
parking brake is NOT automatically applied.

-9-
 

Safety Section

General Hazard Information Always use the overhead guard. The overhead
guard is intended to protect the lift truck operator
from overhead obstructions and from falling
objects.

A truck that is used for handing small objects or

uneven loads must be fitted with a load backrest.

If the lift truck must be operated without the

overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is
i s no
possibility of falling objects from any adjacent
storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
backrest extension (if equipped).

Attach a “Do Not Operate” or similar warning tag to Do not raise loads any higher than necessary and
start switch or controls before servicing or repairing never raise a load higher than 1830 mm (72 in) with
the lift truck. the overhead guard removed.

Do not start or service the lift truck when a “DO Always use load backrest extension when the
NOT OPERATE” or similar warning tag is attached carriage or attachment does not fully support the
to the start switch or controls. load. The load backrest extension is intended to
prevent the load or any part of the load from falling
Wear a hard hat, protective glasses and other backwards into the operator's station.
protective equipment as required by job conditions.
When operating the lift truck, do not depend
de pend only on
Know the width of your attachments so proper flashing lights or back-up alarm (if equipped) to
clearance can be maintained when operating near warn pedestrians.
ped estrians.
fences, boundary obstacles, etc.
Always be aware of pedestrians and do not
Do not wear loose clothing or jewelry that can catch proceed until the pedestrians are aware of your
on controls or other parts of
o f the lift truck. presence and intended actions and have moved
clear of the lift truck and/or load.
Keep the lift truck, especially the deck and steps,
free of foreign material such as debris, oil tools and Do not drive lift truck up to anyone standing in front
other items which are not part of the lift truck. of an object.

Secure all loose items such as lunch boxes, tools Obey all traffic rules and warning signs.
and other items which are not part of the lift truck.
Keep hands, feet and head inside the operator
Know the appropriate work-site hand signals and station. Do not hold onto the overhead guard while
who gives them. Accept signals from one person operating the lift truck. Do not climb on any part of
the mast or overhead guard or permit others to do
only. so.

Do not allow unauthorized personnel to ride on the

forks or any other part of the lift truck, at any time.

When working in a building or dock, observe floor

load limits and overhead clearances.

-10-
 

Safety Section

Inhaling Freon gas through a lit cigarette or other Operation Information

smoking method or inhaling fumes released from a
flame contacting Freon can cause bodily harm or Mounting and Dismounting
death. Do not smoke when servicing air
conditioners or wherever Freon gas may be Mount and dismount the lift truck carefully.
present.
Clean your shoes and wipe your hands before
Never put maintenance fluids into glass containers.
c ontainers. mounting.
Use all cleaning solutions with care.
Use both hands and face the lift truck when
Do not use steam, solvent, or high pressure to mounting and dismounting.
clean electrical components.
Use the handgrips for mounting and dismounting.
Report all needed repairs.
Do not try to climb on or off the lift truck when
carrying tools or supplies.

Do not use any controls as handholds when

entering or leaving the operator's station.

Never get on or off a moving lift truck. Never jump

off the lift truck.

Keep hands and steering wheel free of slippery

material.

Before Starting the Lift Truck

Perform a walk-around inspection daily and at the
Inspect the part of the chain that is normally start of each shift. Refer to the topic “Walk-around
operated over the crosshead roller. When the chain Inspection” in “Every 10 Service Hours or Daily”
bends over the roller, the movement of the parts section of this manual.
against each other causes wears.
Adjust the seat so that full brake pedal travel can
Inspect to be sure that chain link pins do not extend be obtained with the operator's back against the
outside of the bore hole. seat back.

If any single link pin is extended beyond its Make sure the lift truck is equipped with a lighting
connecting corresponding link, it should be system as required by conditions.
suspected of being broken inside of its bore hole.
Make sure all hydraulic controls are in the HOLD
Inspect the chain anchor and the anchor links for position.
wear.
Make sure the direction control lever is in the
Do not change any factory set adjustment values NEUTRAL position.
(including engine rpm setting) unless you have both
authorization and training. Especially Safety Make sure the parking brake is engaged.
equipment and switches may not be removed or
adjusted incorrectly. Repairs, adjustments and Make sure no one is standing and/or working on,
maintenances that are not correct can make a underneath or close to the lift
l ift truck before operating
dangerous operating condition. the lift truck.

For any checkup, repair, adjustments, maintenance Operate the lift truck and controls only from the
and all other work concerning your forklift truck, operator's station.
please contact your DOOSAN dealer. We would
like to draw your attention to the fact that any
secondary damages due to improper handling,
insufficient maintenance, wrong repairs or the use
of other than original DOOSAN spare parts waive
any liability by DOOSAN.
DOOSAN.

-11-
 

Safety Section

Make sure the lift truck horn,

h orn, lights, backup alarm (if Operating the Lift Truck
equipped) and all other devices are working
properly.
Always keep the lift truck under
und er control.
Check for proper operation of mast and
attachments. Pay particular attention to unusual Obey all traffic rules and warning signs.
noises or erratic movement which might indicate a
problem. Never leave the lift truck with the engine operating,
or with the parking
par king brake disengaged.
Make sure service and parking brakes, steering,
and directional controls are operational. Operate the engine only in a well ventilated area.

Make sure all personnel are clear of lift truck and Lower a mast, with or without load, before turning
travel path. or traveling. Tip over could result. Watch out for
overhead obstructions.
Refer to the topic “Lift Truck Operation” in the
“Operation Section” of this manual for specific Always observe floor load limits and overhead
starting instructions. clearance.

Start, turn, and brake smoothly. Slow down for

Starting the Lift truck turns, grades, slippery or uneven surfaces.
s urfaces.

Do not start the engine or move any of the controls

if there is a “DO NOT OPERATE” or similar warning Use special care when operating on grades. Do not
tag attached to the start switch or controls. angle across or turn on grades. Do not use lift truck
on slippery grades. Travel with forks downgrade
Before Operating the Lift Truck when unloaded. Travel with load upgrade.

Test brakes, steering controls, horn and other Do not overload, or handle offset, unstable, or
devices for proper operation. Report any faulty loosely stacked loads. Refer to load capacity plate
performance. Do not operate lift truck until repaired. on the lift truck. Use extreme caution when
handling suspended, long, high or wide load.
Learn how your lift truck operates. Know its safety
devices. Know how the attachments work. Before
moving the lift truck, look around. Start, turn and
brake smoothly.

An operator must constantly observe his lift truck

for proper operation.

-12-
 

Safety Section

  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 truck or trailer brakes are applied and wheel
chocks in place (or be certain unit is locked to the
loading dock) before entering onto trucks or trailers.

If trailer is not coupled to tractor, make sure the

trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
prevent upending or corner dipping.

Tilt the elevated load forward only when directly Be certain dock plates are in good condition and
over unloading area and with load as low as properly placed and secured. Do not exceed the
possible. rated capacity of dock boards or bridge plates.

Do not stunt ride or indulge in horseplay. Lift Truck Parking

When leaving the operator station, park the lift truck
Always look and keep a clear view of the path of
in authorized areas only. Do not block traffic.
travel.

Travel in reverse if load or attachment obstructs

visibility. Use extreme caution if visibility is
obstructed.

Stay in designated
ditches, traveland
other drop-offs path, clear ofwhich
surfaces dock edges,
cannot
safely support the lift truck.

Slow down and use extra care through doorways,

intersections and other location where visibility is
reduced.

Slow down for cross aisles, turns, ramps, dips,

uneven or slippery surfaces
sur faces and in congested areas,
   Park the lift truck level, with the forks lowered and
avoid pedestrians, other vehicles, obstruction, pot
the mast tilted forward until the fork tips touch the
holes and other hazards or objects in the path of
floor.
travel.
   Move the direction control lever to NEUTRAL.
Always use overhead guards except where
operation conditions do not permit. Do not operate
   Engage the parking brake.
lift truck in high stacking areas without overhead

guards.    Turn the key switch off and remove the key.
When stacking, watch for falling objects. Use load
   Turn the disconnect switch to OFF
O FF (if equipped).
backrest extension and overhead guard.
   Block the drive wheels when parking on an
Refer to the topic “Operation Techniques” in the
incline.
“Operation Section” of this manual.

-13-
 

Safety Section

Maintenance Information They will throw or cut any object or tool that falls or
is pushed into them.
Perform all maintenance unless otherwise
o therwise specified
specified
as follows: Do not use a kinked or frayed wire rope cable.
Wear gloves when handling the wire rope cable.
 Park the lift truck in authorized areas only.
 
   Park the lift truck level, with the forks lowered and Retainer pins, when struck with force, can fly out
the mast tilted forward until the fork tips touch the and injure nearby persons. Make sure the area is
floor. clear of people when driving retainer pins.
  
 Place thethe
Engage
  transmission controls in neutral.
parking brake. Wear protective glasses when striking a retainer pin
   Stop the engine. to avoid injury to your eyes.
   Remove the start switch key and turn the
disconnect switch OFF (if equipped). Chips or other debris can fly off objects when struck.
   Block the drive wheels when parking on an Make sure no one can be injured by flying debris
incline. before striking any object.

Pressure Air Falling Objects Protective Structure (FOPS)

Pressure air can cause personal injury. When using This is an attached guard located above the
pressure air for cleaning, wear a protective face operator's compartment and secured to the lift
shield, protective clothing and protective shoes. truck.

The maximum air pressure must be below 205 kPa To avoid possible weakening of the Falling Objects
(30 psi) for cleaning purposes. Protective Structure (FOPS), consult a DOOSAN
dealer before altering, by adding weight to, welding
on, or cutting or drilling holes into the structure.
Fluid Penetration
 Always use a board or cardboard when checking The overhead guard is not intended to protect
for a leak. Escaping fluid under pressure, even a against every possible impact. The overhead guard
pinhole size leak, can penetrate body tissue, may not protect against some objects penetrating
causing serious injury, and possible death. If fluid is into the operator's station from the sides or ends of
injected into your skin, it must be treated by a the lift truck.
doctor familiar with this type  of injury immediate
i mmediately.
ly.
The lift truck is equipped with an overhead guard
and FOPS as standard. If there is a possibility of
Crushing or Cutting Prevention overhead objects falling through the guard, the
Support equipment and attachments properly when guard must be equipped with smaller holes or a
working beneath them. Do not depend on hydraulic Plexiglas cover.
cylinders to hold it up. Any attachment can fall if a
control is moved, or if a hydraulic line breaks.
b reaks. Any altering done that is not specifically authorized
by DOOSAN invalidates DOOSAN's FOPS
Never attempt adjustments while the lift truck is certification. The protection offered by this FOPS
moving or the engine is running unless otherwise will be impaired if it has
ha s been subjected to structural
specified. damage. Structural damage can be caused by an
overturn accident, by falling objects, etc.
Where there are attachment linkages, the
clearance in the linkage area will increase or Do not mount any item such as fire extinguishers,
decrease with movement of the attachment. first aid kits and lights by welding brackets to or
drilling holes in any FOPS structure. See your
Stay clear of all rotating and moving parts. DOOSAN dealer for mounting guidelines.

Keep objects away from moving fan blades.

-14-
 

Safety Section

Burn Prevention Fire or Explosion Prevention

Coolant All fuels, most lubricants and some coolant
mixtures are flammable.
At operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines to Fuel leaked or spilled onto hot surfaces
su rfaces or electrical
heaters or the engine contain hot water or steam. components can cause a fire.
Any contact can cause severe burns.
b urns.
Do not smoke while refueling or in a refueling area.
Steam can cause personal injury.
Do not smoke in areas where batteries
ba tteries are charged,
Check the coolant level only after engine has been or where flammable materials are stored.
sto red.
stopped and the filter cap is cool enough to remove
with your bare hand. Batteries in series can be located in separate
compartments. When using jumper cables always
Remove the cooling system filter cap slowly to connect positive(+) cable to positive(+) terminal of
relieve pressure. battery connected to starter solenoid and
negative(-) cable from external source to starter
Cooling system additive contains alkali that can negative(-) terminal.
cause personal injury. Avoid contact with the skin (If not equipped with starter negative(-) terminal,
and eyes and do not drink.
d rink. connect to engine block.)
Allow cooling system components to cool before See the Operation Section of this manual for
draining. specific starting instructi
in structions.
ons.
Oils Clean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have all
Hot oil and
Do not components
allow can cause personal
hot oil or components injury.
to contact the loose or frayed electrical wires tightened, repaired
skin. or replaced before operating the lift truck.

At operation temperature, the hydraulic tank is hot Keep all fuels and lubricants stored in properly
and can be under pressure. marked containers and away from all unauthorized
persons.
Remove the hydraulic tank filter cap only after the
engine has been stopped and the filter cap is cool Store all oily rags or other flammable material in a
enough to remove with your bare hand. protective container, in a safe place.

Remove the hydraulic tank filter cap slowly to Do not weld or flame cut on pipes or tubes that
relieve pressure. contain flammable fluids. Clean them thoroughly
with nonflammable solvent before welding or flame
Relieve all pressure in air, oil fuel or cooling cutting on them.
systems before any lines, fittings or related items
are disconnected or removed. Remove all flammable materials such as fuel, oil
and other debris before they accumulate on the lift
Batteries truck.

Batteries give off flammable fumes which can Do not expose the lift truck to flames, burning
bu rning brush,
explode. etc., if at all possible.

Do not smoke when observing the battery Shields, which protect hot exhaust components
electrolyte levels. from oil or fuel spray in the event of a line, tube or
seal failure, must be installed correctly.
Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes.
e yes. Do not operate in areas where explosive gases
exist or are suspected.
Always wear protective glasses when working with
batteries.

-15-
 

Safety Section

Fire Extinguisher  End fittings damaged or leaking.

 
   Outer covering chafed or cut and wire reinforcing
Have a fire extinguisher-type BC and 1.5KG exposed.
minimum capacity-on rear overhead guard leg with    Outer covering ballooning locally.
latch and know how to use it. Inspect and have it    Evidence of kinking or crushing of the flexible
serviced as recommended on its instruction plate. part of hose.
   Armoring embedded in the outer
ou ter cover.
Ether    End fittings displaced.

Ether is poisonous and flammable.

Breathing ether vapors or repeated contact of ether Make sure that

are installed all clamps,
correctly guardsvibration,
to prevent and heat rubbing
shields
with skin can cause personal injury. against other parts, and excessive heat during
operation.
Use ether only in well-ventilated
well-ventilated areas.
Do not smoke while changing ether cylinders. Tire Information
Explosions of air-inflated tires have resulted from
Use ether with care to avoid fires. heat-induced gas combustion inside the tires. The
heat, generated by welding or heating rim
Do not store replacement ether cylinders in living components, external fire, or excessive use of
areas or in the operator's compartment. brakes can cause gaseous combustion.
Do not store ether cylinders in direct sunlight or at A tire explosion is much more violent than a
temperatures
tempe ratures above 39°C
39°C (102°
(10 2°F).
F). blowout. The explosion can propel the tire, rim and
axle components as far as 500 m (1500 ft) or more
Discard cylinders in a safe place. Do not puncture from the lift truck. Both the force of the explosion
or burn cylinders.
c ylinders. and the flying debris can cause personal injury or
Keep ether cylinders out of the reach of death, and property damage.
unauthorized personnel.

Lines, Tubes and Hoses

Do not bend or strike high pressure lines. Do not
install bent or damaged lines, tubes or hoses.

Repair any loose or damaged fuel and oil lines,

tubes and hoses. Leaks can cause fires. Contact
your DOOSAN dealer for repair or replacement.

Check lines, tubes and hoses carefully. Do not use

your 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 Do not approach a warm tire closer than the
connections to the recommended torque. Replace if outside of the area represented by the shaded area
any of the following conditions are found. in the above drawing.

-16-
 

Safety Section

Dry nitrogen (N2) gas is recommended for inflation Operator Restraint System(If
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure. Equipped)
Nitrogen mixes properly with air.
Warning Signs and Labels
Nitrogen inflated tires reduce the potential of a tire Your DOOSAN lift truck has the following tipover
explosion, because nitrogen does not support warning decals.
combustion. Also, nitrogen helps prevent oxidation
and the resulting deterioration of rubber and Make sure that you can read all safety signs. Clean
corrosion of rim components. or replace these if you cannot read the words or
see the pictures. When cleaning the labels use a
Proper nitrogen inflation equipment and training in cloth, water and soap. Do not
no t use solvent, gasoline,
its use are necessary to avoid over-inflation. A tire etc. You must replace a label if it is damaged,
blowout or rim failure can result from improper or missing or cannot be read. If a label is on a part
misused equipment. that is replaced, make sure a new label is installed
on the replaced part. See you DOOSAN Lift Truck
Stand behind the tread and use a self-attaching dealer for new labels.
chuck when inflation a tire. The most effective method of preventing serious
injury or death to yourself or others is to familiarize
Servicing, changing tires and rims can be yourself with the proper operation of the lift truck, to
dangerous and should be done only by trained be alert, and to avoid actions or conditions which
personnel using proper tools and procedures. If can result in an accident.
correct procedures are not followed while servicing
tires and rims, the assemblies could burst with
explosive force and cause serious personal injury WARNING
or death. Follow carefully the specific information
Tipover can occur if the truck is improperly
provided by your tire or rim servicing personnel or
dealer. operated. In the event of tipover, injury or death
could result.

-17-
 

Safety Section

  If Optional Suspension Seat (weight

adjusting type) Equipped

Forward and Backward Adjustment

The seat can be adjusted by pushing the lever on

the right side of seat.

The “Survive in tipover” warning is located on the

overhead guard. It shows the proper use of the Forward and Backward
operator restraint system. Adjustment

Seat Adjustment

Adjust the seat before operating the lift truck.

After adjusting, set the seat to make sure it is
properly locked. Do not adjust the seat while the
truck is in motion .

Move the lever, slide the seat to the desired

position, and release the lever.
l ever.

Adjust the seat before operating the lift truck. After

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 moves up
and down.

-18-
 

Safety Section

Weight adjustment Seat Belt

The Operator Restraint System, Prevents the
Pull the weight adjustment lever upwards anda nd move operator from jumping from the operator’s
right or left side. compartment in the event of a forward or side
Adjust to driver’s weight in 7 steps (50 ~ 110 kg) tipover. The system is designed to keep the
operator on the seat and in the operator’s
compartment in the event of a tipover.
NOTICE
Inspection
Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and down. 
down. 

1.  If the seat belt is torn, if pulling motion is

interrupted during extension of the belt, or if the
belt cannot be inserted into the buckle properly,
replace the seat belt
bel t assembly.
Backrest Inclination

The backrest angle can be adjusted by using the

lever on the left side of
o f seat.

2.  Belt Maintenance - Every 500 service hours.

Check that the belt fastening works properly
and that winding device is free from run lock
when jerked. Check that the belt is suitably
fastened to the seat. Check that the seat is
correctly secured to the hood and the chassis.
On visual inspection, fastenings must be intact,
otherwise, contact the safety manager.

WARNING
Your DOOSAN truck comes equipped with a
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DOOSAN operator restraint system.

-19-
 

Safety Section

 
WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen
a bdomen in an accident.

3.  In the event of a tipover, the seat and restraint

system should be inspected for damage and
replaced, if necessary.

NOTE:  Operator restraints shall be examined at

the regular truck service intervals. It is
recommended that they be replaced if any
of the following
fo llowing conditions are found:

• Cut or frayed strap

• Worn or damaged hardware including anchor
points

• Buckle or retractor malfunction

• Loose stitching

WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered 3.  Be sure to fasten the belt across your hips, not
from some abdominal disease, consult a doctor across your abdomen.
before you use the seat belt.
be lt.
NOTE:  The belt is designed to automatically adjust
to your size and movement. A quick pull on
Fasten the Seat Belt
the belt will confirm that the automatic
adjuster will hold the belt position in the
event of an accident.

Release the Seat Belt

1. Grip the plate (connector) of the belt and pull the

1. Grip
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 it is
i s latched.
Push the button of the buckle to release the belt.
2. Make sure the belt is not twisted. The belt will automatically retract when released.
Hold the plate of the belt and allow the belt to
slowly retract.

-20-
 

Safety Section

Avoiding Lift Truck Tipover Stability and Center of Gravity

Lift Truck Stability

The stability of the lift truck is determined by the

Counterbalanced lift truck design is based on the location of its CG; or, if the truck is loaded, the
balance of two weights on opposite sides of a combined CG of the truck and load. The lift truck
fulcrum (the front axle). The load on the forks must has moving parts and, therefore, has a CG that
be balanced by the weight of the lift truck. The moves. The CG moves forward or backward as the
location of the center of gravity of both the truck mast is tilted forward or backward. The CG moves
and the load is also a factor. This basic principle is up or down as the mast moves up or down. The CG
used for picking up a load. The ability of the lift and, therefore, the stability of the loaded lift truck,
truck to handle a load is discussed in terms of are affected by a number of factors such as:
  both forward and sideways   
center of
stability.  gravity and the size, weight, shape and position of the load
   the height to which the load is lifted
li fted

Center of Gravity (CG)    the amount of forward or backward tilt

   tire pressure

   dynamic forces created when the lift truck is

accelerated, braked or turned

   condition and grade of surfaces on which the lift

truck is operated

The point within an object, at which the whole

weight of the object may be regarded as being
concentrated, is called the center of gravity or CG.
If the object is uniform, its geometric center will
coincide with its CG. If it is not uniform, the CG
could be at a point outside of the object. When the
lift truck picks up a load, the truck and load have a
new combined CG.
These same factors are also important
i mportant for unloaded
lift trucks. They tip over sideways easier than a
loaded lift truck carrying its load in the lowered
position.

-21-
 

Safety Section

Lift Truck Stability Base Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
mast, and having no special-purpose attachment.
In addition, the capacity load assumes that the load
center is no further from the top of the forks than it
is from the face of the backrest. If these conditions
do not exist, the operator may have to reduce the
safe operating load because the truck stability may

be
its reduced. The lift truck
capacity/nameplate should
does not not be operated
indicate if
capacity
load.

NOTE:   If the
NOTE: the load is not
not uniform, the heaviest
portion should be placed closer to the
backrest and centered on the forks.
For the lift truck to be stable (not tip over forward or
to the side), the CG must stay within the area of the
lift truck stability base – a triangular area between NOTICE
the front wheels and the pivot of the steer wheels. If 1. Capacity/Nameplates originally attached to
the CG moves forward of the front axle, the lift truck forklifts sold by DOOSAN shall not be removed,
will tip forward. If the CG moves outside of the line altered or replaced without DOOSAN’s approval.
on either side of the stability base, the lift truck will
tip to the side. 2. DOOSAN assumes no responsibility for lift trucks
placed in service without a valid DOOSAN
WARNING Nameplate.

Dynamic forces (braking, acceleration, turning) 3. If necessary

nece ssary to change your specification, contact
also affect stability and can produce tipover your DOOSAN lift truck dealer.
even when the CG is within the stability
triangle.

Capacity Load (Weight and Load Center)

The capacity load of the lift truck is shown on the

capacity/nameplate riveted to the truck. It is
determined by the weight and load center. The load
center is determined by the location of the CG of
the load.

The load center shown on the nameplate is the

horizontal distance from the front face of the forks,
or the load 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.
dimension.

-22-
 

Safety Section

Safety Rules

Do not operate a lift truck unless you are in the

operator’s seat.
seat. Keep hands and feet inside the
Only properly trained and authorized personnel operator’s compartment. Do not put anyany part of
should operate forklift trucks. Wear a hard hat and the body outside of the operator’s compartment.
safety shoes when operating a lift truck. Do not Never put any part of body into the mast structure
wear loose clothing. or between the mast and the truck

Inspect and check the condition of your forklift truck Do not start, stop, turn or change direction
using the operator's check list before starting work. suddenly or at high speed. Sudden movement can
Immediately report to your supervisor any obvious cause the lift truck to tip over. Slow the speed of
defects or required repairs. your truck and use the horn near corners, exits,
entrances, and near people.

Do not operate your truck in unauthorized areas.

Know your forklift truck and think
th ink safety. Never operate a lift truck with wet hands or shoes.
Do not compromise safety. Never hold any controls with grease on your
yo ur hands.
Follow all safety rules and read all warning signs. Your hands or feet will slide off of the controls and
cause an accident.

-23-
 

Safety Section

Do not raise anyone on the forks ofo f your lift truck. Do not overload. Always handle loads within the
Do not let other people ride on the truck. rated capacity shown on the capacity plate.
Lift trucks are designed to carry loads, not people. Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.

Do not operate your truck without the load backrest

extension and overhead guard. Keep the load
against the backrest with the mast tilted backward
Do not drive on soft ground.
Observe all signs, especially those on maximum
permitted floor loadings, elevator capacities and
clearance heights.
Handle loads carefully and check them closely for
stability and balance.

Do not lift or move loads that are not safe. Do not

pick up an off center load. Such a load increases
the possibility of a tipover to the side. Make sure
loads are correctly stacked and positioned across
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 Do not drive on slippery surfaces.
balance. Do not lift a load with one fork. Sand, gravel, ice or mud can cause a tipover.
If unavoidable, slow down.

-24-
 

Safety Section

Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward.
for ward.
load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards.
cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.

Look out for overhead obstructions when raising or Do not jump off if your truck
tru ck starts to tip over.
stacking loads. Do not travel with a raised load. Do Stay in your seat to survive.
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.

Go up ramps in forward direction and down ramps

in reverse direction when moving loads.
Never elevate a load with the forklift truck on an
Do not move loose loads that are higher than the incline.
load backrest. Go straight off and straight down. Use an assistant
Be alert for falling loads when stacking. when going up or down a ramp
ra mp with a bulky load.
Travel with the load tilted back and the forks as low
as possible.
possible.
This will increase stability to the truck and load and
permit better visibility for you.

-25-
 

Safety Section

Do not stack or turn on ramps.

r amps.
Do not drive in forward direction when loads restrict
Do not attempt to pick-up or deposit a load unless
your visibility. Operate your lift truck in reverse to
the lift truck is level. Do not turn on or drive across
an incline. improve visibility except when moving up a ramp.

Be careful when operating a lift truck near the edge

Do not go over rough terrain. If unavoidable, slow
of a loading dock or ramp. Maintain a safe distance
down.
from the edge of docks, ramps and platforms.
Cross railroad tracks slowly and diagonally
Always watch tail swing.
whenever possible. A railroad crossing can give a
loaded forklift truck a real jolt. For smoother The truck can fall over the edge and cause injury or
death.
crossing, cross the railroad diagonally so one wheel
crosses at a time.

Do not operate on bridge plates unless they can

support the weight of the truck and load.
Avoid running over loose objects.
obje cts.
Make sure that they
th ey are correctly positioned.
Look in the direction of travel. Look out for other
persons or obstructions in your path of travel. Put blocks on the vehicle you enter to keep it from
moving.
An operator must be in full control of his lift truck at
all times.

-26-
 

Safety Section

Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully
Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in
make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and
Never overtake other vehicles. turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work.

Do not use your lift truck to push or tow another

truck.
Do not let another push or tow
to w your truck.
If a truck will not move, call a service
se rvice technician.
Exhaust from all internal combustion engines
contains carbon monoxide, a colorless, odorless,
tasteless, poisonous gas. Exposure to carbon
monoxide can cause serious injury or health
problems, including death and avoid unnecessary
idling of the engine. If nausea, dizziness or
headaches are experienced stop the truck and
seek fresh air.

Forklift trucks may only be refueled at specially

reserved locations. Switch off the engine when
refueling.
Smoking and handling of naked flames during
refueling are strictly prohibited. This prohibition
p rohibition also
applies during the changing of the LPG (liquefied
propane gas) tank.
Mop up spilt fuel and do not forget to close the fuel
tank before restarting the engine.

-27-
 

Safety Section

How to Survive in a Tipover

WARNING
In 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.

Hold on tight.

Always use operator restraint system.

Brace your feet and keep them within the operator’s

compartment.

Don’t jump.

-28-
 

Safety Section

Lean away from the direction of fall.

Lean forward.

-29-
 

General Section

Specifications
CHARACTERISTICS
1 MANUFACTURER DOOSAN DOOSAN
D20S-5 D25S-5
2 MODEL
(YANMAR,TIER2) (YANMAR,TIER2)
3 CAPACITY at rated load center kg 2000 2500
4 LOAD CENTER distance mm 500 500
5 POWER TYPE elect
electric
ric , diesel, gas, LPG-gas diesel diesel
6 OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated
7 TIRES C=cushion, P=pneumatic p p
8 WHEELS(x=driven) number of front/rear 2/2 2/2
DIMENSIONS
9 LIFT WITH STD maximum fork height with rated load mm 3230 3230
10 TWO-STAGE MAST free lift mm 152 152
11 FORK CARRIAGE ISO class II II
12 thickness x width x length mm 40x100x105
40x100x1050
0 40x100x1050
40x100x1050
FORKS
13 fork spacing (maximum x minimum) mm 275x1035 275x1
275x1035035
14 TILT OF MAST forward/backw
forward/backwardard deg 6/10 6/10
15 length to fork face mm 2530 2595
16 width mm 1170 1170
17 OVERALL mast lowered height mm 2175 2175
18 DIMENSIONS mast extended height mm 4490 4490
19 overhead guard height mm 2183 2183
20 seat height mm 1026 1026
21 OUTSIDE TURNING RADIUS mm 2220 2265
22 LOAD MOMENT CONSTANT mm 480 480
。

23
23 90   STAC
STACKING
KING AISLE mm 2700 2745
90。   INTERSECTING
INTERS ECTING AISLE mm 1970 2000
a
PERFORMANCE
24 travel, loaded/un
loaded/unloaded
loaded km/hr 21/21.5 21/21.5
25 SPEED lift, loaded/unloaded
loaded/un loaded mm/s 530/550 520/550
26 lowering, loaded/unl
loaded/unloaded
oaded mm/s 510/460 510/460
27 DRAWBAR
DRAWBA R PULL at 1.6km/hr
1.6km/hr,, loaded/u
loaded/unloaded
nloaded kg 1765 1740
28 GRADEABILITY
GRADEA BILITY at 1.6km/hr
1.6km/hr,, loaded/u
loaded/unloaded
nloaded % 33 28
time reached at max speed,
29 ACCELERATION sec
loaded/unloaded
WEIGHT
30 TOTAL WEI
WEIGHT
GHT at unloaded kg 3580 3950
31 at loaded,
loaded , front/r
front/rear
ear kg 4930/650 5660/790
AXLE LOAD
32 at unloaded, front/r
front/rear
ear kg 1720/1860 1650/2300
CHASSIS
33 number of front/r
front/rear
ear 2/2 2/2
34 TIRES front size 7.00x15-12 7.00x15-12
35 rear size
siz e 6.50x10-10 6.50x10-10
36 WHEE L BASE mm 1625 1625
37 TREAD
TREA D front/rear mm 975/1000 975/1000
38 GROUND at loaded,
loaded , the lowest point mm 115 115
39 CLEARANCE at loaded, center of wheelbase mm 143 143
40 SEVICE BRAKE foot/hyd foot
foot/hyd
/hyd
41 PARKING BRAKE hand/mech hand/mech
DRIVE
42 BATTERY voltage/capacity
voltage/capacity V/AH 12/85 12/85
43 manufacturer/model
manufacturer /model YANMAR/4TNV 98 YANMAR/4 TNV98
44 ENGINE rated output / rpm kw(hp) 46.3(62.1)/2200
46.3(62.1)/22 00 46.3(62.1)/2200
45 max.
max. torq
torque
ue / rpm
rpm N-m(
N-m(lb•
lb•ft
ft)) 240(
240(17
1777)/1
)/13
320 240(
240(17177
7)/1
)/13
320
46 cycle/cylinders/displacement
cycle/cylinders/displacement cc 4/4/3319 4/4/3319
47 type powershiftt
powershif powershift
TRANSMISSION
48 number of speeds forward/
forward/reverse
reverse 1/1 1/1
OPERATING
49 system/attachment
system /attachment bar 181/156 195/156
PRESSURE
equivelent continuous sound
50 NOISE LEVEL pressure level (Leq) at operator's ear dB(A)
(DI : BITA/CE prEN 12053)

-30-
 

General Section

DOOSAN DOOSAN DOOSAN 1

D30S-5 D33S-5 D35C-5
2
(YANMAR,TIER2) (YANMAR,TIER2) (YANMAR,TIER2)
3000 3250 3500 3
500 500 500 4
diesel diesel diesel 5
rider-seated rider-seated rider-seated 6
p p p 7
2/2 2/2 2/2 8

3230 3230 3000 9

152 152 152 10
III III III 11
45x125x1050 45x125x1050 45x125x1050 12
286x1044 286x1044 286x1044 13
6/10 6/10 6/10 14
2700 2730 2765 15
1197 1197 1255 16
2165 2165 2165 17
4490 4490 4260 18
2183 2183 2183 19
1026 1026 1026 20
2365 2395 2420 21
485 485 495 22
2850 2880 2915 23
2050 2100 2170 23a
 
20/20.5 20/20.5 20.5/21 24
500/550 490/550 480/550 25
510/460 510/460 510/460 26
1830 1820 1750 27
25 23.5 21.5 28
  29

 
4450 4630 4810 30
6580/870 6940/940 7340/970 31
1840/2610 1800/2830 1780/3030 32
 
2/2 2/2 2/2 33
28x9x15-12 28x9x15-12
28x9x15-1 2 250x15-18 34
6.50x10-10 6.50x10-12 6.50x10-12 35
1700 1700 1700 36
982/1000 982/1000 1026/1000 37
105 105 105 38
143 143 143 39
foot/hyd foot/hyd foot/hyd 40
hand/mech hand/mech hand/mec
hand/mech h 41
 
12/85 12/85 12/85 42
YAN
ANMA
MAR/
R/4T
4TNV
NV98
98 YA
YANM
NMAR
AR//4TNV
4TNV98
98 YAN
ANMA
MAR/
R/4T
4TNV
NV98
98 43
46.3(62.1) /2200 46.3(62.1)/
46.3(62.1)/2200
2200 4
46.3(62
6.3(62.1)/2200
.1)/2200 44
240(177)/1320 240(177)/1
240(177)/1320
320 240(177)/1
240(177)/1320320 45
4/4/3319 4/4/3319 4/4/3319 46
powershift powershift powershift 47
1/1 1/1 1/1 48
216/156 216/156 216/156 49

  50

-31-
 

General Section

Specifications
CHARACTERISTICS
1 MANUFACTURER DOOSAN DOOSAN
D20S-5 D25S-5
2 MODEL
(YANMAR,TIER3) (YANMAR,TIER3)
3 CAPACITY at rated load center kg 2000 2500
4 LOAD CENTER distance mm 500 500
5 POWER TYPE elect
electric
ric , diesel, gas, LPG-gas diesel diesel
6 OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated
7 TIRES C=cushion, P=pneumatic p p
8 WHEELS(x=driven) number of front/rear 2/2 2/2
DIMENSIONS
9 LIFT WITH STD maximum fork height with rated load mm 3230 3230
10 TWO-STAGE MAST free lift mm 152 152
11 FORK CARRIAGE ISO class II II
12 thickness x width x length mm 40x100x105
40x100x1050
0 40x100x1050
40x100x1050
FORKS
13 fork spacing (maximum x minimum) mm 275x1035 275x1
275x1035035
14 TILT OF MAST forward/backw
forward/backwardard deg 6/10 6/10
15 length to fork face mm 2530 2595
16 width mm 1170 1170
17 OVERALL mast lowered height mm 2175 2175
18 DIMENSIONS mast extended height mm 4490 4490
19 overhead guard height mm 2183 2183
20 seat height mm 1026 1026
21 OUTSIDE TURNING RADIUS mm 2220 2265
22 LOAD MOMENT CONSTANT mm 480 480
。

23
23 90   STAC
STACKING
KING AISLE mm 2700 2745
90。   INTERSECTING
INTERS ECTING AISLE mm 1970 2000
a
PERFORMANCE
24 travel, loaded/un
loaded/unloaded
loaded km/hr 19/19.5 19/19.5
25 SPEED lift, loaded/unloaded
loaded/un loaded mm/s 530/550 520/550
26 lowering, loaded/unl
loaded/unloaded
oaded mm/s 510/460 510/460
27 DRAWBAR
DRAWBA R PULL at 1.6km/hr
1.6km/hr,, loaded/u
loaded/unloaded
nloaded kg 1765 1740
28 GRADEABILITY
GRADEA BILITY at 1.6km/hr
1.6km/hr,, loaded/u
loaded/unloaded
nloaded % 33 28
time reached at max speed,
29 ACCELERATION sec
loaded/unloaded
WEIGHT
30 TOTAL WEI
WEIGHT
GHT at unloaded kg 3580 3950
31 at loaded,
loaded , front/r
front/rear
ear kg 4930/650 5660/790
AXLE LOAD
32 at unloaded, front/r
front/rear
ear kg 1720/1860 1650/2300
CHASSIS
33 number of front/r
front/rear
ear 2/2 2/2
34 TIRES front size 7.00x15-12 7.00x15-12

35
36 WHEE L BASE rear size
siz e mm 6.50x10-10
1625 6.50x10-10
1625
37 TREAD
TREA D front/rear mm 975/1000 975/1000
38 GROUND at loaded,
loaded , the lowest point mm 115 115
39 CLEARANCE at loaded, center of wheelbase mm 143 143
40 SEVICE BRAKE foot/hyd foot
foot/hyd
/hyd
41 PARKING BRAKE hand/mech hand/mech
DRIVE
42 BATTERY voltage/capacity
voltage/capacity V/AH 12/85 12/85
43 manufacturer/model
manufacturer /model YANMAR/4TNE 98 YANMAR/4 TNE98
44 ENGINE rated output / rpm kw(hp) 43.7(58.6)/2300
43.7(58.6)/23 00 43.7(58.6)/2300
45 max.
max. torq
torque
ue / rpm
rpm N-m(
N-m(lb•
lb•ft
ft)) 181(
181(13
1333)/1
)/16
600 181(
181(13133
3)/1
)/16
600
46 cycle/cylinders/displacement
cycle/cylinders/displacement cc 4/4/3319 4/4/3319
47 type powershiftt
powershif powershift
TRANSMISSION
48 number of speeds forward/
forward/reverse
reverse 1/1 1/1
OPERATING
49 system/attachment
system /attachment bar 181/156 195/156
PRESSURE
equivelent continuous sound
50 NOISE LEVEL pressure level (Leq) at operator's ear dB(A)
(DI : BITA/CE prEN 12053)

-32-
 

General Section

DOOSAN DOOSAN DOOSAN 1

D30S-5 D33S-5 D35C-5
2
(YANMAR,TIER3) (YANMAR,TIER3) (YANMAR,TIER3)
3000 3250 3500 3
500 500 500 4
diesel diesel diesel 5
rider-seated rider-seated rider-seated 6
p p p 7
2/2 2/2 2/2 8

3230 3230 3000 9

152 152 152 10
III III III 11
45x125x1050 45x125x1050 45x125x1050 12
286x1044 286x1044 286x1044 13
6/10 6/10 6/10 14
2700 2730 2765 15
1197 1197 1255 16
2165 2165 2165 17
4490 4490 4260 18
2183 2183 2183 19
1026 1026 1026 20
2365 2395 2420 21
485 485 495 22
2850 2880 2915 23
2050 2100 2170 23a
 
18/18.5 18/18.5 18.5/19 24
500/550 490/550 420/550 25
510/460 510/460 510/460 26
1830 1820 1750 27
25 23.5 21.5 28
  29

