Doosan D20S-5 Operation

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

-1-
Table of Contents

Information Section

Foreword....................................................................2

Safety Section

Important Safety Information ....................................4
Safety .........................................................................5
Warning Signs and Labels ................................5
Parking brake.....................................................9
General Hazard Information........................... 10
Operation Information..................................... 11
Maintenance Information................................ 14
Operator Restraint System(If Equipped)....... 17
Avoiding Lift Truck Tipover............................. 21
Safety Rules.................................................... 23
How to Survive in a Tipover ........................... 28

General Section

Specifications.......................................................... 30
Noise and Vibration................................................ 42
Capacity Chart (Without Sideshifter Pneumatic).. 43
Capacity Chart (With Sideshifter Pneumatic)....... 47
Capacity Chart (Without Sideshifter cushion)....... 51
Capacity Chart (With Sideshifter cushion)............ 55
Serial Number......................................................... 59
Operator's Warning and Identification Plate......... 62

Operation Section

Operators Station and Monitoring Systems......... 63
Seat Switch System (If Equipped)......................... 67
Lift Truck Controls .................................................. 69
Refueling................................................................. 71
Before Starting the Engine..................................... 74
Starting the Engine................................................. 76
Dual Fuel System................................................... 79
Lift Truck Operation................................................ 82
Mono-Ped Control System (Option).................... 117
Auto Shift Controller ASC-100 (If Equipped) ...... 118
Operating Techniques.......................................... 121
Parking the Lift Truck ........................................... 125
Lift Fork Adjustment ............................................. 126
Storage Information.............................................. 127
Transportation Hints............................................. 128
Towing Information............................................... 129

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck
Forks...................................................................... 130
Tire Inflation Information....................................... 134
Torque Specifications........................................... 135
Cooling System Specifications............................. 137
Fuel Specifications................................................ 139
Lubricant Information............................................ 141
Lubricant Viscosities and Refill Capacities ......... 143
Maintenance Intervals .......................................... 144
When Required..................................................... 148
Every 10 Service Hours or Daily.......................... 155
First 50 - 100 Service Hours or a Week.............. 161
First 250 Service Hours or a Month..................... 166
Every 250 Service Hours or Monthly................... 167
Every 500 Service Hours or 3 Months................. 176
Every 1000 Service Hours or 6 Months .............. 185
Every 1500 Service Hours or 9 Months .............. 191
Every 2000 Service Hours or Yearly................... 194
Every 2500 Service Hours or 15 Months ............ 201
Every 3000 Service Hours or 18 Months ............ 204

Index Section

Index...................................................................... 205

Information Section

-2-
Foreword

Literature Information
This manual should be stored in the operators
compartment in the literature holder or seat back
literature storage area.

This manual contains safety, operation,
transportation, lubrication and maintenance
information.

Some photographs or illustrations in this publication
show details or attachments that can be different
from your lift truck. Guards and covers might have
been removed for illustrative purposes.

Continuing improvement and advancement of
product design might have caused changes to your
lift truck which are not included in this publication.
Read, study and keep this manual with the lift truck.

Whenever a question arises regarding your lift truck,
or this publication, please consult your DOOSAN
dealer for the latest available information.

Safety
The Safety Section lists basic safety precautions. In
addition, this section identifies the text and
locations of warning signs and labels used on the
lift truck.
Read and understand the basic precautions listed
in the Safety Section before operating or
performing lubrication, maintenance and repair on
this lift truck.

Operator Restraint System (If Equipped)
This manual contains safety, operation and
maintenance information for the DOOSAN operator
restraint system. Read, study and keep it handy.

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.

Photographs or illustrations guide the operator
through correct procedures of checking, operation
and maintenance of the DOOSAN operator
restraint system.

SAFE and EFFICIENT OPERATION of a lift truck
depends to a great extent on the skill and alertness
on the part of the operator. To develop this skill the
operator should read and understand the Safe
Driving Practices contained in this manual.

Forklift trucks seldom tipover, but in the rare event
they do, the operator may be pinned to the ground
by the lift truck or the overhead guard. This could
result in serious injury or death.

Operator training and safety awareness is an
effective way to prevent accidents, but accidents
can still happen. The DOOSAN operator restraint
system can minimize injuries. The DOOSAN
operator restraint system keeps the operator
substantially within the confines of the operators
compartment and the overhead guard.

This manual contains information necessary for
Safe Operation. Before operating a lift truck, make
sure that the necessary instructions are available
and understood.

Operation
The Operation Section is a reference for the new
operator and a refresher for the experienced one.
This section includes a discussion of gauges,
switches, lift truck controls, attachment controls,
transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the lift truck.
Operating techniques outlined in this publication
are basic. Skill and techniques develop as the
operator gains knowledge of the lift truck and its
capabilities.
Information Section

-3-
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 the design. ENVIRONMENT
MANAGEMENT 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.

Safety Section

-4-

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 training, skills and tools before attempting 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 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 other 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, work method or operating technique not 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 by the operation, lubrication, maintenance or repair procedures 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.

Safety Section

-5-
Safety

The safety rules and regulations in this section are
representative of some, but not all rules and
regulations noted under the Occupational Safety
and Health Act (OSHA) and are paraphrased
without representation that the OSHA rules and
regulations have been reproduced verbatim.

Please refer to 1910. 178 in Federal Register Vol.
37, No. 202, the National Fire Protection
Association No. 505 (NFPA), American National
Standard, ANSI B56. 1 Safety Standard for Low lift
and High Lift Trucks and subsequent revisions for a
complete list of OSHA rules and regulations as to
the safe operation of powered industrial lift trucks.
Since regulations vary from country to country
outside in U.S.A., operate this lift truck in
accordance with local regulations.

DOOSAN lift trucks are manufactured according to
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
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so.

Warning Signs and Labels
There are several specific safety signs on your lift
truck. Their exact location and description of the
hazard are reviewed in this section. Please take the
time to familiarize yourself with these safety signs.
Make sure that you can read all warning and
instruction labels. Clean or replace these labels if
you cannot read the words or see the pictures.
When cleaning the labels use a cloth, water and
soap. Do not use solvent, gasoline, etc.
You must replace a label if it is damaged, missing
or cannot be read. If a label is on a part that is
replaced, make sure a new label is installed on the
replaced part. See your dealer for new labels.

Traing Required To Operate or Service
Warning

Located on the right side of the steering wheel.

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

Safety Section

-6-
General Warning to Operator

Located on the right side of the operator's seat
(STD).

Located on the overhead guard (If Convenience
Package Equipped).

WARNING
Only trained and authorized personnel may
operate this machine. For safe operation, read
and follow the operation and maintenance
Manual furnished with this lift truck and
observe the following warnings:

1. Before starting machine. Check all controls and
warning devices for proper operation.

2. Refer to machine identification plate for
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.
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
machine.

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.

16. Machine should be equipped with overhead
guard or equivalent protection. Where load
requires it, use a load backrest extension. Use
extreme caution if operating without these
devices.

17. Parking - Lower lifting mechanism to floor. Put
directional control or shift lever in neutral. Set
parking/secondary brake. Turn ON - OFF
switch off. Chock wheels if machine is on incline.
Disconnect battery when storing electric
machines.

18. Observe safety rules when handling fuel for
engine powered machine and when changing
batteries for electric machines.

Safety Section

-7-
Pressure Warning
WARNING
Contents under pressure may be hot. Allow to
cool before opening.

Located on the radiator top tank by the radiator
cap.

Hand Placement Warning
WARNING

No hands. Do not place hands in this area. Do
not touch, lean on, or reach through the mast or
permit others to do so.

Located on the mast.

No Standing On Fork Warning
No Standing Under Fork Warning
WARNING
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 lift cylinder.

Load Backrest Must Be In Place
Warning
WARNING
Operation without this device in place may be
hazardous.

Located on the load backrest.
Safety Section

-8-

Overhead Guard Must Be In Place
Warning
WARNING
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 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).

Moving Fan Warning
WARNING
To avoid personal injury, stay clear of moving
fan.

Located inside the engine compartment cover.

Safety Section

-9-
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.

Safety Section

-10-
General Hazard Information

Attach a Do Not Operate or similar warning tag to
start switch or controls before servicing or repairing
the lift truck.

Do not start or service the lift truck when a DO
NOT OPERATE or similar warning tag is attached
to the start switch or controls.

Wear a hard hat, protective glasses and other
protective equipment as required by job conditions.

Know the width of your attachments so proper
clearance can be maintained when operating near
fences, boundary obstacles, etc.

Do not wear loose clothing or jewelry that can catch
on controls or other parts of the lift truck.

Keep the lift truck, especially the deck and steps,
free of foreign material such as debris, oil tools and
other items which are not part of the lift truck.

Secure all loose items such as lunch boxes, tools
and other items which are not part of the lift truck.

Know the appropriate work-site hand signals and
who gives them. Accept signals from one person
only.
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 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).

Do not raise loads any higher than necessary and
never raise a load higher than 1830 mm (72 in) with
the overhead guard removed.

Always use load backrest extension when the
carriage or attachment does not fully support the
load. The load backrest extension is intended to
prevent the load or any part of the load from falling
backwards into the operator's station.

When operating the lift truck, do not depend only on
flashing lights or back-up alarm (if equipped) to
warn pedestrians.

Always be aware of pedestrians and do not
proceed until the pedestrians are aware of your
presence and intended actions and have moved
clear of the lift truck and/or load.

Do not drive lift truck up to anyone standing in front
of an object.

Obey all traffic rules and warning signs.

Keep hands, feet and head inside the operator
station. Do not hold onto the overhead guard while
operating the lift truck. Do not climb on any part of
the mast or overhead guard or permit others to do
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.
Safety Section

-11-
Inhaling Freon gas through a lit cigarette or other
smoking method or inhaling fumes released from a
flame contacting Freon can cause bodily harm or
death. Do not smoke when servicing air
conditioners or wherever Freon gas may be
present.

Never put maintenance fluids into glass containers.
Use all cleaning solutions with care.

Do not use steam, solvent, or high pressure to
clean electrical components.

Report all needed repairs.

Inspect the part of the chain that is normally
operated over the crosshead roller. When the chain
bends over the roller, the movement of the parts
against each other causes wears.

Inspect to be sure that chain link pins do not extend
outside of the bore hole.

If any single link pin is extended beyond its
connecting corresponding link, it should be
suspected of being broken inside of its bore hole.

Inspect the chain anchor and the anchor links for
wear.

Do not change any factory set adjustment values
(including engine rpm setting) unless you have both
authorization and training. Especially Safety
equipment and switches may not be removed or
adjusted incorrectly. Repairs, adjustments and
maintenances that are not correct can make a
dangerous operating condition.

For any checkup, repair, adjustments, maintenance
and all other work concerning your forklift truck,
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.
Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.

Clean your shoes and wipe your hands before
mounting.

Use both hands and face the lift truck when
mounting and dismounting.

Use the handgrips for mounting and dismounting.

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
start of each shift. Refer to the topic Walk-around
Inspection in Every 10 Service Hours or Daily
section of this manual.

Adjust the seat so that full brake pedal travel can
be obtained with the operator's back against the
seat back.

Make sure the lift truck is equipped with a lighting
system as required by conditions.

Make sure all hydraulic controls are in the HOLD
position.

Make sure the direction control lever is in the
NEUTRAL position.

Make sure the parking brake is engaged.

Make sure no one is standing and/or working on,
underneath or close to the lift truck before operating
the lift truck.

Operate the lift truck and controls only from the
operator's station.
Safety Section

-12-
Make sure the lift truck horn, lights, backup alarm (if
equipped) and all other devices are working
properly.

Check for proper operation of mast and
attachments. Pay particular attention to unusual
noises or erratic movement which might indicate a
problem.

Make sure service and parking brakes, steering,
and directional controls are operational.

Make sure all personnel are clear of lift truck and
travel path.

Refer to the topic Lift Truck Operation in the
Operation Section of this manual for specific
starting instructions.

Starting the Lift truck

Do not start the engine or move any of the controls
if there is a DO NOT OPERATE or similar warning
tag attached to the start switch or controls.

Before Operating the Lift Truck
Test brakes, steering controls, horn and other
devices for proper operation. Report any faulty
performance. Do not operate lift truck until repaired.

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.
Operating the Lift Truck

Always keep the lift truck under control.

Obey all traffic rules and warning signs.

Never leave the lift truck with the engine operating,
or with the parking brake disengaged.

Operate the engine only in a well ventilated area.

Lower a mast, with or without load, before turning
or traveling. Tip over could result. Watch out for
overhead obstructions.

Always observe floor load limits and overhead
clearance.

Start, turn, and brake smoothly. Slow down for
turns, grades, slippery or uneven surfaces.

Use special care when operating on grades. Do not
angle across or turn on grades. Do not use lift truck
on slippery grades. Travel with forks downgrade
when unloaded. Travel with load upgrade.