 
4450 4630 4810 30
6580/870 6940/940 7340/970 31
1840/2610 1800/2830 1780/3030 32
 
2/2 2/2 2/2 33
28x9x15-12 28x9x15-12
28x9x15-1 2 250x15-18 34
6.50x10-10 6.50x10-12 6.50x10-12 35
1700 1700 1700 36
982/1000 982/1000 1026/1000 37
105 105 105 38
143 143 143 39
foot/hyd foot/hyd foot/hyd 40
hand/mech hand/mech hand/mec
hand/mech h 41
 
12/85 12/85 12/85 42
YAN
ANMA
MAR/
R/4T
4TNE
NE98
98 YA
YANM
NMAR
AR//4TNE
4TNE98
98 YAN
ANMA
MAR/
R/4T
4TNE
NE98
98 43
43.7(58.6) /2300 43.7(58.6)/
43.7(58.6)/2300
2300 4
43.7(58
3.7(58.6)/2300
.6)/2300 44
181(133)/1600 181(133)/1
181(133)/1600
600 181(133)/1
181(133)/1600600 45
4/4/3319 4/4/3319 4/4/3319 46
powershift powershift powershift 47
1/1 1/1 1/1 48
216/156 216/156 216/156 49

  50

-33-
 

General Section

Specifications
CHARACTERISTICS
1 MANUFACTURER
2 MODEL
3 CAPACITY at rated load center kg
4 LOAD CENTER distance mm
5 POWER TYPE electric, diesel, gas, LPG-gas
6 OPERATOR TYPE stand-on, ride-seated

7 TIRES C=cushion, P=pneumatic

8 WHEELS(x=driven)
WHEELS(x=driven) number of front/rea
front/rearr
DIMENSIONS
9 maximum fork height with rated load mm
LIFT WITH STD TWO-STAGE MAST
10 free lift mm
11 FORK
FORK CARRIAGE ISO class
12 thickness x width x length mm
FORKS
13 fork spacing (maximum x minimum) mm
14 TILT OF MAST forward/backward
forward/backw ard deg
15 length without forks mm
16 width mm
17 OVERALL mast lowered height mm
18 DIMENSIONS mast extended height mm
19 overhead guard height mm
20 seat height mm
21 OUTSIDE TURNING RADIUS mm
22 LOAD MOMENT CONSTANT mm
23 90   STACKING AISLE
。 mm
23a 90   INTERSECTING AISLE
。 mm
PERFORMANCE
24 travel, loaded/
loaded/unloaded
unloaded km/hr
25 SPEED lift, loaded/unloade
loaded/unloadedd mm/s
26 lowering, loaded/unl
loaded/unloaded
oaded mm/s
27 DRAWBAR PULL at 1.6km/hr, loaded/un
loaded/unloaded
loaded kg
28 GRADEABILITY
GRADEABILITY at 1.6km/hr, loaded/un
loaded/unloaded
loaded %
time reached at max speed,
29 ACCELERATION sec
loaded/unloaded
WEIGHT
30 TOTAL WEIGHT at unloaded kg
31 at loaded, front/re
front/rear
ar kg
AXLE LOAD
32 at unloaded, front/re ar kg
CHASSIS
33 number of front/rea
front/rearr
34 TIRES front size
35 rear size

36 WHEEL BASE mm
37 TREAD front/r
front/rear
ear mm
38 GROUND at loaded, the lowest point mm
39 CLEARANCE at loaded, center of wheelbase mm
40 SEVICE BRAKE
41 PARKING BRAKE
DRIVE
42 BATTERY voltage/
voltage/capacity
capacity V/AH
43 manufacturer/model
44 rated output / rpm kw(hp)
ENGINE
45 max. torque / rpm N•m(lb•ft)
46 cycle/cylinders/displacement cc
47 type
TRANSMISSION
48 number of spe eds forward/reverse
OPERATING
49 system/attachment bar
PRESSURE
equivelent continuous sound
50 NOISE LEVEL dB(A)
pressure level (Leq) at operator's ear (DI : BITA/CE prEN 12053)

-34-
 

General Section

DOOSAN DOOSAN DOOSAN 1

G20E-5 G25E-5 G30E-5 2
2000 2500 3000 3
500 500 500 4
LP LP LP 5
rider-sea ted rider-s eated rider-seate
rider-seatedd 6
p p p 7
2/2 2/2 2/2 8

3230 3230 3230 9

152 152 152 10
II II III 11
40x100x1050 40x100x1050
40x100x10 50 45x1 25x1050 12
275x1035 275x1035 286x1044 13
6/10 6/10 6/10 14
2530 2595 2700 15
1170 1170 1197 16
2175 2175 2165 17
4490 4490 4490 18
2183 2183 2183 19
1026 1026 1026 20
2220 2265 2365 21
480 480 485 22
2700 2745 2850 23
1970 2000 2050 23a
 
19/20 19/20 18/19 24
530/600 510/600 500/600 25
510/460 510/460 510/460 26
1440 1415 1485 27
27 22.5 20.5 28

  29
 
3570 3940 4380 30
4940/630 5670/770 6310/1050 31
1730/1840 1660/2280 1800/2580 32
 
2/2 2/2 2/2 33
7.00x15-12 7.00x15-12 28x9x15-12 34
6.50x10-10 6.50x10-10 6.50x10-10 35
1625 1625 1700 36
975/1000 975/1000 982/1000 37
115 115 105 38
143 143 143 39
foot/hyd foot/hyd foot/hyd 40
hand/mech hand/mech
hand/mec h hand/mech 41
 
12/45 12/45 12/45 42
G420F(E) G420F(E) G420F(E) 43
39.
39.9(5
9(53.5
3.5)/2
)/250
500
0 39.9
39.9(53.
(53.5)/
5)/250
2500
0 39
39.9
.9(53.
(53.5)/
5)/25
2500
00 44
157(116)/1600 157(116)/1600 157(116)/1600 45
4/4/1975 4/4/1975 4/4/1975 46
powershiftt
powershif powershift
powershif t powershift 47
1/1 1/1 1/1 48

181/156 195/156 216/156 49

  50

-35-
 

General Section

Specifications
CHARACTERISTICS
1 MANUFACTURER DOOSAN DOOSAN
2 MODEL G20P-5 G25P-5
3 CAPACITY at rated load center kg 2000 2500
4 LOAD CENTER distance mm 500 500
5 POWER TYPE electric, diesel, gas, LPG-gas lp lp
6 OPERATOR TYPE stand-on, ride-seated rider-seated rider-seated

7 TIRES C=cushion, P=pneumatic p p

8 WHEELS(x=driven) number
number of front/rear 2/2 2/2
DIMENSIONS
9 LIFT WITH STD maximum fork height with rated load mm 3230 3230
10 TWO-STAGE MAST free lift mm 152 152
11 FORK CARRIAGE ISO class II II
12 thickness x width x length mm 40x100x105
40x100x1050
0 40x100x105
40x100x1050
0
FORKS
13 fork spacing (maximum x minimum) mm 275x1035 275x1035
14 TILT OF MAST forward/b
forward/backward
ackward deg 6/10 6/10
15 length without forks mm 2530 2595
16 width mm 1170 1170
17 OVERALL mast lowered height mm 2175 2175
18 DIMENSIONS mast extended height mm 4490 4490
19 overhead guard height mm 2183 2183
20 seat height mm 1026 1026
21 OUTSIDE TURNING RADIUS mm 2220 2265
22 LOAD MOMENT CONSTANT mm 480 480
23 90   STACKING AISLE
。 mm 2700 2745
23a 90   INTERSECTING AISLE
。 mm 1970
1970 2000
PERFORMANCE
24 travel, loaded/unl
loaded/unloaded
oaded km/hr 19/20 19/20
25 SPEED lift, loaded/
loaded/unloaded
unloaded mm/s 530/600 510/600
26 lowering, loaded
loaded/unloaded
/unloaded mm/s 510/460 510/460
27 DRAWBAR
DRAWBA R PULL at 1.6km/hr
1.6km/hr,, loaded/unloade d kg 1750 1725
28 GRADEABILITY
GRADEA BILITY at 1.6km/hr,
1.6km/hr , loaded/unloade d % 33 28
time reached at max speed,
29 ACCELERATION sec
loaded/unloaded
WEIGHT
30 TOTAL WEIGHT at unloaded kg 3570 3940
31 at loaded, front/rear kg 4940/630 5670/770
5670/770
AXLE LOAD
32 at unloaded, front/r
front/rear
ear kg 1730/1840 1660/2280
CHASSIS
33 number of front/rear 2/2 2/2
34 TIRES front size 7.00x15-12 7.00x15-
7.00x15-12
12
35 rear size 6.50x10-10 6.50x10-10

36 WHEEL
WHEE L BASE mm 1625 1625
37 TREAD
TREA D front/r
front/r ear mm 975/1000 975/1000
38 GROUND at loaded, the lowest point mm 115 115
39 CLEARANCE at loaded, center of wheelbase mm 143 143
40 SEVICE BRAKE foot/hyd foot/hyd
41 PARKING BRAKE hand/mech hand/mech
DRIVE
42 BATTERY voltage/
voltage/capacity
capacity V/AH 12/65 12/65
43 manufacturer/model
manufacture r/model G424F(E) G424F(E)
44 rated output / rpm kw(hp) 47.7(64)/2550 47.7(64)/2550
ENGINE
45 max. torque / rpm N•m(lb•ft
N•m(lb•ft)) 182(135)/2200 182(135)/220
182(135)/2200 0
46 cycle/cylinders/displacement
cycle/cylinders/displacement cc 4/4/2405 4/4/2405
47 type powershiftt
powershif powershift
powershif t
TRANSMISSION
48 number of speeds forward/
forward/reverse
reverse 1/1 1/1
OPERATING
49 system/attachment
system /attachment bar 181/156 195/156
PRESSURE
equivelent continuous sound
50 NOISE LEVEL pressure level (Leq) at operator's ear dB(A)
(DI : BITA/CE prEN 12053)

-36-
 

General Section

DOOSAN DOOSAN DOOSAN 1

G30P-5 G33P-5 G35C-5 2
3000 3250 3500 3
500 500 500 4
lp lp lp 5
rider-seated rider-seated rider-seated 6
p p p 7
2/2 2/2 2/2 8

3230 3230 3000 9

152 152 152 10
III III III 11
45
45x12
x125x1
5x105
050
0 45x12
45x125x1
5x105
050
0 45
45x12
x125x1
5x1050
050 12
286x1044 286x1044 286x1044 13
6/10 6/10 6/10 14
2700 2730 2765 15
1197 1197 1255 16
2165 2165 2165 17
4490 4490 4260 18
2183 2183 2183 19
1026 1026 1026 20
2365 2395 2420 21
485 485 495 22
2850 2880 2915 23
2050 2100 2170 23a
 
18/19 18/19 18.5/19.5 24
500/600 500/600 420/600 25
510/460 510/460 510/460 26
1815 1805 1735 27
25.5 24 21.5 28

  29
 
4380 4560 4750 30
6310/1050 6890/920 7300/950 31
1800/2780 1760/2800 1750/3000 32
 
2/2 2/2 2/2 33
28x9x15-12 28x9x15-12 250x15-18 34
6.50x10-10 6.50x10-12 6.50x10-12
6.50x10-1 2 35
1700 1700 1700 36
982/1000 982/1000 1026/1000 37
105 105 105 38
143 143 143 39
foot/hyd foot/hyd foot/hyd 40
hand/mech hand/mech hand/mech 41
 
12/65 12/65 12/65 42
G424F(E))
G424F(E G424F(E) G424F(E) 43
47
47.7
.7(64
(64)/2
)/2550
550 47
47.7
.7(64
(64)/25
)/2550
50 47
47.7
.7(64
(64)/2
)/255
550
0 44
182(1
82(13 35)/
5)/2200
2200 182(1
82(1335)/2
5)/220
200
0 182(
182(13
135)
5)/2
/220
200
0 45
4/4/2405 4/4/2405 4/4/2405 46
powershiftt
powershif powershift powershift 47
1/1 1/1 1/1 48

216/156 216/156 216/156 49

  50

-37-
 

General Section

Specifications
CHARACTERISTICS
1 MANUFACTURER DOOSAN
2 MODEL GC20E-5
3 CAPACITY at rated load center kg 2000
4 LOAD CENTER distance mm 500
5 POWER TYPE elect
electric
ric , diesel, gas, LPG-gas LP
6 OPERATOR TYPE stand-on, ride-seated rider-seated

7
8 TIRES
WHEELS(x=driven) C=cushion
C=cushion,
number of ,front/rear
P=pneumatic C
2/2
DIMENSIONS
9 LIFT WITH STD maximum fork height with rated load mm 3230
10 TWO-STAGE MAST free lift mm 152
11 FORK CARRIAGE ISO class II
12 thickness x width x length mm 40x100x1050
40x100x1050
FORKS
13 fork spacing (maximum x minimum) mm 297x905
14 TILT OF MAST forward/backwar d deg 6/8
15 length without forks mm 2218
16 width mm 1110
17 OVERALL mast lowered height mm 2130
18 DIMENSIONS mast extended height mm 4480
19 overhead guard height mm 2150
20 seat height mm 1038
21 OUTSIDE TURNING RADIUS mm 2000
22 LOAD MOMENT CONSTANT mm 367
23 90   STACKING AISLE
。 mm 2367
23a 90   INTERSECTING AISLE
。
mm 1798
PERFORMANCE
24 travel, loaded/un
loaded/unloaded
loaded km/hr 16/16
25 SPEED lift, loaded/un
loaded/unloaded
loaded mm/s 530/600
26 lowering, loaded/u
loaded/unloaded
nloaded mm/s 510/460
27 DRAWBAR
DRAWBA R PULL at 1.6km/hr
1.6km/hr,, loaded/u
loaded/unloaded
nloaded kg 1795
28 GRADEABILITY at 1.6km/hr, loaded/unload
loaded/unloadeded % 35.5
time reached at max speed,
29 ACCELERATION sec
loaded/unloaded
WEIGHT
30 TOTAL WEIGHT at unloaded kg 3410
31 at loaded, front/rear kg 4770/640
4770/640
AXLE LOAD
32 at unloade
unloaded,
d, front/rear kg 1540/1
1540/1870
870
CHASSIS
33 number of front/r
front/rear
ear 2/2
34 TIRES front size 21x7-15
35 rear siz e 16x5-10.5
36 WHEEL BASE mm 1410
37 TREAD
TREA D front/rear mm 932/983
38 GROUND at loaded, the lowest point mm 90
39 CLEARANCE at loaded, center of wheelbase mm 135
40 SEVICE BRAKE foot/hyd
41 PARKING BRAKE hand/mech
hand/mech
DRIVE
42 BATTERY voltage/
voltage/capacity
capacity V/AH 12/45
43 manufacturer/ model G420F(E)
44 rated output / rpm kw(hp) 39.9(53.5) /2500
ENGINE
45 max. torque / rpm N•m(lb•ft) 157(116)/1
157(116)/1600
600
46 cycle/cylinders/displacement
cycle/cylinders/displacement cc 4/4/1975
47 type powershift
TRANSMISSION
48 number of speeds forward/rever se 1/1
OPERATING
49 system/attac hment bar 181/156
PRESSURE
equivelent continuous sound
50 NOISE LEVEL pressure level (Leq) at operator's ear (DI : BITA/CE dB(A)
prEN 12053)

-38-
 

General Section

DOOSAN DOOSAN DOOSAN 1

GC25E-5 GC30E-5 GC33E-5 2
2500 3000 3000(6500LBS ) 3
500 500 600 4
LP LP LP 5
rider-seated
rider-s eated rider-sea ted rider-seat
rider-seated
ed 6
C C C 7
2/2 2/2 2/2 8

3230 3230 3230 9

152 152 152 10
II III III 11
40x100x1050 45x125x1050 45x125x1050 12
297x905 282x954 282x954 13
6/8 6/8 6/8 14
2268 2333 2368 15
1110 1110 1110 16
2130 2130 2130 17
4480 4480 4480 18
2150 2150 2150 19
1038 1038 1038 20
2045 2105 2135 21
367 373 373 22
2412 2478 2508 23
1822 1872 1907 23a
 
16/16 16/16 16/16 24
510/600 500/600 500/600 25
510/460 510/460 510/460 26
1775 1750 1740 27
30 25.5 23.5 28
29

3710 4180 4350 30

5500/710 6330/850 6490/860 31
1460/2250 1470/2710 1420/2930 32

2/2 2/2 2/2 33

21x7-15 21x8-15 21x8-15 34
16x5-10.5 16x6-10.5 16x6-10.5 35
1410 1410 1410 36
932/983 907/956 907/956 37
90 90 90 38
135 135 135 39
foot/hyd foot/hyd foot/hyd 40
hand/mech hand/mech hand/mech 41

12/45 12/45 12/45 42

G420F(E) G420F(E
G420F(E)) G420F(E) 43
39.9(
9.9(53
53.5
.5)/
)/25
2500
00 39.9
39.9(5
(53.
3.5)
5)/2
/250
500
0 39.
39.9(53
9(53.5
.5)/
)/2
2500
500 44
157(116)/1600 157(116)/1600 157(116)/1600 45
4/4/1975 4/4/1975 4/4/1975 46
powershiftt
powershif powershift
powershif t powershift 47
1/1 1/1 1/1 48

195/156 216/156 216/156 49

50

-39-
 

General Section

Specifications
CHARACTERISTICS
1 MANUFACTURER DOOSAN
2 MODEL GC20P-5
3 CAPACITY at rated load center kg 2000
4 LOAD CENTER distance mm 500
5 POWER TYPE elect
electric
ric , diesel, gas, LPG-gas LP
6 OPERATOR TYPE stand-on, ride-seated rider-seated
rider-seated

7
8 TIRES
WHEELS(x=driven) C=cushion
C=cushion,
number of ,front/rear
P=pneumatic C
2/2
DIMENSIONS
9 LIFT WITH STD maximum fork height with rated load mm 3230
10 TWO-STAGE MAST free lift mm 152
11 FORK CARRIAGE ISO class II
12 thickness x width x length mm 40x100x1050
40x100x1050
FORKS
13 fork spacing (maximum x minimum) mm 297x905
14 TILT OF MAST forward/backward
forward/backward deg 6/8
15 length without forks mm 2218
16 width mm 1110
17 OVERALL mast lowered height mm 2130
18 DIMENSIONS mast extended height mm 4480
19 overhead guard height mm 2150
20 seat height mm 1038
21 OUTSIDE TURNING RADIUS mm 2000
22 LOAD MOMENT CONSTANT mm 367
23 90   STACKING AISLE
。 mm 2374
23a 90   INTERSECTING AISLE
。
mm 1798
PERFORMANCE
24 travel, loaded/un
loaded/unloaded
loaded km/hr 16/16
25 SPEED lift, loaded/un
loaded/unloaded
loaded mm/s 530/600
26 lowering, loaded/u
loaded/unloaded
nloaded mm/s 510/460
27 DRAWBAR
DRAWBA R PULL at 1.6km/hr
1.6km/hr,, loaded/u
loaded/unloaded
nloaded kg 2170
28 GRADEABILITY at 1.6km/hr, loaded/unload
loaded/unloadeded % 44
time reached at max speed,
29 ACCELERATION sec
loaded/unloaded
WEIGHT
30 TOTAL WEIGHT at unloaded kg 3430
31 at loaded, front/rear kg 4780/650
4780/650
AXLE LOAD
32 at unloade
unloaded,
d, front/rear kg 1550/1880
1550/1880
CHASSIS
33 number of front/r
front/rear
ear 2/2
34 TIRES front size 21x7-15
35 rear siz e 16x5-10.5
36 WHEEL BASE mm 1410
37 TREAD
TREA D front/rear mm 932/983
38 GROUND at loaded , the lowest point mm 90
39 CLEARANCE at loaded, center of wheelbase mm 135
40 SEVICE BRAKE foot/hyd
41 PARKING BRAKE hand/mech
DRIVE
42 BATTERY voltage/
voltage/capacity
capacity V/AH 12/65
43 manufacturer/ model G424F(E)
44 rated output / rpm kw(hp) 47.7(64)/2550
ENGINE
45 max. torque / rpm N•m(lb•ft) 182(135)/2200
182(135)/2200
46 cycle/cylinders/displacement
cycle/cylinders/displacement cc 4/4/2405
47 type powershift
TRANSMISSION
48 numberr of speeds forward/
numbe forward/reverse
reverse 1/1
OPERATING
49 system/attachment
system /attachment bar 181/156
PRESSURE
equivelent continuous sound
50 NOISE LEVEL pressure level (Leq) at operator's ear (DI : BITA/CE prEN dB(A)
12053)

-40-
 

General Section

DOOSAN DOOSAN DOOSAN 1

GC25P-5 GC30P-5 GC33P-5 2
2500 3000 3000(6500LBS
3000(6500LBS)) 3
500 500 600 4
LP LP LP 5
rider-seated
rider-seated rider-seated rider-seated 6
C C C 7
2/2 2/2 2/2 8

3230 3230 3230 9

152 152 152 10
II III III 11
40x100x1050 45x125x1050 45x125x1050 12
297x905 282x954 282x954 13
6/8 6/8 6/8 14
2268 2333 2368 15
1110 1110 1110 16
2130 2130 2130 17
4480 4480 4480 18
2150 2150 2150 19
1038 1038 1038 20
2045 2105 2135 21
367 373 373 22

2419 2479 2509 23

1822 1872 1907 23a

16/16 16/16 16/16 24

510/600 500/600 500/600 25
510/460 510/460 510/460 26
2050 2125 2115 27
37 31 29 28
29

3730 4200 4370 30

5510/720 6340/860 6500/870 31
1470/2260 1490/2710 1430/2940 32

2/2 2/2 2/2 33

21x7-15 21x8-15 21x8-15 34
16x5-10.5 16x6-10.5 16x6-10.5 35

1410 1410 1410 36

932/983 907/956 907/956 37
90 90 90 38
135 135 135 39
foot/hyd foot/hyd foot/hyd 40
hand/mech hand/mech hand/mech 41

12/65 12/65 12/65 42

G424F(E) G424F(E) G424F(E) 43
47.7(64)/2550 47.7(64)/2550 47.7(64)/2550 44
182(135)/2200
182(135)/2 200 182(135)/2200 182(135)/2200 45
4/4/2405 4/4/2405 4/4/2405 46
powershift powershift powershift 47
1/1 1/1 1/1 48

195/156 216/156 216/156 49

50
 41

General Section

Noise and Vibration

Sound Pressure Level at Whole-body Vibration

Power level(LWA )
Operator’s ear (Leq.) Level
By Noise Directive
Directive
according to EN12053 according to EN13059
Model 2000/14/EC 2
Guaranteed Sound (m/s )

dB(A) dB(A) Mean Uncertainty

TIER - II (4TNV98 E/G)

D20S-5,D25S-5,D30S-5,
82 104
D33S-5, D35C-5
(W/O Cabin) 
Cabin) 
TIER - III (4TNE98 E/G)
D20S-5,D25S-5,D30S-5,
82 104
D33S-5, D35C-5
(W/O Cabin) 
Cabin) 
0.7 0.2
TIER - III (G420F(E) E/G)
G20E-5,G25E-5,G30E-5 82 104
(W/O Cabin)

TIER - III (G424F(E) E/G)

G20P-5,G25P-5,G30P-5,
84 106
G33P-5,G35C-5
(W/O Cabin)

TIER - III (G420F(E) E/G)

GC20E-5,GC25E-5,GC30E-5,
80 *NA
GC33E-5
(W/O Cabin)
1.1 0.3
TIER - III (G424F(E) E/G)
GC20P-5,GC25P-5,GC30P-5,
82 *NA
GC33P-5
(W/O Cabin)

* NA : Not Applicable 
 42

General Section

Capacity Chart (Without Sideshifter Pneumatic)

MODEL
SINGLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   G
 ,
   5
  -
   E
   0
   2
   G
 ,
   5
  -
   S
   0
   2
   D

   5
  -
   P
   5
   2
   G
 ,
   5
  -
   E
   5
   2
   G
 ,
   5
  -
   S
   5
   2
   D

   5
  -
   P
   0
   3
   G
 ,
   5
  -
   E
   0
   3
   G
 ,
   5
  -
   S
   0
   3
   D
 43

General Section

Capacity Chart (Without Sideshifter Pneumatic)

MODEL
SINGLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   G
 ,
   5
  -
   S
   3
   3
   D

   5
  -
   C
   5
   3
   G
 ,
   5
  -
   C
   5
   3
   D
 44

General Section

Capacity Chart (Without Sideshifter Pneumatic)

MODEL
DOUBLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   G
 ,
   5
  -
   E
   0
   2
   G
 ,
   5
  -
   S
   0
   2
   D

   5
  -
   P
   5
   2
   G
 ,
   5
  -
   E
   5
   2
   G
 ,
   5
  -
   S
   5
   2
   D

   5
  -
   P
   0
   3
   G
 ,
   5
  -
   E
   0
   3
   G
 ,
   5
  -
   S
   0
   3
   D
 -45-

General Section

Capacity Chart (Without Sideshifter Pneumatic)

MODEL
DOUBLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   G
 ,
   5
  -
   S
   3
   3
   D

   5
  -
   C
   5
   3
   G
 ,
   5
  -
   C
   5
   3
   D
 -46-

General Section

Capacity Chart (With Sideshifter Pneumatic)

MODEL
SINGLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   G
 ,
   5
  -
   E
   0
   2
   G
 ,
   5
  -
   S
   0
   2
   D

   5
  -
   P
   5
   2
   G
 ,
   5
  -
   E
   5
   2
   G
 ,
   5
  -
   S
   5
   2
   D

   5
  -
   P
   0
   3
   G
 ,
   5
  -
   E
   0
   3
   G
 ,
   5
  -
   S
   0
   3
   D
 -47-

General Section

Capacity Chart (With Sideshifter Pneumatic)

MODEL
SINGLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   G
 ,
   5
  -
   S
   3
   3
   D

   5
  -
   C
   5
   3
   G
 ,
   5
  -
   C
   5
   3
   D
 -48-

General Section

Capacity Chart (With Sideshifter Pneumatic)

MODEL
DOUBLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   G
 ,
   5
  -
   E
   0
   2
   G
 ,
   5
  -
   S
   0
   2
   D

   5
  -
   P
   5
   2
   G
 ,
   5
  -
   E
   5
   2
   G
 ,
   5
  -
   S
   5
   2
   D

   5
  -
   P
   0
   3
   G
 ,
   5
  -
   E
   0
   3
   G
 ,
   5
  -
   S
   0
   3
   D
 -49-

General Section

Capacity Chart (With Sideshifter Pneumatic)

MODEL
DOUBLE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   G
 ,
   5
  -
   S
   3
   3
   D

   5
  -
   C
   5
   3
   G
 ,
   5
  -
   C
   5
   3
   D
 -50-

General Section

Capacity Chart (Without Sideshifter cushion)

MODEL 
NARROW TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   C
   G
 ,
   5
  -
   E
   0
   2
   C
   G

   5
  -
   P
   5
   2
   C
   G
 ,
   5
  -
   E
   5
   2
   C
   G

   5
  -
   P
   0
   3
   C
   G
 ,
   5
  -
   E
   0
   3
   C
   G
 -51-

General Section

Capacity Chart (Without Sideshifter cushion)

MODEL 
NARROW TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   C
   G
 ,
   5
  -
   E
   3
   3
   C
   G
 -52-

General Section

Capacity Chart (Without Sideshifter cushion)

MODEL 
WIDE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   C
   G
 ,
   5
  -
   E
   0
   2
   C
   G

   5
  -
   P
   5
   2
   C
   G
 ,
   5
  -
   E
   5
   2
   C
   G

   5
  -
   P
   0
   3
   C
   G
 ,
   5
  -
   E
   0
   3
   C
   G
 -53-

General Section

Capacity Chart (Without Sideshifter cushion)

MODEL 
WIDE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   C
   G
 ,
   5
  -
   E
   3
   3
   C
   G
 -54-

General Section

Capacity Chart (With Sideshifter cushion)

MODEL 
NARROW TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   C
   G
 ,
   5
  -
   E
   0
   2
   C
   G

   5
  -
   P
   5
   2
   C
   G
 ,
   5
  -
   E
   5
   2
   C
   G

   5
  -
   P
   0
   3
   C
   G
 ,
   5
  -
   E
   0
   3
   C
   G
 -55-

General Section

Capacity Chart (With Sideshifter cushion)

MODEL 
NARROW TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   C
   G
 ,
   5
  -
   E
   3
   3
   C
   G
 -56-

General Section

Capacity Chart (With Sideshifter cushion)

MODEL 
WIDE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   0
   2
   C
   G
 ,
   5
  -
   E
   0
   2
   C
   G

   5
  -
   P
   5
   2
   C
   G
 ,
   5
  -
   E
   5
   2
   C
   G

   5
  -
   P
   0
   3
   C
   G
 ,
   5
  -
   E
   0
   3
   C
   G
 -57-

General Section

Capacity Chart (With Sideshifter cushion)

MODEL 
WIDE TIRE 
STD, FFL  FFT 
 

   5
  -
   P
   3
   3
   C
   G
 ,
   5
  -
   E
   3
   3
   C
   G
 -58-

General Section

Serial Number

Serial Number Locations

For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.

2.0 liter Spark-Ignition Engine Serial Number

(G420F(E))

•_____________________________

Lift Truck Serial Number

•_____________________________

2.4 liter Spark-Ignition Engine Serial Number

(G424F(E))

•_____________________________
3.3 liter Diesel Engine (4TNV9
(4 TNV98)
8) Serial Number

•_____________________________

3.3 liter Diesel Engine (4TNE9

(4 TNE98)
8) Serial Number

•_____________________________
 -59-

General Section

Power Shift Transmission Serial Number

•_____________________________

Drive Axle Serial Number

•_____________________________

Typical Example

Side Shifter Serial Number (If Equipped)

•_____________________________
 -60-

General Section

Attachment Abbreviations (Includes

Special Forks)
SC -Special Carriage-increased width,
height or outreach

SSS -Shaft-type Sideshift Carriage

HSS -Hook-type Sideshift Carriage (ITA)

CW -Counterweight

SF -Special Forks

SWS -Swing Shift, Sideshift

RAM -Ram or Boom

DBCBH -Double Cube Block Handler

HFP -Hydraulic Fork Positioner

CR -Crane Arm or Crane Boom

TH -Tire Handler

CTH -Container Handler

LPP -Load Push-Pull Device

CC -Carton Clamp

RC -Roll Clamp

LS -Load Stabilizer

PWH -Pulp Wood Handler

SS-ST Sideshift-Side Tilt Carriage

 -61-

General Section

Operator's Warning and Identification Plate

Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT CAPACITY and
ATTACHMENT
ATTACH MENT PLATES. DO NOT exceed
e xceed capacity as equipped
equ ipped load ratings.

Operator's Warning Plate Identification, Lift Capacity and

Attachment Plate 

Located on the right side of the operator's seat.

Located on the cowl to the right side of the steering
column.
If Convenience Package Equipped
Below are abbreviations
IDENTIFICATION, that may
LIFT appear on and
CAPACITY the
ATTACHMENT
ATTACH MENT PLATES and their meanings.

Mast Abbreviations
STD - Standard Mast (single inner member,
low free lift)
FF - Full Free Lift Mast (single inner member
with high free lift duplex cylinder)
FFT - Triple Lift Mast (two inner members)
with either low or full free lift
characteristics.
QUAD
QUAD - Qua
Quadru
druple
ple (Qu
(Quad)
ad) Mas
Mast(w
t(with
ith tthre
hree
e in
inner
ner
members)
Located on the overhead guard.
NOTE:  When only a mast-type is listed on the
identification
forks are used.plate, a standard carriage and
 -62-

Operation Section

Operator’s Station and Monitoring Systems

Instrument Panel
Your lift truck may not have the same indicator or warning lights as shown in the 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, the symbol for each of the items is identified and a
ann explanatio
explanation
n of their function and location is described on
the following pages.

Diesel (12V)

LPG/GAS (12V)
 -63-

Operation Section

1.  Engine Oil Pressure Indicator Light -

1.  7. Transmission Oil Temperature Gauge
Indicates insufficient engine oil pressure. - Indicates transmission oil temperature. If
The light will come on when the ignition both tenth & ninth flash out of phase while
switch is turned to the ON position. The operating the lift truck, excessive transmission oil
light should go off after the engine is started. If the temperature is indicated. Park the lift truck and stop
s top
light turns on while operating the lift truck, the engine.
insufficient engine oil pressure is indicated. Park
the lift truck and stop the engine.
e ngine. 8. G420F(E)/G424F(E) Engine
Malfunction Indicator Lamp (MIL)
2. Alternator Indicator Light - Indicates if G420F(E) and G424F(E) engine control systems
the battery charging system is operational.
The light will come on when the ignition are equipped with built-in fault diagnostics. Deteted
switch is turned to the ON
O N position. system faults can be displayed by the Malfunction
Indicator Lamp (MIL) as Diagnostic Fault Codes
The light should go off after the engine is started, (DFC) or flash codes, and viewed in detail with the
indicating the alternator is producing sufficient use of service tool software. When the ignition key
voltage to charge the battery. If the light turns on is turned ON the MIL will perform a self-test,
with the engine running, check the alternator illuminate once and then go OFF. If a detected falut
charging system for a malfunction. condition exists, the fault or faults will be stored in
the memory of the engine control module (ECM).
3. Diesel Engine Start Preheat Indicator Once a fault occurs the MIL will illuminate and
Light - The light will come ON when the remain ON. This signals the operator that a faults
key is turned to the ON position from the has been detected by the SECM.
OFF position. This indicates that the glow plugs are
preheating the pre-combustion chambers for easier 9. Seat Belt Warning Light (If
starting. Equipment)
Indicates when the seat belt dose not fastened by
The amount of time needed to preheat the operator.
pre-combustion chambers is approximately seven The light will come on when the ignition switch is
seconds, depending on the surrounding air turned to the on position.
temperature. When the light goes OFF the The light should go off after engine
e ngine is started.
maximum pre-combustion chamber temperature
has been reached and the key can be turned to the 10. Service hour Meter -  -  Indicates the
START position to start the engine. total number of hours the engine and the
lift truck have operated. The hour meter
4.  Diesel Engine Water in Fuel Filter
4.  will operate when the ignition switch is in the ON
Indicator Light -  -  Indicates when the position, whether the engine is running or not. The
engine is running, there is water in the fuel hour meter is used to determine lubrication and
filter exceeds 100cc. maintenance intervals.
The light will come ON when the ignition switch is light-  The light will
11. Parking indicator light- 
turned to the ON position. The light should go off come ON when the parking lever is applied.
after the engine is started. If the light turns on with
the engine running, park the lift truck and stop the Floodlights-  Push down on the
12. Front Floodlights- 
engine. switch(14), to the first step, to turn the front
Drain some fuel (and any water) until clean fuel floodlights on.
flows from the filter which approximately takes 5 to Front and Rear Floodlights  – Push down on the
6 seconds switch(14), to the second step, to turn both the front
fron t
and rear floodlights on. The floodlights are optional.
- Indicates fuel level
5. Fuel Level Gauge - Indicates
(Gas, Diesel, or Dual Fuel Trucks Only) 13. Transmission Neutral Position Light
-  Indicates the neutral position of
6. Engine Coolant Temperature Gauge -  -  transmission.  
transmission.
Indicates coolant temperature. If both tenth
& ninth flash out of phase while operating 14. Front and Floodlights Switch – The
a nd Rear Floodlights
the lift truck, overheating is indicated. Park the lift front floodright is ON when push down switch
truck and stop the engine. to the first step.
Check the cooling system for a malfunction. Both The front and rear floodlights are ON when push down
tenth & ninth will flash out of phase when the switch to the second step.
coolant temperature reaches approximately 106°C
(223°F) on all engines.
 -64-

Operation Section

15. Low Level Light of LP GAS – Indicates

the low Level of LP GAS (LP or DUAL only)

16. Directional Turning Indicator Light

17

17. Horn Switch - Push on the horn

button to sound the horn.
 -65-

Operation Section

Electrical Disconnect Switch (If Engine Compartment

Equipped)

1. The engine compartment is accessible by pulling

the latch (GC Series), or pushing down the lever
1. ON - Connects the battery for electrical
located at cowl (G.D Series) and raising the hood
power to all electrical circuits.
and seat assembly (Note: Unlock latch before
pulling-if key equipped)
2. OFF - Disconnects the battery from all
electrical circuits.

2. The hood and seat assembly is held up by a

support cylinder. Make certain the air cylinder is
operating properly and securely hold the hood up
before doing anything in the engine
compartment.
 -66-

Operation Section

Seat Switch System (If Equipped)

NOTICE

Prior to operating the lift truck, be sure to

understand and check the SEAT SWITCH
SYSTEM.
While in normal operation and on level ground,
select a direction with the derectional lever and with
the park brake released. You will note that the truck
will move slowly in the selected direction. If you lift
yours hips off of the seat, within three seconds, the
SEAT SWITCH SYSTEM will desengage the
transmission allowing the truck to coast but not
automatically stop.
The lift truck is equipped with a SEAT SWITCH
To restore the lift truck to normal operation, while
SYSTEM. In normal operation if the direction lever sitting in the operator's seat depress the brake
is placed in either forward or reverse, the lift truck pedal to hold the lift truck, return the directional
will move at a speed proportional to the accelerator lever to the neutral position, and then reselect a
pedal's position. If the operator leavers the seat direction of travel (either forward or reverse). The
without setting the parking brake, within three transmission will then re-engage.
seconds after leaving the seat, the SEAT SWITCH If seat or seat switch replacement becomes
SYSTEM will automatically disengage the necessary, be sure to use genuine DOOSAN
transmission. The directional lever, however, will Infracore lift truck parts. Lift trucks should never be
remain in that forward or reverse location although operated without an operational SEAT SWITCH
internally the transmission will have shifted into SYSTEM.
neutral.

Before exiting the lift truck, the parking brake

should always be applied.
.

WARNING
WHEN LEAVING MACHINE APPLY PARKING
BRAKE!
PARKING BRAKE IS NOT AUTOMATICALLY
APPLIED.

NOTE:  Some trucks may be equipped (ask your

dealer if this applies to your truck) with an
alarm that will sound if the parking brake is
not applied when leaving the machine.
 -67-

Operation Section

  WARNING Tilt Steering Column

When closing the engine hood, be careful not to
pinch your hand.

Circuit Breaker

To adjust the steering column, push down the

knob(1), and move the steering column to the
desired position, then release the knob(1).

-Protects the main

Circuit Breaker -Protects
electrical circuits. To reset the circuit Fuel Selector Switch
breaker, push the button in. Located in the (G420F(E)/G424F(E) Dual Fuel
engine compartment.
Only)
Seat
NOTE:  
NOTE: Seat arrangements may vary.
Basic operation will be similar.

Seat adjustment should be checked at the

beginning of each shift and when operators
change.

Lock the seat into position before operating, to

prevent an unexpected seat change.

Adjust seat to allow full brake pedal travel with

operator’s back against seat back. 1. LPG - This position supplies electrical

power to theswitch
the ignition LP fuelock
is in solenoid,
the ON orwhenthe
START position.
With the LP fuel tank valve open, LP can then flow
the tank through the converter to the carburetor.

2. OFF – This position shuts off all fuel

supply to the carburetor/injector.

3. GAS - This position supplies electrical

power to gasoline fuel pump and injector
This will allow gasoline fuel to flow from
the tank
tank through
through the
the fuel
fuel filter and fuel
fuel
pump to the injector.
NOTE:  The seat can only be correctly adjusted
with the operator fully seated.
 -68-

Operation Section

Lift Truck Controls

Direction Control Lever Service Brake Pedal

1. Forward - Push the lever forward for Push DOWN on the brake pedal to slow
FORWARD direction travel. or stop the lift truck.