Do not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plate
on the lift truck. Use extreme caution when
handling suspended, long, high or wide load.
Safety Section

-13-

Tilt the elevated load forward only when directly
over unloading area and with load as low as
possible.

Do not stunt ride or indulge in horseplay.

Always look and keep a clear view of the path of
travel.

Travel in reverse if load or attachment obstructs
visibility. Use extreme caution if visibility is
obstructed.

Stay in designated travel path, clear of dock edges,
ditches, other drop-offs and surfaces which 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 and in congested areas,
avoid pedestrians, other vehicles, obstruction, pot
holes and other hazards or objects in the path of
travel.

Always use overhead guards except where
operation conditions do not permit. Do not operate
lift truck in high stacking areas without overhead
guards.

When stacking, watch for falling objects. Use load
backrest extension and overhead guard.

Refer to the topic Operation Techniques in the
Operation Section of this manual.
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.

Be certain dock plates are in good condition and
properly placed and secured. Do not exceed the
rated capacity of dock boards or bridge plates.

Lift Truck Parking
When leaving the operator station, park the lift truck
in authorized areas only. Do not block traffic.

Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor.

Move the direction control lever to NEUTRAL.

Engage the parking brake.

Turn the key switch off and remove the key.

Turn the disconnect switch to OFF (if equipped).

Block the drive wheels when parking on an
incline.

Safety Section

-14-
Maintenance Information
Perform all maintenance unless otherwise specified
as follows:

Park the lift truck in authorized areas only.
Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor.
Place the transmission controls in neutral.
Stop the engine.
Remove the start switch key and turn the
disconnect switch OFF (if equipped).
Block the drive wheels when parking on an
incline.

Pressure Air
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.

Fluid Penetration
Always use a board or cardboard when checking
for a leak. Escaping fluid under pressure, even a
pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated by a
doctor familiar with this type of injury immediately.

Crushing or Cutting Prevention
Support equipment and attachments properly when
working beneath them. Do not depend on hydraulic
cylinders to hold it up. Any attachment can fall if a
control is moved, or if a hydraulic line breaks.

Never attempt adjustments while the lift truck is
moving or the engine is running unless otherwise
specified.

Where there are attachment linkages, the
clearance in the linkage area will increase or
decrease with movement of the attachment.

Stay clear of all rotating and moving parts.

Keep objects away from moving fan blades.
They will throw or cut any object or tool that falls or
is pushed into them.

Do not use a kinked or frayed wire rope cable.
Wear gloves when handling the wire rope cable.

Retainer pins, when struck with force, can fly out
and injure nearby persons. Make sure the area is
clear of people when driving retainer pins.

Wear protective glasses when striking a retainer pin
to avoid injury to your eyes.

Chips or other debris can fly off objects when struck.
Make sure no one can be injured by flying debris
before striking any object.

Falling Objects Protective Structure (FOPS)
This is an attached guard located above the
operator's compartment and secured to the lift
truck.

To avoid possible weakening of the Falling Objects
Protective Structure (FOPS), consult a DOOSAN
dealer before altering, by adding weight to, welding
on, or cutting or drilling holes into the structure.

The overhead guard is not intended to protect
against every possible impact. The overhead guard
may not protect against some objects penetrating
into the operator's station from the sides or ends of
the lift truck.

The lift truck is equipped with an overhead guard
and FOPS as standard. If there is a possibility of
overhead objects falling through the guard, the
guard must be equipped with smaller holes or a
Plexiglas cover.

Any altering done that is not specifically authorized
by DOOSAN invalidates DOOSAN's FOPS
certification. The protection offered by this FOPS
will be impaired if it has been subjected to structural
damage. Structural damage can be caused by an
overturn accident, by falling objects, etc.

Do not mount any item such as fire extinguishers,
first aid kits and lights by welding brackets to or
drilling holes in any FOPS structure. See your
DOOSAN dealer for mounting guidelines.
Safety Section

-15-
Burn Prevention
Coolant
At operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot water or steam.
Any contact can cause severe burns.

Steam can cause personal injury.

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

Remove the cooling system filter cap slowly to
relieve pressure.

Cooling system additive contains alkali that can
cause personal injury. Avoid contact with the skin
and eyes and do not drink.

Allow cooling system components to cool before
draining.

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

At operation temperature, the hydraulic tank is hot
and can be under pressure.

Remove the hydraulic tank filter cap only after the
engine has been stopped and the filter cap is cool
enough to remove with your bare hand.

Remove the hydraulic tank filter cap slowly to
relieve pressure.

Relieve all pressure in air, oil fuel or cooling
systems before any lines, fittings or related items
are disconnected or removed.

Batteries
Batteries give off flammable fumes which can
explode.

Do not smoke when observing the battery
electrolyte levels.

Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes.

Always wear protective glasses when working with
batteries.
Fire or Explosion Prevention
All fuels, most lubricants and some coolant
mixtures are flammable.

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

Do not smoke while refueling or in a refueling area.

Do not smoke in areas where batteries are charged,
or where flammable materials are stored.

Batteries in series can be located in separate
compartments. When using jumper cables always
connect positive(+) cable to positive(+) terminal of
battery connected to starter solenoid and
negative(-) cable from external source to starter
negative(-) terminal.
(If not equipped with starter negative(-) terminal,
connect to engine block.)

See the Operation Section of this manual for
specific starting instructions.

Clean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have all
loose or frayed electrical wires tightened, repaired
or replaced before operating the lift truck.

Keep all fuels and lubricants stored in properly
marked containers and away from all unauthorized
persons.

Store all oily rags or other flammable material in a
protective container, in a safe place.

Do not weld or flame cut on pipes or tubes that
contain flammable fluids. Clean them thoroughly
with nonflammable solvent before welding or flame
cutting on them.

Remove all flammable materials such as fuel, oil
and other debris before they accumulate on the lift
truck.

Do not expose the lift truck to flames, burning brush,
etc., if at all possible.

Shields, which protect hot exhaust components
from oil or fuel spray in the event of a line, tube or
seal failure, must be installed correctly.

Do not operate in areas where explosive gases
exist or are suspected.
Safety Section

-16-
Fire Extinguisher
Have a fire extinguisher-type BC and 1.5KG
minimum capacity-on rear overhead guard leg with
latch and know how to use it. Inspect and have it
serviced as recommended on its instruction plate.

Ether
Ether is poisonous and flammable.

Breathing ether vapors or repeated contact of ether
with skin can cause personal injury.

Use ether only in well-ventilated areas.
Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in living
areas or in the operator's compartment.

Do not store ether cylinders in direct sunlight or at
temperatures above 39C (102F).

Discard cylinders in a safe place. Do not puncture
or burn cylinders.

Keep ether cylinders out of the reach of
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
connections to the recommended torque. Replace if
any of the following conditions are found.
End fittings damaged or leaking.
Outer covering chafed or cut and wire reinforcing
exposed.
Outer covering ballooning locally.
Evidence of kinking or crushing of the flexible
part of hose.
Armoring embedded in the outer cover.
End fittings displaced.

Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation.

Tire Information
Explosions of air-inflated tires have resulted from
heat-induced gas combustion inside the tires. The
heat, generated by welding or heating rim
components, external fire, or excessive use of
brakes can cause gaseous combustion.

A tire explosion is much more violent than a
blowout. The explosion can propel the tire, rim and
axle components as far as 500 m (1500 ft) or more
from the lift truck. Both the force of the explosion
and the flying debris can cause personal injury or
death, and property damage.

Do not approach a warm tire closer than the
outside of the area represented by the shaded area
in the above drawing.

Safety Section

-17-
Dry nitrogen (N
2
) gas is recommended for inflation
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.

Nitrogen inflated tires reduce the potential of a tire
explosion, because nitrogen does not support
combustion. Also, nitrogen helps prevent oxidation
and the resulting deterioration of rubber and
corrosion of rim components.

Proper nitrogen inflation equipment and training in
its use are necessary to avoid over-inflation. A tire
blowout or rim failure can result from improper or
misused equipment.

Stand behind the tread and use a self-attaching
chuck when inflation a tire.

Servicing, changing tires and rims can be
dangerous and should be done only by trained
personnel using proper tools and procedures. If
correct procedures are not followed while servicing
tires and rims, the assemblies could burst with
explosive force and cause serious personal injury
or death. Follow carefully the specific information
provided by your tire or rim servicing personnel or
dealer.
Operator Restraint System(If
Equipped)
Warning Signs and Labels
Your DOOSAN lift truck has the following tipover
warning decals.

Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or
see the pictures. When cleaning the labels use a
cloth, water and soap. Do not use solvent, gasoline,
etc. You must replace a label if it is damaged,
missing or cannot be read. If a label is on a part
that is replaced, make sure a new label is installed
on the replaced part. See you DOOSAN Lift Truck
dealer for new labels.
The most effective method of preventing serious
injury or death to yourself or others is to familiarize
yourself with the proper operation of the lift truck, to
be alert, and to avoid actions or conditions which
can result in an accident.

WARNING
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.

Safety Section

-18-

The Survive in tipover warning is located on the
overhead guard. It shows the proper use of the
operator restraint system.

Seat Adjustment

Move the lever, slide the seat to the desired
position, and release the lever.

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.

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.

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 .

Forward and Backward
Adjustment
Safety Section

-19-
Weight adjustment

Pull the weight adjustment lever upwards and move
right or left side.
Adjust to drivers weight in 7 steps (50 ~ 110 kg)

NOTICE

Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and down.

Backrest Inclination

The backrest angle can be adjusted by using the
lever on the left side of seat.

Seat Belt
The Operator Restraint System, Prevents the
operator from jumping from the operators
compartment in the event of a forward or side
tipover. The system is designed to keep the
operator on the seat and in the operators
compartment in the event of a tipover.

Inspection

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 assembly.

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.

Safety Section

-20-

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 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
from some abdominal disease, consult a doctor
before you use the seat belt.

Fasten the Seat Belt

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

2. Make sure the belt is not twisted.

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

3. Be sure to fasten the belt across your hips, not
across your abdomen.

NOTE: The belt is designed to automatically adjust
to your size and movement. A quick pull on
the belt will confirm that the automatic
adjuster will hold the belt position in the
event of an accident.

Release the Seat Belt

Push the button of the buckle to release the belt.
The belt will automatically retract when released.
Hold the plate of the belt and allow the belt to
slowly retract.
Safety Section

-21-
Avoiding Lift Truck Tipover
Lift Truck Stability

Counterbalanced lift truck design is based on the
balance of two weights on opposite sides of a
fulcrum (the front axle). The load on the forks must
be balanced by the weight of the lift truck. The
location of the center of gravity of both the truck
and the load is also a factor. This basic principle is
used for picking up a load. The ability of the lift
truck to handle a load is discussed in terms of
center of gravity and both forward and sideways
stability.

Center of Gravity (CG)

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.
Stability and Center of Gravity

The stability of the lift truck is determined by the
location of its CG; or, if the truck is loaded, the
combined CG of the truck and load. The lift truck
has moving parts and, therefore, has a CG that
moves. The CG moves forward or backward as the
mast is tilted forward or backward. The CG moves
up or down as the mast moves up or down. The CG
and, therefore, the stability of the loaded lift truck,
are affected by a number of factors such as:
the size, weight, shape and position of the load

the height to which the load is lifted

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

These same factors are also important for unloaded
lift trucks. They tip over sideways easier than a
loaded lift truck carrying its load in the lowered
position.
Safety Section

-22-
Lift Truck Stability Base

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
the front wheels and the pivot of the steer wheels. If
the CG moves forward of the front axle, the lift truck
will tip forward. If the CG moves outside of the line
on either side of the stability base, the lift truck will
tip to the side.

WARNING
Dynamic forces (braking, acceleration, turning)
also affect stability and can produce tipover
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.
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 reduced. The lift truck should not be operated if
its capacity/nameplate does not indicate capacity
load.

NOTE: If the load is not uniform, the heaviest
portion should be placed closer to the
backrest and centered on the forks.

NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DOOSAN shall not be removed,
altered or replaced without DOOSANs approval.

2. DOOSAN assumes no responsibility for lift trucks
placed in service without a valid DOOSAN
Nameplate.

3. If necessary to change your specification, contact
your DOOSAN lift truck dealer.

Safety Section

-23-
Safety Rules

Only properly trained and authorized personnel
should operate forklift trucks. Wear a hard hat and
safety shoes when operating a lift truck. Do not
wear loose clothing.

Inspect and check the condition of your forklift truck
using the operator's check list before starting work.
Immediately report to your supervisor any obvious
defects or required repairs.

Do not operate your truck in unauthorized areas.
Know your forklift truck and think safety.
Do not compromise safety.
Follow all safety rules and read all warning signs.

Do not operate a lift truck unless you are in the
operators seat. Keep hands and feet inside the
operators compartment. Do not put any part of
the body outside of the operators compartment.
Never put any part of body into the mast structure
or between the mast and the truck

Do not start, stop, turn or change direction
suddenly or at high speed. Sudden movement can
cause the lift truck to tip over. Slow the speed of
your truck and use the horn near corners, exits,
entrances, and near people.