RELEASE the brake pedal to allow the lift

2. Neutral - Move the lever to center truck to move.
position for NEUTRAL.
NEUTRAL.

3. Reverse
REVERSE
REVER - Pull thetravel.
SE direction lever
tra vel.back for Accelerator Pedal

Transmission Inching Control

Pedal

Push DOWN on the pedal to increase

engine rpm (speed). 

RELEASE the pedal to decrease engine

rpm (speed).
Inching Control Pedal - Pushing down on
the inching pedal, modulates the hydraulic
pressure to the clutch packs, permitting
disc slippage.

Further pushing on the pedal completely relieves

clutch pack pressure and applies the service
brakes to stop and hold the lift truck.

NOTE:  The purpose of the inching control pedal is

to provide precise inching control at slow
travel speed, with high engine rpm. This is
used for fast hydraulic lift during load
approach, pickup or positioning.
 -69-

Operation Section

Parking Brake Lever Tilt Control

Pull the lever BACK to engage the parking

brake. 1. Mast Tilt Forward - Push the lever
FORWARD smoothly
smoothly to tilt the mast
forward.
Push the lever FORWARD to release the
parking brake.
2. Mast Hold - When the lever is i s released
it will return to the HOLD
H OLD or center position.
Tilting action will stop.

Lift Control 3. Mast Tilt Back - Pull the lever BACK

smoothly to tilt the mast backward. 
backward. 

Sideshift Attachment (If Equipped)

NOTE:  To prevent a sudden change of position of

the load, operate all lift, tilt and attachment
controls smoothly.
1. Lower Position - Push the lever
FORWARD smoothly
smoothly to lower
l ower the load.
1. Sideshift Left - Push the lever
2. Hold Position - When the lever is FORWARD to shift the carriage to the left.
released it will return to the HOLD or center
position. Lifting or lowering action will stop. 2. Sideshift Hold - When the lever is
released it will return to the HOLD or
3. Lift Position - Pull the lever BACK center position. Sideshifting action will
smoothly to lift the load.
load . stop.

3. Sideshift Right - Pull the lever BACK to

shift the carriage to the right.
 -70-

Operation Section

Refueling
Gasoline or Diesel Engine
Equipped
WARNING

Explosive fumes may be present during

refueling.
Do not smoke in refueling
re fueling areas.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to those indoors.
Stop the engine and get off the lift truck during 1.  Park the lift truck only at a designated safe
refueling. location. Place the transmission in NEUTRAL.
Lower the forks to the ground. Engage the
parking brake. Stop the engine.
NOTICE
Do not allow the lift truck to become low on fuel or
completely run out of fuel. Sediment or other
impurities in the fuel tank could be drawn into the
fuel system. This could result in difficult starting or
damage to components.

Fill the fuel tank at the end of each day of operation

to drive out moisture 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 2.  Open the filter cap.

Do not fill the tank to the top. Fuel expands when it 3.  Fill the fuel tank slowly. Close the filter cap.
gets warm and may overflow. If spillage occurs, wipe off excess fuel and was
down area with water.

NOTE:  Drain water and sediment from fuel tank as

required by prevailing conditions. Also,
drain water and sediment from the main
fuel storage tank weekly and before the
tank is refilled. This will help prevent water
or sediment being pumped from the
storage tank into the lift truck fuel tank.
tan k.
 -71-

Operation Section

Changing LP Tanks
WARNING
Only trained, authorized personnel should fill or
exchange LP tanks.
Personnel engaged in filling of LP containers
should wear protective clothing such as face
shield, long sleeves and gauntlet gloves.
Do not refuel or store LP powered lift trucks
near any underground entrance, elevator shafts
or any other place where LP could collect in a
pocket causing a potentially dangerous 2.  Close the fuel shut off valve at
a t the LP tank. Run
condition. the engine until it stops, then turn off the ignition
switch and the disconnect switch (if equipped). 
equipped). 
Examine all LP containers before filling and
again before reuse, for damage to various 3.  Disconnect the fuel supply line.
valves, liquid gauge, fittings and hand valve
wheels.
All defective or damaged LP containers must be
removed from service.
Explosive fumes may be present during
refueling.
Do not smoke in refueling
re fueling areas.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to indoor locations.
loc ations.
Stop the engine and get off the lift truck during
refueling.
The careless handling of LP containers can If Swing out type LP-Cradle Equipped
result in a serious accident.
accide nt.
Use extreme care when transporting containers
to prevent damage to them.

1.  Park the lift truck on level ground, with the

parking brake applied, the transmission in
NEUTRAL, the forks lowered and the engine
running at low idle.

4.  Loosen the retaining clamps and remove the

tank.

5.  Check the mounting to be sure the locating pin

(dowel) is not missing or broken.
 -72-

Operation Section

NOTICE
If the location pin (dowel) is missing or broken, be
sure the pin is replaced.

11. Position the replacement tank so that the

locating pin (dowel) is in place.

WARNING

The LP tank must not extend past the

6.  Check to be sure that the LP warning plate is in counterweight
position on the lift truck, and is legible.
le gible.

7.  Check to be sure the replacement tank is of the 12. Clamp the tank securely.
correct type.
13. Connect the fuel supply line.
line .
8.  Inspect the replacement tank for damage such
as dents, scrapes or gouges and for indication 14. Open the fuel valve by slowly turning it
of leakage at valves or threaded connections. counterclockwise. If the
th e fuel valve is opened
o pened too
quickly, a back pressure check valve will shut
off the fuel supply. If this happens, close the
fuel valve completely. Wait five seconds and
then open the fuel valve very slowly.

15. Inspect the LP fuel lines

l ines and fittings with a soap
solution after filling the tank or when looking for
leaks.

9.  Check for debris in the relief valve, for damage

to various valves and liquid level gauge.

10. Inspect the quick - disconnect couplings for

deterioration, damage or missing flexible seals.
 -73-

Operation Section

Before Starting the Engine

Walk - Around Inspection
Make a thorough walk - around inspection before
mounting the lift truck or starting the engine. Look
for such items as loose bolts, debris buildup, oil or
coolant leaks. Check condition of tires, mast,
carriage, forks or attachments. Have repairs made
as needed and all debris removed.

7.  Inspect the overhead guard for damage and

loose or missing mounting bolts.

8.  Inspect the hydraulic system for leaks, worn

hoses or damaged lines.

9.  Look for transmission and drive axle leaks on

the truck and on the ground.
g round.

1.  Inspect the operator’s compartment for loose

items and cleanliness.
cleanliness.

2.  Inspect the instrument panel for broken or

damaged indicator 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.

10. Inspect the engine compartment for oil, coolant

and fuel leaks.

5.  Inspect the carriage, forks or attachments for

wear, damage and loose or missing bolts.
6.  Inspect the tires and wheels for cuts, gouges,
foreign objects, inflation pressure and loose or
missing bolts.
 -74-

Operation Section

11. Measure the engine crankcase oil level with the 13. Observe the fuel level gauge after starting the
dip stick. Maintain the oil level between the truck. Add fuel if necessary.
MAX. and MIN., (or FULL and ADD) notches
no tches on
the dip stick.
WARNING
Personal injury may occur from accidents
caused by improper seat adjustment. Always
adjust the operator’s seat before starting the lift
truck engine.
Seat adjustment must be done at the beginning
of each shift and when operators change.
c hange.

12. Observe the engine coolant level in the coolant

recovery bottle. With the engine cold, maintain
the level to the COLD mark. If the recovery
bottle is empty, also fill the radiator at the top
tank.

14. To position the seat,

s eat, PUSH the lever away from
the seat track and move the seat forward or
backward to a comfortable position.
 -75-

Operation Section

Starting the Engine

Prestart Conditions Gasoline Engine
NOTE:  The engine will not start unless the
transmission directional control lever is in
the NEUTRAL position. NOTICE
Do not leave the key in ON position when engine is
not running.
Do not engage the starter more than 10 seconds at
any one time.

1.  Don’t press accelerator pedal, and turn the

ignition switch to the START position.

2.  Once the engine starts, release the ignition

switch.

3.  If the engine does not start, repeat step 1.

1. Engage the parking brake, if not already 4.  If engine coolant is cold, engine speed could be
engaged. Place the transmission directional higher than low idle speed. Don’t drive forklift
control lever in the NEUTRAL position. until engine speed becomes normal low idle
speed.

NOTICE
If the inside of engine cylinder is wet by gasoline,
the engine could not start. In this case, press
accelerator pedal fully and turn the ignition switch
to ON position for 10 seconds. The inside of
cylinder would be dry because ECM does not allow
gasoline fuel injection. Repeat it three times. Don’t
press accelerator pedal and turn the Ignition switch
to the START position to start engine.

2. Lift trucks equipped with electrical disconnect

switches; the engine will not start unless the
disconnect switch is in the ON (closed) position.
 -76-

Operation Section

LP Engine Diesel Engine

WARNING Starting a Cold Diesel Engine
LP fuel is flammable and can cause personal 1.  Turn the key to the ON position. The start pre
heat light will come ON. The preheat light will
injury.
stay ON approximately seven seconds,
Inspect LP fuel lines and fitting for leaks.
lea ks. depending on the surrounding air temperature.

Inspect tank for secure mounting.

NOTICE
Do not engage the starter for more than 10
seconds.

2.  When the preheat light goes OFF, turn the key
to the START position, with the accelerator
pedal pressed.

3.  Release the key when the engine starts and

release the accelerator pedal to a low idle
position.

4.  If the engine stalls or does not start, turn the

key to the OFF position, then repeat steps 1
thru 3.
1.  Turn the tank fuel valve ON by slowly turning
the valve counterclockwise. Observe the LP
gauge (if equipped).
Starting a Warm Diesel Engine
2.  Don’t press accelerator pedal, and turn the 1.  Turn the key to the ON position and then to
ignition switch to the START position. START position, without waiting for the preheat
light to go OFF. At the same time press the
3.  Once the engine starts, release the ignition accelerator.
switch.
2.  Release the key when the engine starts and
4.  If the engine does not start, repeat step
s tep 2. release the accelerator pedal to a low idle
position.
5.  If engine coolant is cold, engine speed could be
higher than normal low idle speed. Don’t drive
forklift until engine speed becomes normal low
idle speed.
 -77-

Operation Section

Starting From a 12 Volt External

Source
WARNING
Sparks occurring near the battery could cause
vapors to explode.

Always connect
ground cable to a the external
point power
away from andsource
below
the battery, and well clear of fuel system
components.

NOTICE
Do not reverse battery cables. It can cause damage
to the alternator.
Always connect the external power source cables
in parallel with the lift truck battery cables :
POSITIVE(+) to POSITIVE(+) and NEGATIVE( - )
to NEGATIVE( - ).
Attach ground cable last, remove first. All lift trucks
equipped with DOOSAN built internal combustion
engines are NEGATIVE( - ) ground.
 -78-

Operation Section

Dual Fuel System

Changing From Gasoline to LP –
Gas

4. Open the fuel valve, on the LP tank, by slowly

turning the valve counterclockwise.
counterclockwise.

NOTE:  The Underwriter’s Laboratory (U.L.) 5. Turn the ignition switch key to the OFF position
and then to the START position to start the
requires that the gasoline tank must be at
least one - quarter full when operating on engine. Release it when the engine starts.
LP. This will allow the lift truck to be
restarted on gasoline and moved to an
approved
a refueling
hazardous area. area, when operating in Changing From LP to Gasoline
1. Park the lift truck level in an authorized refueling 1.  Park the lift truck level in an authorized
area with the forks lowered, the parking brake refueling area with the forks lowered, the
applied, the transmission in NEUTRAL and the parking brake applied, the transmission in
engine running. NEUTRAL and the engine running.

2
3 4

2. Move lever (1), on the fuel selector switch to the

OFF (2) position. Leave lever (1) in this position 2.  Close the fuel valve on the LP tank. hood open. 
until the engine stops.

3. Move lever (1) to the LPG (3) position.

 -79-

Operation Section

2
3 4

3.  Move lever (1) from the LPG (3) POSITION to

the OFF (2) position. Allow the engine to run
until the fuel in the line runs out and engine
stops.

4.  Move lever (1) from the LPG (3) position to the
GAS (4) position.

5.  Turn the ignition switch key to the OFF position.

po sition.

6.  Turn the ignition switch key to the START

position and start the engine. Release it when
the engine starts.
 -80-

Operation Section

After Starting the Engine 4.  The diesel engine water in fuel filter indicator
light(4), will not come ON with the engine
Observe all indicator lights and gauges frequently running, unless water in fuel filter exceeds
during operation, to make sure all systems are 100cc. Stop the engine immediately and drain
working properly. The entire indicator lights will the water if the light comes ON.
come ON with the ignition switch in the ON position
before the engine is started. 5.  Observe the fuel level gauge (5) for fuel level
in the tank.
Diesel (12V)
6.  The engine coolant temperature gauge pointer
(6) will be in the green band with the engine
running, unless the coolant temperature is
excessive.

7.  The transmission oil temperature gauge

pointer (7) will be in the green band with the
engine running, unless the oil temperature is
excessive.

LPG/GAS (12V)

3 8.  Observe the hour meter (8) to make sure it is

operating properly.

1.  The engine oil pressure indicator light (1), will

not come ON with the engine running, unless
there is low orif no
immediately, theoil pressure.
light Stop
comes ON.
O N. the engine

2.  The alternator indicator light (2), should not

come ON during normal operation. The
alternator is not charging if the light comes ON
with the engine running.

3.  The spark-ignition G420/424F(E) engine

MIL(Malfunction Indicator Light)(3) will not
come ON with the engine running, unless the
fault or faults are stored in the memory of the
engine control module(ECM). Stop the engine
and check the electric engine control system if
the light comes ON. Refer G420F(E)/G424F(E)
Engines of this section.
 -81-

Operation Section

Lift Truck Operation

Power Shift Transmission/ Drive
axle WARNING
A lift truck with the engine running but without
1.  Start the engine. See topic “Starting the an operator can move slowly (creep) if the

Engine”. transmission is engaged.

This could result in personal
pers onal injury.
Always place the transmission control lever in
the NEUTRAL (center) position and apply the
parking brake before dismounting the lift truck.
truc k.

2.  Push down on the service brake pedal to hold

the lift truck until ready to move it.
3.  Release the parking brake.

NOTE:  The parking brake must be released before

the directional control can be used.
u sed. 5.  Release the service brake.

6.  Push down on the accelerator pedal to obtain

the desired travel speed. Release the pedal to
decrease travel speed.

WARNING
Sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift
truck to tip over.
Stop the loaded lift truck completely, before
shifting to reverse.
Failure to comply could result in personal
injury.
4.  Select the direction of travel by pushing the
directional lever FORWARD for forward
direction or by pulling the lever BACK for NOTE:  Where conditions permit, directional
reverse direction. changes can be made under full power at
speeds up to 6 km/h (3.73 mph). A speed
of 6 km/h (3.73 mph) is a fast walk.
Directional shift changes at speeds above
6 km/h (3.73 mph) are considered abusive.
Bring the lift truck to a complete stop where
load stability or other factors prevent safe
operation under full power
po wer shifts.
 -82-

Operation Section

  Inching

7.  To change the lift truck direction of travel,

release the accelerator pedal.
NOTE:  The purpose of the inching pedal is to
8.  Push down on the service brake pedal to provide precise lift truck inching control at
reduce the lift truck speed as necessary. very slow travel speed and high engine
rpm. This is used for fast hydraulic lift,
during load approach, pick up or load
positioning.

1. To inch (creep) in either direction, slowly push

down on the inching pedal. This will start to apply
the service brakes and allow the transmission
clutch discs to slip.

2. Vary the position of the inching pedal and the

accelerator pedal to control the inching speed
and distance.

3. Pushing down further on the inching pedal will

disengage the transmission completely and apply
9.  Move the directional lever to the desired the service brakes fully to stop and hold the lift
direction of travel. Slowly push down on the truck. This will provide full engine power for fast
accelerator pedal as the lift truck changes hydraulic lift.
direction.

10. When the direction change is completed,

continue to push down on the accelerator pedal WARNING
to obtain the desired travel speed.
Do not use inching pedal instead of brake
pedal.
It will give wearing to transmission
tr ansmission clutch disc.

11. To stop the lift truck when traveling in either

direction, release the accelerator pedal.

12. Push down on the service brake pedal and

bring the lift truck to a smooth
smo oth stop.
 -83-

Operation Section

Electronic
Electronic Controlled Spark-Ignition Engines
G420FE Engine and G424FE Engine

EMS (Engine management system) of G420FE engine control module (SECM) uses two heated
engine and G424FE engine is a closed loop system exhaust gas oxygen sensors (HEGO) in the
utilizing a 3-way catalytic muffler to reduce the exhaust system to monitor exhaust gas content.

emission level
maximum in the
effect exhaust
from gas. In order
the catalyst,o rder to obtain
an accurate One HEGO
muffler and is
oneinstalled in front
is installed of the
after the catalytic
catalytic
control of the air fuel ratio is required. A small muffler.

EMS schematic of G420FE Dual fuel engine

The SECM makes any necessary corrections to the Even engine coolant temperature and adequate oil
air fuel ratio by controlling the inlet fuel pressure to pressure are monitored by the SECM. The SECM
the air/fuel mixer by modulating the dual fuel trim controller has full adaptive learning capabilities,
valves (FTV) connected to the regulator. Reducing allowing it to adapt control function as operating
the fuel pressure leans the air/fuel mixture and conditions change. Factors such as ambient
increasing the fuel pressure enriches the air/fuel temperature, fuel variations, ignition component
mixture. To calculate any necessary corrections to wear, clogged air filter, and other operating
the air fuel ratio, the SECM uses a number of variables are compensated.
different sensors to gain information about the
engine’s performance. Engine speed is monitored MPI (multi-point injection) is used for this system.
by the SECM through a variable reluctance (VR) or Fuel injection pressure and flow rate depend on
Hall Effect sensor. Intake manifold air temperature engine-specific fuel injection requirements. A
and absolute pressure are monitored with a TMAP variety of regulators and injectors can be used to fit
sensor. MI-07 is a drive-by-wire (DBW) system individual needs. The gasoline fuel pressure
connecting the accelerator pedal to the electronic regulator is a one-way, non-return configuration. All
throttle
cables through
are not the electrical
used. harness;
A throttle mechanical
position sensor gasoline
production specific
parts andcomponents are automotive
validated to strict automotive
(TPS) monitors throttle position in relation to the standards. Four (4) sequential injection channels
accelerator pedal position sensor (APP) command. are supported.
 -84-

Operation Section

G420F Engine and G424F Engine

EMS (Engine management system) of G420F engine and G424F engine is an open loop LP system and/or
closed loop gasoline system. 3-way catalytic muffler is not used for th
this
is system.

LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM.
Manifold pressure from the TMAP, rpm from the crank position sensor and throttle position is used by the
SECM
positiontosensors
calculate load. Feedback from the electronic throttle is still provided to the SECM by the throttle
(TPS).

EMS schematic of G420F Dual Fuel engine

 -85-

Operation Section

Basic Troubleshooting(LP)
 
The MI-07 systems are equipped with built-in fault basic checks that should be made before referring
diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or
displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
and are covered in the Advanced Diagnostics
section. Items such as fuel level, plugged fuel fuel Locating a problem in a propane engine is done
lines, clogged fuel filters and malfunctioning exactly the same way as with a gasoline engine.
pressure regulators may not set a fault code by the Consider all parts of the ignition and mechanical
Small Engine Control Module (SECM). Below are systems as well as the fuel system.

Problem Probable Cause Corrective Action

Fuel container empty Fill fuel container
Engine Cranking    Do not exceed 80% of liquid
but Will Not Start capacity
Liquid valve closed Slowly open liquid valve
Excess flow valve closed Reset excess flow valve
   Close liquid valve

   Wait for a “click” sound

   Slowly open liquid valve

Plugged fuel line Remove obstruction from the fuel line

   Close liquid fuel valve

   Using caution, disconnect the fuel

line (some propane may escape)

   Clear obstruction with compressed

air
   Re-connect fuel line

   Slowly open liquid fuel valve

   Leak test

Broken Fuse - SECM Replace Fuse for SECM

   See Maintenance Section, Fuses
replacement
Clogged fuel filter Repair/replace as required
   See Maintenance Section, LP Fuel

Filter replacement
Faulty vapor connection between Check connection
the pressure regulator/converter    Verify no holes in hose

and the mixer    Clamps must be tight

   Look for kinked, pinched and/or

collapsed hose
Fuel Lock-off malfunction Repair/replace
Repair/replace Fuel Lock-off
   See Engine Service Manual

Pressure regulator/converter Test pressure regulator/conv

r egulator/converter
erter o
operation
peration
malfunction    See Engine Service Manual

Incorrect air/fuel or ignition/spark See Advanced Diagnostics

control
No VR Sensor Signal Verify the VR signal is present
   See Advanced Diagnostics  
 -86-

Operation Section

Problem Probable Cause Corrective Action

Fuel container almost empty LPG Vapor from liquid outlet
Difficult to Start   Fill fuel container
  Do not exceed 80% of liquid capacity

Excess flow valve closed Reset excess flow valve

  Close liquid valve

  Wait for open
Slowly a “click” sound
liquid valve
Clogged fuel filter Repair/replace as required
  See Maintenance Section, LP Fuel
Filter replacement
Plugged fuel line Remove obstruction from the fuel line
  Close liquid fuel valve
  Using caution, disconnect the fuel line
(some propane may escape)
  Clear obstruction with compressed air
  Re-connect fuel line
  Slowly open liquid fuel valve
  Leak test
Faulty vapor connection between Check connection
the pressure regulator/converter   Verify no holes in hose
and the mixer   Clamps must be tight
  Look for kinked, pinched and/or
collapsed hose
Pressure regulator/converter Test pressure regulator/conv
r egulator/converter
erter o
operation
peration
malfunction   See Engine Service Manual
Fuel container almost empty LPG Vapor from liquid outlet
  Fill fuel container
  Do not exceed 80% of liquid capacity
Air filter clogged Check air filter
  Clean/replace as required
Incorrect air/fuel or ignition control See Advanced Diagnostics
Engine Mecha
Mechanical
nical See Engine Service Manual
 -87-

Operation Section

Problem Probable Cause Corrective Action

Fuel container almost empty LPG Vapor from liquid outlet
Will Not Run   Fill fuel container
Continuously   Do not exceed 80% of liquid capacity
Excess flow valve closed Reset excess flow valve
  Close liquid valve
  Wait for a “click” sound
Slowly open liquid valve
Clogged fuel filter Repair/replace as required
  See Maintenance Section, LP Fuel
Filter replacement
replacement

Plugged fuel line Remove obstruction from the fuel line

  Close liquid fuel valve
  Using caution, disconnect the fuel line
(some propane may escape)
  Clear obstruction with compressed air
  Re-connect fuel line
  Slowly open liquid fuel valve & Leak
test
Pressure regulator freezes Check level in cooling system
  Must be full, check coolant strength
 
-35F minimum
Check coolant hoses
  Watch for kinks and/or pinched hoses
  Verify one pressure hose and one
return hose
Fuel Lock-off malfunction Repair/replace Fuel Lock-off
  See Engine Service Manual
Incorrect idle speed or ignition See Advanced Diagnostics
problem
Engine Mechanical See Engine Service Manual
Fuel container almost empty LPG Vapor from liquid outlet
Will Not   Fill fuel container
Accelerate/Hesita   Do not exceed 80% of liquid capacity
tion During Excess flow valve closed Reset excess flow valve
Acceleration   Close liquid valve
  Wait for a “click” sound
Slowly open liquid valve
 -88-

Operation Section

Problem Probable Cause Corrective Action

Clogged fuel filter Repair/replace as required
Will Not   See Maintenance
Accelerate/Hesita Section, LP Fuel Filter replacement
tion During Faulty vapor connection between Check connection
Acceleration the pressure regulator/converter   Verify no holes in hose


and the mixer 

 
  Clamps
Look for must be pinched
kinked, tight and/or
collapsed hose
Throttle butterfly valve not opening See Advanced Diagnostics
or sticking
Foot Pedal signal incorrect or
intermittent
Incorrect air/fuel or ignition
igni tion control
Engine Mecha
Mechanical
nical See Engine Service Manual
Fuel container almost empty LPG Vapor from liquid outlet
Engine Stalls   Fill fuel container
  Do not exceed 80% of liquid capacity
Excess flow valve closed Reset excess flow valve
  Close liquid valve
  Wait for a “click” sound
Slowly open liquid valve

Clogged fuel filter Repair/replace

  as required
See Maintenance Section, LP Fuel
Filter replacement
Plugged fuel line Remove obstruction from the fuel line
  Close liquid fuel valve
  Using caution, disconnect the fuel line
(some propane may escape)
  Clear obstruction with compressed air
  Re-connect fuel line
  Slowly open liquid fuel valve & Leak
test
 -89-

Operation Section

Problem Probable Cause Corrective Action

Fuel Lock-off malfunction Repair/replace Fuel Lock-off
Engine Stalls   See Engine Service Manual
Faulty vapor connection between Check connection
the pressure regulator/converter   Verify no holes in hose
and the mixer   Clamps must be tight
  Look for kinked, pinched and/or
collapsed hose
Pressure regulator freezes Check level in cooling system
  Must be full, check coolant strength
  -35F minimum
  Check coolant hoses
  Watch for kinks and/or pinched hoses
hose s
  Verify one pressure hose and one
return hose
Pressure regulator malfunctio
malfunction
n Test pressure regulator operation
  See Engine Service Manual
Vacuum leak Check for vacuum leaks
  Between mixer and throttle body
  Between throttle body and intake
manifold
  Between intake manifold and cylinder
head
Air/Fuel Mixer malfunction
malfunction Check mixer
 
See Engine Service Manual
Engine Mechanical See Engine Manufacturers Service Manual

Faulty vapor connection between Check connection

Rough Idle the pressure regulator/converter   Verify no holes in hose
and the mixer   Clamps must be tight
  Look for kinked, pinched and/or
collapsed hose
Pressure regulator malfunction
malfunction Test pressure regulator operation
  See Engine Service Manual

Vacuum leak Check for vacuum leaks

  Between mixer and throttle body
  Between throttle body and intake
manifold
  Between intake manifold and cylinder
head
Air/Fuel Mixer malfunction
malfunction Check mixer
  See Engine Service Manual
 -90-

Operation Section

Problem Probable Cause Corrective Action

Incorrect Idle speed control 
control   See Advanced Diagnostics & See Engine
Rough Idle Incorrect timing or spark control Service Manual
Engine Mechanical See Engine Service Manual
Incorrect Idle speed control See Advanced Diagnostics & See Engine
High Idle Speed Throttle sticking Service Manual

Foot pedal sticking or incorrect

pedal signal Check
  Seepedal return spring
Advanced travel for binding
Diagnostics
Clogged fuel filter Repair/replace as required
Poor High Speed   See Maintenance section, Fuel Filter
Performance replacement

Plugged fuel line Remove obstruction from the fuel line

  Close liquid fuel valve
  Using caution, disconnect the fuel line
(some propane may escape)
  Clear obstruction with compressed air
  Re-connect fuel line
  Slowly open liquid fuel valve & Leak
test
Air filter clogged Check air filter
  Clean/replace as required
Faulty vapor connection between Check connection


the pressure
and the mixer regulator/converter 
 
  Verify
Clamps nomust
holes
beintight
hose
  Look for kinked, pinched and/or
collapsed hose
Pressure regulator malfunction Test pressure regulator operation
  See Engine Service Manual
Air/Fuel Mixer malfunction Check mixer
  See Engine Service Manual
Restricted exhaust system Check exhaust system
  Measure exhaust back pressure 
control  
Incorrect ignition control 
See Advanced Diagnostics & See Engine
Incorrect air/fuel control
Service Manual
Incorrect throttle position
 -91-

Operation Section

Problem Probable Cause Corrective Action

Air/Fuel Mixer malfunction Check mixer
Excessive Fuel   See Engine Service Manual
Consumption/LP Air filter clogged Check air filter
G Exhaust Smell   Clean/replace as required
Vacuum leak Check system vacuum hoses from
regulator to FTV and mixer
  Repair/replace as necessary
Pressure regulator malfunction/fuel Test pressure regulator operation
pressure too high   See Engine Service Manual
Faulty FTV Check FTV for housing cracks or
obstructions
  See Advanced Diagnostics FTV
operation
  Repair and/or replace as necessary
control  
Weak ignition and/or spark control  See Advanced Diagnostics
Incorrect air/fuel control 
control   See Advanced Diagnostics
Exhaust system leaks Repair exhaust system
Oxygen sensor failure Replace as necessary
  See Advanced Diagnostics
 -92-

Operation Section

Basic Troubleshooting (Gasoline)

Problem Probable Cause Corrective Action

Fuel tank empty Fill fuel container
Engine Cranking   The tank should be at least ¼ full to
but Will Not Start properly prime the fuel pump.
(Gas)  
Fuel select switch is not on GAS
Clogged fuel filter Repair/replace as required
  See Maintenance section Primary
and Secondary Fuel Filter replacement
Faulty vapor connection between Check connection
the pressure regulator/ converter   Verify no holes in hose
and the mixer (LPG)   Clamps must be tight
  Look for kinked, pinched and/or
collapsed hose
Electric Fuel Pump malfunction Check electrical connection
(GAS)   Check Relay and fuse
Turn key ON and verify pump is operating
Fuel Pressure regulator malfunction Test pressure regulator operation
  See Engine Service Manual
Fuel Injector malfunction Test Injector operation
  See Engine Service Manual
Incorrect air/fuel or ignition/ spark See Advanced Diagnostics
control
No VR Sensor Signal Verify the VR signal is present 
present 
  See Advanced Diagnostics
 -93-

Operation Section

Problem Probable Cause Corrective Action

Fuel tank almost empty Fuel Pump Cavitations
Difficult to Start   The tank should be at least ¼ full to
(Gas) properly prime the fuel pump
  Fuel select switch is not on GAS
Clogged fuel filter Repair/replace as required
  See Maintenance section, Primary and
Secondary Fuel Filter replacement
re placement
Electric Fuel Pump malfunction Check electrical connection
(GAS)   Check Relay and fuse Turn key ON
and verify pump is operating
  See Engine Service Manual
Pressure regulator malfunction Test pressure regulator operation
  See Engine Service Manual
Fuel Injector malfunction Test Injector operation
  See Engine Service Manual
Air filter clogged Check air filter
  Clean/replace as required
Incorrect air/fuel or ignition control See Advanced Diagnostics
Engine Mechanical See Engine Service Manual
Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Will Not Run running the lift truck on LPG If the problem does not exist in LPG mode
Continuously proceed with the corrective action steps
below.
(Gas)
If the problem also exists in LPG mode then
the root cause is most likely to be
something other than the fuel system

  See Advanced Diagnostics

Fuel tank almost empty Fuel Pump Cavitations
  The tank should be at least ¼ full to
properly prime the fuel pump
Clogged fuel filter Repair/replace as required
  See Maintenance section, Primary and
Secondary Fuel Filter replacement
re placement
 -94-

Operation Section

Problem Probable Cause Corrective Action

Electric Fuel Pump malfunction Check electrical connection
Will Not Run (GAS)   Check Relay and fuse Turn key ON
Continuously and verify pump is operating
(Gas)   See Engine Service Manual

Pressure regulator malfunction Test pressure regulator operation

  See Engine Service Manual

Fuel Injector malfunction Test Injector operation

  See Engine Service Manual

Incorrect idle speed or ignition See Advanced Diagnostics

problem
Engine Mechanical See Engine Service Manual
Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Will Not running the lift truck on LPG If the problem does not exist in LPG mode
Accelerate/Hesita proceed with the corrective action steps
tion During below.
Acceleration or If the problem also exists in LPG mode then
Engine Stalls the root cause is most likely to be
(Gas) something other than the fuel system
  See Advanced Diagnostics
Fuel tank almost empty Fuel Pump Cavitations
  The tank should be at least ¼ full to
properly prime the fuel pump

Clogged fuel filter Repair/replace as required

  See Maintenance section, Primary and
Secondary Fuel Filter replacement
re placement

Pressure regulator malfunction Test pressure regulator operation

  See Engine Service Manual

Fuel Injector malfunction Test Injector operation

 -95-

Operation Section

Problem Probable Cause Corrective Action

Throttle butterfly valve not opening See Advanced Diagnostics
Will Not or sticking
Accelerate/Hesita Foot Pedal signal incorrect or
tion During intermittent
Acceleration or Incorrect air/fuel or ignition control
Engine Stalls
(Gas) Engine Mechanical See Engine Service Manual

Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Rough Idle (Gas) running the lift truck on LPG If the problem does not exist in LPG mode
proceed with the corrective action steps
below.

If the problem also exists in LPG mode then

the root cause is most likely to be
something other than the fuel system

  See Advanced Diagnostics & Service

Manual
Pressure regulator malfunction Test pressure regulator operation

  See Engine Service Manual
Clogged fuel filter Repair/replace as required
  See Maintenance section, Primary and
Secondary Fuel Filter replacement
re placement
Pressure regulator malfunction Test pressure regulator operation
  See Engine Service Manual
Fuel Injector malfunction Test Injector operation
  See Engine Service Manual
Vacuum leak Check for vacuum leaks
  Between mixer and throttle body
  Between throttle body and intake
manifold
  Between intake manifold and cylinder
head
 -96-

Operation Section

Problem Probable Cause Corrective Action

control  
Incorrect Idle speed control  See Advanced Diagnostics & Engine
Rough Idle (Gas) Incorrect timing or spark control Service Manual
Engine Mechanical See Engine Service Manual

Incorrect Idle speed control See Advanced Diagnostics & Engine

High Idle Speed
(Gas) Service Manual
Throttle sticking

Foot pedal sticking or incorrect Check pedal return spring travel for binding
pedal signal
See Advanced Diagnostics
 -97-

Operation Section

Problem Probable Cause Corrective Action

Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Poor High Speed running the lift truck on LPG If the problem does not exist in LPG mode
Performance proceed with the corrective action steps
(Gas) below.

If the problem also exists in LPG mode then

the root cause is most likely to be
something other than the fuel system

See Advanced Diagnostics & Dual Fuel

Engine Service Manual
Clogged fuel filter Repair/replace as required
  See Maintenance section, Fuel Filter
replacement
Plugged fuel line Remove obstruction from the fuel line
  Close liquid fuel valve
  Using caution, disconnect the fuel line
(some propane may escape)
  Clear obstruction with compressed air
  Re-connect fuel line
  Slowly open liquid fuel valve & Leak
test
Air filter clogged Check air filter
 
Clean/replace as required
Faulty vapor connection between Check connection
the pressure regulator/converter   Verify no holes in hose
and the mixer   Clamps must be tight
  Look for kinked, pinched and/or
collapsed hose
Pressure regulator malfunction Test pressure regulator operation
  See Dual Fuel Engine Service Manual

Problem Probable Cause Corrective Action

Air/Fuel Mixer malfunction Check mixer
Poor High Speed   See Engine Service Manual
Performance Restricted exhaust system Check exhaust system
  Measure exhaust back pressure
(Gas) control  
Incorrect ignition control  See Advanced Diagnostics & Engine
Incorrect air/fuel control Service Manual
Incorrect throttle position
 -98-

Operation Section

Advanced Diagnostics Displaying Fault Codes (DFC) from

SECM Memory
MI-07 systems are equipped with built-in fault
diagnostics. Detected system faults can be To enter code display mode you must turn OFF O FF the
displayed by the Malfunction Indicator Lamp (MIL) ignition key. Now turn ON the key but do not start
as Diagnostic Fault Codes (DFC) or flash codes, the engine. As soon as you turn the key to the ON
and viewed in detail with the use of the Service Tool position you must cycle the foot pedal by depressing
software. When the ignition key is turned on, the MIL it to the floor and
a nd then fully releasing the pedal
will illuminate and remain on until the engine is (pedal maneuver). You must fully cycle the foot
started. Once the engine is started, the MIL lamp will pedal three (3) times within five (5) seconds to
go out unless one or more fault conditions are enable the display codes feature of the SECM.
present. If a detected fault condition exists, the fault Simply turn the key OFF to exit exi t display mode. The
or faults will be stored in the memory of the small code list will continue to repeat until the key is
engine control module (SECM). Once an active fault turned OFF.
occurs the MIL will illuminate and remain ON. This
signals the operator that a fault has been detected
by the SECM.

Reading Diagnostic Fault Codes

All MI-07 fault codes are three-digit codes. When the

fault codes are retrieved (displayed) the MIL will
flash for each digit with a short pause
p ause (0.5 seconds)
between digits and a long pause (1.2 seconds)
between fault codes. A code 12 is displayed at the
end of the code list.

EXAMPLE: A code 461 (ETCSticking)

(ETCSticking) has
has been
detected and the engine has shut down and the MIL M IL
has remained ON. When the codes are displayed
the MIL will flash four times (4), pause, then flash six si x
times (6), pause, then flash one time (1) This
identifies a four sixty one (461), which is the
ETCSticking
ETCSticki ng fault. If any
a ny additional faults were
stored, the SECM would again have a long pause,
then display the next fault by flashing each digit.
Since no other faults were stored there will be a lo long
ng
pause then one flash (1), pause, then two flashes
fla shes
(2). This identifies a twelve, signifying the end of the
fault list. This list will then repeat.

(1) Malfunction Indicator Lamp(MIL) for Engine control system.

 -99-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes)

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE

CORRECTIVE ACTION FIRST CHECK
NONE
None, used as end of the fault list
l ist
12 Signifies the end of one pass NONE
identification
through the fault list
(1) TurnOnMil Check INJ1 wiring for an open circuit
Inj1Open
131 Gasoline Injector 1 open (2)LiquidO2Ctrl
Disable SECM (Signal)
Switched 12V toA5 to Injector
Injector 1 Pin1BPin A
circuit, broken injector 1 wire
(3) Delayed Check Injector 1 Resistance, 12 to14
or defective injector
EngineShutdown ohms (cold)
(1) TurnOnMil Check INJ2 wiring for an open circuit
Inj2Open
(2) Disable SECM (Signal) A8 to Injector 2 Pin A
Gasoline Injector 2 open
132 LiquidO2Ctrl Switched 12V to Injector 2 Pin B
circuit, broken injector 2 wire
(3) Delayed Check Injector 2 Resistance, 12 to14
or defective injector
EngineShutdown ohms (cold)
(1) TurnOnMil Check INJ3 wiring for an open circuit
Inj3Open
(2) Disable SECM (Signal) A4 to Injector 3 Pin A
Gasoline Injector 3 open
133 LiquidO2Ctrl Switched 12V to Injector 3 Pin B
circuit, broken injector 3 wire
(3) Delayed Check Injector 3 Resistance, 12 to14
or defective injector
EngineShutdown ohms (cold)
(1) TurnOnMil Check INJ4 wiring for an open circuit
Inj4Open
(2) Disable SECM (Signal) A7 to Injector 4 Pin A
Gasoline Injector 4 open
134 circuit, broken injector 4 wire LiquidO2Ctrl Switched 12V to Injector 4 Pin B
(3) Delayed Check Injector 4 Resistance, 12 to 14
or defective injector
EngineShutdown ohms (cold)
Check ECT sensor connector and wiring
ECTRangeLow (1) TurnOnMil for a short to GND
G ND
141
Coolant Sensor failure or (2) DelayedEngi
D elayedEngine
ne SECM (Signal) Pin B15 To ECT Pin 3
(14)
shorted to GND Shutdown SECM (Sensor GND) Pin B1 to ECT Pin 1
SECM (System GND) Pin A16, B17
Check if ECT sensor connector is
ECTRangeHigh (1) TurnOnMil
151 disconnected or for an open ECT circuit
Coolant sensor disconnected (2) DelayedEngi
D elayedEngine
ne
(15) SECM (Signal) Pin B15 to ECT Pin 3
or open circuit Shutdown
SECM (Sensor GND) Pin B1 to ECT Pin 1

(*) Fault actions shown are default values specified by the OEM.
 -100-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE

CORRECTIVE ACTION FIRST CHECK

Check coolant system for radiator

blockage, proper coolant level and for
fo r
ECTOverTempFault
leaks in the system.
Engine coolant temperature is
161 high. The sensor has (1) TurnOnMil
(2) DelayedEngi
D elayedEngine
ne Possible ECT short to GND, check ECT
signal wiring
(16) measured an excessive
Shutdown SECM (Signal) Pin B15 to ECT Pin 3
coolant temperature typically
SECM (Sensor GND) Pin B1 to ECT Pin 1
due to the engine overhe
o verheating.
ating.
SECM (System GND) Pin A16, B17
Check regulator for coolant leaks
leak s

ECT_IR_Fault
Check for coolant system problems, e.g.
171 Engine coolant temperature TurnOnMil
defective or stuck thermostat
th ermostat
not changing as expected
FuelSelectConflict Check fuel select switch connection for
fo r a
Conflict in fuel select signals, (1) TurnOnMil short to GND
181 normally set if both of the fuel (2) Delayed SECM (SIGNAL) Pin A12
select signals are shorted to EngineShutdown SECM (SIGNAL) Pin A15
ground SECM (Sensor GND) Pin B1
Check CAM sensor connections
CamEdgesFault
No CAM signal when engine is SECM
Pin 2 (SIGNAL) Pin B10 to CAM sensor
191 known to be rotating, broken None SECM (Sensor GND) Pin B1 to CAM
crankshaft sensor leads or sensor Pin 3
defective CAM sensor Switched 12V to CAM sensor Pin 1
Check for defective CAM sensor
Check CAM sensor connections
CamSyncFault
SECM (SIGNAL) Pin B10 to CAM sensor
Loss of synchronization on the
Pin 2
CAM sensor, normally due to
192 None SECM (Sensor GND) Pin B1 to CAM
noise on the signal or an
sensor Pin 3
intermittent connection on the
Switched 12V to CAM sensor Pin 1
CAM sensor
Check for defective CAM sensor
Check Crankshaft sensor connections
CrankEdgesFault
SECM (SIGNAL) Pin B5 to Crank
Cran k sensor
No crankshaft signal when
Pin 3
engine is known to be rotating,
193 broken crankshaft sensor None SECM
sensor (Sensor
Pin 2 GND) PIN B1 to Crank
Cran k
leads or defective crank
Switched 12V to Crank sensor Pin 1
sensor
Check for defective Crank sensor
Check Crankshaft sensor connections
CrankSyncFault
SECM (SIGNAL) Pin B5 to Crank
Cran k sensor
Loss of synchronization on the
Pin 3
crankshaft sensor, normally
194 None SECM (Sensor GND) Pin B1 to Crank
due to noise on the signal or
sensor Pin 2
an intermittent connection on
Switched 12V to Crank sensor Pin 1
the crankshaft sensor
Check for defective Crank sensor

(*) Fault actions shown are default values specified by the OEM.
 -101-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

DFC
DFC PROBA
PROBABL
BLE
E FAULT
FAULT FAUL
FAULT
T AC
ACT
TION * CORR
CORREC
ECTI
TIVE
VE AC
ACTI
TION
ON FIRS
FIRST
T CH
CHEC
ECK
K
TPS1RangeLow Check throttle connector connection and
TPS1 sensor voltage out of TPS1 sensor for an open circuit or short to
221 range low, normally set if the (1) TurnOnMil GND
(22) TPS1 signal has shorted to (2) CutThrottle SECM Pin B23 (signal) to ETC Pin 6
ground, circuit has opened or SECM Pin B1 (sensor GND) to ETC Pin 2
sensor has failed SECM (system GND) Pin A16, B17
TPS2RangeLow Check throttle connector connection and
TPS2 sensor voltage out of TPS2 sensor for an open circuit or short to
range low, normally set if the (1) TurnOnMil GND
222
TPS2 signal has shorted to (2) CutThrottle SECM Pin B4 (signal) to ETC Pin 5
ground, circuit has opened or SECM Pin B1 (sensor GND) to ETC Pin 2
sensor has failed SECM (system GND) Pin A16, B17
TPS1RangeHigh
TPS1 sensor voltage out of Check throttle connector and TPS1 sensor
231 range high, normally set if the (1) TurnOnMil wiring for a shorted circuit
ci rcuit
(23) TPS1 signal has shorted to (2) CutThrottle SECM Pin B23 (signal) to ETC Pin 6
power or the ground for the SECM Pin B1 (sensor GND) to ETC Pin 2
sensor has opened
TPS2RangeHigh
TPS2 sensor voltage out of Check throttle connector and TPS1 sensor
232 range high, normally set if the (1) TurnOnMil wiring for a shorted circuit
ci rcuit
TPS2 signal has shorted to (2) CutThrottle SECM Pin B4 (signal) to ETC Pin 5
power or the ground for the SECM pin B1 (sensor GND) to ETC Pin 2
sensor has opened
TPS1AdaptLoMin
241 Learned closed throttle end of
None N/A
(24) TPS1 sensor range lower than
expected
TPS2AdaptLoMin
Learned closed throttle end of
242 None N/A
TPS2 sensor range lower than
expected
TPS1AdaptHiMax
251 Learned WOT end of TPS1
None N/A
(25) 
(25)  sensor range higher than
expected
TPS2AdaptHiMax
Learned WOT end of TPS2
252 None N/A
sensor range higher than
expected
TPS1AdaptHiMin
Learned WOT end of TPS1
271 None N/A
sensor range lower than
expected

(*) Fault actions shown are default values specified by the OEM.
 -102-

Operation Section

Table 2. Diagnostic Fault Codes (Fla

(Flash
sh Codes)
Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

TPS2AdaptHiMin
Learned WOT end of TPS2
272 None N/A
sensor range lower than
expected
TPS1AdaptLoMax
Learned closed throttle end
281 None N/A
of TPS1 sensor range higher
than expected
TPS2AdaptLoMax
Learned closed throttle end of
282 None N/A
TPS2 sensor range higher
than expected
TPS_Sensors_Conflict Check the throttle connector and pins for
TPS sensors differ by more corrosion.
than expected amount To check the TPS disconnect the throttle
NOTE: The TPS is not a connector and measure the resistance
(1) TurnOnMil from:
291  s erv iceabl
ic eable
e item and
and c an
(2) CutThrottle
only
onl y be repaired by TPS Pin 2 (GND) to Pin 6 (TPS1 SIGNAL)
replacing
repl acing the D V-E V throttle
throttle (0.7 Ω  ± 30%)
assembly.  TPS Pin 3 (PWR) to Pin 6 (TPS1 SIGNAL)
(1.4 Ω  ± 30%)
Check TMAP connector and MAP signal
wiring for an open circuit
TMAP Pin 4 to SECM Pin B18 (signal)
MAPTimeRangeLow
TMAP Pin 1 to SECM Pin B1 (sensor GND)
Manifold Absolute Pressure
TMAP Pin 3 to SECM Pin B24 (XDRP +5
sensor input is low, normally
Vdc)
331 set if the TMAP pressure
TurnOnMil Check the MAP sensor by disconnecting
di sconnecting
(33)  
(33) signal wire has been
the TMAP connector and measuring at the
disconnected
disconnecte d or shorted to sensor:
ground or the circuit has TMAP Pin 1(GND) to
opened to the SECM
Pin 4 (pressure signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to
Pin 4 (pressure signal KPA) (3.4kΩ - 8.2kΩ)
Check TMAP connector and MAP signal
wiring for an open circuit
MAPRangeLow TMAP Pin 4 to SECM Pin B18 (signal)
TMAP Pin 1 to SECM Pin B1 (sensor GND)
Manifold Absolute Pressure
TMAP Pin 3 to SECM Pin B24 (XDRP +5
sensor input is low, normally
Vdc)
set if the TMAP pressure (1) TurnOnMil
332 Check the MAP sensor by disconnect-ing
di sconnect-ing
signal wire has been (2) EngineShutdown
the TMAP connector and measuring at the
disconnected
disconnecte d or shorted to sensor:
ground or the circuit has TMAP Pin 1(GND) to
opened to the SECM
Pin 4 (pressure signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to
Pin 4 (pressure signal KPA) (3.4kΩ - 8.2kΩ)

(*) Fault actions shown are default values specified by the OEM.
 -103-

Operation Section

Table 2. Diagnostic Fault Codes (Fla

(Flash
sh Codes)
Codes) cont’d.

DFC
DFC PROBA
PROBABL BLE
E FAULT
FAULT FAULT
FAULT AC
ACTI
TION
ON * CO
CORRRREC
ECTI
TIVE
VE AC
ACTI
TION
ON FIRS
FIRST
T CH
CHE
ECK
MAPTimeRangeHigh Check TMAP connector and MAP signal wiring
Manifold Absolute Pressure for a shorted circuit
Sensor Input is High, normally TMAP Pin 4 to SECM Pin B18 (signal)
set if the TMAP pressure TMAP Pin 1 to SECM Pin B1 (sensor GND)

341 signal
shortedwire has become
to power, shorted to TurnOnMil TMAP
Check Pin 3 to SECM
the MAP sensorPin
byB24 (XDRP +5 Vdc)
disconnect-ing the
(34) 
(34)  TMAP connector and measuring at the sensor:
the IAT signal, the TMAP has
failed or the SECM has failed. TMAP Pin 1(GND) to
Pin 4 (pressure signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to
Pin 4 (pressure signal KPA) (3.4kΩ - 8.2kΩ)
MAPRangeHigh Check TMAP connector and MAP signal wiring
Manifold Absolute Pressure for a shorted circuit
Sensor Input is High, normally TMAP Pin 4 to SECM Pin B18 (signal)
set if the TMAP pressure TMAP Pin 1 to SECM Pin B1 (sensor GND)
signal wire has become (1) TurnOnMil TMAP Pin 3 to SECM Pin B24 (XDRP +5 Vdc)
342 shorted to power, shorted to (2) Engine Check the MAP sensor by disconnecting the
the IAT signal, the TMAP has Shutdown TMAP connector and measuring at the sensor:
failed or the SECM has failed TMAP Pin 1(GND) to
Pin 4 (pressure signal KPA) (2.4kΩ - 8.2kΩ)

TMAP Pin 3 (power)

Pin 4 (pressure signaltoKPA) (3.4kΩ - 8.2kΩ)
MAP_IR_HI Check for vacuum leaks. Check that TMAP
351 MAP sensor indicates higher TurnOnMil sensor is mounted properly. Possible defective
defective
pressure than expected TMAP sensor.
MAP_IR_LO
352 MAP sensor indicates lower TurnOnMil Possible defective TMAP sensor.
pressure than expected
MAP_STICKING
Check that TMAP sensor is mounted properly.
353 MAP sensor not changing as TurnOnMil
Possible defective TMAP sensor.
expected
Check TMAP connector and IAT signal wiring
IATRangeLow for a shorted circuit
Intake Air Temperature TMAP Pin 2 to SECM Pin B12 (signal)
Sensor Input is Low normally TMAP Pin 1 to SECM Pin B1 (sensor GND)
371
set if the IAT temperature TurnOnMil To check the IAT sensor of the TMAP
(37)  
(37)
sensor wire has shorted to disconnect the TMAP connector and measure
chassis ground or the sensor the IAT resistance
has failed. Resistance is approx 2400 ohms at room
temperature.

(*) Fault actions shown are default values specified by the OEM.
 -104-

Operation Section

Table 2. Diagnostic Fault Codes (Fla

(Flash
sh Codes)
Codes) cont’d.

DFC
DFC PROBA
PROBABL
BLE
E FAULT
FAULT FAULT
FAULT AC
ACTI
TION
ON * CO
CORR
RREC
ECTI
TIVE
VE AC
ACTI
TION
ON FIRS
FIRST
T CH
CHE
ECK
Check TMAP connector and IAT signal wiring
IATRangeHigh for a shorted circuit
Intake Air Temperature TMAP Pin 2 to SECM Pin B12 (signal)
Sensor Input is High normally TMAP Pin 1 to SECM Pin B1 (sensor GND)
381
(38)  
(38) set if the IAT temperature TurnOnMil To check the IAT sensor of the TMAP
sensor wire has been disconnect the TMAP connector and measure
disconnected
disconnecte d or the circuit has the IAT resistance
opened to the SECM. Resistance is approx 2400 ohms at room
temperature.
IAT_IR_Fault Check connections to TMAP sensor. Check
391 Intake Air Temperature not None that TMAP sensor is properly mounted to
changing as expected manifold.
Check coil driver wiring and connector for open
circuit
SECM Pin A9 (EST1) to OEM O EM ignition system.
EST1_Open See application note.
EST1 output open, possibly Verify GND on ignition module
421 TurnOnMil
open EST1 signal or defective Pin A (of both connectors)
spark module Verify +12 Vdc on ignition module
Pin B (of both connectors)
Refer
details.to application manual for specific
s pecific engine
Check coil driver wiring and connector for open
circuit
SECM Pin A10 (EST2) to OEM ignition
EST2_Open system. See application note.
EST2 output open, possibly Verify GND on ignition module
422 TurnOnMil
open EST2 signal or defective Pin A (of both connectors)
spark module Verify +12 Vdc on ignition module
Pin B (of both connectors)
Refer to application manual for specific
s pecific engine
details.
Check coil driver wiring and connector for open
circuit
SECM Pin A3 (EST3) to OEM O EM ignition system.
EST3_Open See application note.
423 EST3 outputsignal
open EST3 open,orpossibly
defective TurnOnMil Verify GND
Pin A (of onconnectors)
both ignition module
spark module Verify +12 Vdc on ignition module
Pin B (of both connectors)
Refer to application manual for specific
s pecific engine
details.

(*) Fault actions shown are default values specified by the OEM.
 -105-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC
DFC PROB
ROBAB
ABL
LE FAUL
FAULT
T FAUL
FAULT
T AC
ACT
TION * CORR
CORREC
ECTI
TIVE
VE AC
ACTI
TION
ON FIRS
FIRST
T CH
CHEC
ECK
K
Check coil driver wiring and connector for
open circuit
SECM Pin A6 (EST4) to OEM ignition
EST4_Open system. See application manual.
424 EST4 output open, possibly TurnOnMil Verify GND on ignition module
open EST4 signal or defective Pin A (of both connectors)
spark module Verify +12 Vdc on ignition module
Pin B (of both connectors)
Refer to application manual for specific
engine details.
EST5_Open
425 EST5 output open, possibly
None N/A
open EST5 signal or defective
spark module
EST6_Open
426 EST6 output open, possibly
None N/A
open EST6 signal or defective
spark module
EST7_Open
EST7 output open, possibly
427 None N/A
open EST7 signal or defective
spark module
EST8_Open
EST8 output open, possibly
428 None N/A
open EST8 signal or defective
spark module
EST1_Short
EST1 output shorted high or
431 low, EST1 signal shorted to None N/A
ground or power or defective
spark module

(*) Fault actions shown are default values specified by the OEM.
 -106-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

EST2_Short
EST2 output shorted high or
432 low, EST2 signal shorted to None N/A
ground or power or defective
spark module
EST3_Short
EST3 output shorted high or
433 low, EST3 signal shorted to None N/A
ground or power or defective
spark module
EST4_Short
EST4 output shorted high or
434 low, EST4 signal shorted to None N/A
ground or power or defective
spark module
EST5_Short
EST5 output shorted high or
435 low, EST5 signal shorted to None N/A
ground or power or defective
spark module
EST6_Short
EST6 output shorted high or
436 low, EST6 signal shorted to None N/A
ground or power or defective
spark module

(*) Fault actions shown are default values specified by the OEM.
 -107-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

EST7_Short
EST7 output shorted high or
437 low, EST7 signal shorted to None N/A
ground or power or defectiv
de fective
e
spark module
EST8_Short
EST8 output shorted high or
438 low, EST8 signal shorted to None N/A
ground or power or defectiv
de fective
e
spark module
Check for debris or obstructions inside
ETC_Sticking
the throttle body
Electronic Throttle Control is Perform the throttle test using the
sticking. This can occur if the Service Tool and re-check for fault
faul t
throttle plate (butterfly valve)
• Check throttle-plate shaft for bearing
inside the throttle bore is
wear
sticking. The plate sticking can
be due to some type of • Check the ETC driver wiring for an
(1) TurnOnMil
461 open circuit
obstruction, a loose throttle (2) EngineShutdown
(26) plate, or worn components shaft SECM Pin A17 to ETC + Pin 1
(3) CutThrottle
bearings. SECM Pin A18 to ETC - Pin 4
NOTE: The throttle
throttle as s embly
embly Check the ETC internal motor drive by
is not a s ervi
erviceab
ceable
le item an
and d disconnecting
disconnect ing the throttle connector and
can only be repaired by measuring the motor drive resistance at
the throttle
replacing
repl acing th
the
e DV -E V throttl
throttle
e
TPS Pin 1 (+DRIVE
( +DRIVER) R) to
as s embl
embly.
y.  
Pin 4 (-DRIVER)
( -DRIVER) ~3.0-4.0Ω 
Check the ETC driver wiring for an open
circuit
ETC_Open_Fault
SECM Pin A17 to ETC + Pin 1
Electronic Throttle Control Driver
SECM Pin A18 to ETC - Pin 4
has failed, normally set if driver (1) TurnOnMil
Check the ETC internal motor drive by
471 signals have failed open or (2) CutThrottle
disconnecting
disconnectin g the throttle connector and
become disconnected,
measuring the motor drive resistance at
electronic throttle or SECM is
the throttle
defective.
TPS Pin 1 (+DRIVE
( +DRIVER) R) to
Pin 4 (-DRIVER)
( -DRIVER) ~3.0-4.0Ω 
ETCSpringTest
Electronic Throttle Control
Spring Return Test has failed.
The SECM will perform a safety
test of the throttle return spring
following engine shutdown. If the
drive mechanism is damaged, or (1) TurnOnMil
481 Perform throttle spring test by cycling
the return spring has lost tension (2) EngineShutdown
(28)  
(28) the ignition key and re-check for fault
the throttle will fail the test
te st and (3) CutThrottle
set the fault.
NOTE:  The throttle
NOTE: throttle as s embly
embly
is not a s erviceab
ervi ceable
le item an
andd
can only be repaired by
replaci
repla ci ng the DV -E V throttle
throttle
as s embl
embly.
y.  

(*) Fault actions shown are default values specified by the OEM.
 -108-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

Check ETC driver wiring for a shorted circuit
HbridgeFault_ETC SECM Pin A17 to ETC + Pin 1
Electronic Throttle Control SECM Pin A18 to ETC - Pin 4
Driver has failed. • Perform the throttle test using the Service
491 Indeterminate fault on (1) TurnOnMil Tool and re-check for fault
Hbridge driver for Check the ETC internal motor drive by
(29)  
(29) (2) CutThrottle
electronic throttle control. disconnecting
disconnect ing the th
throttle
rottle connector and
Possibly either ETC+ or measuring
measurin g the motor drive resistance at the
ETC- driver signals have throttle
been shorted to ground TPS Pin 1 (+DRIVER) to
Pin 4 (-DRIVER
(- DRIVER)) ~3.0-4.0Ω 
Check engine oil level
(1) TurnOnMil
521 LowOilPressureFault Check electrical connection to the oil
(2) DelayedEngine
(52)  
(52) Low engine oil pressure pressure switch
Shutdown
SECM Pin B9 to Oil Pressure Switch
Check battery voltage
• Perform maintenance check on electrical
connections to the battery and chassis
ground
• Check battery voltage during starting and
531 SysVoltRangeLow with the engine running to verify charging
TurnOnMil system and alternator
al ternator function
function
(53)  
(53) System voltage too low
• Measure battery power at SECM with a
multimeter (with key on)
SECM Pin A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin A23 (DRVP) to
SECM Pin B17 (DRVG)
Check battery and charging system voltage
• Check battery voltage during starting and
with the engine running
• Check voltage regulator, alternator, and
charging system
(1) TurnOnMil • Check battery and wiring for overheating
541 SysVoltRangeHigh
(2) DelayedEngine and damage
(54)  
(54) System voltage too high
Shutdown •

Measure battery power at SECM with a

multimeter (with key on)
SECM Pin A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin A23 (DRVP) to
SECM Pin B17 (DRVG)

(*) Fault actions shown are default values specified by the OEM.
 -109-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

Measure transducer power at the

TMAP connector with a multimeter
TMAP Pin 3 XDRP +5 Vdc to
TMAP Pin 1 XDRG GND
Verify transducer power at the
(1) TurnOnMil SECM with a multimeter
SensVoltRangeLow
551 (2) DelayedEngine SECM Pin B24 +5 Vdc to SECM
Sensor reference voltage
(55) 
(55)  Shutdown Pin B1 XDRG GND
XDRP too low
Verify transducer power at
ETC with a multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2 XDRG
GND
Verify transducer power to the foot pedal with a
multimeter.
Measure transducer power at the
TMAP connector with a multimeter
TMAP Pin 3 XDRP +5 Vdc to
TMAP Pin 1 XDRG GND
Verify transducer power at the
(1) TurnOnMil SECM with a multimeter
561 SensVoltRangeHigh (2) DelayedEngine SECM Pin B24 +5 Vdc to
Sensor reference voltage
(56)  
(56) Shutdown SECM Pin B1 XDRG GND
XDRP too high
Verify transducer power at ETC with a
multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2 XDRG
GND
Verify transducer power to the foot pedal with a
multimeter.
HardOverspeed Usually associated with additional ETC faults
Engine speed has (1) TurnOnMil • Check for ETC Sticking or other
o ther ETC faults
571
exceeded the third level (3 (2) HardRevLimit
H ardRevLimit Verify if the lift truck was motored down a steep
(57)  
(57)
of 3) of overspeed (3) EngineShutdow
EngineShutdownn grade
protection
MediumOverspeed Usually associated with additional ETC faults
(1) TurnOnMil
Engine speed has • Check for ETC Sticking or other
o ther ETC faults
(2) MediumRevLimit
572 exceeded the second level Verify if the lift truck was motored down a steep
(2 of 3) of overspeed (3) DelayedEngine grade
Shutdown
protection
SoftOverspeed Usually associated with additional ETC faults
Engine speed has • Check for ETC Sticking or other
o ther ETC faults
(1) TurnOnMil
573 exceeded the first level (1 Verify if the lift truck was motored down a steep
(2) SoftRevLimit
of 3) of overspeed grade
protection
APP1RangeLow
APP1 sensor voltage out
of range low,
lo w, normally set Check foot pedal connector
611 TurnOnMil
if the APP1 signal has
(61)  
(61) • Check APP1 signal at SECM PIN B7
shorted to ground, circuit
has opened or sensor has
failed

(*) Fault actions shown are default values specified by the OEM.
 -110-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION FIRST

DFC PROBABLE FAULT FAULT ACTION *
CHECK
APP2RangeLow
APP2 sensor voltage out of range Check foot pedal connector
612
low, normally set if the APP2 signal TurnOnMil • Check APP2 signal at SECM PIN
(65)  
(65)
has shorted to ground, circuit has B16
opened or sensor has failed
APP1RangeHigh
APP1 sensor voltage out of range Check foot pedal connector
621 TurnOnMil
(62)  
(62) high, normally set if the APP1 signal • Check APP1 signal at SECM PIN
has shorted to power or the ground
g round B7
for the sensor has opened
APP2RangeHigh
622 APP2 sensor voltage out of range Check foot pedal connector
high, normally set if the APP2 signal TurnOnMil • Check APP2 signal at SECM PIN
(66)  
(66)
has shorted to power or the ground B16
for the sensor has opened
Check APP connector and pins for
APP1AdaptLoMin corrosion
631
Learned idle end of APP1 sensor TurnOnMil • Cycle the pedal several times and
(63)  
(63)
range lower than expected check APP1 signal at SECM Pin
B7
Check APP connector and pins for

632 APP2AdaptLoMin
Learned idle end of APP2 sensor TurnOnMil corrosion
• Cycle the pedal several times and
(67) 
(67) 
range lower than expected check APP2 signal at SECM Pin
B16
Check APP connector and pins for
641 APP1AdaptHiMax
corrosion
Learned full pedal end of APP1 TurnOnMil
(64)  
(64) Cycle the pedal several times and
sensor range higher than expected
e xpected
check APP1 signal at SECM Pin B7
Check APP connector and pins for
642 APP2AdaptHiMax
corrosion
Learned full pedal end of APP2 TurnOnMil
(68)  
(68) Cycle the pedal several times and
sensor range higher than expected
e xpected
check APP2 signal at SECM Pin B16
Check APP connector and pins for
APP1AdaptHiMin
corrosion
651 Learned full pedal end of APP1 TurnOnMil
Cycle the pedal several times and
sensor range lower than expected
check APP1 signal at SECM Pin B7
Check APP connector and pins for
APP2AdaptHiMin
corrosion
652 Learned full pedal end of APP2 TurnOnMil
sensor range lower than expected Cycle the pedal several times and
check APP2 signal at SECM Pin B16
Check APP connector and pins for
APP1AdaptLoMax
corrosion
661 Learned idle end of APP1 sensor TurnOnMil
Cycle the pedal several times and
range higher than expected
check APP1 signal at SECM Pin B7
Check APP connector and pins for
APP2AdaptLoMax
662 TurnOnMil corrosion
Learned idle end of APP2 sensor
Cycle the pedal several times and
range higher than expected
check APP2 signal at SECM Pin B16
Check APP connector and pins for
corrosion
APP_Sensors_Conflict • Cycle the pedal several times and
691 
691  APP position sensors do no not track (1) TurnOnMil check APP1 signal at SECM Pin
(69) well, intermittent connections to APP (2) Cut Throttle B7
or defective pedal assembly • Cycle the pedal several times and
check APP2 signal at SECM Pin
B16

(*) Fault actions shown are default values specified by the OEM.
 -111-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBA
ROBABL
BLE
E FAU
AULT
LT FA
FAUL
ULT
T ACTI
CTION * CORR
CORREC
ECT
TIVE
IVE AC
ACTI
TION
ON FIR
FIRST CHEC
CHECK
K
Check FTV1 for an open wire or FTV connector
LSDFault_Dither1 (1) TurnOnMil being disconnected
Dither Valve 1 Fault, signal (2) Disable FTV1 Pin 1 (signal) to SECM Pin A1
711
has opened or shorted to GasO2 Ctrl FTV1 Pin 2 (power) to SECM (DRVP) Pin A23
(71)  
(71) ground or power or defective (3) Disable Check FTV1 for an open coil by disconnecting
dither 1 valve the FTV connector and measuring the
GasPost O2Ctrl
resistance (~26Ω ± 2Ω )
Check FTV1 for an open wire or FTV connector
LSDFault_Dither2 (1) TurnOnMil being disconnected or signal shorted to GND
GN D
Dither Valve 2 Fault, signal (2) Disable FTV2 Pin 1 (signal) to SECM Pin A2
712 has opened or shorted to GasO2 Ctrl FTV2 Pin 2 (power) to SECM (DRVP) Pin A23
ground or power or defective (3) Disable Check FTV1 for an open coil by disconnecting
dither 2 valve GasPost O2Ctrl the FTV connector and measuring the
resistance (~26Ω ± 2Ω )
713 LSDFault_CSValve None N/A
LSDFault_CheckEngine
Check Engine Lamp Fault,
714 None Check ‘Check Engine Lamp’ for an open wire or
signal has opened or shorted shorted to GND
to ground or power or
defective check engine lamp
LSDFault_CrankDisable

715 Crank Disable

has opened or Fault,
shortedsignal
to None N/A
ground or power or defective
crank disable relay
Check fuel pump for an open wire or connector
being disconnected or signal shorted to GNDGN D
Fuel Pump Pin B (signal) from SECM Pin A13
LSDFault_FuelPump
Fuel pump fault, signal has Fuel Pump Pin A (power) from main relay 1 Pin
A23
716 opened, shorted to ground or TurnOnMil
Check Fuel Pump for an open coil by
power, or defective fuel disconnecting the Fuel Pump connector and
pump
measuring the resistance
(~26Ω ± 3Ω)
Check for 12V to fuel pump
Check fuel lock off valve for an open wire or
or
connector being disconnected or signal shorted
LSDFault_LockOff to GND
Fuel lock off Valve Fault, Lock off Pin B (signal) from SECM Pin A11
Lock off Pin A (power) from main relay 1 Pin
717 signal has opened or shorted TurnOnMil A23
to ground or power or
Check lock off valve for an open coil
  c oil by
defective Fuel lock off valve
disconnecting the lock off valve connector and
measuring the resistance (~26Ω ± 3Ω)
Check for 12V to lock off valve
LSDFault_MIL
Malfunction Indicator Lamp
718 Fault, signal has opened or None None
shorted to ground or power
or defective MIL lamp
(1) TurnOnMil
GasFuelAdaptRangeLo (2) Disable Check for vacuum leaks.
721 In LPG mode, system had to Check fuel trim valves, e.g. leaking valve or
(72)  
(72) adapt rich more than GasO2 Ctrl hose
expected (3) Disable Check for missing orifice(s).
o rifice(s).
GasPost O2Ctrl
GasDesEquivLo
In LPG mode, system had to
722 adapt rich more than None N/A
expected  
expected
 ( ) Fault actions shown are default values specified by the OEM.

-112-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

GasFuelAdaptRangeHi (1) TurnOnMil Check dual dither valves, e.g. plugged valve or
In LPG mode, system had (2) Disable hose.
731
(73) 
(73)  to adapt lean more than GasO2 Ctrl Check for plugged orifice(s).
ori fice(s).
(3) Disable
expected GasPost O2Ctrl
GasDesEquivHi
732 In LPG mode, system had None N/A
to adapt rich more than
expected
Check that Pre-catalyst O2 sensor connections
connections
are OK.
GasO2NotActive O2 (signal) Pin 3 to SECM Pin B13
(1) TurnOnMil O2 Pin 2 (HEATER GND) to SECM (DRVG
Pre-catalyst O2 sensor (2) DisableGas GNG) Pins A16, B17
741 inactive on LPG, open O2
(74) 
(74)  sensor signal or heater O2Ctrl O2 Pin 1 (HEATER PWR) to SECM (DRVP +
(3) Disable 12V) Pin A23
leads, defective O2
GasPost O2Ctrl Verify O2 sensor heater circuit is operating by
sensor measuring heater resistance (2.1Ω ± 0.4Ω)
O2 Pin 2 (HEATER GND) to Pin 1 (HEATER
PWR)
Check that Post-catalyst O2 sensor
connections
O2 are3OK.
(signal) Pin to SECM Pin B19
O2 Pin 2 (HEATER GND) to SECM (DRVG
GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2 Heater
Relay. Relay pin 87. This relay only turns on
GasPostO2NotActive after engine has been running for some time
Post-catalyst O2 sensor
(1) TurnOnMil and SECM has calculated that water
inactive on LPG, open O2 (2) DisableGasPost
DisableGasPost
742 sensor signal or heater condensation in exhaust has been removed
re moved by
leads, defective O2 O2Ctrl exhaust heat. Post O2 Heater Relay has
SECM (DRVP + 12V) applied to the relay coil
sensor.
power. The relay coil ground is controlled by
SECM Pin A20 to activate the relay to flow
current through the post O2 heater.
hea ter.
Verify O2 sensor heater circuit is operating by
measuring heater resistance (2.1Ω ± 0.4Ω )
O2 Pin 2 (HEATER GND) to Pin 1 (HEATER
PWR)

743 GasCatInactive None N/A

GasO2FailedLean (1) TurnOnMil Check for vacuum leaks.

Pre-catalyst O2 sensor (2) DisableGas Check dual dither valves, e.g. leaking valve or
751 indicates extended lean O2Ctrl hose.
operation on LPG (3) Disable Check for missing
mi ssing orifice(s).
GasPost O2Ctrl
Correct other faults that may contribute to 752
(e.g. faults pertaining to dither valves, Pre-Cat
GasPostO2FailedLean O2, Post Cat O2 sensor)
(1) TurnOnMil
752 Pre-catalyst O2 sensor Check for vacuum leaks
indicates extended lean (2) DisableGasPost
DisableGasPost
O2Ctrl Check for leaks in exhaust, catalytic converter,
operation on LPG HEGO sensors; repair leaks.
Check all sensor connections (see fault 742
corrective actions).
 

GasO2FailedRich (1) TurnOnMil Check dual dither valves, e.g. plugged valve or
(2) DisableGas hose.
771  
(77)
(77)  Pre-catalyst O2 sensor
indicates extended rich O2Ctrl Check for plugged orifice(s).
ori fice(s).
operation on LPG (3) DisableGasPost
DisableGasPost
O2Ctrl
 (*) Fault actions shown are default values specified by the OEM.

-113-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

Correct other faults that may contribute to 772

(e.g. faults pertaining to FTVs, Pre-Cat O2,
GasPostO2FailedRich (1) TurnOnMil
Pre-catalyst O2 sensor Post Cat O2 sensor)
772 (2) DisableGasPost Look for leaks in exhaust, catalytic converter,
indicates extended rich O2Ctrl HEGO sensors; repair leaks.
operation on LPG
Check all sensor connections (see fault 742
corrective actions). 
LiqFuelAdaptRangeHi (1) TurnOnMil Check for vacuum leaks.
In Gasoline mode, system (2) Disable Low gasoline fuel pressure, perform gasoline
821 had to adapt lean more LiquidO2 Ctrl pressure test.
than expected (3) Disable LiqPost Injector problems, e.g. plugged, defective
O2Ctrl injector.
822 LiqDesEquivHi None N/A

LiqFuelAdaptRangeLow (1) TurnOnMil Low gasoline fuel pressure, perform gasoline

In Gasoline mode, system (2) Disable pressure test
831 LiquidO2 Ctrl Injector problems, e.g. leaking, defective
had to adapt rich more than (3) Disable LiqPost injector.
expected
O2Ctrl
832 LiqDesEquivLo None N/A
Check that Pre-catalyst O2 sensor connections
are OK.
O2 (signal) Pin 3 to SECM Pin B13
LiqO2NotActive O2 Pin 2 (HEATER GND) to SECM (DRVG
Pre-catalyst O2 sensor (1) TurnOnMil GNG) Pins A16, B17
841 inactive on gasoline, open (2) DisableLiquid O2 Pin 1 (HEATER PWR) to SECM (DRVP +
O2 sensor signal or heater O2Ctrl 12V) PIN A23
leads, defective O2 sensor Verify O2 sensor heater circuit is operating by
measuring heater resistance (2.1Ω ± 0.4Ω )
O2 Pin 2 (HEATER GND) to Pin 1 (HEATER
PWR)
Check that Post-catalyst O2 sensor
connections are OK.
O2 (signal) Pin 3 to SECM Pin B19
O2 Pin 2 (HEATER GND) to SECM (DRVG
GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2 Heater

LiqPostO2NotActive Relay.
after Relayhas
engine pin been
87. This relayfor
running only turnstime
some on
Post-catalyst O2 sensor (1) TurnOnMil and SECM has calculated that water
842 inactive on gasoline, open (2) DisableLiqPost condensation in exhaust has been removed
re moved by
O2 sensor signal or heater O2Ctrl exhaust heat. Post O2 Heater Relay has
leads, defective O2 sensor. SECM (DRVP + 12V) applied to the relay coil
power. The relay coil ground is controlled by
SECM Pin A20 to activate the relay to flow
current through the post O2 heater.
hea ter.
Verify O2 sensor heater circuit is operating by
measuring heater resistance (2.1Ω ± 0.4Ω )
O2 Pin 2 (HEATER GND) to Pin 1 (HEATER
PWR)
843 LiqCatInactive None N/A

LiqO2FailedLean Check for vacuum leaks.

Pre-catalyst O2 sensor (1) TurnOnMil Low gasoline fuel pressure, perform gasoline
851 (2) DisableLiquid pressure test.
indicates extended lean
operation on gasoline O2Ctrl Injector
injector problems, e.g. plugged, defective
 (*) Fault actions shown are default values specified by the OEM.

-114-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

Correct other faults that may contribute to 852
(e.g. faults pertaining to Injectors, MAP, IAT,
LiqPostO2FailedLean
(1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor)
Pre-catalyst O2 sensor
852 (2) DisableL
DisableLiqPost
iqPost Look for leaks in exhaust, catalytic converter,
indicates
indicates extended lean
operation on gasoline O2Ctrl HEGO
Check sensors; repair
all sensor leaks.
connections (see fault 842
corrective actions).
LiqO2FailedRich
(1) TurnOnMil High gasoline fuel pressure, perform gasoline
Pre-catalyst O2 sensor
871 (2) DisableL
DisableLiquid
iquid pressure test
indicates
indicates extended rich
O2Ctrl Injector problems, e.g. leaking, defective injector
operation on gasoline
Correct other faults that may contribute to 872
(e.g. faults pertaining to Injectors, MAP, IAT,
LiqPostO2FailedRich
(1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor)
Pre-catalyst O2 sensor
872 (2) DisableLiq Look for leaks in exhaust, catalytic converter,
indicates
indicates extended rich
PostO2Ctrl HEGO sensors; repair leaks.
operation on gasoline
Check all sensor connections (see fault 842
corrective actions). 
O2RangeLow
Pre-catalyst O2 sensor
911 voltage out of range low, None N/A
sensor signal shorted to
ground

O2_PostCatRangeLow
Post-catalyst
Post-catalyst O2 sensor
912 voltage out of range low, None N/A
sensor signal shorted to
ground

O2RangeHigh Check if O2 sensor installed before catalyst is

(1) TurnOnMil
Pre-catalyst O2 sensor shorted to +5Vdc or battery.
(2) DisableLiquid O2Ctrl
O 2Ctrl
921 voltage out of range high, O2 (signal) Pin 3 to SECM Pin B13
(3) DisableGas
sensor signal shorted to SECM (XDRP + 5V) Pin B24
O2Ctrl
power SECM (DRVP + 12V) Pin A23
(1) TurnOnMil
O2_PostCatRangeHigh (2) Disable asoline Check if O2 sensor installed after catalyst is
Post-catalyst
Post-catalyst O2 sensor Post-catalyst shorted to +5Vdc or battery.
922 voltage out of range low, O2Ctrl O2 (signal) Pin 3 to SECM Pin B19
sensor signal shorted to (3) Disable LPG Possible voltage sources: SECM (XDRP + 5V)
ground Post-catalyst Pin B24 and SECM (DRVP + 12V) Pin A23
O2Ctrl
FuelTempRangeLow
Fuel Temperature Sensor Check fuel temp sensor connector and wiring for
Input is Low normally set if a short to GND
G ND
931 the fuel temperature TurnOnMil SECM (signal)
(signal) Pin B14 to FTS Pin 1
sensor wire has shorted to SECM (sensor
(sensor GND) Pin B1 to FTS Pin 2
chassis ground or the SECM (system GND) Pin A16, B17
sensor has failed.
FuelTempRangeHigh
Fuel Temperature Sensor Check if fuel temp sensor connector is
Input is High normally set if disconnected or for an open FTS circuit
932 the fuel temperature TurnOnMil SECM (signal)
(signal) Pin B14 to FTS Pin 1
sensor wire has been SECM (sensor GND) Pin B1 to
disconnected
disconnec ted or the circuit FTS Pin 2
has opened to the SECM.
 ( ) Fault actions shown are default values specified by the OEM.