Never operate a lift truck with wet hands or shoes.
Never hold any controls with grease on your hands.
Your hands or feet will slide off of the controls and
cause an accident.
Safety Section

-24-

Do not raise anyone on the forks of your lift truck.
Do not let other people ride on the truck.
Lift trucks are designed to carry loads, not people.

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 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
balance. Do not lift a load with one fork.

Do not overload. Always handle loads within the
rated capacity shown on the capacity plate.
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 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 drive on slippery surfaces.
Sand, gravel, ice or mud can cause a tipover.
If unavoidable, slow down.

Safety Section

-25-

Do not permit anyone to stand or walk under the
load or lifting mechanism. The load can fall and
cause injury or death to anyone standing below.

Look out for overhead obstructions when raising or
stacking loads. Do not travel with a raised load. Do
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.

Do not move loose loads that are higher than the
load backrest.
Be alert for falling loads when stacking.
Travel with the load tilted back and the forks as low
as possible.
This will increase stability to the truck and load and
permit better visibility for you.

Do not elevate the load with the mast tilted forward.
Do not tilt the elevated loads forwards.
This will cause the lift truck to tip over forward.

Do not jump off if your truck starts to tip over.
Stay in your seat to survive.

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
incline.
Go straight off and straight down. Use an assistant
when going up or down a ramp with a bulky load.
Safety Section

-26-

Do not stack or turn on ramps.
Do not attempt to pick-up or deposit a load unless
the lift truck is level. Do not turn on or drive across
an incline.

Do not go over rough terrain. If unavoidable, slow
down.
Cross railroad tracks slowly and diagonally
whenever possible. A railroad crossing can give a
loaded forklift truck a real jolt. For smoother
crossing, cross the railroad diagonally so one wheel
crosses at a time.

Avoid running over loose objects.
Look in the direction of travel. Look out for other
persons or obstructions in your path of travel.
An operator must be in full control of his lift truck at
all times.

Do not drive in forward direction when loads restrict
your visibility. Operate your lift truck in reverse to
improve visibility except when moving up a ramp.

Be careful when operating a lift truck near the edge
of a loading dock or ramp. Maintain a safe distance
from the edge of docks, ramps and platforms.
Always watch tail swing.
The truck can fall over the edge and cause injury or
death.

Do not operate on bridge plates unless they can
support the weight of the truck and load.
Make sure that they are correctly positioned.
Put blocks on the vehicle you enter to keep it from
moving.

Safety Section

-27-

Do not operate your truck close to another truck.
Always keep a safe distance from other trucks and
make sure there is enough distance to stop safely.
Never overtake other vehicles.

Do not use your lift truck to push or tow another
truck.
Do not let another push or tow your truck.
If a truck will not move, call a service technician.

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 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.

Park your lift truck in authorized areas only. Fully
lower the forks to the floor, put direction lever in
NEUTRAL position, engage the parking brake, and
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.

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.

Safety Section

-28-
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.

Always use operator restraint system.

Dont jump.

Hold on tight.

Brace your feet and keep them within the operators
compartment.

Safety Section

-29-

Lean away from the direction of fall.

Lean forward.

General Section

-30-
Specifications
CHARACTERISTICS
1 MANUFACTURER DOOSAN DOOSAN
2 MODEL
D20S-5
(YANMAR,TIER2)
D25S-5
(YANMAR,TIER2)
3 CAPACITY at rated load center kg 2000 2500
4 LOAD CENTER distance mm 500 500
5 POWER TYPE electric, 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 maximum fork height with rated load mm 3230 3230
10
LIFT WITH STD
TWO-STAGE MAST free lift mm 152 152
11 FORK CARRIAGE ISO class II II
12 thickness x width x length mm 40x100x1050 40x100x1050
13
FORKS
fork spacing (maximum x minimum) mm 275x1035 275x1035
14 TILT OF MAST forward/backward deg 6/10 6/10
15 length to fork face mm 2530 2595
16 width mm 1170 1170
17 mast lowered height mm 2175 2175
18 mast extended height mm 4490 4490
19 overhead guard height mm 2183 2183
20
OVERALL
DIMENSIONS
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
23
a
90 INTERSECTING AISLE mm 1970 2000
PERFORMANCE
24 travel, loaded/unloaded km/hr 21/21.5 21/21.5
25 lift, loaded/unloaded mm/s 530/550 520/550
26
SPEED
lowering, loaded/unloaded mm/s 510/460 510/460
27 DRAWBAR PULL at 1.6km/hr, loaded/unloaded kg 1765 1740
28 GRADEABILITY at 1.6km/hr, loaded/unloaded % 33 28
29 ACCELERATION
time reached at max speed,
loaded/unloaded
sec
WEIGHT
30 TOTAL WEIGHT at unloaded kg 3580 3950
31 at loaded, front/rear kg 4930/650 5660/790
32
AXLE LOAD
at unloaded, front/rear kg 1720/1860 1650/2300
CHASSIS
33 number of front/rear 2/2 2/2
34 front size 7.00x15-12 7.00x15-12
35
TIRES
rear size 6.50x10-10 6.50x10-10
36 WHEEL BASE mm 1625 1625
37 TREAD front/rear mm 975/1000 975/1000
38 at loaded, the lowest point mm 115 115
39
GROUND
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/capacity V/AH 12/85 12/85
43 manufacturer/model YANMAR/4TNV98 YANMAR/4TNV98
44 rated output / rpm kw(hp) 46.3(62.1)/2200 46.3(62.1)/2200
45 max. torque / rpm N-m(lbft) 240(177)/1320 240(177)/1320
46
ENGINE
cycle/cylinders/displacement cc 4/4/3319 4/4/3319
47 type powershift powershift
48
TRANSMISSION
number of speeds forward/reverse 1/1 1/1
49
OPERATING
PRESSURE
system/attachment bar 181/156 195/156
50 NOISE LEVEL
equivelent continuous sound
pressure level (Leq) at operator's ear
(DI : BITA/CE prEN 12053)
dB(A)

General Section

-31-

DOOSAN DOOSAN DOOSAN 1
D30S-5
(YANMAR,TIER2)
D33S-5
(YANMAR,TIER2)
D35C-5
(YANMAR,TIER2)
2
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 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/mech 41

12/85 12/85 12/85 42
YANMAR/4TNV98 YANMAR/4TNV98 YANMAR/4TNV98 43
46.3(62.1)/2200 46.3(62.1)/2200 46.3(62.1)/2200 44
240(177)/1320 240(177)/1320 240(177)/1320 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