-115-

Operation Section

Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

TransOilTemp (1) TurnOnMil
Refer to drivetrain manufacturer’s
933 Excessive transmission oil (2) DelayedEngine
transmission service procedures.
temperature Shutdown  
Perform service procedure related to
991 ServiceFault1
Service Interval 1 has been None Service Interval 1
reached (determined by OEM)
ServiceFault2 Perform service procedure related to
992 Service Interval 2 has been None Service Interval 2
reached (determined by OEM)
ServiceFault3 Perform service procedure related to
993 Service Interval 3 has been None Service Interval 3
reached (determined by OEM)
ServiceFault4
Service Interval 4 has been Replace Pre-catalyst HEGO sensor
994 TurnOnMil
reached-replace HEGO Replace Post-catalyst HEGO sensor
sensors
ServiceFault5
995 Service Interval 5 has been TurnOnMil Replace engine timing belt
reached-replace
reached-replac e timing belt

(*) Fault actions shown are default values specified by the OEM.
 -116-

Operation Section

Mono-Ped Control System (Option)

Forward-Push the left side (2) of the pedal

Forward-Push
for FORWARD direction travel.

Neutral-The lift truck should not move when

Neutral-The
the Mono-Ped pedal is released..

Push the right side (1) of the pedal

Reverse-Push
Reverse-
for REVERSE direction travel.

The MONO-PED pedal controls the speed and

direction of the lift truck. Pushing on the right side of
the pedal (1) causes the lift truck to move in
REVERSE. The optional reverse lights and optional
back-up alarm will be ON in the REVERSE position.
Pushing on the left side of the pedal (2) causes the
lift truck to move
mo ve in FORWARD.
The speed of the truck increases as the pedal is
depressed
 -117-

Operation Section

Auto Shift Controller ASC-100 (If Equipped)

Product Description Adjustments
The Autoshift controller is an electrical control SW2
system, specially designed for use on forklift trucks (Direction Inhibit Point)
with internal combustion engines. NOTCH Vehicle Speed
Its primary
driving purpose
the truck is to of
outside prevent the operator
the design from
parameters, 0 3.3 km/h ( 2.05 mph )
e.g. selecting the reverse gear when traveling in 1 3.6 km/h ( 2.24 mph )
excess of 5.1 km/h ( 3.17 mph) in a forward 2 3.9 km/h ( 2.42 mph )
direction, and vice versa.
3 4.2 km/h ( 2.61 mph )
The Autoshift controller is mounted on a convenient 4 4.5 km/h ( 2.80 mph )
position away from excessive heat sources and the 5 4.8 km/h ( 2.98 mph )
truck’s electrical system is retrofitted. An inductive 6 5.1 km/h ( 3.17 mph )
speed sensor is mounted on the differential housing
where it will pick up a pulse from a yoke tooth 7 5.4 km/h ( 3.36 mph )
pattern. This pulse is used to monitor the truck in 8 5.7 km/h ( 3.54 mph )
motion and its travel speed. To enable the system 9 6.0 km/h ( 3.73 mph )
to change gears smoothly, the shift points for offset
speed are adjustable.

The Autoshift controller prevents strain and abuse

Direction Inhibit Point

to
halftheshaft,
transmission. It also
excessive tire prevents
wear anddamage to the
heat to the
  This is -accomplished
factory on each machine with a
adjusted controller.
transmission.
   The SW2 is for adjustment of optimal direction
inhibit speed.
WARNING
Improper operation or maintenance could result    Factory - setting value is 5.1 km/h ( 3.17 mph )
in injury or death. Do not operate or work
w ork on the
   SW1 is not used.
lift truck unless you are properly trained. For
safe operation, carefully read and follow this
Operation and Maintenance Manual.

Adjustment Switch
 -118-

Operation Section

Diagnostics Features Operation

ASC-100 has an internal indicator on the right side This system can basically operate in 2 pre-selected
of the controller for displaying the selected gear modes.
and the abnormal condition.    Automatic mode (Direction Inhibit mode):
Selected as factory-setting.
factory-setting.
Below is a description applicable for many ASC-    Manual mode (Fail-Safe mode): manual
100 implementations. operation in emergency.

Display for Operator Automatic mode (Direction Inhibit

This information is given during normal operating mode)
when something special happens. Start the engine. See topic
topi c “Starting the engine”.
  
For example, on ASC-100’s with the speed sensor,
  Push down on the service brake pedal to hold the
one of the indicators is used to indicate a sensor lift truck until ready to move it.
problem.
   Release the parking brake.

   Check diagnostics display on controller. See

Display Description Remark “Diagnostics Features”.
A Automatic operation
P Speed sensor open Flashing
NOTICE
F Controller fault Flashing
The parking brake must be released before the
6 Forward Sol. Short Flashing
direction control lever can be used.
u sed.
7 Reverse Sol. Short Flashing

Display for Troubleshooting


The gear direction is selected with the direction
 
control lever.
   In automatic mode, if the turbine speed in a for
This information is input signal for diagnostics.
This test is used to verify an operation of direction ward direction is higher than direction inhibit
control lever. speed, though the reverse gear is selected by
operator, the direction of travel will not be
changed until the speed is reduced sufficiently by
Display Description Remark
pushing down on the service brake pedal.
A Automatic operation  
3 Forward s/w input Lever input test
WARNING
4 Reverse s/w input Lever input test
  When you want to change the direction of travel,
you must push down on the service brake pedal to
reduce the travel speed.
In automatic mode, the lift truck’s stopping distance
may be longer than in manual mode. BE
CAUTIOUS!

   When the directional change is completed,

continue to push down on the accelerator pedal
to obtain the desired travel speed. 
 -119-

Operation Section

Manual Mode (Fail-Safe mode)

The system still allows movement of the vehicle in
case of controller breakdown by selecting the
manual mode with the Fail-Safe mode Switch in the
controller.

WARNING
In the manual mode, direction inhibition
function can not be operated normally. The
sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift
truck to tip.

If the controller fails

An operator can operate the truck manually by
selecting the Manual mode with the Fail-Safe mode
switch on the PCB (Printed
( Printed Circuit Board).

Fail-Safe mode switch

NOTICE
Direction Inhibit Function is usable
u sable in factory-setting
controller. If you don’t want to use this function,
make sure to select the manual mode with the
Fail-Safe mode switch on PCB.
 -120-

Operation Section

Operating Techniques
Inching into Loads Lifting the Load
1.  Lift the load carefully and tilt the mast back a
short distance.

Typical Example

1.  Move the lift truck slowly FORWARD into

position and engage the load. The lift truck Typical Example
should be square with load, forks spaced
evenly between pallet stringers and as far apart 2.  Tilt the mast further back
ba ck to cradle the load.
as load permits.

Typical Example
Typical Example
3.  Operate the lift truck in reverse until the load is
2.  Move the lift truck FORWARD until the load clear of the other material.
touches the carriage. 4.  Lower the cradled load to the travel position.

NOTE:  Lift and tilt speeds are controlled by engine

rpm.
 -121-

Operation Section

Traveling With the Load Unloading

NOTICE
Travel with the load as low as possible, while still
maintaining ground clearance.

Typical Example

1.  Move the lift truck into the unloading

u nloading position.

Typical Example

1.  Travel with the load uphill on upgrades and

downgrades.

Typical Example

2.  Tilt the mast FORWARD only when directly

over the unloading area.

WARNING

Typical Example
Do not tilt the mast forward with the load unless
directly over the unloading area, even if the
power is off.
2.  For better vision, travel in reverse with bulky
loads.
 -122-

Operation Section

  Turning

Typical Example

3.  Deposit the load and BACK away carefully to

disengage the forks. 1.  When turning sharp corners, keep close to the
inside corner. Begin the turn when the inside
drive wheel meets the corner.

Typical Example

4.  Lower the carriage and forks to the travel

position or to the park
pa rk position. 2.  In narrow aisles, keep away from the stockpile
when turning into the aisle. Allow for counter
weight swing.
 -123-

Operation Section

Lifting Drums or Round Objects Operating in 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 air, also, check for
fo r leakage
of water.

2.  Check the fan belt tension and adjust to proper

tension.

3.  Even if the engine overheats and the coolant

boils over, let the engine idle for a while with
1.  Block drums or round objects. Tilt the mast opening engine hood until temperature falls
FORWARD and slide the fork tips along the before shutting off the engine.
floor to get under the load.
loa d.

2.  Before lifting, tilt the mast BACK slightly until

the load is cradled on the forks.
 -124-

Operation Section

Parking the Lift Truck

5. Turn the key in the ignition switch to the OFF
position and remove the key.

NOTE:  Park the lift truck level with the fork

for k lowered
and the mast tilted forward until the fork
touches the floor. Block the drive wheels
when parking on an incline. NOTE: If a LP equipped lift truck is stopped or
parked for an indefinite or prolonged
1. Park in an authorized area only. Do not block period of time, shut off the LP fuel tank
traffic. If LP equipped, do not park near elevator valve.
shafts or any other area where LP could collect
in a pocket
dangerous (low area), causing a potentially
condition. 6. Actuate
remove theeach loading
residual lever several
pressure times to
in the respective
cylinders and hoses.

If Parking Brake Alarm Equipped

2. Place the transmission controls in NEUTRAL.

3. Engage the parking brake.

4. Tilt the mast forward and lower the fork to the

ground. WARNING
When leaving machine apply parking brake!
WARNING Parking brake is not automatically applied.
Alarm will sound if parking brake is not applied.
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.
 -125-

Operation Section

Lift Fork Adjustment

WARNING
When adjusting the fork spread, be careful not
to pinch your hand between forks and the
carriage slot.

Hook-on type Fork

1.  Move up the hook pin to the free position.

2.  Raise the hook pin in each fork to side the fork
on the carriage bar.

3.  Adjust the forks in the position

posi tion most appropriate
for the load and as wide as possible for load
stability.

4.  When adjusting the forks, make sure that the

weight of the load is centered
cente red on the truck.

5.  After adjustment, set the fork locks to keep the

forks in place.

WARNING
Make sure the forks are locked before carrying
a load.
 -126-

Operation Section

Storage Information
Before Storage To Operate the Lift Truck after a
Before storing your lift truck, clean and inspect as Long Time Storage
the following procedures.
 Remove covers and antirust from each of the
 
components and exposed parts.

Wipe
of theaway
 
truckgrease, oil, etc.
with waste adhering
cloth, and useto the body
water, if
   Drain the engine crankcase, transmission (clutch

type machine), differential and final reduction

needed. gear, clean the inside of them and add new
n ew oil.
   While cleaning the truck, check general condition
   Drain off foreign matter and water from the
of the truck. Especially check the truck body for
hydraulic oil tank and fuel tank.
dents or damage and tires for wear or nails or
   Remove the head cover from the engine cylinder.
stones in the tread.
Oil valves and rocker shaft and check each valve
   Fill the fuel tank with fuel specified.
for proper operation.
   Check for leakage of hydraulic
hyd raulic oil, engine oil, fuel,
   Add cooling water to the specified level.
or coolant, etc.
   Charge the battery and mount it on the machine.
   Apply grease, where needed.
Connect the cables.
   Check for looseness of nuts and bolts, especially
   Perform pre - operational checks carefully. (refer
hub nuts. to “Before Starting the Engine”)
   Check mast rollers to see that they rotate
   Warm up the machine.
smoothly.
   Prime the oil into the lift cylinders by actuating
ac tuating the
lift lever all the way several times.

  Drain off coolant
antifreeze completely in cold weather, if
is not used.

Long Time Storage

Perform the following service and checks in
addition to the “Parking the lift truck” services.

 Taking the rainy season into consideration, park

 
the machine at a higher and hard ground.
ground .
   Avoid parking on soft grounds such as an asphalt

ground in summer.
   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.antirust to the exposed parts which tend to
Apply
 
rust.
   Cover components such as the breather and air

cleaner which may be caught with

wi th humidity.
   The machine should be operated at least once a

week. Fill the cooling system, if cooling water is

discharged, and mount the battery. Start the
engine and warm up thoroughly. Move the
machine a little forwards and backwards.
Operate the hydraulic controls several times.
ti mes.
 -127-

Operation Section

Transportation Hints
Lift Truck Shipping Machine Lifting and Tiedown
Check travel route for overpass clearances. Make Information
sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
overhead guard or cab. NOTICE
To prevent the lift truck from slipping while loading, Improper lifting or tiedowns can allow load to shift
or shifting in transit, remove ice, snow or other and cause injury and/or damage.
da mage.
slippery material from the loading dock and the
truck bed before loading.
l oading. 1. Weight and instructions given herein apply to lift
trucks as manufactured by DOOSAN.
NOTICE 2. Use proper rated cables and slings for lifting.
Obey all state and local laws governing the height, Position the crane for level lift truck lift.
weight, width and length of a load.
Observe all regulations governing wide loads. 3. Spreader bar widths should be sufficient to
prevent contact with the lift truck.

NOTICE 4. Use the tiedown locations provided for lift truck

tiedown.
Remove ice, snow or other slippery material from
the shipping vehicle and the loading
l oading dock. Check the state and local laws governing weight,
width and length of a load.

Contact your DOOSAN Lift Truck dealer for

shipping instructions for your lift truck.

Always block the trailer or the rail car wheels before

before
loading the lift truck.

Position the lift truck on the truck bed or the rail car.

Apply the parking brake and place the transmission

control in NEUTRAL.

Tilt the mast forward and lower forks to the floor.

Turn the ignition switch to the OFF position and

remove the key. If LP equipped, shut off the LP fuel
tank.

Block the wheels and secure the lift truck with

tiedowns.
 -128-

Operation Section

Towing Information
Consult your DOOSAN Lift Tuck dealer for towing a
WARNING disabled lift truck.
Personal injury or death could result when
towing a disabled lift truck incorrectly.

Block
beforethe lift truckthe
releasing wheels to prevent
brakes. The lift movement
truck can
roll free if it is not blocked.
Follow the recommendations below, to properly
perform the towing procedure.

These towing instructions are for moving a disabled

lift truck a short distance, at low speed, no faster
than 2 km/h (1.2 mph), to a convenient location for
repair. These instructions are for emergencies only.
Always haul the lift truck if long distance moving is
required. 1.  Release the parking brake.

Shield must be provided on the towing lift truck to NOTICE

protect the operator if the tow line or bar should
break. Release the parking brake to prevent excessive
wear and damage to the parking brake system.
Do not allow riders on the lift truck being towed
unless the operator can control the steering and/or 2.  Check that the service brake pedal is released.
braking.
3.  Key switch is in the OFF position.
Before towing, make sure the tow line or bar is in
good condition and has enough strength for the 4.  Direction control lever is in neutral.
towing situation involved. Use a towing line or bar
with a strength of at least 1.5 times the gross 5.  Fasten the tow bar to the lift
l ift truck.
weight of the towing lift truck for a disabled lift truck
stuck in the mud or when towing on a grade. 6.  Remove the wheel blocks. Tow the lift truck
slowly. Do not tow any faster than 2 km/h (1.2
Keep the tow line angle to a minimum. Do not mph).
exceed a 30°angle from the straight
str aight ahead position.
positio n.
Connect the tow line as low as possible on the lift
truck that is being towed. WARNING

Quick lift truck movement could overload the tow Be sure all necessary repairs and adjustments
line or bar and cause it to break. Gradual and have been made before a lift truck that has been
smooth lift truck movement will work better.
b etter. towed to a service area is put back into
operation.
Normally, the towing lift truck should be as large as
the disabled lift truck. Satisfy yourself that the
towing lift truck has enough brake capacity, weight
and power, to control both lift trucks for the grade
and the distance involved.

To provide sufficient control and braking when

moving a disabled lift truck down
do wnhill,
hill, a larger towing
lift truck or additional lift trucks connected to the
rear could be required. This will prevent
uncontrolled rolling.

The different situation requirements cannot be

given, as minimal towing lift truck capacity is
required on smooth level surfaces to maximum on
 inclines or poor surface
su rface conditions.

-129-

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

The following section gives practical guidelines for Some countries have standards or regulations
inspection, maintenance and repair of lift truck forks. which apply specifically to the inspection and repair
It also provides general information on the design of forks.
and application of forks and the common cause of
fork failures. Users may also refer to the International
Organization For Standardization-ISO Technical
Lift truck forks can be dangerously weakened by Report 5057- Inspection and Repair of Fork Arms
improper repair or modification. They can also be and ISO Standard 2330 - Fork Arms - Technical
damaged by the cumulative effects of age, abrasion,
abr asion, Characteristics and Testing.
corrosion, overloading and misuse.
A fork failure during use can cause damage to the While there are no specific standards or regulations
equipment and the load. A fork failure can also in the United States, users should be familiar with
cause serious injury. the requirements for inspection and maintenance of
lift trucks as provided by the 29 Code Federal
A good fork inspection and maintenance program Register 1910.178 Powered Industrial Truck, and
along with the proper application can be very ANSI/ASME Safety Standard(s) B56.1, B56.5 or
effective in preventing sudden failures on the job. B56.6 as applicable to the type of machine(s) in
Repairs and modifications should be done only by use.
the fork manufacturer or a qualified technician who
knows the material used and the required welding
and heat treatment process. Environment Protection
Users should evaluate the economics of returning
the forks to the manufacturer for repairs or When servicing this lift truck, use an authorized
purchasing new forks. This will vary depending on servicing area and an approved container to collect
many factors including the size and type of fork. coolant, oil, fuel, grease, electrolyte and any other
potential environmental pollutant before any lines,
Forks should be properly sized to the weight and fittings or related items are disconnected or
length of the loads, and to the size of the machine removed. After servicing, dispose of those
on which they are used. The general practice is to materials in an authorized place and container.
use a fork size such that the combined rated When cleaning the lift truck, be sure to use an
capacity of the number of forks used is equal to or authorized area.
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 or side of the fork shank.
   A fork rated at 1500 pounds at 24 inch load

center will be stamped 1500x24.

   A fork rated at 2000 kg at 600 mm load center

will be stamped 2000x600.
2000x600.

The manufacturer identification and year and date

of manufacture are also usually shown.
 -130-

Maintenance Section

Causes of Fork Failure    Repetitive Overloadi

O verloading
ng

Improper Modification or Repair Repetitive cycling of loads which exceeds the

fatigue strength of the material can lead to fatigue
Fork failure can occur as a result of a field failure. The overload could be caused by loads in
modification involving welding, flame cutting or excess of the rated fork capacity and by use of the
other similar processes which affect the heat forks tips as pry bars. Also, by handling loads in a
treatment and reduces the strength of the fork. manner which causes the fork tips to spread and
the forks to twist laterally about their mountings.
In most cases, specific processes and techniques
are also required to achieve proper welding of the    Wear
particular alloy steels involved. Critical areas most
likely to be affected by improper processing are the Forks are constantly subjected to abrasion as they
heel section, the mounting components and the slide on floors and loads. The thickness of the fork
fork tip. blade is gradually reduced to the point where it may
not be capable of handling the load for which it was
designed.
Bent or Twisted Forks
   Stress Risers
Forks can be bent out of shape by extreme
overloading, glancing blows against walls or other Scratches, nicks and corrosion are points of high
solid objects or using the fork tip as a pry bar. stress concentration where cracks can develop.
These cracks can progress under repetitive loading
Bent or twisted forks are much more likely to break in a typical mode of fatigue failure.
and cause damage or injury. They should be
removed from service immediately.
Overloading
Fatigue Extreme overloading can cause permanent
per manent bending
or immediate failure of the forks. Using forks of less
Parts which are subjected to repeated
r epeated or fluctuating capacity than the load or lift truck when lifting loads
loads can fail after a large
la rge number of loading cycles and using forks in a manner
m anner for which they were notno t
even though the maximum stress was below the designed are some common causes of overloadin
overloading.g.
static strength of the part.

The first sign of a fatigue failure is usually a crack

which starts in an area of high stress concentration.
This is usually in the heel section or on the fork
mounting.

As the crack progresses under repetitive load

cycling, the load bearing cross section of the
remaining metal is decreased
becomes insufficient to supportinthe
sizeload
untiland
it
complete failure occurs.

Fatigue failure is the most common mode of fork

failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.
 -131-

Maintenance Section

Fork Inspection 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 the forks have been previously used, perform

the “12 Month Inspection”.
If the forks are rusted, see “Maintenance and
Repair”.

2.  Make sure fork blades are level to each other

within acceptable tolerances. See “Forks, Step
4,” in the “2000 Service Hours or Yearly” in
“Maintenance Intervals”
Establish a daily and 12 month inspection routine
by keeping a record for the forks on each lift truck. 3.  Make sure positioning lock is in place and
Initial information should include the machine serial working Lock forks in position before using
number on each the forks are used, the fork truck. See “Forks, Step 7”, in the “2000 Service
manufacturer, type, original section size, original Hours or Yearly” in “Maintenance Intervals”.
length and capacity. Also list any special
characteristics specified in the fork design.
Daily Inspection
Record the date and results of each inspection,
making sure the following information is included. 1.  Visually inspect forks for cracks, especially in
the heel section, around the mounting brackets,
   Actual wear conditions, such as percent of and all weld areas. Inspect for broken or jagged
original blade thickness remaining. fork tips, bent or twisted blades and shanks.

   Any damage, failure or deformation which might 2.  Make sure positioning lock is in place and
impair the use of the truck. working. Lock the forks in position before using
the truck. See “2000 Service Hours or Yearly” in
   Note any repairs or maintenance. “Maintenance Intervals”.

An ongoing record of this information will help in 3.  Remove all defective forks from service.
identifying proper inspection intervals for each
operation, in identifying and solving problem areas
and in anticipating time for replacement of the
forks.
 -132-

Maintenance Section

12 Months Inspection With the fork restrained in the same manner as

its mounting on the lift truck, apply the test load
Forks should be inspected, at a minimum, every 12 twice, gradually and without shock. Maintain the
months. If the truck is being used in a multi-shift or test for 30 seconds each time.
heavy duty operation, they should be checked
every six months. See “Forks” in the “2000 Service Check the fork arm before and after the second
Hours or Yearly” in “Maintenance
“Maintenance Intervals.” application of the test load. It shall not show any
permanent deformation.

Maintenance and Repair Consult the fork manufacturer for further

information as may be applicable to the specific
1.  Repair forks only in accordance with the fork involved.
manufacturer’s recommendations.
Testing is not required for repairs to the positioning
Most repairs or modifications should be done lock or the markings.
only by the original manufacturer of the forks or
an expert knowledgeable of the materials,
design, welding and heat treatment process.

2.  The following repairs or modifications SHOULD

NOT be attempted.

  Flame cutting holes or cutouts in fork

blades.
  Welding on brackets or new mounting
hangers.
  Repairing cracks or other damage by
welding.
  Bending or resetting.

3.  The following repairs MAY be performed.

  Forks may be sanded or lightly ground, to

remove rust, corrosion or minor defects
from the surfaces.

  Heel sections may be ground with 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 and shank length.

  Repair or replace the positioning locks on

hook type forks.

  Repair or replace most fork retention

devices used with other fork types.

4.  A fork should be load tested before being

returned to service on completion of repairs
authorized and done in accordance with the
manufacturer’s recommendations.

Most manufacturers and standards require the

repaired fork to be tested with a load 2.5 times
the specified capacity and at the load center
marked on the fork arm.
ar m.
 -133-

Maintenance Section

Tire Inflation Information

Tire Inflation Tire Shipping Pressure
The tire inflation pressures shown in the following
chart are cold inflation shipping pressures.

Ply Rating or Shipping Pressure

Size 
Strength Index
kPa  psi 
6.5X10 10 790 115
7.0X15 12 825 120
28X9-15 12 825 120
1
 Standard tire, ply
p ly rating and inflation pressures.

The operating inflation pressure is based on the

weight of a ready - to - work machine without
WARNING attachments, at rated payload, and in average
operating conditions. Pressures for each
Personal injury or death could result when tires are application may vary and should always be
inflated incorrectly. obtained from your tire supplier.
Use a self - attaching inflation chuck and stand
behind the tread when inflating a tire. NOTE:  Fill tires to the recommended pressures
listed ± 35 kPa (5 psi). Tires can be filled
Proper inflation equipment and training in using the with nitrogen.
equipment are necessary to avoid over-inflation. A
tire blowout or rim failure can result from improper
or misused equipment.
Tire Inflation Pressures
Adjustment
Tire inflati
inflation
on in a warm shop area,
a rea, 18° to 21°
21 °C (65°
NOTICE
to 70°F),
70°F), will be underinflated if
i f the machine
m achine works
Set the tire inflation
inflation equipment regulator at no
n o more in freezing temperatures. Low pressure shortens
than 140 kPa (20 psi) over the recommended tire the life of a tire.
tire .
pressure.
 -134-

Maintenance Section

Torque Specifications

Metric Hardware Torque for Standard Bolts, Nuts,

Most of the nuts,
nu ts, bolts, studs, and threaded holes in and Taperlock Studs
your lift truck are metric. In this manual we provide
specifications in
measurement. both replace
Always metric and U.S.
metric customary
hardware with NOTICE
metric hardware. See the parts books for proper
replacement. The two charts below give general torques for bolts,
b olts,
nuts, and taperlock studs of SAE Grade 5 or better
NOTE:  For proper fit, use only metric tools on quality.
metric hardware. Non-metric tools might
slip and cause injury.

Torques for Bolts and Nuts with

Torque for Standard Hose Clamps Standard Threads
- Worm Drive
Thread Size Standard Nut and Bolt Torque
NOTICE Inch  N•m lb•ft
The chart below gives the torques for initial
installation of hose clamps on new hose and for 1/4 12 ± 4 9±3
reassembly or retightening of hose clamps on 5/16 25 ± 7 18 ± 5
existing hose.
3/8 45 ± 7 33 ± 5
7/16 70 ± 15 50 ± 11
1/2 100 ± 15 75 ± 11
Initial Installatio
Insta llation
n
Clamp Width  Torque On New Hose 9/16 150 ± 20 110 ± 15

N•m1  lb•in 5/8 200 ± 25 150 ± 18

16 mm (.625 in) 7.5 ± 0.5 65 ± 5 3/4 360 ± 50 270 ± 37

13.5 mm (.531 in) 4.5 ± 0.5 40 ± 5 7/8 570 ± 80 420 ± 60

8 mm (.312 in) 0.9 ± 0.2 8 ±2 1 875 ± 100 640 ± 75

Reassembly or 1 1/8 1100 ± 150 820 ± 110

Retightening 1 1/4 1350 ± 175 1000 ± 130

Clamp Width 
Torque On Existing Hose 1 3/8 1600 ± 200 1180 ± 150

N•m
1
  lb•in  1 1/2 2000 ± 275 1480 ± 200
1
1 Newton meter (N•m) is approximately the same as 0.1 kg •m. 
16 mm (.625 in) 4.5 ± 0.5 40 ± 5
13.5 mm (.531 in) 3.0 ± 0.5 25 ± 5
8 mm (.312 in) 0.7 ± 0.2 6 ±2
1
1 Newton meter (N•m) is approximately the same as 0.1 kg•m.
 -135-

Maintenance Section

Torques for Taperlock Studs Torque for Metric Fasteners

Thread Size Standard Taperlock Stud Torque NOTICE

Inch  N•m
1
lb•ft
  Be very careful never to mix metric with U.S.
1/4 8±3 6±2 customary (standard) fasteners. Mismatched or
incorrect fasteners will cause lift truck damage or
5/16 17 ± 5 13 ± 4 malfunction and may even result
re sult in personal injury.
3/8 35 ± 5 26 ± 4
Original fasteners removed from the lift truck should
7/16 45 ± 10 33 ± 7 be saved for reassembly whenever possible. If new
1/2 65 ± 10 48 ± 7 fasteners are needed, they must be of the same
size and grade as the ones that are
a re being replaced.
5/8 110 ± 20 80 ± 15
3/4 170 ± 30 125 ± 22 The material strength identification is usually
u sually shown
on the bolt head by numbers (8.8, 10.9, etc.). This
7/8 260 ± 40 190 ± 30 chart gives standard torques for bolts and nuts with
1 400 ± 60 300 ± 45 Grade 8.8.

1/8 500 ± 700 370 ± 50 NOTE:  Metric hardware must be replaced with
1/4 650 ± 80 480 ± 60 metric hardware. Check parts book.

3/8 750 ± 90 550 ± 65

Thread Size Standard Torque
1/2 870 ± 100 640 ± 75 Metric  1
N•m   lb•ft
1
1 Newton meter (N•m) is approximately the same as 0.1 kg•m. 
M6 12 ± 4 9±3
M8 25 ± 7 18 ± 5
M10 55 ± 10 41 ± 7
M12 95 ± 15 70 ± 11
M14 150 ± 20 110 ± 15
M16 220 ± 30 160 ± 22
M20 450 ± 70 330 ± 50
M24 775 ± 100 570 ± 75
M30 1600 ± 200 1180 ± 150
M36 2700 ± 400 2000 ± 300
1
1 Newton meter (1 N•m) is approximately the same as 0.1
kg•m.
2
ISO - International
Inte rnational Standards organization.
 -136-

Maintenance Section

Cooling System Specifications

Coolant Information Filling at over 20 liters (5 U.S. gallons) per minute
can cause air pockets ini n the cooling system.
NOTE:  The following information is generic and
valid for lift trucks. After draining and refilling the cooling system,
operate the engine with the radiator cap removed
Engine operating temperatures have increased to until the coolant reaches normal operating
improve engine efficiency. This means proper temperature and the coolant level stabilizes. Add
cooling system maintenance is especially important. coolant as necessary to fill the system to the proper
Overheating, overcooling, pitting, cavitation erosion, level.
cracked heads, piston seizures, and plugged
radiators are classic cooling system failures. In fact, Never operate without a thermostat in the cooling
coolant is as important as the quality of fuel and system. Cooling system problems can arise without
lubricating oil. a thermostat.

NOTICE
DOOSAN recommends that the coolant mixture
contain 50% commercially available automotive
antifreeze, and 50% water.

The coolant mix with concentration of antifreeze

smaller than 30% does not provide sufficient
corrosion protection. Concentrations over 60%
adversely affect freeze protection and heat transfer
rates.

Never add coolant to an overheated engine, engine

damage can result. Allow the engine to cool first.
If the machine is to be stored in, or 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 antifreeze, when shipped from
the factory unless special requirements are defined.

Check the specific gravity of the coolant solution

frequently
protection. in cold weather to ensure adequate

Clean the cooling system if it is contaminated, the

engine overheats or foaming is observed in the
radiator.

Old coolant should be drained, the system cleaned

and new coolant added every 2000 service hours
or yearly.

Refer to topic, “Cooling System - Clean, Change” in

Every 2000 Service Hours or Yearly section.
se ction.
 -137-

Maintenance Section

Coolant Water Antifreeze

Hard water, or water with high levels of calcium and
magnesium ions, encourages the formation of
insoluble chemical compounds by combining with NOTICE
cooling system additives such as silicates and DOOSAN recommends using automotive antifreeze
phosphates. suitable for gasoline engines having aluminum alloy
parts. Antifreeze of poor
poo r quality will cause corrosion
The tendency of silicates and phosphates to of the cooling system, and thus always use
precipitate out-of-solution increases with increasing automotive antifreeze prepared by a reliable maker,
water hardness. Hard water or water with high and never use it mixed with antifreeze of different
levels of calcium and magnesium ions encourages brand.
the formation of insoluble chemicals, especially
after a number of heating and cooling cycles. DOOSAN recommends
recommends that the coolant mix ccontain
ontain
50% commercially available automotive antifreeze,
DOOSAN prefers the use of distilled water or or equivalent and acceptable water to maintain and
deionized water to reduce the potential and severity adequate water pump cavitation temperature for
of chemical insolubility.
i nsolubility. efficient water pump performance.
Premix coolant solution to provide protection to the
Acceptable Water lowest expected outside (ambient) temperature.
Water Content Limits (PPM) Pure undiluted antifreeze will freeze at -23°C 
Chlorides (Cl) 50 maximum (-10°F).
Sulfates (SO4) 50 maximum
Use a greater concentration (above 50%) of
Total hardness 80mg/l commercially available automotive antifreeze only
Total solids 250 maximum as needed for anticipated outside (ambient)
PH 6.0 to 8.0 temperatures. Do not exceed the recommendations,
recommendations,
ppm = parts per million
m illion provided with the commercially available
automotive antifreezes, regarding the coolant
Using water that meets the minimum acceptable mixture of antifreeze to water.
water requirement may not prevent drop-out of
these chemical compounds totally, but should
minimize the rate to acceptable levels.
Make proper antifreeze additions.
Adding pure antifreeze as a makeup solution for
cooling system top-up is an unacceptable practice.
It increases the concentration of antifreeze in the
cooling system which increases the concentration
of dissolved solids and undissolved chemical
inhibitors in the cooling system. Add antifreeze
mixed with water to the same freeze protection as
your cooling system.

Use the chart below to assist in determining the

concentration of antifreeze to use.

Antifreeze Concentration
Concentrations
s
Prote
otection T
Te
emperature Conce
ncentr
ntrations
Protect ion to -15
-15°°C (5°F) 30% antifre eze and 70% water

Prot ection to -23

-23°°C (-10°
(-10°F)
F) 40% antifre eze and 60% water

Prot ection to -37

-37°°C (-34°
(-34°F)
F) 50% antifre eze and 50% water

Prot ection to -51

-51°°C (-60°
(-60°F)
F) 60% antifre eze and 40% water
 -138-

Maintenance Section

Fuel Specifications
General Fuel Information Crude oil is used to describe oils/fuels that are not
refined and are in the original state as when
Use only fuel as recommended in this section. pumped from the ground. Certain types of crude
oils can be burned in DOOSAN Engines.

NOTICE PREFERRED DISTILLATE FUEL

FOR DISEL ENGINES
Fill the fuel tank at the end of each day of operation
to drive out moisture laden air and to prevent Specifications Requirements*
condensation. Maintain a constant level near the Aromatics (AST D1319) 35% Max.
top of the day tank to avoid drawing moisture into
the tank as the level decreases. Ash (ASTM D482) 0.02% Weight Max.
Cetane Number 35Min. for 45 max.
Do not fill the tank to the top. Fuel expands as it
gets warm and can overflow. (ASTM D613) 40 Min. for DI Engines
Not Above Lowest Expected
Do not fill the fuel filters with fuel before installing Could Point (ASTM D287) 
them. Contaminated fuel will cause accelerated Ambient Temperature
wear to the fuel system parts. Gravity API (ASTM D287) 30 Min. and 45 Max.
6°C (10°F) Below Ambient
Pour Point (ASTM D97) 
Drain the water and sediment from main fuel Min.
storage tank before it is refilled. This will help Sulfur (ASTM D2788, 0.5% Max.
prevent water and/or sediment from being pumped
D3605 or D1552) (See Sulfur Topic)
from the fuel storage tank into the engine fuel tank.
Viscosity, Kinematic @ 20.0 cSt Max.
38°C
38°C (10
(100°
0°F) (ASTM D445) 1.4 cSt Min.
Diesel Specifications Water & Sediment
0.01% Max.
(ASTM D1796)
Fuel Types *As delivered to fuel system 
DOOSAN Diesel Engines have the ability to burn a
wide variety of fuels. These fuels are divided into
two general groups, preferred and
an d permissible. Fuel Sulfur Content
The percentage of sulfur in the fuel will affect the
The Preferred Fuels provide maximum engine engine oil recommendations. Fuel sulfur is
service life and performance. They are distillate chemically changed during combustion to form both
b oth
fuels. They are commonly called diesel fuel, MDO sulfurous and sulfuric acid. These acids chemically
diesel, furnace oil, gas oil or kerosene (for cold attack metal surfaces and cause corrosive
cor rosive wear.
weather operation).
Certain additives used in lubricating oils contain
Experience has proven that distillate fuels meeting
the following basic specifications will result in alkaline compounds
neutralize thatmeasure
these acids. The are formulated to
of this reserve
optimum engine performance and durability. alkalinity in lubricating oil is known as its Total Base
Number (TBN). TBN is essential to neutralize the
DOOSAN strongly encourages the use of fuels that acids from combustion gases and to minimize
meet the Preferred Fuels specification.
spe cification. corrosive wear.
The permissible fuels are crude oils or blended Any API classification performance of oil should
fuels. Use of these fuels can result in higher have sufficient TBN for fuels with less than 0.5%
maintenance costs and reduced engine service life. sulfur. For fuels with 0.5% to 1.5% sulfur by weight,
engine oil must have a TBN of 20 times the
percentage of fuel sulfur as measured by the ASTM
(American Society of Testing Materials) D-2896
method. (ASTM D-2896 can normally be found at
your local technological society, library or college).
 -139-

Maintenance Section

DOOSAN recommends infrared analysis (in Gasoline Specifications

conjunction with wear metal analysis) of used oil in
determining the effectiveness of oil TBN and acid Only unleaded gasoline should be used for
neutralization. DOOSAN forklift trucks.
The gasoline in which methanol is contained is not
For fuel with sulfur exceeding 1.5% by weight, use recommended. The gasoline in which ethanol is
oil with a TBN of 30 and reduce the oil change contained is not recommended, either.
interval by one half. Also, infrared analysis and
wear metal analysis should be used to establish oil It is recommended to use gasoline fuel that has
change intervals. octane number 87, to prevent
p revent knocking trouble.

Periodically request fuel sulfur content information

from your fuel supplier. Fuel sulfur content can LP Specifications
change with each bulk delivery.
LP is “liquefied petroleum gas”. The exact
composition of LP varies slightly between different
parts of the country and different refineries. HD5 or
HD10 is recommended for DOOSAN forklift trucks.

Composition of HD5 
Propane (C3 H8 ) 90.0 %
Propylene up to 5 %
Butane (C4 H10 ) 2.0 %
iso - Butane 1.5 %
Methane (CH4 ) 1.5 %
Total 100 %

WARNING
Remember LP is heavier than air and will sink
to the lowest spot possible. Avoid areas near
floor drains or lubrication pits where escaped
fuel may collect.
 -140-

Maintenance Section

Lubricant Information
Lubricant Information Hydraulic Oil (HYDO)
Certain abbreviations follow Society of Automotive The following commercial classifications can be
Engineers (SAE) J754 nomenclature and some used in the hydraulic system.
classifications follow SAE J183 abbreviatio
abbreviations.
ns.

ISO 6743/4
  HM
The MIL specifications are U.S.A. Military  AFNOR NFE 48-603
  HM
Specifications.    DIN 51524 TEIL 2 H-LP
   HAGGLUNDS DENISON HFO-HF2
The recommended oil viscosities can be found in the    CINCINNATI P68,69,70
Lubricant Viscosities chart in this publication.
Viscosity: ISO VG32
Grease is classified by the National Lubricating
Grease Institute (NLGI) based on ASTM D217-68 Industrial premium hydraulic oils that have passed
Worked Penetration characteristics which are given the Vickers vane pump test (35VQ25).
a defined consistency
consi stency number. These oils should have antiwear, antifoam, antirust
and antioxidation additives for heavy duty use as
stated by the oil supplier. ISO viscosity grade of 32
Engine Oil (DEO and EO) would normally be selected.

The following oil specifications provide guidelines for

the selection of commercial products: NOTICE
Make-up oil added to the hydraulic tanks must mix
 Gasoline/LP Engine : API SJ or higher
 
with the oil already in the systems. Use only
   Diesel Engine : API CH4, ACEA E5
petroleum products unless the systems are
equipped for use with special products. If the
hydraulic oil becomes cloudy, water or air is entering
NOTICE the system. Water or air in the system will cause
Failure to follow the oil recommendations can cause pump failure. Drain the fluid, retighten all hydraulic
shortened engine lift due to carbon deposits or suction line clamps, purge and refill the system.
Consult your DOOSAN Lift Truck dealer for purging
excessive wear. instructions.

Consult the EMA Lubricating Oils Data Book for a

listing of oil brands.
b rands. Drive Axle Oil
NOTE:  The percentage of sulfur in the fuel will NOTE:  Do not use Gear Oil in the final drives or
affect the engine oil recommendations.
r ecommendations. differentials. Gear Oil can cause seal
For fuel sulfur effects, the Infrared Analysis material to fail and possibly leak oil.

or
to the ASTM D2896
evaluate procedureneutralization
the residual can be used NOTE:  Failure to follow the recommendation will
properties of engine oil. The sulfur products cause shortened life due to excessive gear
formation depends on the fuel sulfur content, wear.
oil formulation, crankcase blow-by, engine
operating conditions and ambient The API CD/TO-2 specification or MIL-L-2104D, Eor
temperature. F oils could be used.

NOTE:  Multi-grade oils are not blended by

DOOSAN for use in transmissions.
Multi-grade oils which use high molecular
weight polymers as viscosity index
improvers lose their viscosity effectiveness
by permanent and temporary shear of the
viscosity index improver and therefore, are
not recommended for transmission and
drive train compartments.
 -141-

Maintenance Section

Lubricating Grease (MPGM) Brake Fluid

Use Multipurpose Molybdenum Grease (MPGM) for
all lubrication points. If MPGM grease can not be
used, multipurpose type grease which contains 3%
to 5% molybdenum disulfide can be used.

NLGI No.2 grade is suitable for most temperatures.

Use NLGI No.1 or No.0 grade for extremely low
temperature.

Transmission Oil

NOTICE
This oil is formulated for transmissions and drive Oil Cooled Disc Brake Only
trains only, and should not be used in engines.
Use heavy duty hydraulic brake fluid certified by oil
Shortened engine life will result.
re sult.
supplier to meet the latest version of following
classifications.
NOTE:  Multi-grade oils are not blended by
DOOSAN for use in transmissions. • ISO 6743/4 HM
Multi-grade oils which use high molecular • AFNOR NFE 48-603 HM
weight
improverspolymers as viscosity
lose their viscosity index
effectiveness • DIN 51524 TEIL 2 H-LP
• HAGGLUNDS DENISON HFO-HF2
by permanent and temporary shear of the
• CINCINNATI
CINCINNATI P68,69,70
viscosity index improver and therefore, are
not recommended for transmission and
drive train compartments.
compartments. Viscosity : ISO VG32

NOTE:  Failure to follow this recommendation can Brake reservoir oils that have passed the Vickers
cause shortened transmission life due to vane pump test (35VQ25). These oils should have
material incompatibility, inadequate antiwear, antifoam, antirust and antioxidation
frictional requirements for disk materials additives for heavy duty use as stated by the oil
and/or excessive gear wear. supplier. ISO viscosity grade of 32 would normally
be selected.
The API CD/TO - 2 specification
spe cification or MIL - L 2104D, E
or F oil could be
b e used. The following products are authorized for use.

Supplier Product Name

TOTAL AZOLLAZS
SHELL TELLUS
MOBIL DTE20S’
CALTEX RANDO HD
ESS NOTO H
CASTROL HYSPIN AWS
 -142-

Maintenance Section

Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities
LUBRICANT VISCOSITIES REFILL CAPACITIES - (APPROXIMATE)
FOR AMBIENT (OUTSIDE) TEMPERATURES  Co
Comp
mpar
arttment
ment or Syst
System
em Lite
Liters
rs U.S Gal.. 
U.S Gal
Compartment Oil °C °F Engine Crankcase w/Filter
or System Viscosities Min Max Min Max G420F & G420F(E) 2.0 liter 4.2  1.11 
G420F(E) Gasoline & LP
SAE 10W30 -2
-20 +40 -4 + 104
Engine Engine Crankcase w/Filter
Crankcase G424F & G424F(E) 2.4 liter 4.5  1.19 
(Gasoline and LP
SAE 5W30 -30 +30 - 22 + 86 Engine Crankcase w/Filter
LP)
7.6  2.00 
SJ 
API SJ  4TNV98 Diesel

G424F(E) Engine Crankcase w/Filter

SAE 10W30  -20 +40 -4  +104 9.2 2.43
4TNE98 Diesel
Engine
Cooling System
Crankcase
w/Coolant Recovery Bottle
(Gasoline and 8.5  2.25 
SAE 5W30 -30 +30 - 22 + 86 G420F & G420F(E) 2.0 liter
LP)
Gasoline & LP 
SJ 
API SJ  Cooling System
Engine w/Coolant Recovery Bottle
Crankcase 9.0  2.38 
G424F & 424F(E) 2.4 liter
(Diesel) SAE 15W40  -15 +50 -5  +122 LP 
CH4, 
API CH4,  Cooling System
E5 
ACEA E5  w/Coolant Recovery Bottle 10.7  2.83 
Power Shift 4TNV98 &4TNE98 Diesel 
SAE 10W -20 +22 -4 + 72
Transmission Fuel Tank - G, D Series
51  13.74 
& Drive Axle Gasoline or Diesel
Housing SAE 30 +1 0 +50 +50 + 122 Fuel Tank - GC Series
40  10.56 
CD/TO-2 
API CD/TO-2  Gasoline

Hydraulic and G Series 15.2kg 33.5lb

ISO VG 22 -30 +20 - 22 + 68 LP
Power GC Series 15.2kg 33.5lb
ISO VG 32 -20 +30 -4 + 86
Powershift G, D Se
Series
ries 13.0 3.43
Steering Transmission
System ISO VG 46 -10 +40 +14 + 104 GC Series 11.2 3.0
ISO 6743/4 G, D Series 9.2 2.43
ISO VG 68 0 +50 +32 + 122 Drive Axle
HM  GC Series
Series 10.0 2.64
Brake Hydraulic & Power Steering System 34  8.98 
Reservoir Brake Reservoir (Only for OCDB) 1.0 0.3
(Only for ISO VG32 -20 +30 -4 + 86
OCDB)
ISO 6743/4HM
 
The SAE grade number indicates the viscosity of oil.
A proper SAE grade number should be selected
according to ambient temperature.
 -143-

Maintenance Section

Maintenance Intervals First 250 Service Hours or a Month

Hydraulic Return Filter – Change ....

..........
...........
..........
.........
....166
166

NOTICE Every 250 Service Hours or Monthly

All maintenance and repair, except Every 10
Service Hours or Daily, on the lift truck must be Air Intake
In take System - Check, Clean..........
Clean..........................
......... 167 
...167
performed by qualified and authorized personnel Brake Oil Level - Check.............................. .......... 169 
Che ck........................................
only. Hydraulic Oil Level – Check......
Check ............
............
...........
...............169  
..........169
Drive Axle Oil Level - Check ...... ...........
...........
...........
...............170  
..........170
Mast, Carriage, Lift Chains & Attachments - Inspect,
NOTICE Lubricate
Lubric ate...................
..................................................
............................................. 170 
..............170
Careless disposal of waste oil can harm the Steering Mechanism - Check, Lubricate ........... ............. 170 
..170
environment and can be dangerous to persons. Battery Terminal - Clean, Inspect ..... ...........
...........
...........
........ 171 
..171
Always dispose of waste oil to authorized personnel Engine Oil & Filter (LP & Gasoline Engine Only) -
only. Change ........................................................ .......... 171 
..................................................................
PCV Valve System - Inspect, In spect, Clean.....
Clean ..........
...............172  
..........172
Wheel Bolts & Nuts - Inspect In spect ..........
................
...........
...............173  
..........173
When Required Inspect Tightness (GC - Series) ..... ...........
...........
...............173  
..........173
Governor Lever and Engine Speed Control (Diesel
Fuel Tank Filter Cap and Screen (If Equipped) - Engine Only) - Check ,Adjust........
,Adjust..............
............
...........
..........
....... 174
Clean .........................
..................................................................... 148 
............................................
Seat, Hood Latch & Support Cylinder - Check, Every 500 Service Hours or 3 Months
Lubricate........................
Lubric ate....................................................... ......... 148 
........................................
Fuses, Bulbs, Circuit Breaker & Relay - Change, Belts - Check,
Check , Adjust ..............................
............................................ 176 
..............176
Reset .........................
..................................................................... 149 
............................................ Mast Hinge Pin – Lubricate.....
Lubricate ...........
............
............
.................. 176 
..........
Priming the Fuel Fuel System(Diesel
System(Diesel Engine Only) Only) ... 150  Tilt Cylinders - Check, Adjust, Lubricate ........... ............. 176 
..176
Water Seperator (Diesel Engine Only) - Check, Crosshead Rollers - Inspect
Inspect....................... .......... 177 
.................................
Drain ..............................
...................................................................... 152 
........................................ Transmission Oil Filter – Change ..... ..........
..........
...........
......... 178 
...178
Tires and Wheels (D, G-Series) - Inspect, Check ................................... 178 
Overhead Guard – Inspect ...................................
.............................................................
.............................. .................. 154 
................................................. Drive Axle Oil & Strainer - Change, Clean .... ....... 179 
.........
Carriage Roller Extrusion – Adjust...............
Adjust...........................
.. 154 Steer Suspension – Inspect ..........
................
............
.................. 180 
..........
Parking Brake - Test, Adjust ...........
.................
...........
...............180  
..........180
Every 10 Service Hours or Daily Inching & Braking Control Shaft - Lubricate....
Lu bricate........ 180 
....180
Horn and Lights (If Equipped) - Check......
Check ........... .....180  
..........180
Inspect Engine for Fluid Leaks ..........
................
.................. 155 
............ Inspect Vacuum Lines and Fittings
(G420F(E)/G424F(E)
(G420F(E)/G424F (E) Engine Only)......
Only) ...........
...............181  
..........181
Engine Oil Level - Check ..........
...............
..........
...........
................. 155 
...........
Coolant Level – Check.....
Check ....................
...........
...........
...........
...........
.........
.... 156  Fuel
(G420F(E)/G424F(E)
(G420F(E)/G424F Trim (E) Engine Valve(FTV) Only)......
Only) ........... Inspection
...............181  
..........181
Air Cleaner Indicator-Check.......
Indicator-Check............ ...........
............
............... 157 
.........
Inspect Electrical System (G420F(E)/G424F(E)
Inspect Foot Pedal Operation (G420F(E)/G424F(E)
Engine Only)..........................................................
Only)..........................................................181 181 
Only)) ..............................
Only ...................................................................... 157 
........................................
Inspect Engine for Exhaust Leaks.......... Leaks................ ........ 157 
............ Fuel Filter (Diesel Engine Engine Only) - Change .... ....... 182 
.........
Engine Oil & Filter (Diesel Engine Only) - Change
Walk-Around Inspection - Inspect ..... ..........
................... 157 
............
........................................................
............................................................................... 183 
.......................183
Mast Channels – Lubricate......
Lubricate ........... ..........
...........
................... 158 
...........
Transmission Oil Level – Check.............
Check.................. ............. 159 
........ Water Separator (4TNV98 Diesel Engine Only) -
Clean.....................................................................
Clean...................................... ................................. 184
Parking Brake - Inspect...............................
Inspect ........................................
......... 159

First 50 - 100 Service Hours or a Week Every 1000 Service Hours or 6 Months

Engine Oil & Filter (Diesel Engine Only) - Change Hydraulic Return Filter, Breather & Strainer - Check,
.............................................................
.............................. .................. 161 
................................................. Change ........................................................ .......... 185 
..................................................................
Transmission Oil, Oil Filter & Strainer - Check, Transmission Oil, Oil Filter & Strainer - Check,
 
Clean, Change ......................................................
...................................................... 162 Clean, Change ......................................................
......................................................186
........ 186
Drive Axle Oil - Change........................................ 164   Lift Chains - Test, Check, Adjust ............
..................
............ 186 
 Parking Brake - Test, Adjust ..........
................
...........
...........
...........
..... 164 Universal Joint – Inspect ...........
................
..........
...........
.................. 188 
..........
Air Intake System - Change .....
..........
..........
..........
..........
.............188  
........188

-144-

Maintenance Section

Inspect Coolant Hoses (LP, Dual Fuel

......................................................... 189 
Engine Only) .........................................................
LP Regulator/Converter Inspection (LP, Dual Fuel
......................................................... 189 
Engine Only) .........................................................
Fuel Lines & Fittings - Check.........
Check..........................
................ 189 
...........
Inspect Mixer Assembly (G420F(E)/G424F(E)
......................................................... 189 
Engine Only) .........................................................
Inspect Throttle Assembly (G420F(E)/G424F(E)
......................................................... 189 
Engine Only) .........................................................
Engine Valve Lash (Diesel Engine Only) - Check,
Adjust.....................................................................
Adjust..................................................................... 190

Every 1500 Service Hours or 9 Months

Inspect Ignition System (LP, Gasoline & Dual Fuel

Engines
Engine ....................................................... 191 
s Only) .......................................................
Replace Spark Plugs (G424F(E) LP, Dual Fuel
......................................................... 191 
Engine Only) .........................................................
Replace LP Fuel Filter Element (LP, Dual Fuel
......................................................... 192 
Engine Only) .........................................................
Fuel Filter
Fil ter (LP Engine Only) .......... ................
...........
................ 192 
...........
Testing Fuel Lock-off Operation (LP Engine Only)
 
.............................................................
...............................................................................
Fuel Injectors (Diesel Engine Only) – Inspect, .................. 192
Clean, Test.........................
Test ........................................................ .... 193 
...................................
Crankcase Breather System (4TNV98 Diesel
Engine Only) - Inspect.................................
Inspe ct..........................................
......... 193

Every 2000 Service Hours or Yearly

Engine Valve Lash (Diesel Engine Only) – Check,

...................... 194 
Adjust.....................................................................
Adjust...............................................
Steer Wheel Bearings - Reassemble.........
Reassemble.............. .... 194 
.........
Drive Wheel Bearing (Power Shaft and Drive
.......................................... 196 
Wheel) – Reassemble ..........................................
Cooling System – Clean, Clean , Change ..... ..........
................... 197 
............
Forks – Inspect .....................................................
..................................................... 199

Every 2500 Service Hours or 15 Months

Hydraulic Oil - Check, Clean, Change ........... ..... 201 

................
Inspect Battery System.....
System .......... ...........
............
............
................... 201 
...........
Replace Oxygen Sensor (G420F(E)/G424F(E)
......................................................... 202 
Engine Only) .........................................................
Replace Spark Plugs (G420F(E) Engine Only).. 202 
Checking the TMAP Sensor (G420F(E)/G424F(E)
......................................................... 203 
Engine Only) .........................................................
Inspect for Intake Leaks (G420F(E)/G424F(E)
Engine Only) .........................................................
......................................................... 203

Every 3000 Service Hours or 18 Months

Timing
Dual Belt
Fuel [G420F(E)/G424F(E)
Engine LP,............
Only] - Change........ Gasoline,
Change...................... 204
 -145-

Maintenance Section

Quick Reference to Maintenance Schedule   FIRST EVERY 

   k   s   s   s   s

  e   y
   l   s    h    h   y
   l    h
   t    h
   t
  e    h    h    h    t    t   r   n   n
   t    t    t   n   n   a   o   o
   W   n   y
   l   n   n   o   o   e
  a   o    i   o   o    M    M    Y    M    M
  r    M   a    M    M    5    8
  o    D   a    6    9   a    1    1
  s   a    3   r   r   r   r   r
  r   r   a   r   r   o   o   o   o   o
  u   o   r   o   o   s   s   s   s   s
  o   s   o   s   s   r   r   r   r   r
ITEM
EMS
S SERVI
ERVIC
CES PAGE    d    H   r   s   r   r   u   u   u   u   u
  u   r   u   u   o   o   o   o   o
  e
  r   e   o   u   o   o    H    H    H    H    H
   i   c
   i    H   o    H    H
  u   e   e   e   e   e
  q
  e   r
  v
  e   c
  e
   i    H   c
  e
  e    i   c
  e
   i    i
  c
  v
  r    i
  c
  v
  r    i
  c
  v
  r    i
  c
  v
  r    i
  c
  v
  r
   R    S   v   c   v
   i   v
  r   v   r   r   e   e   e   e   e
  n    0   e   r   e   e    S    S    S    S    S
  e    0    S   e    S    S
   h    1    S    0    0    0    0    0    0
  -    0    0    0    0    0    0    0
   W    0    5    0    5    0    0    5    0    5    0
   5    2    1    2    5    1    1    2    2    3
Air C leaner Indic ato r C heck 157 O
Air In tak e Syste m C hange 188 O
Air In tak e Syste m C heck, C lean 167 O
Battery Te rminal C lea n, Inspec t 171 O
Belts C heck, Adjus t 176 O
Brake Oil Level C heck 169 O
Carr
Carria
iage
ge Rolle
Rollerr Extrus
Extrusio
ion
n Adjus
Adjustt 154
154 O
Checking the TMAP Sensor (G420F(E)/G424F(E) Engine
203 O
Only)
Coolan t Level C heck 156 O
Cooling Sy st
stem C lea n
n,, Cha n
ng
ge 197 O
C ra
rankca
nkcase
se Brea
Breatther Syst
System
em (4T
4TN
N V98
V98 D iies
esel
el Eng
Engin
ine
e Only)
nly) Ins
nsp
pec
ectt 193
193 O

Cros shead R olle rs Inspec t 177 O

Driv e Axle Oil C hange 164 O
Driv e Axle Oil & Strainer C hange, C le an 179 O
Driv e Axle Oil L evel C heck 170 O
Drive
Drive Wh
Whee
eell Bear
Bearin
ing
g (P
(Pow
ower
er Shaf
Shaftt and
and Driv
Drive
e Whe
Wheel
el)) Reas
Reasse
semb
mble
le 19
196
6 O
Engine Oil & Fil ter (Diesel Engin e On ly ) C hange 161 , 18 3 O O
Engine Oil & Fil ter (LP & Gasolin e Engin e Only ) C hange 171 O
Engine Oil L evel C heck 155 O
Engine Valve Las h (Dies el En gine Only) C heck, Adjus t 190 , 19 4 O O
Fork s Inspec t 199 O
Fuel Fil ter (Diese l E ngine Only) C hange 182 O
Fuel Fil ter (LP Engi ne Only) 192 O
Inspect, Clean,
Fuel Injectors (Diesel Engine Only) 193 O
Test
Fuel Lines & Fi ttings C heck 189 O
Fuell Tank
Fue Tank Filter Cap and Screen
Screen (If
(If Equ
Equipped
ipped)) Cle
Clean
an 148 O
Fuel Trim Valve(FTV) Inspection (G420F(E)/G424F(E)
181 O
Engine Only)
Fus
Fuses,
es, Bulbs,
Bulbs, Cir
Circuit
cuit Bre
Breaker
aker & Rela
Relay
y Change,
Change, Reset
Reset 149 O
Governor Lever and Engine Speed Control (Diesel Engine
C heck ,Adjus t 174 O
Only)
Horn and Lights (If Equi ppe d) C heck 180 O
Check, Clean,
Hydraulic Oil 201 O
Change
Hy draulic Oil Level C heck 169 O
Hy draulic R eturn Fil te r C hange 166 O
Hy draulic R eturn Fil te r, Br eath er & Strai ner C heck, C hange 185 O
Inchin g & Braking Con trol Shaf t Lub ricat e 180 O
Insp
Inspec
ectt Batte
Battery
ry Sy
Syst
stem
em 20
201
1 O
Inspec t C oolan t Hos es (LP, Dual Fu el Engin e Only) 189 O
Inspec t El ectrical Sy stem (G 42 0F(E)/G 424 F(E) Engine Only ) 181 O
Inspec t E ngin e for Exhaust L eaks 157 O
Inspect Engin e for Fluid Leaks 155 O
 Inspec t Foo t Ped al Ope ra tion (G4 20 F( E)/G42 4 F(E) O nly) 157 O
Inspect
Inspect for Intake
Intake Leaks
Leaks (G
(G420F(
420F(E)/
E)/G424F
G424F(E)
(E) Eng
Engine
ine Only)
y) 203 O

-146-

Maintenance Section

Quick Reference to Maintenance Schedule   FIRST EVERY 

   k   s   s   s   s

  e   y
   l   s    h    h   y
   l    h
   t    h
   t
  e    h    h    h    t    t   r   n   n
   t    t    t   n   n   a   o   o
   W   n   n
  y   o
   l   n   o   o   e
  a   o    i   o    M    M    Y    M    M
  r    M   a    M    M    5    8
  o    D   a    6    9   a    1    1
  s   a    3   r   r   r   r   r
  r   r   a   r   r   o   o   o   o   o
  u   o   r   o   o   s   s   s   s   s
  o   s   o   s   s   r   r   r   r   r
ITEM
EMS
S SERVI
ERVIC
CES PAGE    d    H   r   s   r   r   u   u   u   u   u
  u   r   u   u   o   o   o   o   o
  e
  r   e   o   u   o   o    H    H    H    H    H
   i   c
   i    H   o    H    H
  u   e   e   e   e   e
  q
  e   r
  v
  e   c
  e
   i    H   c
  e
  e    i   c
  e
   i    i
  c
  v    i
  c
  v    i
  c
  v    i
  c
  v    i
  c
  v
   R    S   v   c   v
   i   v   r   r   r   r   r
  r   v   r   r   e   e   e   e   e
  n    0   e   r   e   e    S    S    S    S    S
  e    0    S   e    S    S
   h    1    S    0    0    0    0    0    0
  -    0    0    0    0    0    0    0
   W    0    5    0    5    0    0    5    0    5    0
   5    2    1    2    5    1    1    2    2    3
Inspect Ignition System (LP, Gasoline & Dual Fuel Engines
191 O
Only)
Inspec t Mixe r As se
se mbly (G 420F (E)/G4 24F (E) Engi n
ne
e Only) 189 O
Inspec t Throt tle As se mbly (G4 20 F(E )/
)/G42 4 F(E ) Engine Only ) 189 O
Inspec t Tigh tnes s (GC - Series ) 173 O
Inspect Vacuum Lines and Fittings (G420F(E)/G424F(E)
181 O
Engine Only)
Test, Check,
Lift Chains 186 O
Adjust
LP Regulator/Converter Inspection (LP, Dual Fuel Engine
189 O
Only)
Mas t Ch ann els Lub ricat e 158 O

Mas t Hin ge Pin Lub ricat e 176 O

Inspect,
Mast, Carriage, Lift Chains & Attachments 170 O
Lubricate
Overhe ad G uard Inspec t 178 O
Parking Brak e Inspec t 159 O
Parking Brak e Tes t, Adjus t 164 , 18 0 O O
PCV Valv e Sys te m Inspec t, Clea n 172 O
Primi ng the Fuel Syste m(D iesel En gine Only) 150 O
Replac e LP Fuel Filt er Eleme nt ( LP, Dual Fuel Engin e Only ) 192 O
Repl
Replac
ace
e Oxyg
Oxygen
en Sens
Sensor
or (G
(G42
420F
0F(E
(E)/
)/G4
G424
24F(
F(E)
E) Engi
Engine
ne Onl
nly)
y) 202
202 O
Replace
Replace Spark
Spark Plugs
Plugs (G
(G420F(
420F(E)
E) Engine
Engine Only)
Only) 202 O
Replac e S p
pa
ark Plugs (G4 24F (E) LP , Du al F uel Engi n
ne
e Only) 191 O
Seat, Hood L atc h & Sup port Cylinder C heck, L ubric ate 148 O
Stee r Sus pensio n Inspec t 180 O
Stee r Wh ee
eel B ea
ea rirings Re
ea
assembl e 194 O
Stee ring Mech anis m C heck, L ubric ate 170 O

Tes titing Fuel Loc k-

k-o ffff Ope rra
atio n (LP Engin e Only ) 192 O
Check, Adjust,
Tilt Cylinders 176 O
Lubricate
Timing Belt [G420F(E)/G424F(E) LP, Gasoline, Dual Fuel
Change 204 O
Engine Only]
Tires a nd W heels (D , G-Seri es) Inspec t, Chec k 154 O
Trans miss ion Oil Fil te r C hange 178 O
Trans miss ion Oil Lev el C heck 159 O
Check, Clean,
Transmission Oil, Oil Filter & Strainer 162 , 18 6 O O
Change
Unive rsal J oint Inspec t 188 O
Walk-Aroun d Ins pec tio n Inspec t 157 O
Water Se par ator (4 TNV98 Dies el En gine Only) C lea n 184 O
Water Se per ator (Diesel Engi ne Only) C heck, D rain 152 O
Wheel Bolts & Nu ts Inspec t 173 O
 -147-

Maintenance Section

When Required
You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Fuel Tank Filter Cap and Screen Seat, Hood Latch & Support
(If Equipped) - Clean Cylinder - Check, Lubricate
Park the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
engine stopped.

1.  Check the operation of the seat adjuster rod.

Make sure that the seat slides freely on its
track.
Lightly oil the seat slider tracks if necessary.

1.  Remove the filter cap assembly. Clean in clean,

nonflammable solvent.

2.  Dry cap assembly.

3.  Install filter cap assembly.

WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.

4.  Drain moisture and sediment from fuel tank as 2.  Push the lever down to raise the hood and seat
required by prevailin
p revailing
g conditions. assembly. Make certain the support cylinder will
hold the hood open.
(Note: Unlock latch before pulling it - if key
equipped)

Typical Example
 3.  Lightly oil the hood latch mechanism and the
rod for the hood support cylinder.

-148-

Maintenance Section

Fuses, Bulbs, Circuit Breaker &

Relay - Change, Reset
Fuses
NOTE:  If a fuse filament separates, use only the
same type and size fuses for replacement.
If the filament in a new fuse separates,
have the circuits and instruments
i nstruments checked.

NOTICE
Always replace fuses with ones of the correct
ampere rating. Remove the front cover from the fuse box located
under the cowl.

Fuse - Protects an electrical circuit from an

overload. Opens (filament separates) if an overload
occurs.

Bulbs
Bulbs are identified as follows:
follo ws:
1. Bulb-head lamp halogen (12V-35W)
*2. Bulb-back up (12V-10W)
*3. Bulb-turn signal (12V-23W)
*4. Bulb-stop & tail (12V-23/8W)
Typical Example
*Optional lamp or light
Check the fuses. Use a flashlight, if necessary.

Fuses are identified as follows:

1. Horn - 10 amps.
2. Head/Rear Lamp - 15 amps.
3. Fwd./Rev.
Fwd./Rev. Solenoid, lamp Relay
Relay & Back-up
Lamp/alarm - 10 amps.
4. Instrument Panel & Fuel
Fuel Shutoff - 15 amps.
5. Turn Signal Lamp, Stop/Strobe
Stop/Strobe Lamp & C.S.D.
C.S.D.
6. Start Relay
Relay - 5 amp.
amp.
 Check the fuses. Use a flashlight, if necessary.

-149-

Maintenance Section

Circuit Breaker Priming the Fuel System(Diesel

Engine Only)

4TNV98 Diesel Engine Only

The fuel system needs to be primed under certain

conditions.

   Before starting the engine for the first time

   After running out of fuel and fuel has been
added to the fuel tank

1.  Raise the hood and seat assembly. Make sure    After fuel system maintenance such as
the support cylinder securely holds the hood changing the fuel filter and draining the
open. water separator, or replacing a fuel system
component.

To prime the fuel system

1.  Turn the key to the ON ON   position for 10 to 15

seconds. This will allow the electric fuel pump
to prime the fuel system.
s ystem.

NEVER  use the starter motor to crank the

2.  NEVER 
engine in order to prime the fuel system. This
may cause the starter motor to overheating and
damage the coils, pinion and ring gear

2.  The main circuit breaker is located on the rear 4TNE98 Diesel Engine Only
of the support for the hydraulic
h ydraulic controls.

NOTE:  To reset circuit breakers push in on the The fuel system needs to be primed under certain
button. The button should stay in if the conditions.
breaker is reset. If the button
bu tton will not stay in,
or comes out shortly after reset, have the
circuits checked.    Before starting the engine for the first time.

   After running out of fuel and fuel has been

added to the fuel tank.
   After fuel system maintenance such as
changing the fuel filter and draining the
fuel filter / water separator, or replacing a
fuel system component.
component.

To prime the fuel system on engines equipped with

an electric fuel pump:

1.  Place an approved container under the air

bleed port.
2.  Loosen the air bleed port 2 or 3 turns.

3.  Turn the key to the ON position for 10 to 15

 seconds or until the fuel coming out of the air
bleed port is free of
o f bubbles.
4.  Tighten the air bleed port.

-150-

Maintenance Section

5.  Wipe up any spills and properly dispose of fuel.

6.  NEVER use the starter motor to crank the
engine in order to prime the fuel system. This
may cause the starter motor to overheat and
damage the coils, pinion and / or ring gear.
g ear.

To
withprime the fuel
an electric fuelsystem on engines not equipped
system:

1.  Place an approved container under the air

bleed port.
2.  Loosen the air bleed port (Figure 2, (1)) 2
(1)) 2 or 3
turns.
3.  Operate the fuel priming pump (Figure 2, (2)) (2)) 
until the fuel coming out of the air bleed port is
free of bubbles.
4.  Tighten the air bleed port.
5.  Wipe up any spills and properly dispose of fuel.
6.  NEVER use the starter motor to crank the
engine in order
may cause the to primemotor
starter the fuel system. This
to overheat and
damage the coils, pinion and / or ring gear.
g ear.

Fig ure 2
 -151-

Maintenance Section

Water Seperator (Diesel Engine WARNING

Only) - Check, Drain If the fuel filter/water separator is positioned
higher than the fuel level in the fuel tank, water
4TNV98 Diesel Engine Only may not drip out when the fuel filter/water
separator drain cock is opened. If this happens,
Drain the fuel filter / water separator whenever turn the air vent screw on the top of the fuel

there are contaminants,

the bottom of the cup.such as water,
NEVER waitcollected in
until the filter/water
counterclockwise.separator 2-3 turns
scheduled periodic maintenance if contaminants Be sure to tighten the air vent screw after the
are discovered. water has drained out.

The cup of the separator is made from

semi-transparent material. In the cup is a red
colored float ring. The float ring will rise to the 5.  Open the fuel cock (Figure 5-7, (3)). 
(3)). 
surface of the water to show how much needs to be
drained. Also, some optional fuel filter / water 6.  Be sure to prime the diesel fuel system when
separators are equipped with a sensor to detect the you are finished. See topic “Priming the Fuel
amount of contaminants. This sensor sends a System – When required”
signal to an indicator to alert the operator.
op erator.
7.  Check for leaks.
Drain the fuel filter / water separator
separa tor as follows:

1.  Position an approved container under the fuel

filter / the
collect water separator (Figure 5-7, (1)) 
c ontaminants.
contaminants. (1))  to

Fig ure 5-
5-7
7

2.  Close (Figure 5-7, (2)) 

(2))  the fuel cock (Figure
(3)).
5-7, (3)).

3.  Loosen the drain cock (Figure 5-7, (4)) 

(4))  at the
bottom of the fuel filter / water separator. Drain
any water collected
collected inside.

4.  Hand-tighten the drain cock.

 -152-

Maintenance Section

4TNE98 Diesel Engine Only Test Fuel System for Leaks(LP and Dual Fuel
Engines Only)
NEVER wait until the scheduled periodic
maintenance if the fuel filter indicator comes on.

The fuel filter / water separator contains a sensor to

detect the amount of water and contaminants. This
sensor sends a signal to an indicator to alert the
operator.

Drain the fuel filter / water separator

separa tor as follows:
Check
Points
1.  Position an approved container under the fuel
filter / water separator (Figure 5-1, (1)) 
(1))  to 1.  Obtain a leak check squirt bottle or pump spray
collect the contaminants.
c ontaminants. bottle.

2.  Fill the bottle with an approved leak check

2.  Loosen the drain cock (Figure 5-1, (2)) at the solution.
bottom of the fuel filter / water separator. Drain
any water collected
collected inside. 3.  Spray a generous amount of the solution on the
fuel system fuel lines and connections, starting

3.  Hand tighten the drain cock. at the storage container.

4.  Wait approximately 15-60 seconds then
perform a visual inspection of the fuel system.
4.  Be sure to prime the diesel fuel system when Leaks will cause the solution to bubble.
you are done. See Priming the Fuel System.
5.  Repair any leaks before continuing.

6.  Crank the engine through several revolutions.

This will energize the fuel lock-off and allow fuel
to flow to the pressure regulator/converter.
Apply additional leak check solution to the
regulator/converter fuel connections and
housing. Repeat leak inspection as listed
above.

7.  Repair any fuel leaks before continuing.

WARNING
Prior to any service or maintenance activity,
Fig ure 5-
5-1
1
Test Fuel System for Leaks.
 -153-

Maintenance Section

Tires and Wheels (D, G-Series) - Carriage Roller Extrusion – Adjust

Inspect, Check
1.  Set the mast vertical.
WARNING
Servicing and changing tires and rims can be 2.  Lower the carriage completely.
dangerous and should be done only by trained
3.  On full free lift and full free triple lift models, the
personnel using proper tools and procedures. bottom of the inner mast must be flush with the
If correct procedures are not followed while bottom of the stationary mast.
servicing tires and 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
ser vicing man or dealer.
de aler.

Check Inflation and Damage

Da mage
Inspect tires for wear, cuts, gouges and foreign
objects. Look for bent rims and correct seating of
locking ring.

Check tires for proper inflation. See “Tire Inflation

Pressures”.

To inflate tires always use a clip-on chuck with a 4.  Measure the distance from the bottom of the
minimum 60 cm (24 inches) length of hose to an inner upright to the bottom of carriage bearing.
in-line valve and gauge.
5.  The measurement (A) must be as follows in
Always stand behind the tread of the tire. NOT in Chart below.
front of the rim.
Height of carriage roller extrusion (A)
STD mast FF mast FFT mast
0 41 41

Do not re-inflate a tire that has been run while flat

or underinflated, without first checking to make sure
the locking ring on the rim is not damaged and is in
the correct position.

When tires are changed, be sure to clean all rim

parts and, if necessary, repaint to stop detrimental
effects of corrosion. Sand blasting is recommended
for removal of rust.

Check all components carefully and replace any

cracked, badly worn, damaged and severely rusted
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts.
 Do not, under any
an y circumstances, attempt to rework,
weld, heat or braze
b raze any rim components.

-154-

Maintenance Section

Every 10 Service Hours or Daily

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Gasoline and LP Engines

Inspect Engine for Fluid Leaks
1.  Start the engine and allow it to reach dperating
temperatures.
2.  Turn the engine off.
3.  Inspect the entire for oil and/or coolant leaks.
4.  Repair as necessary before continuing.

Engine Oil Level - Check

1.  Raise the hood and seat assembly.

WARNING 1.  Maintain oil level between the MAX. and MIN.
marks on the dipstick.
Hot oil Do
injury. and
notcomponents can
allow hot oil or cause personal
components to
contact skin. Diesel Engines

1.  Maintain oil level between the MAX. and MIN.

marks on the dipstick.
 -155-

Maintenance Section

Coolant Level – Check 3.  Start and run the engine to stabilize the coolant
level in the filter neck. If low, add coolant until it
reaches the top of the filter neck. Install the
WARNING radiator cap. Observe coolant level in the
At operating temperature, the engine coolant is expansion bottle. If necessary, add coolant to
hot and under pressure. bring the coolant to the appropriate line on the
expansion bottle.
Steam can cause personal injury.
Check the coolant level only after the engine 4.  Stop the engine.
has been stopped and the filter cap is cool 5.  Inspect the cooling system for leaks, hose
enough to touch with your bare hand. cracks or loose connections.
connections.
Remove the filter cap slowly to relieve
r elieve pressure.
Cooling system conditioner contains alkali. WARNING
Avoid contact with the skin and eyes to prevent
Pressure air can cause personal injury.
personal
When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
Maximum air pressure must be less than 205
kPa (30 psi) for cleaning purposes.

6.  Blow any dust and lint from the radiator fins.
fin s.

4TNV98 Diesel Engine

1.  Observe the coolant level

le vel with engine cold.
Maintain coolant level to the proper line on
expansion bottle. If the expansion bottle has no
coolant, it will be necessary to check coolant at
the radiator filter neck.

2.  Remove the radiator cap. Fill radiator to the top

of the filter neck. Inspect radiator cap. Replace
if damaged. Install the radiator cap.
 -156-

Maintenance Section

Air Cleaner Indicator-Check Walk-Around Inspection - Inspect

Checking Service Indicator For maximum service life of the lift truck, make a
thorough walk-around inspection. Look around and
under the truck for such items as loose or missing
bolts, debris or dirt buildup, fuel, oil or coolant leaks
and cut or gouged tires.

Have any repairs made and debris removed, as

needed.

1.  Observe the air cleaner service indicator.

2.  Service the air cleaner when the RED band in

the service indicator, locks in the visible position.
See topic, “Air Intake System - Check,
Che ck, Clean” in
“Every 250 Service Hours or Monthly”.
1.  Inspect the tires and wheels for cuts, gouges,
NOTE:  Service the element more frequently, as foreign objects, inflation pressure and loose or
required, in severe dust or lint conditions. missing bolts.
Also, service it more frequently where the
operator is required to wear a respirator.
re spirator. 2.  Inspect the mast and lift chains for wear, broken
links, pins and loose rollers.
3.  Close hood and seat assembly.
3.  Inspect the hydraulic system for leaks, worn
hoses or damaged lines.
Inspect Foot Pedal Operation
4.  Look for transmission and drive axle leaks on
(G420F(E)/G424F(E) Only) the lift truck and on the ground.
g round.
1.  Verify foot pedal travel is smooth without
sticking.

WARNING
When the acceleration pedal harness is
connected or disconnected, should be worked
key OFF condition.
c ondition.
If not, occured malfunction, can cause the
personal injury.

Inspect Engine for Exhaust Leaks 5.  Inspect the operator’s compartment for loose
items and cleanliness.
cleanliness.
1.  Start the engine and allow it to reach operating
temperatures. 6.  Inspect the instrument panel for broken gauges
and indicator lights.
2.  Perform visual inspection of exhaust system.
Repair any/all leaks found. 7.  Test the horn and other safety devices for
proper operation.
 -157-

Maintenance Section

  Mast Channels – Lubricate

8.  Inspect the cooling system for leaks, worn

hoses and debris buildup. The channels on the roller-type mast require a
break-in period. Apply a light film of lubricant on the
9.  Inspect engine compartment for oil, coolant and channels where the rollers ride. This will prevent
fuel leaks. metal peel until the rollers set a pattern.

10. Inspect the forks.

 Visually inspect forks for cracks, especially in the

 
heel section, around the mounting brackets, and
all weld areas.
   Inspect for broken or jagged fork tips, bent or

twisted blades and shanks.

   Make sure positioning lock is in place and
working.
Lock the forks in position before using the truck.
See Step 7 of “Forks” in “Every 2000 Service
Hours or Yearly”.
   Remove all defective forks from service.
 -158-

Maintenance Section

Transmission Oil Level – Check Parking Brake - Inspect

WARNING Inspection from Operator's Seat, Engine
Hot oil and components can cause personal
OFF
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 with the forks lowered,
parking brake applied and the transmission
controls in NEUTRAL.

3.  With the service brake applied and the engine

at low idle, shift the directional control lever to
forward and then to reverse, to fill the clutches.
4.  Shift the direction control lever to the NEUTRAL 1.  Grasp the parking brake lever with your hand
position. and press down the release button with your
thumb. The lever should move freely forward
5.  Remove the dip stick/filter cap. Observe the oil and backward.
level.