General Section

-32-
Specifications
CHARACTERISTICS
2 MODEL
D20S-5
(YANMAR,TIER3)
D25S-5
(YANMAR,TIER3)
5 POWER TYPE electric, diesel, gas, LPG-gas diesel diesel
DIMENSIONS
10
LIFT WITH STD
13
FORKS
15 length to fork face mm 2530 2595
16 width mm 1170 1170
20
OVERALL
DIMENSIONS
23
a
90 INTERSECTING AISLE mm 1970 2000
PERFORMANCE
24 travel, loaded/unloaded km/hr 19/19.5 19/19.5
26
SPEED
29 ACCELERATION
loaded/unloaded
sec
WEIGHT
32
AXLE LOAD
CHASSIS
34 front size 7.00x15-12 7.00x15-12
35
TIRES
rear size 6.50x10-10 6.50x10-10
39
GROUND
DRIVE
43 manufacturer/model YANMAR/4TNE98 YANMAR/4TNE98
44 rated output / rpm kw(hp) 43.7(58.6)/2300 43.7(58.6)/2300
45 max. torque / rpm N-m(lbft) 181(133)/1600 181(133)/1600
46
ENGINE
48
TRANSMISSION
49
OPERATING
PRESSURE
50 NOISE LEVEL
dB(A)

General Section

-33-

D30S-5
(YANMAR,TIER3)
D33S-5
(YANMAR,TIER3)
D35C-5
(YANMAR,TIER3)
2
3000 3250 3500 3
500 500 500 4
diesel diesel diesel 5
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 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

12/85 12/85 12/85 42
YANMAR/4TNE98 YANMAR/4TNE98 YANMAR/4TNE98 43
43.7(58.6)/2300 43.7(58.6)/2300 43.7(58.6)/2300 44
181(133)/1600 181(133)/1600 181(133)/1600 45
4/4/3319 4/4/3319 4/4/3319 46
1/1 1/1 1/1 48
216/156 216/156 216/156 49
50
General Section

-34-
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) number of front/rear
DIMENSIONS
9 maximum fork height with rated load mm
10
LIFT WITH STD TWO-STAGE MAST
free lift mm
11 FORK CARRIAGE ISO class
12 thickness x width x length mm
13
FORKS
fork spacing (maximum x minimum) mm
14 TILT OF MAST forward/backward deg
15 length without forks mm
16 width mm
17 mast lowered height mm
18 mast extended height mm
19 overhead guard height mm
20
OVERALL
DIMENSIONS
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/unloaded km/hr
25 lift, loaded/unloaded mm/s
26
SPEED
lowering, loaded/unloaded mm/s
27 DRAWBAR PULL at 1.6km/hr, loaded/unloaded kg
28 GRADEABILITY at 1.6km/hr, loaded/unloaded %
29 ACCELERATION
loaded/unloaded
sec
WEIGHT
30 TOTAL WEIGHT at unloaded kg
31 at loaded, front/rear kg
32
AXLE LOAD
at unloaded, front/rear kg
CHASSIS
33 number of front/rear
34 front size
35
TIRES
rear size
36 WHEEL BASE mm
37 TREAD front/rear mm
38 at loaded, the lowest point mm
39
GROUND
CLEARANCE at loaded, center of wheelbase mm
40 SEVICE BRAKE
41 PARKING BRAKE
DRIVE
42 BATTERY voltage/capacity V/AH
43 manufacturer/model
44 rated output / rpm kw(hp)
45 max. torque / rpm Nm(lbft)
46
ENGINE
cycle/cylinders/displacement cc
47 type
48
TRANSMISSION
number of speeds forward/reverse
49
OPERATING
PRESSURE
system/attachment bar
50 NOISE LEVEL
pressure level (Leq) at operator's ear (DI : BITA/CE prEN 12053)
dB(A)

General Section

-35-

G20E-5 G25E-5 G30E-5 2
2000 2500 3000 3
500 500 500 4
LP LP LP 5
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 45x125x1050 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

12/45 12/45 12/45 42
G420F(E) G420F(E) G420F(E) 43
39.9(53.5)/2500 39.9(53.5)/2500 39.9(53.5)/2500 44
157(116)/1600 157(116)/1600 157(116)/1600 45
4/4/1975 4/4/1975 4/4/1975 46
1/1 1/1 1/1 48
181/156 195/156 216/156 49
50
General Section

-36-
Specifications
CHARACTERISTICS
2 MODEL G20P-5 G25P-5
5 POWER TYPE electric, diesel, gas, LPG-gas lp lp
DIMENSIONS
10
LIFT WITH STD
13
FORKS
15 length without forks mm 2530 2595
16 width mm 1170 1170
20
OVERALL
DIMENSIONS
23a 90 INTERSECTING AISLE mm 1970 2000
PERFORMANCE
24 travel, loaded/unloaded km/hr 19/20 19/20
26
SPEED
29 ACCELERATION
loaded/unloaded
sec
WEIGHT
32
AXLE LOAD
CHASSIS
34 front size 7.00x15-12 7.00x15-12
35
TIRES
rear size 6.50x10-10 6.50x10-10
39
GROUND
DRIVE
43 manufacturer/model G424F(E) G424F(E)
44 rated output / rpm kw(hp) 47.7(64)/2550 47.7(64)/2550
45 max. torque / rpm Nm(lbft) 182(135)/2200 182(135)/2200
46
ENGINE
48
TRANSMISSION
49
OPERATING
PRESSURE
50 NOISE LEVEL
dB(A)

General Section

-37-

G30P-5 G33P-5 G35C-5 2
3000 3250 3500 3
500 500 500 4
lp lp lp 5
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

18/19 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 35
1700 1700 1700 36
982/1000 982/1000 1026/1000 37
105 105 105 38
143 143 143 39

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)/2200 182(135)/2200 45
4/4/2405 4/4/2405 4/4/2405 46
1/1 1/1 1/1 48
216/156 216/156 216/156 49
50
General Section