6.  Maintain the oil level between the Min and Max 2.  Remove
The leveryour thumb
should from
resist the release
movement button.
when pulled
marks on the dip stick/filter cap. fully back and a clicking sound should be heard.
When the oil temperature is 40°C approximately, The lever should remain fully back until you
the cold side mark on the dipstick is applicable. press the release button with your thumb.
When the oil temperature is 80°C approximately,
the hot side mark on the dipstick is applicabl
applicable.
e. 3.  Report a missing, damaged or loose parking
brake lever, any inability or difficulty engaging
and releasing the parking brake lever, or any
restricted movement of the parking brake lever.

Inspection from Operator's Seat, Engine

ON
PARKING BRAKE SWITCH

1.  With the parking brake engaged, the direction

control lever in NEUTRAL and the engine
running, shift the direction control lever to
FORWARD.

2.  The lift truck should not move forward or feel

like it wants to move forward, even when the
engine is accelerated briefly.

3.  Repeat this procedure in REVERSE. Report

truck movement or tendency to move under
power with the parking brake engaged.
 -159-

Maintenance Section

PARKING BRAKE

NOTE:  The parking brake is required to be

adjusted to hold the lift truck with capacity
load on a 15% grade.
If there is a 15% grade in your workplace,
engage a capacity load and drive over to
the grade. If the maximum grade in your
workplace is less than 15% or if the
maximum load carried by the lift truck is
less than the lift truck's load capacity, pick
up the maximum load and drive to the
steepest grade in your workplace.
w orkplace.

1. Raise the forks or load engaging attachment

about 30 cm (12 in) from the floor.

2. Drive forward up the grade, or in reverse down

the grade, and stop the lift truck with the service
brakes.

3. Engage the parking brake and release the

service brakes.

4. If the lift truck moves down the grade, control its

speed with the service brakes, release the
parking brake and return directly to the
inspection area.

5. Park the lift truck, engage the parking brake, shift

the direction control lever to NEUTRAL, lower the
forks or load engaging attachment to the floor,
shut OFF the engine, remove the key, chock the
tires, terminate the inspection, tag the lift truck
"Do Not Operate" and immediately report the
failure of the parking brake to hold the lift truck.
 -160-

Maintenance Section

First 50 - 100 Service Hours or a Week

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Engine Oil & Filter (Diesel Engine 6.  Remove the oil drain plug (Figure 5-2, (1)) from
(1)) from
the engine oil pan. Allow oil to drain.
Only) - Change
7.  After all oil has been drained from the engine,
The engine oil in a new engine becomes
reinstall the oil drain plug (Figure 5-2, (1)) and
(1)) and
contaminated from the initial break-in of internal
parts. It is very important that the initial oil and filter tighten to 139.8 - 47.0 ft•lb (53.9 - 63.7 N•m; 5.
5 - 6.5 kgf•m).
kg f•m).
change is performed as scheduled
8.  Dispose of used oil properly
NOTE:  The oil drain plug may be in another
location if an optional oil pan is used..

Drain the engine oil as follows: R emove

emove the eng ine oil filter
filter as follows:
follows:  

1.  Make sure the engine is level. 1.  Turn the engine oil filter (Figure 5-2, (2)) 
(2)) 
counterclockwise (Figure 5-2, (3)) using a filter
2.  Start the engine and bring it up to operating wrench.
temperature.

3.  Stop the engine.

4.  Remove one of the oil filler caps (Figure 5-1,

 to vent the engine crankcase and allow the
(1)) to
(1))
engine oil to drain more easily.

5.  Position a container under the engine to collect

waste oil.

F g
i  ure
ur e 5-2 

2.  Clean the engine oil filter mounting face.

3.  Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise (Figure 5-2,
(4))   until it contacts the mounting surface.
(4))
Tighten to 14 - 17 ft•lb (19.6 - 23.5 N•m; 2.0 -
2.4 kgf•m) or one additional turn using the filter
wrench.
 4.  Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-14.
Fig ure 5-
5-1
1 

-161-

Maintenance Section

  WARNING Transmission Oil, Oil Filter &

NEVER overfill the engine with engine oil.
o il.
Strainer - Check, Clean, Change
ALWAYS keep the oil level between the upper WARNING
and lower lines on the oil cap/dipstick.
ca p/dipstick.
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
5.  Warm up the engine by running it for five contact skin.
minutes and check for any engine oil leaks.

6.  After engine is warm, shut it off and let it sit for Park the lift truck level, with the forks lowered,
10 minutes. parking brake engaged, direction control lever in
NEUTRAL and the engine
e ngine stopped.
7.  Recheck the engine oil level.
le vel.

8.  Add engine oil (Figure 5-3, (5)) as needed until

the level is between the upper (Figure 5-3, (2)) 
(2)) 
and lower lines (Figure 5-3, (3)) shown
(3)) shown on the
dipstick (Figure 5-3, (1)).
(1)).

1.  Remove drain plug (1). Allow the oil to drain

into a suitable container. Clean the magnetic
drain plug. Check O-ring seal and replace if
necessary. Remove the spring and the strainer.

2.  Wash the strainer assembly in clean,

Fig ure 5
5-3
-3  nonflammable solvent and dry it. Install the
strainer assembly. 
9.  Reinstall the oil filler cap (Figure 5-3, (4))
(4)).. If
any engine oil is spilled, wipe it away with a
clean cloth.

NOTICE
Servicing of the engine oil and oil filter element will
largely affect the engine performance as well as the
 engine life.
Engine oil and filter element must be changed after
the first 50 hours.

-162-

Maintenance Section

  12. Maintain the oil level between the Min and Max

marks on the dip stick/filter cap.
When the oil temperature is 40°4 0°C
C approximately,
the cold side mark on the dipstick
di pstick is applicable.
applicable.
When the oil temperature is 80°8 0°C
C approximately,
the hot side mark on the dipstick is applicable.
applicable.

13. Check for oil leaks at the filters

fi lters and drain plug.

14. Stop the engine. Install the floor mat and floor

plate.

3.  Remove the floor mat and the floor plate.

Remove and discard the oil filter.

4.  Wipe off the filter base. Make certain that all of
the old seal is removed.

5.  Apply a small amount of clean oil on the seal of

the new filter.
fil ter.

6.  Install the filter by hand. When the filter

contacts the base, tighten an additional 3/4
turn.

7.  Remove the dip stick/filter cap. Fill the

compartment with oil. See “Refill Capacities”.
Install the dip stick/filter
sti ck/filter cap.

8.  Start the engine.

9.  With the service brake applied and engine at

low idle, shift the direction control lever to
forward and reverse to fill the clutches.

10. Shift the direction control lever into NEUTRAL.

Engage the parking brake.

11. Remove the dip stick/filter cap. Observe the oil

level.
 -163-

Maintenance Section

Drive Axle Oil - Change Parking Brake - Test, Adjust

Park the lift truck on a level surface. Apply the Parking Brake Testing
parking brake. Place the directional control lever in
NEUTRAL and stop the engine.
NOTICE
OSHA requires the parking brake to hold the lift
truck, with capacity load, on a 15% grade.
Testing requires a test load equal to the capacity of
the truck and a 15% grade.
g rade.
If the maximum grade in the workplace is less than
its capacity, use the Parking Brake inspection
procedure covered in ‘Inspection from Operator’s
Seat, Engine On’ in “Every 10 Service Hours or
Daily” section.

1.  Pick up capacity load and drive over to a 15%

grade.
1.  Remove drain plug. Allow the oil to drain into a 2.  Drive forward up the 15% grade. Halfway up
suitable container. Clean the magnetic drain the grade, stop the lift truck with its service
plug. Check O - ring seal and replace if brakes.
necessary.

2.  Install the drain plug. 3.  Engage thebrake.

the service parking brake and slowly release

3.  Remove the dip stick/filter cap.

Fill the drive axle housing with oil.
See “Refill Capacities”.

4.  Start the lift truck.

With the engine at low idle, place the directional
control lever to the NEUTRAL.

5.  Maintain the oil level between lower mark and

upper mark on the dip stick/filter cap.

4.  Engage the parking brake and shift the

transmission to NEUTRAL. Slowly release the
service brakes.

5.  The parking brake adjustment is proper if it

holds the lift truck on the grade. The parking
brake needs adjusting if it does not hold the lift
truck on the grade.

6.  If the lift truck starts to move in reverse down

6.  Install the dip stick/filter
sti ck/filter cap. the grade with the parking brake engaged, stop
it with the service brakes, disengage the
NOTE:  Tighten the dipstick plug fully not to allow parking brake and reverse slowly down the
foreign parts(rain, water etc) to enter into grade controlling your speed with the service
drive axle. brakes.
 -164-

Maintenance Section

  WARNING
To prevent personal injury, the operator MUST
be ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck
starts to move.

Parking Brake Adjusting

1.  Park the lift truck on a level surface, lowered
the forks, shift the transmission to NEUTRAL
and shut OFF the engine and block the wheels
securely.
7.  Loosen lock nut (5). Tighten screw (6) to 6 to 7
2.  Chock the lift truck's tires to prevent N•m (50 to 60 lb•in). Loosen the screw (6) 1 1/6
unintentional movement. turns and tighten the lock nut (5).

NOTICE
Turn the adjustment screw (6) clockwise to tighten.
Turning the screw (6) too far counterclockwise
could allow parts to fall into the bottom of the
transmission.
The transmission would than require disassembly
to remove the parts.
p arts.

8.  Reinstall the floor plate and floor mat.

9.  Engage the parking brake, remove the tire

chocks and test the parking brake. Refer to
‘Parking Brake Testing’ in the preceding
3.  Remove the floor mat and floor plate. section.

4.  Make sure the parking brake lever is released.

5.  Make sure the brake lever (1) is held against

stop pin (2). If the brake lever (1) is held against
the stop pin (2), go to step 7. If the brake lever
(1) is NOT held against the stop pin (2), go to
step 6.

6.  Remove the pin (3) and the cotter pin (4).
Tighten the nut (6) to compress the spring (7)
 further
(5) untiland pull(3)
the pin downward and
fits into the turnlever
brake the clevis
when
the lever (1) is held against the stop pin (2).
Then install the pin (3) and the cotter pin (4)
and return the nut (6) to the clevis (5).

-165-

Maintenance Section

First 250 Service Hours or a Month

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Hydraulic Return Filter – Change .

WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
skin.
contact skin.

Park the lift truck level with the forks lowered,

parking brake engaged, transmission in NEUTRAL
and the engine stopped.

1.  Loosen the bolts of the hydraulic tank top plate

assembly.

2.  Remove the return filter from tank top plate

assembly.

3.  Change the return filter.

4.  Install the tank top plate assembly and fasten

the bolts.

5.  Start the engine and operate the hydraulic

controls, and the steering system, through a
few cycles to fill the lines. Look for oil
oi l leaks.

6.  Stop the engine and check the oil level. With all
cylinders retracted, maintain the oil level to the
FULL mark on the dip stick/filter cap assembly.
 -166-

Maintenance Section

Every 250 Service Hours or Monthly

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Air Intake System - Check, Clean 1.  To service the air cleaner, raise the hood and
seat assembly. Make certain the support
Precleaner (If Equipped) cylinder securely holds the hood open. Loosen
the cover latches and remove the cover.

NOTICE

Never service precleaner with the engine running.

2.  Rotate the element slightly to separate it from

its base and remove it from the air cleaner
housing.

3.  Clean and inspect the element or replace with a

1.  Check the precleaner bowl for dirt build-up. new element. See topic, “Cleaning Primary
If the dirt is up to the line, remove the Filter Element”.
precleaner bowl and empty it. Periodically wash
the cover and bowl in water. 4.  Clean the inside of air cleaner housing and the
cover. Inspect all connections between the air
cleaner and carburetor. Check intake hose for
Servicing Filter Element cracks, damage necessary to prevent leakage.

NOTICE NOTICE

Never service filter with the engine running. Do not allow

cleaning dirty air
the inside of to
theenter the intake
air cleaner hose when
housing.

5.  Check the air cleaner housing for loose latches.

6.  Reset the air cleaner service indicator.

7.  Install the air filter element.

8.  Install the cover and tighten the cover latches.

9.  Start the engine and observe the position of the

indicator. If the indicator shows RED after the
installation of the primary element, install
another clean or a new element or, replace the
secondary element. See topic, “Air Intake
Service the air cleaner when the red target in the System-Change” in “Every 1000 Service Hours
 service indicator stays locked in the visible position or 6 months section
with the engine stopped.
10. Stop the engine and close the hood and seat
assembly.

-167-

Maintenance Section

Cleaning Primary Filter Elements Air-205 kPa (30 psi) Maximum Pressure

WARNING
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.

NOTICE

Do not clean the elements by bumping or tapping Direct air on the inside and outside of the element
them. along the length of the pleats. Check the element
for any tears, rips or damage
Inspect filter elements after cleaning. Do not use a
filter with damaged pleats, gaskets
ga skets or seals.
Water-280kPa (40 psi) Maximum Pressure
When cleaning with pressure air, use 205 kPa (30
psi) maximum pressure to prevent filter element
damage.
When cleaning with pressure water, use 280 kPa
(40 psi) maximum pressure to prevent filter element
damage.

Have spare elements on hand to use while cleaning

used elements.

The primary element should be replaced after 6

months service or after cleaning no more than 3
times.

Direct water on the inside and outside of the

element along the length of the pleats. Air dry it
thoroughly and then examine it.

Detergent
1.  Wash the element in warm water and mild
household detergent.
de tergent.

2.  Rinse the element with clean water.

See instructions in preceding topic for cleaning
with water.

3.  Air dry it thoroughly, and then examine it.

 -168-

Maintenance Section

Checking Element Hydraulic Oil Level – Check

WARNING
At operating temperature, the hydraulic tank is
hot and under pressure.
Hot oil can cause burns.
Remove the filter cap only when the engine is
stopped, and the cap is cool enough to touch
with your bare hand. Remove the filter cap
slowly to relieve pressure.

1.  Operate the lift truck for a few minutes to warm

1.  Insert a light inside the clean dry element and the oil. Park the lift truck on a level surface, with
examine it. Discard the element if tears, rips or the forks lowered, mast tilted back, parking
damage are found. brake engaged, transmission in NEUTRAL and
the engine stopped.
2.  Wrap and store good elements in a clean, dry
place. 2.  Raise the hood and seat assembly. Make sure
the air lift cylinder securely holds the hood
open.
Brake Oil Level - Check

3.  Remove the dip stick/filter cap. Maintain the oil

level to the FULL mark on the dip stick/filter
The brake reservoir is located on the left side of the cap.
steering column.

1.  Remove the filler cap.

2.  Maintain the brake fluid level to the fluid level
mark on the brake system reservoir.
3.  Clean and install the filler cap
 -169-

Maintenance Section

Drive Axle Oil Level - Check 5.  Raise and lower the carriage a few times to
allow lubricant to enter into the chain links.
Park the lift truck on a level surface. Apply the
parking brake. The engine at low idle. Place the
directional control lever in NEUTRAL. NOTICE
Lubricate chains more frequently than normal in
applications where the lift truck is operating in an
atmosphere orwhich
components could
when lift truck cause corrosion
must work of
in rapid lift
cycles.

6.  Inspect the chain anchors and individual links

for wear, loose pins or cracked leaves.

Steering Mechanism - Check,

Lubricate
1.  Remove the dip stick/filter cap. Observe the oil
level.

2.  Maintain the oil level between the lower mark

and upper marks on the dip stick/filter
sti ck/filter cap.

Mast, Carriage, Lift Chains &

Attachments - Inspect, Lubricate
1.  Operate the lift, tilt and attachment controls.
Listen for unusual noises. These may indicate a
need for repair.
1.  Lubricate the steer axle king pins, total of four
2.  Inspect for loose bolts and nuts on the carriage.
c arriage. fittings. Two on the right side and two on the left
Remove any debris from the carriage and mast. side.

3.  Inspect the forks and attachments for free 2.  Lubricate the steering link bearings, total of four
operation and damage. Have repairs made if fittings. Two on the right side and two on the left
necessary. side

3.  Check
steeringformechanism.
any worn or loose
Removecomponents of the
any debris or
trash as

4.  Brush a film of oil on all links of the chain.

 -170-

Maintenance Section

Battery Terminal - Clean, Inspect Engine Oil & Filter (LP & Gasoline
Engine Only) - Change
WARNING
Batteries give off flammable fumes that can
Gasoline, LP Engine Crankcase
explode.
Do not smoke when observing the battery 1.  Operate lift truck a few minutes to warm oil.
o il.
electrolyte levels. Park the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
Electrolyte is an acid and can cause personal engine stopped.
injury if it contacts skin or eyes.
2.  Raise rear of lift truck off ground and block
Always wear protective glasses when working securely.
with batteries.

WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.

1.  Clean the top of the battery and

an d terminals.

2.  Check terminals for corrosion. Coat terminals

with heavy grease.

3.  Remove the crankcase drain plug and allow oil

to drain into a suitable container. Clean and
install drain plug.

4.  Raise the hood and seat assembly.

5.  Remove and discard oil filter

fil ter element.

6.  Wipe sealing surface of oil filter element

 mounting base. Make sure the entire old gasket
is removed.

-171-

Maintenance Section

7.  Before installing a new filter element, apply a PCV Valve System - Inspect,
small amount of clean engine oil to the filter
element gasket. Clean
8.  Install the new filter element. When the gasket G420F(E) Gasoline, LP and Dual Fuel
contacts the base, tighten it 3/4 of a turn more. Engines 
Do not over-tighten.

9.  Raise the lift truck, remove the blocking and

lower the lift truck.

10. Fill the crankcase. See

See “Refill Capacities”.

11. Start the engine and allow the oil to fill the filter
and passages.

12. Check for oil leaks.

G424F(E) LP and Duel Fuel Engines

13. Stop the engine and measure the oil level.

Maintain the oil level to the FULL mark on the
dip stick.

14. Close hood and seat assembly

1.  Loosen the hose clamps and remove the PCV

valve.

2.  Shake the PCV valve. If it rattles, reinstall it. If it

does not rattle, replace it.

3.  Tighten the hose clamps

 -172-

Maintenance Section

Wheel Bolts & Nuts - Inspect Inspect Tightness (GC - Series)

Inspect Tightness (D, G - Series) Drive Wheels

Steer Wheels

Typical Example

Typical Example 1.  Inspect tightness of wheel bolts in a sequence

opposite each other to 245 N•m (180 lb•ft).
1.  Inspect tightness of wheel bolts in a sequence
opposite each other 110 N•m (75 lb•ft).

Drive Wheels

Typical Example

2.  Inspect tightness of wheel nuts in a sequence

opposite each other to 610 N•m (450 lb•ft).
 -173-

Maintenance Section

Governor Lever and Engine Speed WARNING

Control (Diesel Engine Only) - NEVER attempt to adjust the low or high idle
Check ,Adjust speed limit screw. This may impair the safety
and performance of the machine and shorten its
4TNV98 Diesel Engine Only life. If the idle speed limit screws require
adjustment, see your authorized Yanmar
The governor
throttle lever,lever and etc.)
pedal, engineofspeed
the control
machine ( are industrial engine dealer or distributor..
connected together by a throttle cable or rod. If the
cable becomes stretched, or the connections
loosen, the governor lever may not respond to
change of engine speed control position. This may
make operation of the machine unsafe. Check the
cable periodically and adjust if necessary.
n ecessary.

NEVER force the throttle cable or pedal to move.

This may deform the governor lever or stretch the
cable and cause irregular operation of the engine
speed control

Checking and adjusting the governor lever:

1.  Check that the governor lever (Figure 5-11, (1)) 

(1)) 
makes uniform contact with the high idle
(2))  and low idle (Figure 5-11,
(Figure 5-11, (2)) 
 speed limit screws when the engine speed
(3)) speed
(3))
control is in the high idle speed or low idle
speed position.

Fig ure 5-
5-11
11 

2.  If the governor lever does not make contact

with the high idle or low idle speed limit screw,
adjust the throttle cable.

3.  In some engine speed control applications,

 loosen the throttle cable lock nut (Figure 5-11,
 and adjust the cable so the governor lever
(4)) and
(4))
makes proper contact with the high / low idle
speed limit screw

-174-

Maintenance Section

4TNE98 Diesel Engine Only

The governor lever and engine speed

control(accelerator lever, pedal, etc.) of the
machine are connected together by an accelerator
cable or rod. If the cable becomes stretched, or the
connections loosen, the governor lever may not
respond to change of
o f engine speed control position.
This may make operation of the machine unsafe.
Check the cable periodically and adjust if
necessary. Consult your authorized Yanmar
industrial engine dealer or distributor for the
adjustment procedure.

NEVER force the accelerator cable or pedal to

move. This may deform the governor lever or
stretch the cable and cause irregular operation of
the engine speed control.

Checking and adjusting the governor lever:

1.  Check that the governor lever (Figure 5-12, (1))  (1)) 
makes uniform contact with the low idle (Figure
(2)) and high idle (Figu
5-12, (2)) and (Figurere 5-
5-12, (3)) speed
12, (3)) speed
limit screws when the engine speed control is in
the high idle speed or low idle
id le speed position.

2.  If the governor lever does not make contact

with the high idle or low idle speed limit screw,
adjust the accelerator cable.

3.  3. In some engine speed control applications,

loosen the accelerator cable locknut and adjust
the cable so the governor lever makes proper
contact with the high / low idle speed limit
screw.
 Fig ure 5-
5-12
12 

-175-

Maintenance Section

Every 500 Service Hours or 3 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Belts - Check, Adju

Adjust
st Mast Hinge Pin – Lubricate

Typical Example Typical Example

1.  Check the condition and adjustment of the belt. 1.  Lower the forks and tilt the mast forward.
Correct adjustment allows 10 mm (3/8 inch)
deflection under 110 N (25 lb) of force. 2.  Lubricate the two fittings for the mast hinge pins,
one on each side of
o f the mast.

Tilt Cylinders - Check, Adjust,

Lubricate
Chassis Pivot Eyebolts-Lubricate

NOTICE
Failure to loosen the alternator mounting bolt (2)
will cause excessive stress and break the alternator
mounting ear.
Typical Example
2.  To adjust the alternator drive belt, loosen
adjusting bracket bolt (1) and mounting bolt (2). 1.  Remove floor plates. (GC-series only)
Move the alternator in or out as required.
Tighten bolts (1) and (2).
(2 ). 2.  Lubricate two fittings for the pivot eyebolts, one
on each tilt cylinder.

3.  Check the pivot eye pins for loose retainer bolts
and wear.
 -176-

Maintenance Section

Mast Pivot Eyes-Lubricate

Typical Example

Typical Example 3.  To adjust the cylinder rod extension, move the
spacer to the rear and loosen the pinch bolt on
1.  Lubricate two fittings for the mast pivot eyes, the clevis.
one on each side of the pin.
4.  Turn the cylinder rod in or out of the clevis to
2.  Check the pivot eye pins for loose retainer bolts obtain the proper adjustment. Turning the rod
and wear. into the clevis shortens the stroke. Turning the
rod out of the clevis
c levis lengthens the stroke.

Cylinder Rod Extension-Adjust Tighten(70

5.  Name the± pinch boltsCheck
10 abaft). to a the
torque of 95±15
cylinder rods
NOTE:  The following description is for forward tilt. again for even travel.
For cylinder rod back tilt, the collar should
be stationary by the tilt eye. If it is not, the
O-ring inside the collar may need to be
replaced. To adjust back tilt, spacers must Crosshead Rollers - Inspect
be added or removed.
Check Operation
1.  Operate the mast through a lift
l ift cycle. Watch the
chains move over the crosshead rollers. Make
sure the chain is tracking over the rollers
properly.

Typical Example

1.  Check to make sure the tilt cylinders extend

and retract evenly.

2.  If one cylinder

cylinder continues to move after
a fter the other Typical Example
cylinder has stopped in full forward or backward
tilt, an adjustment must be made to one 2.  Check for damaged crosshead rollers, guards
cylinder. and retainer rings.
 -177-

Maintenance Section

Transmission Oil Filter – Change Overhead Guard – Inspect

WARNING
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, direction control lever in
NEUTRAL and the engine
e ngine stopped.

1.  Check tightness of overhead guard mounting

bolts at 95 N•m (70 lb•ft
lb•ft).
).

2.  Check overhead guard for bent or cracked

sections. Have repairs made if needed.

1.  Remove the floor mat and the floor plate.

Remove and discard the oil filter.

2.  Wipe off the filter base. Make certain that all of
the old seal is removed.

3.  Apply a small amount of clean oil on the seal of

the new filter.
fil ter.

4.  Install the filter by hand. When the filter

contacts the base, tighten an additional 3/4
turn.

5.  Start the engine.

6.  With the service brake applied and engine at

low idle, shift the direction control lever to
forward and reverse to fill the clutches.

7.  Shift the direction control lever into NEUTRAL.

Engage the parking brake.

8.  Remove the dip stick/filter cap. Observe the oil

level.

9.  Maintain the oil level between the Min and Max
marks on the dip stick/filter cap. When the oil
temperature
tempe rature is 40°C
40°C approximately,
approximatel y, the cold
side mark on the dipstick is applicable. When
the oil temperature is 80°C
80°C approximately, the
hot side mark on the dipstick is applicable.
 10. Check for oil leaks at the filters.
fil ters.

11. Stop the engine. Install the floor mat and floor

plate.

-178-

Maintenance Section

Drive Axle Oil & Strainer - Change,

Clean

7.  Install the dip stick/filter cap.

Park the lift truck level, with the forks lowered,

parking brake engaged, transmission in NEUTRAL
and engine stopped.

1.  Remove drain plug. Allow the oil to drain into a

suitable container. Clean the magnetic drain
plug. Check O - ring seal and replace if
necessary.

2.  Install the drain plug.

3.  Wash the strainer assembly in clean, non

flammable solvent and dry it. Install the strainer
assembly and reconnect the hose.

4.  Remove the dip stick/filter cap. Fill the drive

axle housing with oil.
See “Refill Capacities.”

5.  Start the lift truck with engine at low idle, place
the directional control lever to the NEUTRAL.

6.  Maintain the oil level between lower mark and

upper mark on the dip stick/filter cap.
 -179-

Maintenance Section

Steer Suspension – Inspect Inching & Braking Control Shaft -

Lubricate  

1.  Inspect the suspension mounting bolts. Tighten

suspension mounting bolts, if necessary, to 240
1.  Lubricate three fittings for the inching and brake
b rake
± 30 N•m (180 ± 20
2 0 lb•ft).
pedal control shaft.

Horn and Lights (If Equipped) -

Check

2.  Look for leaks at the power steering hose

connections.

3.  Remove any trash buildup on the suspension or

the steer axle.
1.  Press horn button, to determine if horn is
operational.

Parking Brake - Test, Adjust 2.  Check and replace all defective
d efective gauges.
See topic, “Parking Brake - Test, Adjust” in “First
50-100 Service Hours or a Week”. 3.  Check all lights such as warning, directional,
backup, driving and flood lights for correct
operation. Replace all burned out bulbs.
b ulbs.
Have repairs made if needed.
 -180-

Maintenance Section

Inspect Vacuum Lines and Fittings

Fittings Inspect Electrical System
(G420F(E)/G424F(E)
(G420F(E)/G424F(E) Engine Only) (G420F(E)/G424F(E)
(G420F(E)/G 424F(E) Engine Only)

1.  Visually inspect vacuum lines and fittings for 1.  Check for loose, dirty or damaged connectors
physical damage such as bittleness, cracks and and wires on the harness including: Fuel
kinks. Repair/replace as required. lock-off, TMAP sensor, O2 sensor, Electronic
throttle, Control Relays, Fuel Trim Valve, Foot
2.  Slovent or oil damage may cause vacuum lines Pedal, and crank sensor.
to become soft resulting in a collapsed line
while the engine is running. 2.  Repair and/or replace as necessary.

3.  If abnormally soft lines are detected, replace as

necessary.

(1) Fuel Trim Valve(FTV)

(2) Vacuum lines

Fuel Trim Valve(FTV) Inspection

(G420F(E)/G424F(E)
(G420F(E)/G 424F(E) Engine Only)
1.  Visually inspect the Fuel trim valve for
abrasions or cracking. Replace as necessary.

2.  To ensure the valve is not leaking a blow-by

test can be performed.
3.  With the engine off, disconnect the electrical
connector to the FTV.

4.  Disconnect the vacuum lines form the FTV to

the pressure regulator/converter, at the
converter’s tee connection.

5.  Lightly blow through the vacuum line connected

to the FTV. Air should not
no t pass through the FTV
when de-energized. If air leaks past the FTV
when de-energized replace replace the FTV.
 -181-

Maintenance Section

Fuel Filter (Diesel Engine Only) - 4TNE98 Diesel Engine Only

Change Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
4TNV98 Diesel Engine Only diesel fuel flow.
Replace the fuel filter at specified intervals to 1.  Stop the engine and allow it to cool.
prevent contaminants from adversely affecting the
diesel fuel flow 2.  Close all fuel cocks in fuel line.
1.  Stop the engine and allow it to cool. 3.  Disconnect the fuel filter sensor connector
(1)). 
(Figure 5-14, (1)). 
2.  Close the fuel cock of the fuel filter / water
separator.

3.  Remove the fuel filter with a filter wrench,

turning it to the left (Figure5-13,(1)).
(Figure5-13,(1)).   When
removing the fuel filter, carefully hold it to
prevent the fuel from spilling. Wipe
Wipe up all spilled
fuel.

Fig ure 5-14

5-14 

4.  Place an approved container under fuel filter.

5.  Carefully open the drain plug (Figure 5-15, (1)) 

(1)) 
to drain fuel from the fuel filter.
Figure5-13 
6.  Remove the fuel filter (Figure 5-14, (2))  (2))  by
turning it to the left (Figure 5-14, (3)). Wipe up
4.  Clean the filter mounting surface and apply a all spilled fuel.
small amount of diesel fuel to the gasket of the
new fuel filter.
Remove
7.  the the  drain
fuel filter
filter  plug
(Figure (Figure
5-15, 5-15,
(2))  by
(2))  (1)) from
(1)) from
turning it to
5.  Install the new fuel filter. Turn to the right the left (Figure 5-15, (3)). 
(3)). 
(2)) and hand-tighten it only until it
(Figure5-13, (2)) and
comes in contact with the mounting surface. 8.  Check the condition of the drain plug O-ring
Tighten to 14-17 ft•lb (19.6-23.5 N•m; (4)).  Replace the O-ring if
(Figure 5-15, (4)). 
2.0-2.4kgf•m) or one additional turn using the damaged.
filter wrench.

6.  Open the fuel cock of the fuel filter / water

separator.

7.  Prime the fuel system. See topic “Priming the

Fuel System” in “When Required”.

8.  Check for leaks.

 -182-

Maintenance Section

  17. Install the new fuel filter (Figure 5-14, (2)) 

(2))  by
turning it to the right (Figure 5-14, (4)) 
(4))  until it
contacts the mounting surface. Tighten one
additional turn.

18. Open all fuel cocks in the fuel line.

line .

19. Reconnect
(Figure 5-14,the
(1)).fuel
(1)).   filter sensor connector

20. Prime the fuel system. See Priming the Fuel

System.

21. Check for fuel leaks.

Engine Oil & Filter (Diesel Engine

Only) - Change
See topic, “Engine Oil & Filter (Diesel Engine Only)
- Change” in “ First 50-100 Service Hours or a
Week”.
Fig ure 5-1
5-15
5 

9.  Set the drain plug aside for reinstallation.

reinstallation.

10. Remove the fuel filter sensor assembly (Figure

5-15, (5)) 
(5))  by turning it to the left (Figure 5-15,
(3)).  
(3)).

11. Carefully remove the in-line fuel filter (Figure

(7))  from the output nipple (Figure 5-15,
5-15, (7)) 
 that goes to the fuel injection pump.
(8)) that
(8))

12. Dispose of the fuel, fuel filters and O-ring (if

replaced) properly. Follow the guidelines of the
EPA or other government agency.

13. Carefully install the new in-line fuel filter

(Figure 5-15, (7)) into
(7)) into the output nipple (Figure
(8)). 
5-15, (8)). 

14. Carefully install the fuel filter sensor assembly

(5)) in the new fuel filter using the
(Figure 5-15, (5)) in
new O-ring supplied with the fuel filter (Figure
(2))  by turning the fuel filter sensor
5-15, (2)) 
assembly to the right (Figure 5-15, (9)).
(9)).

15. Install the drain plug (Figure 5-15, (1)) 

(1))  on the
new fuel filter (Figure 5-15, (3)) by
(3)) by turning the
drain plug to the right (Figure 5-15, (8)).
(8)). Hand
tighten only.
 16. Clean the fuel filter mounting surface (Figure
(10)) and apply a small amount of diesel
5-15, (10)) and
fuel to the gasket of the new filter.

-183-

Maintenance Section

Water Separator (4TNV98 Diesel 6.  Remove the float ring (Figure5-16, (8)) from the
cup. Pour the contaminants into the container
Engine Only) - Clean and dispose of it properly.

7.  Clean the element (Figure5-16, (9)) and

(9)) and inside
Periodically clean the fuel filter / water separator
cup. Replace the element if it is damaged.
element and inside cup.
 
1.  Position an approved container under the cup 8. Install the element and O-ring in the bracket.
b racket.
(1))  of the fuel filter/water
(Figure5-16, (1)) 
separator to collect the contaminants.
conta minants. 9.  Position the float ring in the cup.

10. Check the condition of the cup O-ring. Replace

if necessary.

11. Install the cup to the bracket by tightening the

retaining ring to the right (Figure5-16, (6)) to
(6)) to a
torque of 11-15 ft•lb (15-20 N•m; 1.5-2.0kgf•m).

12. Close the drain cock. Reconnect the sensor

wire if equipped.

13. Open the fuel cock (Figure5-16, (3)). 

(3)). 

14. Prime the fuel system. See topic, “Priming the

Fuel System” in “When required”.

15. Check for leaks

Figure5-16  
Figure5-16

2.  Close (Figure5-16, (2))  the

(2))  fuel cock
(3)). 
(Figure5-16, (3)). 

3.  Loosen the drain cock (Figure5-16, (4)) and

drain the contaminants. See Drain Fuel
Filter/Water Separator.

4.  Turn the retaining ring (Figure5-16, (5)) 

(5))  to the
left (Figure5-16, (10)) 
(10))  and remove the cup
(6)).  If equipped, disconnect the
(Figure5-16, (6)). 
sensor wire (Figure5-16, (7)) (7))  from the cup
before removing the cup.
 5.  Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.

-184-

Maintenance Section

Every 1000 Service Hours or 6 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Hydraulic
& Strainer Return Filter,
- Check, ChangeBreather

WARNING
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
and the engine stopped.
Typical Example

7.  Remove and discard the air breather.

8.  Install a new air breather.

9.  Start the engine and operate the hydraulic

controls, and the steering system, through a
few cycles to fill the lines. Look for oil leaks.

10. Stop the engine and check the oil level. With all
cylinders retracted, maintain the oil level to the
FULL mark on the dipstick/filter cap assembly.

1.  Loosen the bolts of the hydraulic tank top plate

assembly.

2.  Remove the return filter from tank top plate

assembly.

3.  Install new return filter by hand.

4.  Remove the suction strainer from the tank.

5.  Install the new strainer by hand.

6.  Install the tank top plate assembly and fasten

the bolts.
 -185-

Maintenance Section

Transmission Oil, Oil Filter & Check for Equal Tension

Strainer - Check, Clean, Change
See topic, “Transmission Oil, Oil Filter & Strainer-
Check, Clean, Change” in “First 50 - 100 Service
Hours”

Lift Chains - Test, Check, Adjust

Lift Chain Wear Test
Inspect the part of the chain that is normally
operated over the cross head roller. When the
chain bends over the roller, the movement of the
Typical example
parts against each other causes
caus es wears.
Inspect to be sure that chain link pins do not extend
Lift the carriage and the mast high enough for
outside of the link hole. If any single link pin is
getting tension on lift chains. Check the chains, and
extended beyond its connecting corresponding link,
make sure the tension is the same. Lift chains are
it should be suspected of being broken inside of its
required to check for equal tension about every
link hole. Lift chains are required to check for wear
1,000 service hours or 6 months.
about every 1,000 service hours or 6 months.

Chain wear test is a measurement of wear of the WARNING

chain links and pins. Take the following steps to
check chain wear. Personal injury can be caused by sudden
movement of the mast and carriage. Keep
1.  Lift the mast and carriage enough for getting hands and feet clear of any parts that can move.
tension on lift chains.

Lift Chain Adjustment

Typical example

2.  Measure precisely ten links of chain distance at

the center of pins in millimeter. Typical example for carriage equal
eq ual tension

3.  Calculate chain wear rate*. If the tension is not the same on both chains, take
the procedure as follows.
4.  If the chain wears rate is 2% or more, replace
the lift chain. NOTE:  If carriage height is not correct, make
adjustments by following procedures.
*Chain wear rate (%)

= Actual measurement - Pitch** X 10 X 100

Pitch** X 10
**Chain Pitch = 19.05mm (0.75in)
 -186-

Maintenance Section

Carriage Chain Adjustment Mast Chain Adjustment - FF, FFT Mast

Make sure that carriage height is correct. If correct,
adjust the chain for equal tension. If not, adjust the
chain for correct carriage height by adjusting
anchor nuts (1), (2).

NOTE:  See the previous section, “Carriage Roller

Extrusion” in “When Required” for proper
height of carriage.

1. Fully lower the carriage and tilt mast forward or

lift the carriage and put blocks under the carriage
to release the tension from the lift chains.

2. Loosen nut(1) and adjust nut(2) to get proper Typical example for FF mast
distance from bottom of inner upright to the
bottom of carriage bearing.

Typical example for FFT mast

Typical example for carriage chain of STD mast Make sure that mast height is correct. If correct,
adjust chain for equal tension. If not, adjust mast
chain for correct mast height by adjusting anchor
nuts (3), (4).

NOTE:  See the previous section, “Carriage Roller

Extrusion” in “When Required” for proper
inner mast height.

1. Lift the inner mast and put blocks under the inner
mast to release the tension
ten sion from the lift chains.

2. Loosen nut (3) and adjust nut (4) to make inner

mast rail flush with outer
ou ter mast rail bottom.

Typical example for carriage chain of FF, FFT mast 3. Make adjustment anchor nuts (3), (4) for equal
chain tension.
3. Make adjustment anchor nut (1), (2) for equal
chain tension. 4. Raise the inner mast and check equal chain
tension. If not equal, repeat the same procedure
4. Set the mast vertical and raise the carriage and as step 1 through step 3.
check equal 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 (3), (4) after the adjustment is
5. Put LOCTITE No. 242 Tread lock on the threads completed.
of the anchor nuts (1), (2) after the adjustment is
 completed.

-187-

Maintenance Section

Universal Joint – Inspect Air Intake System - Change

Changing Primary Element
See topic, “Air Intake System - Check, Clean” in
“Every 250 Service Hours or Monthly”
M onthly”

Changing Secondary Element

1.  Remove the primary air cleaner element. See
topic “Servicing Filter Element.” Clean the
inside of the air cleaner housin
hou sing
g and cover.

Check for worn or damaged bearings. Have worn

or damaged bearings replaced. Check for loose
retaining bolts and nuts. Tighten the bolts and nuts,
if necessary.
n ecessary.

2.  Remove the secondary element. Inspect the

gasket between the air cleaner housing and the
engine inlet. Replace the gasket if it is
damaged.

NOTICE
Always replace the secondary element. Do not
attempt to reuse it by cleaning.

3.  Install a new secondary element. Install a new

or cleaned primary element. Install the cover.
Tighten the latches.

4.  Start the engine and observe the air cleaner

service indicator. If the indicator shows 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.
 -188-

Maintenance Section

Inspect Coolant Hoses Fuel Lines & Fittings - Check

(LP, Dual Fuel Engine Only) Visually inspect fuel lines and fittings for physical
1.  Visually inspect coolant hoses and clamps. damage. Replace as required.
re quired.
Remember to check the two coolant lines that
connect to the pressure
p ressure regulator/converter. 1 2

2.  Replace any hoses that shows

s hows signs of swelling,
cracking, abrasion or deterioration.