-38-
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 electric, diesel, gas, LPG-gas LP
6 OPERATOR TYPE stand-on, ride-seated rider-seated
7 TIRES C=cushion, P=pneumatic C
8 WHEELS(x=driven) number of front/rear 2/2
DIMENSIONS
9 maximum fork height with rated load mm 3230
10
LIFT WITH STD
TWO-STAGE MAST
free lift mm 152
11 FORK CARRIAGE ISO class II
12 thickness x width x length mm 40x100x1050
13
FORKS
fork spacing (maximum x minimum) mm 297x905
14 TILT OF MAST forward/backward deg 6/8
15 length without forks mm 2218
16 width mm 1110
17 mast lowered height mm 2130
18 mast extended height mm 4480
19 overhead guard height mm 2150
20
OVERALL
DIMENSIONS
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/unloaded km/hr 16/16
25 lift, loaded/unloaded mm/s 530/600
26
SPEED
lowering, loaded/unloaded mm/s 510/460
27 DRAWBAR PULL at 1.6km/hr, loaded/unloaded kg 1795
28 GRADEABILITY at 1.6km/hr, loaded/unloaded % 35.5
29 ACCELERATION
loaded/unloaded
sec
WEIGHT
30 TOTAL WEIGHT at unloaded kg 3410
31 at loaded, front/rear kg 4770/640
32
AXLE LOAD
at unloaded, front/rear kg 1540/1870
CHASSIS
33 number of front/rear 2/2
34 front size 21x7-15
35
TIRES
rear size 16x5-10.5
36 WHEEL BASE mm 1410
37 TREAD front/rear mm 932/983
38 at loaded, the lowest point mm 90
39
GROUND
CLEARANCE
at loaded, center of wheelbase mm 135
40 SEVICE BRAKE foot/hyd
41 PARKING BRAKE hand/mech
DRIVE
42 BATTERY voltage/capacity V/AH 12/45
43 manufacturer/model G420F(E)
44 rated output / rpm kw(hp) 39.9(53.5)/2500
45 max. torque / rpm Nm(lbft) 157(116)/1600
46
ENGINE
cycle/cylinders/displacement cc 4/4/1975
47 type powershift
48
TRANSMISSION
number of speeds forward/reverse 1/1
49
OPERATING
PRESSURE
system/attachment bar 181/156
50 NOISE LEVEL
pressure level (Leq) at operator's ear (DI : BITA/CE
prEN 12053)
dB(A)

General Section

-39-

GC25E-5 GC30E-5 GC33E-5 2
2500 3000 3000(6500LBS) 3
500 500 600 4
LP LP LP 5
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

12/45 12/45 12/45 42
G420F(E) G420F(E) G420F(E) 43
39.9(53.5)/2500 39.9(53.5)/2500 39.9(53.5)/2500 44
157(116)/1600 157(116)/1600 157(116)/1600 45
4/4/1975 4/4/1975 4/4/1975 46
1/1 1/1 1/1 48
195/156 216/156 216/156 49
50

General Section

-40-
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 electric, diesel, gas, LPG-gas LP
6 OPERATOR TYPE stand-on, ride-seated rider-seated
7 TIRES C=cushion, P=pneumatic C
8 WHEELS(x=driven) number of front/rear 2/2
DIMENSIONS
9 maximum fork height with rated load mm 3230
10
LIFT WITH STD
TWO-STAGE MAST
free lift mm 152
11 FORK CARRIAGE ISO class II
12 thickness x width x length mm 40x100x1050
13
FORKS
fork spacing (maximum x minimum) mm 297x905
14 TILT OF MAST forward/backward deg 6/8
15 length without forks mm 2218
16 width mm 1110
17 mast lowered height mm 2130
18 mast extended height mm 4480
19 overhead guard height mm 2150
20
OVERALL
DIMENSIONS
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/unloaded km/hr 16/16
25 lift, loaded/unloaded mm/s 530/600
26
SPEED
lowering, loaded/unloaded mm/s 510/460
27 DRAWBAR PULL at 1.6km/hr, loaded/unloaded kg 2170
28 GRADEABILITY at 1.6km/hr, loaded/unloaded % 44
29 ACCELERATION
loaded/unloaded
sec
WEIGHT
30 TOTAL WEIGHT at unloaded kg 3430
31 at loaded, front/rear kg 4780/650
32
AXLE LOAD
at unloaded, front/rear kg 1550/1880
CHASSIS
33 number of front/rear 2/2
34 front size 21x7-15
35
TIRES
rear size 16x5-10.5
36 WHEEL BASE mm 1410
37 TREAD front/rear mm 932/983
38 at loaded, the lowest point mm 90
39
GROUND
CLEARANCE
at loaded, center of wheelbase mm 135
40 SEVICE BRAKE foot/hyd
41 PARKING BRAKE hand/mech
DRIVE
42 BATTERY voltage/capacity V/AH 12/65
43 manufacturer/model G424F(E)
44 rated output / rpm kw(hp) 47.7(64)/2550
45 max. torque / rpm Nm(lbft) 182(135)/2200
46
ENGINE
cycle/cylinders/displacement cc 4/4/2405
47 type powershift
48
TRANSMISSION
number of speeds forward/reverse 1/1
49
OPERATING
PRESSURE
system/attachment bar 181/156
50 NOISE LEVEL
pressure level (Leq) at operator's ear (DI : BITA/CE prEN
12053)
dB(A)

General Section

-41-

GC25P-5 GC30P-5 GC33P-5 2
2500 3000 3000(6500LBS) 3
500 500 600 4
LP LP LP 5
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

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)/2200 182(135)/2200 45
4/4/2405 4/4/2405 4/4/2405 46
1/1 1/1 1/1 48
195/156 216/156 216/156 49
50

General Section

-42-
Noise and Vibration

Sound Pressure Level at
Operators ear (Leq.)
according to EN12053
Guaranteed Sound
Power level(LWA )
By Noise Directive
2000/14/EC
Whole-body Vibration
Level
according to EN13059
(m/s
2
)
Model
dB(A) dB(A) Mean Uncertainty
TIER - II (4TNV98 E/G)
D20S-5,D25S-5,D30S-5,
D33S-5, D35C-5
(W/O Cabin)
82 104
TIER - III (4TNE98 E/G)
D20S-5,D25S-5,D30S-5,
D33S-5, D35C-5
(W/O Cabin)
82 104
TIER - III (G420F(E) E/G)
G20E-5,G25E-5,G30E-5
(W/O Cabin)
82 104
G20P-5,G25P-5,G30P-5,
G33P-5,G35C-5
(W/O Cabin)
84 106
0.7 0.2
GC20E-5,GC25E-5,GC30E-5,
GC33E-5
(W/O Cabin)
80 *NA
GC20P-5,GC25P-5,GC30P-5,
GC33P-5
(W/O Cabin)
82 *NA
1.1 0.3

* NA : Not Applicable

General Section

-43-
Capacity Chart (Without Sideshifter Pneumatic)