1 3

(1) Fuel lines

(2) LP mixer
(3) Throttle Assembly

(1) LP Regulator/Converter Inspect Mixer Assembly

(2) Coolant hoses
(G420F(E)/G424F(E) Engine Only)
Refer to the LP mixer section of the engine service
LP Regulator/Converter manual for procedures.

Inspection (LP, Dual Fuel Engine

Only) Inspect Throttle Assembly
(G420F(E)/G424F(E) Engine Only)
1.  Visually inspect the pressure
regulator/converter housing for coolant leaks.
1.  Visually inspect the throttle assembly motor
Refer to the pressure regulator/converter
section of the service manual if maintenance is housing for coking, cracks and missing
cover-retaining clips. Repair and/or replace as
required.
necessary.
NOTE:  For pressure testing and internal inspection
NOTE:  Refer to the LP mixer and throttle section of
of the pressure
p ressure regulator/converter, refer to
the pressure regulator/converter section of the service
removing themanual for procedures
mixer and on
inspecting the
the service manual.
throttle plate.
 -189-

Maintenance Section

Engine Valve Lash (Diesel Engine

Only) - Check, Adjust

NOTICE
The valve clearances are to be adjusted at the
times of the following
fol lowing situations.
   When the engine is overhauled and the cylinder

heads are disassembled.

   When severe noise comes from valve train.

   When the engine is not normally operated even

though there is no trouble in the fuel system.

WARNING
To prevent possible injury when adjusting
diesel engines, do not use the starter motor to
turn the flywheel.

Hot engine components can cause burns. 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 to cool the engine cylinder head and block
temperature.

Set the clearance to the nominal appropriate

clearance given in the “Valve Clearance Setting”
shown below.

Valve Clearances 
Engine Valve Clearance
3.3 liter Ex
Exhaus
haustt Valv
Valves
es 0.2 mm (.0.08
(.0.08 in
in))
(4TNV98 &
Intake
Intake Valves 0.2 mm (.0.08 in)
4TNE98) Diesel
 
Refer to the “Service Manual” for the complete
valve adjustment procedure.

In regards to G420F(E) and G424F(E) Engines,

valve adjustment is not necessary because of
automatic adjusting system
 -190-

Maintenance Section

Every 1500 Service Hours or 9 Months

Inspect Ignition System (LP, Replace Spark Plugs (G424F(E)
Gasoline & Dual Fuel Engines LP, Dual Fuel Engine Only)
Only) 1.  Disconnect Battery Cables.
1.  Disconnect Battery Cables. 2.  Using a gentle twisting motion remove the high
voltage cables from the spark plugs. Replace
2.  Remove and inspect the spark plugs. Replace
as required. any damaged cables.
3.  Remove the spark plugs.
3.  Test secondary cables with an Ohmmeter. If the
maximum resistance is higher than 25 kOhms, 4.  Gap the new spark plugs to the proper
repair and/or replace(G424F(E) engine only). specifications.
4.  Inspect the ignition coil for cracks and heat G424F(E) Engine
Engine : 0.9 mm
deterioration. Visually inspect the coil heat sink
fins. If any fins are
a re broken replace as required. 5.  Apply anti-seize compound to the spark plug
threads and install.
G424F(E) Engine : 25 N•m (18 lb•ft)
G420F(E) Engine

WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.

6.  Re-install the high voltage cables.

G424F(E) Engine

(1) Spark Plug Cables

(2) Ignition Coil
 -191-

Maintenance Section

3.  Check bottom cover O-ring seal (6) for damage.

Replace LP Fuel Filter Element Replace if necessary.
(LP, Dual Fuel Engine Only)  

4.  Re-assemble the filter assembly aligning the

Park the lift truck in an authorized refueling area scribe lines on the top and bottom covers.
with the forks lowered, parking brake applied and
the transmission in Neutral. 5.  Install the cover retaining screws, tightening the

1.  Close the fuel shutoff valve on the LP-Fuel tank. screws
cover. in an opposite sequence across the
Run the engine until the fuel in the system runs
out and the engine stops. 6.  Open the fuel valve by slowly turning the valve
counterclockwise.
2.  Turn off the ignition switch.
7.  Crank the engine several revolutions to open
3.  Scribe a line across the filter housing covers, the fuel l ock-off.
ock-off. DO N
NOT
OT START THE ENGINE.
which will be used
u sed for alignment purposes when Turn the ignition key switch to the off position.
po sition.
re-installing the filter cover.
8.  Check the filter housing, fuel lines and fittings
for leaks. Repair as
a s necessary.

1
Filter
Housing
Testing Fuel Lock-off Operation
Scribe (LP Engine Only)
Point
1.  Start engine.

2.  Locate the electrical connector for the fuel lock

3.  Disconnect the electrical connector.

4.  The engine should run out of fuel and stop

(1) screws
within a short period of time.
4.  Remove the cover retaining screws (1). 5.  Turn the ignition key switch off and re-connect
the fuel lock-off connector.

Fuel Filter (LP Engine Only) NOTE:  The length of time the engine runs on
trapped fuel vapor increases with any
Disassembly increase in distance between the fuel
lock-off and the pressure
regulator/converter.
2
4
1

5 2
3 1
6
3
7

1.  Remove top cover (2), magnet (3), spring (4),

and filter element (7) from bottom cover (5).
(5 ).
 (1) LP fuel lock off
2.  Replace the filter element (7). (2) Regulator/Conv
Regulator/Converter
erter
(3) Fuel Trim valve (FTV)

-192-

Maintenance Section

Fuel Injectors (Diesel Engine Only)

O nly)
 – Inspect,
Inspect, Clean
Clean,, Te
Test
st

WARNING

HIGH-PRESSURE HAZARD! 
Avoid skin contact with the high-pressure
diesel fuel spray caused by a fuel system leak
such as a broken fuel injection line.
High-pressure fuel can penetrate your skin and
result in serious injury. If you are exposed to
high-pressure fuel spray, obtain prompt medical
treatment.
NEVER check for a fuel leak with your hands.
ALWAYS use a piece of wood or cardboard.
Have your authorized Yanmar industrial engine
dealer or distributor repair the damage. Figure5-19 
Failure to comply could result in death or 2.  Remove the diaphragm cover, spring,
serious injury. diaphragm plate (Figure5-19, (5)) 
(5))  and
diaphragm.

Proper operation of the fuel injectors is required to 3.  Inspect the diaphragm for tears. Inspect the
obtain the optimum injection pattern for full engine spring for distortion. Replace components if
performance. The EPA / ARB requires that the fuel necessary.
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on 4.  Reinstall the diaphragm, diaphragm plate,
Service Manual   spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.

Crankcase Breather System Failure of the diaphragm and / or spring will cause
(4TNV98 Diesel Engine Only) - the loss of pressure control and allow an excessive
amount of crankcase fumes to be routed to the

Inspect intake
depositsmanifold. Thissystem,
in the intake could high
resultengine
in excessive
exhaust
smoke levels, excessive engine oil consumption,
Proper operation of the crankcase breather system
and / or engine run-on due to the burning of the
is required to maintain the emission requirements
engine oil
of the engine. The EPA / ARB requires that the
crankcase breather system is inspected every 1500
hours.

4TNV98 engines use a crankcase breather system

that has a spring-backed diaphragm (Figure5-19,
 in the valve cover (Figure5-19, (2)).
(1)) in
(1)) (2)). When the
crankcase pressure reaches a predetermin
prede termined
ed value,
the diaphragm opens a passage that allows
crankcase fumes to be routed to the intake
manifold.
 To inspect the diaphragm and spring (Figure5-19,
(3))::
(3))

1.  Remove the bolts retaining the diaphragm

cover (Figure5-19, (4)).
(4)).

-193-

Maintenance Section

Every 2000 Service Hours or Yearly

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Engine Valve Lash (Diesel Engine Steer Wheel Bearings -

Only) – Check, Adjust Reassemble
See topic “Engine valve Lash (Diesel Engine Only) Park the lift truck level with the forks lowered,
 – Check, Adjust”.
Adjust”. In First 250 Service
Service hours. 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.

Typical Example

1.  Lift the steer wheels off the ground. Place

stands or blocking under the frame and steer
axle to support the lift truck.

Typical Example

2.  Remove the hub cap which is pressed into the

wheel hub.
 -194-

Maintenance Section

3.  Straighten the lock washer tangs. 8.  Install the outer wheel bearing and the out
washer. Install a new lock washer and fit the
locknut.

4.  Remove the locknut, lock washer and flat

washer. Typical Example
Remove the outer wheel bearing.
9.  Tighten the locknut to 135 N•m (100 lb•ft)
lb•ft),, while
turning wheel hub to seat the bearing.

10. Loosen the locknut. Retorque it to 50 ± 5N•m

(37 ± 4 lb•ft). Bend the lock washer tang to
secure locknut.
11. Install the hub cap.

12. Raise the lift truck and remove the blocking.

Lower the lift truck to the ground.
g round.

5.  Remove the wheel assembly. Examine the seal

for damage and wear. Replace the seal if
necessary.

6.  Remove the inner bearing. Clean and lubricate

the steering knuckle. Reassemble both the
inner and outer
ou ter bearing cones.

7.  Install the inner bearing. Lubricate the seal and

install the wheel assembly on the knuckle.
 -195-

Maintenance Section

Drive Wheel Bearing (Power Shaft GC-Series Lift Trucks.

and Drive Wheel) – Reassemble

Torque for wheel bolts (1) is 270 ± 25 N•m (200 ±

20 lb•ft).
Consult your DOOSAN lift truck dealer for the
proper wheel bearing reassembling procedure. Tighten wheel bearing nut (2) 135 N•m (100 lb•ft)
Packing of bearings and adjustment procedure while the wheel is turned in both directions. Loosen
must be made by a trained mechanic or dealer the nut completely and tighten nut again to 50 ±5
personnel. N•m (37 ± 4 lb•ft). Bend the lock washer tab into a
Pack power shaft bearings (1) and spindle bearings groove of the nut.
(2). Pack ring gear (3) to the depth of the teeth. Torque for bolts (3) that hold cover to drive axle
housing is 55 ± 10 N•m (40 ± 7 lb•ft).
D, G-Series Lift Trucks
Apply Loctite No. 242 to threads of spindle bolts (4).
Torque for spindle bolts is 115 ± 14 N•m (85 ± 10
lb•ft).

Torque for single or dual wheel mountin

mounting
g nuts (1
(1)) is
644 ± 34 N•m (470 ± 252 5 lb•ft).

Torque for adapter assembly bolts (2) is 285 ± 13

N•m (210 ± 10 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).

-196-

Maintenance Section

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
s lowly to relieve pressure.
Coolant is included antifreeze for forbidding 4TNV98 3.3L Diesel Engine
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.

1.  Turn the radiator cap slowly to relieve the

1. 
pressure, and then remove the cap.

G420F(E) 2.0L LPG/Gasoline Engine

2. Remove the drain plug or water hose on engine

2. Remove
block.
G424F(E) 2.4L LPG/Gasoline Engine

3. Open the radiator drain valve. Allow the coolant

to drain into a suitable container.
Drain the recovery bottle.
 4TNE98 3.3L Diesel Engine

-197-

Maintenance Section

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

4.  After draining the coolant completely, close the

4. 
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.

5. Start and run the engine for

5. Start fo r 30 minutes.

6. Stop the engine and drain the cleaning solution

into a suitable container.

7. Flush the system with clean water, until draining

water is clear.

8. Close the drain valve and install the block drain

8. Close
plug. Fill coolant to top of the filler neck.

9. Start and run the engine to stabilize the coolant

9. Start
level. See topic, “Coolant Level – Check” in
“Every 10 Service hours or Daily”.
 -198-

Maintenance Section

Forks – Inspect

3.  Check the straightness of the upper face of

Forks should be inspected, at a minimum, every 12 blade (D) and the front face of shank (E) with a
months. If the truck is being used in a multi-shift or straight edge.
heavy duty operation, they should be checked
every six months. The fork should be withdrawn from service if the
deviation from straightness exceeds 0.5 percent
1.  Inspect the forks carefully for cracks. Special of the length of the blade and/or the height of
attention should be given to the heel section (A), the shank respectively 5 mm/1000 mm
all weld areas and mounting brackets (B). (0.18"/36").
Inspect the top and bottom hooks on forks used
on hook forks.
mounted type carriages and tubes on shaft

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. 4.  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
entering of the load and cause problems with
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
2.  Check the angle between the upper face of the information.
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
degrees, from
as mayan original
be foundangle
in other
some than 90
special
application forks.

-199-

Maintenance Section

  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.

5.  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, 8.  Check fork markings (N) for legibility. Renew
especially on tapered forks and platens. markings as required to retain
r etain legibility.
Remove the forks from service when the blade
length is no longer adequate for the intended 9.  a. Lift the mast and operate the tilt control lever,
loads. 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. 
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
6.  Check the fork mountings
moun tings (K) for wear, crushing procedure with the second fork. Repeat Step
and other side
excessive localtodeformation,
side wobble which can cause
of the forks. a.
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.

7.  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.

-200-

Maintenance Section

Every 2500 Service Hours or 15 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Hydraulic Oil - Check, Clean, Inspect Battery System

Change 1.  Clean battery outer surfaces with a mixture of
baking soda and water.
WARNING
2.  Inspect battery outer surfaces for damage and
Hot oil and components can cause personal replace as necessary.
injury. Do not allow hot oil or components to
contact skin. 3.  Remove battery cable and clean, repair and/or
replace as necessary.
Park the lift truck level with the forks lowered,
parking brake engaged, transmission in NEUTRAL
and the engine stopped.

1.  Remove the hydraulic tank drain plug. Allow the

oil to drain into a suitable container. Clean and
install the plug.

2.  Remove the dipstick/filter cap assembly.

3.  Fill the hydraulic tank. See topic “Refill

Capacities”. Install the dipstick/filter cap
assembly.

4.  Start the engine and operate the hydraulic

controls, and the steering system, through a
few cycles to fill the lines. Look for oil
oi l leaks.

5.  Stop the engine and check the oil level. With all
cylinders retracted, maintain the oil level to the
FULL mark on the dipstick/filter cap assembly.
 -201-

Maintenance Section

Replace Oxygen Sensor 4.  Assemble new oxygen sensor

Tightening torque : 45 N•m (32.5
(32 .5 lb•ft)
(G420F(E)/G424F(E) Engine Only)
5.  Connect the electrical connector of oxygen
G420F(E) Engine sensor

WARNING
When assembling the filters, check the arrow
mark on the filter surface.
The arrow mark position is same as fuel flow
direction.

Replace Spark Plugs (G420F(E)

Engine Only)

G424F(E) Engine 1. Disconnect Battery Cables.

2. Remove the ignition wiring harness.

3. Remove the ignition coil assy.

3. Remove

4. Remove spark plugs.

4. Remove

5. Gap the new spark plugs to the proper

specifications.
G420F(E) Engine : 0.7 ~ 0.8 mm

6. Apply anti-seize compound to the spark plug

threads and install.
G420F(E) Engine : 25 N•m (18 Ib•ft)

WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.

When indicated by MIL, replace oxygen seasor on 2

the exhaust manifold and oxygen
o xygen sensor on muffler
assembly.

1.  Stop engine and wait until the exhaust pipe and 3
exhaust pipe is cooled.
 2.  Disconnect the electrical connector of oxygen (1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug
sensor

3.  Remove oxygen sensor

-202-

Maintenance Section

Checking the TMAP Sensor Inspect for Intake Leaks

(G420F(E)/G424F(E) Engine Only) (G420F(E)/G424F(E) Engine Only)

1.  Verify that the TMAP sensor (F) is mounted 1.  Visually inspect the intake manifold, throttle
tightly into the manifold adapter (E), with no assembly (2), and manifold adapters (3), for
leakage. looseness and leaks. Repair as necessary.

2.  If the TMAP is found to be loose, remove the

TMAP retaining screw and the TMAP sensor Replace PCV Valve and breather
from the manifold adapter.
element - Change (LP, Gasoline and
3.  Visually inspect the TMAP O-ring seal for Dual Fuel Engines)
damage. Replace as necessary.
G420F(E) Engine
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.

G424F(E) Engine

1.  Loosen the hose clamps and remove the PCV

valve.

2.  Assemble new PCV valve and hose.

3.  Tighten the hose clamps

 -203-

Maintenance Section

Every 3000 Service Hours or 18 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Timing Belt [G420F(E)/G424F(E)

LP, Gasoline,
Only] Dual Fuel Engine
- Change
See the “Service manual” for the procedure and
specification.

WARNING
G420F(E) is dual over-head CAM engine. If
timing belt is not replaced on time, engine could
be damaged.
 -204-

Index Section

Index Changing Primary Element ..........

Changing Secondary Element ...........
................
............
............
.................
...........
...........
......188
...........
.188
.......188
.188
 

Chassis Pivot Eyebolts-Lubricate

Eyebolts-Lubricate ............ .................
...........
.......176
.176  

# Check for Equal Tension ......................................186

......................................186  

Check Inflation and Damage................................154  

12 Months Inspection.....
Inspection ...........
...........
..........
...........
...........
...........
...........
..... 133   Check Operation ...................................................177
...................................................177  

4TNE98 Diesel Engine

Engine Only ..........
..........150,153,175,182
150,153,175,182   Checking Service Indicator...................................157  

4TNV98 Diesel Engine

Engine Only ..........
..........150,152,174,182
150,152,174,182   Checking the TMAP Sensor (G420F(E)/G424F(E)
Engine Only)..........................................................203  

A Circuitt Breaker..........................................
Circui Break er.................................................
....... 68,150  

Cleaning Primary Filter Elements ........... ................

..........
........168
...168  

Accelera tor Pedal ...................................................

Accelerator ................................................... 69
 
Coolant Information...............................................137  

Adjustments
Adjustmen ts .................................................
..........................................................
......... 118
 
Coolant Level – Check..........................................156  

Advanced Diagnostics......................................
Diagnos tics............................................ ...... 99
 
Coolant Water........................................................138  

After Starting the Engine.............................

Engine ........................................
........... 81
 
Cooling System – Clean, Change........................197  

Air Cleaner Indicator-Check.......

Indicator-Check............ ...........
............
............
.........
... 157
 
Cooling System Specifications.............................137  

Air Intake System

Sy stem - Change...........
Change................. ...........
..........
..........
....... 188 Crankcase Breather System (4TNV98 Diesel Engine
 

Air Intake System - Check, Clean ..... ...........

...........
...........
........ 167
 
Only)) - Inspect ...................................................
Only .......................................................193
....193  

Antifreeze
Antifre eze...............................
..............................................................
............................... 138
 
Crosshead Rollers - Inspect.................................177  

Attachment Abbreviations (Includes Special Forks) Crushing or Cutting Prevention.............

Prevention................... ...........
..........
......14
.14  

.............................................................
.................................................................................
.................... 61 Cylinder Rod Extension-Adjust
Extension-Adjust ............
.................
................177  
...........177
 

Auto Shift Controller ASC-100 ASC-100 (If Equipped)......

Equipped) ...... 118  

Automatic mode (Direction Inhibit mode)............

mode)............ 119 D
 

Avoiding Lift Truck Tipover

Ti pover .....
...........
...........
...........
............
............
........
.. 21
21  
D, G-Series Lift Trucks ..... ..........
...........
............
...........
..........
...........
.........196
...196 

B Daily Inspection.....................................................132  

Diagnostics
Diagno stics Features ............................................119
............................................119 

Basic Troubleshooting
Troubleshooting (Gasoline).....
(Gasoline) .......... ...........
...........
.........
.... 93  
Diesel Engine ........................................................
..........................................................
..77
77
 

Basic Troubleshooting(LP)
Troubleshooting(LP) ........... ................
..........
...........
...........
.........
.... 86  
Diesel Engines ...................
.................................................
...................................155
.....155 

Battery Terminal - Clean, Inspect...........

Inspect.............................
........ 171  
Diesel Specifications.............................................139  

Before Operating the Lift Truck ..... ...........

...........
...........
............
........ 12  
Direction Control Lever...........................................69  

Before
Befo re Starting the Engine..................................... 74  
Direction Inhibit Point............................................118  

Before Starting the Lift Truck...............

Truck.....................
...........
..........
.......
.. 11  
Disassembly
Disassemb ly ..................
.................................................
........................................192
.........192 

Before
Befo re Storage...................
Storage .................................................
...................................
..... 127  
Display for Operator..............................................119  

Display for Troubleshooting..................................119

Belts - Check
Check,, Adjust ............................................
............................................ 176
 

Displaying Fault Codes (DFC) from SECM Memory

Bent or Twisted Forks ...........................
...........
............
...........
..........
.........
.... 131  

..................................................................................99
Brake Fluid ........................................................
............................................................
.... 142
 

Drive Axle Oil - Change ........................................164

........................................164
Brake Oil Level - Check C heck ...........
................
..........
...........
...........
...........
........ 169
 

Bulbs......................................................................
Bulbs...................................................................... 149  
Drive Axle Oil & Strainer - Change, Clean .... .........
......179
.179  

Burn Prevention ...................................................... 15 

...................................................... 15  Drive Axle Oil Level - Check.................................170  

Drive Axle Oil.........................................................141  

Drive Wheel Bearing (Power Shaft and Drive Wheel)

C  – Reassemble.......
Reassemble............
..........
...........
...........
...........
...........
..........
...........
...........
......196
.196  

Dual Fuel System....................................................79  

Capacity Chart (With Sideshifter cushion)

..................................................................55,56,57,58  
E
Capacity Chart (With Sideshifter Pneumatic)
..................................................................47,48,49,50
Electrical Disconnect Switch (If Equipped)............66
Equipped)............66
 

Capacity Chart (Without Sideshifter cushion)

Engine Compartment..............................................66  

..................................................................51,52,53,54
Engine Oil & Filter (Diesel Engine Only) - Change
 

Capacity Chart (Without Sideshifter Pneumatic)

......................................................
........................................................................
.................. 161,183  

..................................................................43,44,45,46
Engine Oil & Filter (LP & Gasoline Engine Only) -
 

Carriage Roller Extrusion – Adjust...............

Adjust....................
.......
.. 154  
 Change ...............................
..............................................................
...................................171
....171  

Causes of Fork Failu

Failure
re...................
.........................................
...................... 131  

Center of Gravity (CG) ..........

...............
...........
............
...........
..........
..........
....... 21 Engine
Engine Oil
Oil (DEO
Level -and EO).....................................141
 

Check......................................155
 

Changing From Gasoline to LP – Gas...... Gas ...........

...........
........ 79
Engine Valve Lash (Diesel Engine Only) – Check,
 

Changing From LPL P to Gasoline

Gasoline..... ...........
...........
...........
...........
.......
.. 79
Adjust ........................................................
.............................................................
..... 190,194
 

Changing LP Tanks........................
Tanks ................................................
........................ 72
Environment
Environme nt Management
Manag ement ..............................
.......................................
.........33
 

-205-

Index Section

Environme nt Protection........................................
Environment Prote ction........................................ 130  
H
Every 10 Service Hours or Daily ..........
................
...........
.........
.... 155  

Every 1000 Service Hours

Hours or 6 Months .........................
... 185  
Hand Placement Warning.........................................7  

Every 1500 Service Hours

Hours or 9 Months .........................
... 191  
Hook-on type Fork.................................................126  

Every 2000 Service Hours or Yearly ..........................

.........
... 194  
Horn and Lights
Ligh ts (If Equipped) - Check ..........................
.....180
.180  

Every 250 Service Hours or Monthly

Monthly .................
...........
........ 167  
How to Survive in a Tipover ...........
.................
............
...........
..........
.......28
..28  

Every 2500 Service Hours

Hours or 15 MonthsMonths..... ..........
.......
.. 201  
 

Every 3000 Service Hours

Hours or 18 MonthsMonths..... ..........
.......
.. 204  
Hydraulic Oil -(HYDO)............................................141
Hydraulic Oil Check, Clean, Change.............
Change.................201 ....201  

Every 500 Service Hours or 3 MonthsMonths ...........

................
..... 176  
Hydraulic Oil LeLevelvel – Check ..... ...........
..........
..........
............
...........
......169
.169  

Hydraulic Return Filter – Change.........................166  

F Hydraulic Return Filter, Breather & Strainer - Check,

Change ...............................
..............................................................
...................................185
....185  

Fatigue ..............................................................
..................................................................
.... 131  

Fire or Explosion Prevention.....

Prevention.......... ...........
............
...........
..........
.......
.. 15  
I
First 250 Service Hours or a Month ........... ................
.........
.... 166  

First 50 - 100 Service Hours or a Week.... Week......... ..........

..... 161  
Identification, Lift Capacity and Attachment Plate 62 62  
First Instal
Installation................................................
lation.....................................................
..... 132  
If Convenience Package Equipped........................62  

Fluid Penetration ............

..................
...........
..........
...........
...........
...........
...........
....... 14  
.. 14 If Optional Suspension Seat (weight adjusting type)
Foreword
Fore word ......................................................
....................................................................2
..............2 
Equipped..................................................................18  

Fork Inspection
Inspe ction .....................................................
..................................................... 132  
If Parking Brake Alarm Equipped.........................125  

Forks – Inspect .....................................................

..................................................... 199  
Important Safety Information....................................4  

Fuel Filter (Diesel Engine Only) - Change Change.... ........

......
.. 182  
Improper Modification or Repair...........................131  

Fuel Filter
Fil ter (LP Engine Only) .......... ................
...........
...........
...........
..... 192 
Inching & Braking Control Shaft - Lubricate L ubricate..... ........180
...180 

Fuel Injectors (Diesel Engine Only) – Inspect, Clean, Inching into Loads.................................................121  

Test...................
Test ......................................................
.....................................................
.................. 193 
Inching......................................................................83 
Inching......................................................................83 
Fuel Lines & Fittings - Check.........
Check..........................
...........
...........
..... 189 
Index ..............................
.............................................................
........................................205
.........205 

Fuel Selector Switch (G420F(E)/G424F(E) Dual Inspect Battery System.........................................201  

Fuel Only)............................................
Only)................................................................
.................... 68
 
Inspect Coolant Hoses (LP, Dual Fuel
Fuel Specifications
Specifications ..... ...........
...........
..........
...........
............
...........
..........
.........
.... 139 
Engine Only)..........................................................189  

Fuel Sulfur Content ...........................

...........
............
...........
..........
...........
........
.. 139 
Inspect Electrical System (G420F(E)/G424F(E)
Fuel Tank Filter Cap and Screen (If Equipped) - Engine Only)..........................................................181  

Clean .........................
........................................................
............................................
............. 148 
Inspect Engine for Exhaust Leaks L eaks ..............
...........
..........
........157
...157 

Fuel Trim Valve(FTV) Inspection Inspect Engine for Fluid Leaks.............................155  

(G420F(E)/G424F(E)
(G420F(E)/G424F (E) Engine Only)..........
Only)...............
...........
...... 181 
Inspect Foot Pedal Operation (G420F(E)/G424F(E)
Fuel Types ........................................................
............................................................
.... 139 
Only).......................................................................157  

Fuses.............................
Fuses ............................................................
........................................
......... 149 
Inspect for Intake Leaks (G420F(E)/G424F(E)
Fuses, Bulbs, Circuit Breaker & Relay - Change, Engine Only)..........................................................203  

Reset .........................
........................................................
............................................
............. 149 

Inspect Ignition
Engines System (LP, Gasoline & Dual Fuel
Only)........................................................191  

G Inspect Mixer Assembly (G420F(E)/G424F(E)

Engine Only)..........................................................189  

G420F Engine and G424F Engine.........

Engine.............. ...........
..........
.... 85  
Inspect Throttle Assembly (G420F(E)/G424F(E)
G420F(E) Engine...........................................191,202  
Engine Only)..........................................................189  

G420F(E) Gasoline, LP and Dual Fuel Engines . 172  

Inspect Tightness (D, G - Series).........................173  

G420FE Engine and G424FE G424 FE Engine............

Engine.......................... 84  
Inspect Tightness (GC - Series)...........................173  

G424F(E) Engine...........................................191,202  
Inspect Vacuum Lines and Fittings
G424F(E) LP and Duel Fuel Fuel Engines ...... ............
...........
..... 172  
(G420F(E)/G424F(E) Engine Only) ..... ...........
............
..........181
....181 

Gasoline and LP Engines ..........

...............
...........
............
............
.........
... 155  
Inspection from Operator's Seat, Engine OFF....159  

Gasoline Engine .....................................................

..................................................... 76  
Inspection from Operator's Seat, Engine ON......159 ON......159  

Gasoline or Diesel Engine Equipped ..... ...........

...........
.........
.... 71  
Inspection, Maintenance and Repair of Lift Truck
Gasoline Specifications
Speci fications...............................
........................................
......... 140  
Forks ..............................
.............................................................
........................................130
.........130 

Gasoline, LP Engine Crankcase ...... ............

............
...........
.......
.. 171  
Instrument
Instru ment Panel .....................................................63
.....................................................63
 

GC-Series Lift Trucks

Trucks.. .....................
.........................................
...................... 196  
 General Fuel Information ..........
...............
...........
............
...........
..........
..... 139  

General Hazard Information

Info rmation .....
..........
..........
...........
............
............
........ 10   L
General Warning to Operator ...................................6
...................................6  

Lift Chain Adjustment............................................186

Governor Lever and Engine Speed Control (Diesel
 

Lift Chain Wear Test .............................................186

.............................................186  

Engine Only) - Check ,Adjust ...........

.................
..........
..........
.........
... 174
Lift Chains - Test, Check, Adjust..........................186
 

-206-

Index Section

Lift Control .........................................................

...............................................................
...... 70
  Ope rator's Warning Plate .......................................62
Operator's .......................................62  

Lift Fork Adjustment ..........

...............
...........
............
............
............
............
...... 126  Operator Restraint System(If Equipped) .......... ............2,17
..2,17  

Lift Truck Controls ..........

................
...........
..........
...........
............
...........
..........
.......
.. 69
  Operator’s Station and a nd Monitoring Systems.........
Systems..........63 .63  

Lift Truck Operation

Opera tion........................
................................................
........................ 82
  Overhead
Overh ead Guard – Inspect ...................................178
...................................178  

Lift Truck Parking........................

Parking ....................................................
............................ 13
  Overhead Guard Must Be In Place Warning.......... Warning...........8 .8  

Lift Truck Shipping...........................................

Shippin g..................................................... 128  Overloading
Overload ing ......................................................
...........................................................131
.....131  

Lift Truck Stability

Stabili ty Base..........................................
Base.......................................... 22  

Lift Truck Stability ...........

.................
...........
..........
...........
............
...........
..........
.......
.. 21
 
P
Lifting Drums or o r Round Objects ........... .................
............
.........
... 124 

Lifting the Load .....................................................

..................................................... 121 
Parking Brake - Inspect ........................................159
........................................159  

Literature
Literat ure Information
Informa tion .........................
................................................2
.......................2
 
Parking Brake - Test, Adjust...........
Adjust................
...........
.........
... 164,180  

Load Backrest Must Be In Place Warning...... Warning ........... .........7

....7
 
Parking Brake Adjusting .......................................165
.......................................165  

Long Time Storage ...............................................

............................................... 127 
Parking Brake Lever ...............................................70
...............................................70  

LP Engine................................................................
Engine................................................................ 77 
Parking Brake Testing ..........................................164
..........................................164  

LP Regulator/Converter Inspection (LP, Dual Fuel PARKING BRAKE.................................................160  

Engine Only) .........................................................

......................................................... 189 
Parking brake .........................
........................................................
...................................
....99  

LP Specifications
Specifica tions ........................
..................................................
.......................... 140 
Parking the Lift Truck............................................125  

Lubricant
Lubric ant Information........................................
Info rmation............................................ .... 141 
PCV Valve System - Inspect, Clean ........... ................
.........172
....172  

Lubricant Viscosities
Viscosities and Refill Capacities......... 143  
Power Shift Transmission/ Drive axle......... a xle..............
...........82
......82  

Lubricant
Lubric ant Viscosities....................................
Viscosi ties.............................................
......... 143  Precleaner (If Equipped).......................................167  

Lubricating Grease (MPGM)..........

(MPGM)............... ...........
............
...........
..... 142  Pressure Air.............................................................14  

Pressure
Pressu re Warning ...............................
.....................................................7
......................7  

M Prestart Conditions..................................................76
 

Priming the Fuel System(Diesel Engine Only)....150  

Machine Lifting and Tiedown Tiedown Information.....

Information ........... ...... 128 
Product Description...............................................118  

Maintenance
Maintena nce and Repair.............................
Repair ......................................
......... 133 

Maintenance Information .......... ...............

...........
...........
...........
............
........ 14
  R
Maintenance
Maintena nce Interval
Intervals s .......................................
....................................... 3,144  

Maintenance
Maintena nce .............................................................
..............................................................3
.3
  Reading Diagnostic Fault Codes ........... ................
..........
..........
......99
.99  

Make proper antifreeze additions..............

additions..............................
.... 138  Refill Capacities.....................................................143  

Manual Mode (Fail-Safe mode)..... mode) .....................

............
...........
..... 120  Refueling..................................................................71  

Mast Abbreviations
Abbrevia tions.........................
.................................................
........................ 62
  Replace LP Fuel Filter Element (LP, Dual Fuel
Mast Channels – Lubricate......
Lubricate ........... ..........
...........
...........
...........
........ 158
  Engine Only)..........................................................192  

Mast Hinge Pin Pin – Lubricate

Lubricate.........................
..................................
......... 176  Replace Oxygen Sensor (G420F(E)/G424F(E)
Mast Pivot Eyes-Lubricate
Eyes-Lubricate ...........................
...........
...........
..........
........
... 177  Engine Only)..........................................................202  

Mast, Carriage, Lift Chains & Attachments - Inspect, Replace PCV Valve and breather element - Change
Lubricate........................
Lubric ate.......................................................
........................................
......... 170  (LP, Gasoline and Dual Fuel Engines) ..... ...........
...........203
.....203  

Metric Hardware
Hardwar e ...................................................
................................................... 135  Replace Spark Plugs (G420F(E) Engine Only) ..202  

Mono-Ped Control System (Option).........

(O ption)...............
...........
..... 117  Replace Spark Plugs (G424F(E) LP, Dual Fuel
Mounting and Dismounting
Dismounting ...........
................
...........
...........
...........
.........
... 11
  Engine Only)..........................................................191  

Moving Fan Warning ...................................

.................................................8
..............8
 

S
N
Safe ty Rules .................................................
Safety ............................................................23
...........23
 

No Riders Warning ....................................................8

....................................................8  
Safety......................................................................2,5
 

No Standing On Fork Warning .................................7

.................................7  
Seat Adjustment......................................................18  

No Standing Under Fork Warning ............................7

............................7  
Seat Switch System (If Equipped) ..... ...........
...........
...........
.........67
...67
 

Noise and Vibration......

Vibration ...........
..........
...........
............
............
...........
...........
.........
... 42  
Seat..........................................................................68
 

Seat, Hood Latch & Support Cylinder - Check,

O Lubricate
Lubric ate .......................................................
................................................................148
.........148
 

Serial Number Locations .............................

........................................59
...........59
 

Oil Cooled Disc Brake Only ..........

...............
..........
...........
............
........ 142  
Serial Number..........................................................59  
 Operating
Opera ting in hot weather....................
weather. .....................................
.................. 124  
Service
Servi ce Brake Pedal .......................
...............................................69
........................69  

Opera
Operating
ting
ting Techniques..........................................
Technique s............................................121 Servicing Filter Element........................................167
   

Operating
Opera the Lift Truck........................................
Truck.......................................... 12  
Sideshift Attachment (If Equipped) ...... ...........
...........
...........
.......70
..70  

Operation Information ...........

................
...........
...........
...........
............
...........
..... 11  
Specifications ...........
................
..........
...........
..........
.... 30,32,34,36,38,40  

Operation
Opera tion ...........................................................
...........................................................2,119
2,119   Stability and Center of Gravity ..... ...........
............
............
...........
........21
...21  

Operator's Warning and and Identification Plate ......... ......... 62   Starting a Cold Diesel Engine ...... ...........
...........
...........
..........
..........77
.....77  

-207-

Index Section

Starting a Warm Diesel Engine .......... ................

............
............
........ 77   Water Separator (4TNV98 Diesel Engine Only) -
Starting From a 12 Volt External Source Source ................
.........
... 78   Clean......................................................................184
 

Starting
Startin g the Engine .................................................
................................................. 76   Water Seperator (Diesel Engine Only) - Check,
Starting the Lift truck ..........
................
...........
..........
...........
...........
...........
.........
... 12   Drain.......................................................................152
 

Steer Suspension – Inspect...........

Inspect.................
...........
...........
...........
..... 180   Wheel Bolts & Nuts - Inspect................................173  

Steer Wheel Bearings - Reassemble.........

Reassemble.............. .........
.... 194   When Required ...............................
.....................................................148
......................148
 

Steering Mechanism - Check, Lubricate.............

Lubricate............. 170  

Storage Information
Informa tion........................
..............................................
...................... 127 
127 

Table of Contents ......................................................1

......................................................1
 

Testing Fuel Lock-off Operation (LP Engine Only)

.............................................................
...............................................................................
.................. 192 

Tilt Contro
Control....................................................
l...............................................................
........... 70
 

Tilt Cylinders - Check, Adjust, Lubricate...........

Lubricate............. .. 176 

Tilt Stee
Steeringring Column ...............................................
............................................... 68
 

Timing Belt [G420F(E)/G424F(E) LP, Gasoline, Dual

Fuel Engine Only] - Change...........
Change................. ...........
...........
........
.. 204 

Tire Inflation Information ........... .................

...........
...........
...........
..........
..... 134 

Tire Inflation Pressures Adjustment ........... ................

.........
.... 134 

Tire Inflation
Inflatio n ......................................................
..........................................................
.... 134 

Tire Shipping Pressure...................

Pressure .........................................
...................... 134 

Tires and Wheels (D, G-Series) - Inspect, Check154  

To Operate the Lift Truck after a Long Time Storage

.............................................................
...............................................................................
.................. 127 

Torque for Metric Fasteners .......... ................

...........
...........
...........
..... 136 

Torque for Standard Bolts, Nuts, and Taperlock

Studs
Stud s .........................
........................................................
............................................
............. 135 

Torque for Standard Hose Clamps - Worm Drive135  

Torque Specifications...........................................
Specifica tions........................................... 135  

Torques for Bolts and Nuts with Standard Threads

.............................................................
...............................................................................
.................. 135 

Torques for Taperlock Studs ............ ..................

............
............
........ 136
 

Towing Information
Infor mation.........................
...............................................
...................... 129 

Traing Required To To Operate or Service Warning ...5  

Transmission Inching Control Control Pedal ...... ...........

...........
..........
.... 69
 

Transmission Oil Filter – Change.........Change............... ...........

.........
.... 178 

Transmission Oil Level – Check.............

Check.................. ...........
........
.. 159 

Transmission
Transmi ssion OilOil........................
...................................................
........................... 142 

Transmission Oil, Oil Filter & Strainer - Check,

Clean, Change...............................................162,186  

Transportation
Transpo rtation Hints .............................................
............................................. 128 

Traveling With the Load ........... .................

...........
..........
...........
............
...... 122 

Turning ..............................................................
..................................................................
.... 123 

Universal Joint – Inspect............

Inspect.............................
...........
...........
.........
.... 188  

Unloading
Unloadi ng .........................................................
..............................................................
..... 122