SINGLE TIRE
MODEL
STD, FFL FFT
D
2
0
S
-
5
,

G
2
0
E
-
5
,

G
2
0
P
-
5

D
2
5
S
-
5
,

G
2
5
E
-
5
,

G
2
5
P
-
5

D
3
0
S
-
5
,

G
3
0
E
-
5
,

G
3
0
P
-
5

General Section

-44-

SINGLE TIRE
MODEL
STD, FFL FFT
D
3
3
S
-
5
,

G
3
3
P
-
5

D
3
5
C
-
5
,

G
3
5
C
-
5

General Section

-45-

DOUBLE TIRE
MODEL
STD, FFL FFT
D
2
0
S
-
5
,

G
2
0
E
-
5
,

G
2
0
P
-
5

D
2
5
S
-
5
,

G
2
5
E
-
5
,

G
2
5
P
-
5

D
3
0
S
-
5
,

G
3
0
E
-
5
,

G
3
0
P
-
5

General Section

-46-

DOUBLE TIRE
MODEL
STD, FFL FFT
D
3
3
S
-
5
,

G
3
3
P
-
5

D
3
5
C
-
5
,

G
3
5
C
-
5

General Section

-47-
Capacity Chart (With Sideshifter Pneumatic)

SINGLE TIRE
MODEL
STD, FFL FFT
D
2
0
S
-
5
,

G
2
0
E
-
5
,

G
2
0
P
-
5

D
2
5
S
-
5
,

G
2
5
E
-
5
,

G
2
5
P
-
5

D
3
0
S
-
5
,

G
3
0
E
-
5
,

G
3
0
P
-
5

General Section

-48-

SINGLE TIRE
MODEL
STD, FFL FFT
D
3
3
S
-
5
,

G
3
3
P
-
5

D
3
5
C
-
5
,

G
3
5
C
-
5

General Section

-49-

DOUBLE TIRE
MODEL
STD, FFL FFT
D
2
0
S
-
5
,

G
2
0
E
-
5
,

G
2
0
P
-
5

D
2
5
S
-
5
,

G
2
5
E
-
5
,

G
2
5
P
-
5

D
3
0
S
-
5
,

G
3
0
E
-
5
,

G
3
0
P
-
5

General Section

-50-

DOUBLE TIRE
MODEL
STD, FFL FFT
D
3
3
S
-
5
,

G
3
3
P
-
5

D
3
5
C
-
5
,

G
3
5
C
-
5

General Section

-51-
Capacity Chart (Without Sideshifter cushion)

NARROW TIRE
MODEL
STD, FFL FFT
G
C
2
0
E
-
5
,

G
C
2
0
P
-
5

G
C
2
5
E
-
5
,

G
C
2
5
P
-
5

G
C
3
0
E
-
5
,

G
C
3
0
P
-
5

General Section

-52-

NARROW TIRE
MODEL
STD, FFL FFT
G
C
3
3
E
-
5
,

G
C
3
3
P
-
5

General Section

-53-

WIDE TIRE
MODEL
STD, FFL FFT
G
C
2
0
E
-
5
,

G
C
2
0
P
-
5

G
C
2
5
E
-
5
,

G
C
2
5
P
-
5

G
C
3
0
E
-
5
,

G
C
3
0
P
-
5

General Section

-54-

WIDE TIRE
MODEL
STD, FFL FFT
G
C
3
3
E
-
5
,

G
C
3
3
P
-
5

General Section

-55-
Capacity Chart (With Sideshifter cushion)

NARROW TIRE
MODEL
STD, FFL FFT
G
C
2
0
E
-
5
,

G
C
2
0
P
-
5

G
C
2
5
E
-
5
,

G
C
2
5
P
-
5

G
C
3
0
E
-
5
,

G
C
3
0
P
-
5

General Section

-56-

NARROW TIRE
MODEL
STD, FFL FFT
G
C
3
3
E
-
5
,

G
C
3
3
P
-
5

General Section

-57-

WIDE TIRE
MODEL
STD, FFL FFT
G
C
2
0
E
-
5
,

G
C
2
0
P
-
5

G
C
2
5
E
-
5
,

G
C
2
5
P
-
5

G
C
3
0
E
-
5
,

G
C
3
0
P
-
5

General Section

-58-

WIDE TIRE
MODEL
STD, FFL FFT
G
C
3
3
E
-
5
,

G
C
3
3
P
-
5

General Section

-59-
Serial Number

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

Lift Truck Serial Number

_____________________________

3.3 liter Diesel Engine (4TNV98) Serial Number

_____________________________

3.3 liter Diesel Engine (4TNE98) Serial Number

_____________________________

2.0 liter Spark-Ignition Engine Serial Number
(G420F(E))

_____________________________

2.4 liter Spark-Ignition Engine Serial Number
(G424F(E))

_____________________________
General Section

-60-

Power Shift Transmission Serial Number

_____________________________

Drive Axle Serial Number

_____________________________

Typical Example

Side Shifter Serial Number (If Equipped)

_____________________________

General Section

-61-
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

General Section

-62-
Operator's Warning and Identification Plate

Familiarize yourself with the OPERATORS WARNING PLATE and IDENTIFICATION, LIFT CAPACITY and
ATTACHMENT PLATES. DO NOT exceed capacity as equipped load ratings.

Operator's Warning Plate

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

If Convenience Package Equipped

Located on the overhead guard.
Identification, Lift Capacity and
Attachment Plate

Located on the cowl to the right side of the steering
column.

Below are abbreviations that may appear on the
IDENTIFICATION, LIFT CAPACITY and
ATTACHMENT 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 - Quadruple (Quad) Mast(with three inner
members)

NOTE: When only a mast-type is listed on the
identification plate, a standard carriage and
forks are used.
Operation Section

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Operators 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 an explanation of their function and location is described on
the following pages.

Diesel (12V)

LPG/GAS (12V)

Operation Section

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1. Engine Oil Pressure Indicator Light -
Indicates insufficient engine oil pressure.
The light will come on when the ignition
switch is turned to the ON position. The
light should go off after the engine is started. If the
light turns on while operating the lift truck,
insufficient engine oil pressure is indicated. Park
the lift truck and stop the engine.

2. Alternator Indicator Light - Indicates if
the battery charging system is operational.
The light will come on when the ignition
switch is turned to the ON position.

The light should go off after the engine is started,
indicating the alternator is producing sufficient
voltage to charge the battery. If the light turns on
with the engine running, check the alternator
charging system for a malfunction.

3. Diesel Engine Start Preheat Indicator
Light - The light will come ON when the
key is turned to the ON position from the
OFF position. This indicates that the glow plugs are
preheating the pre-combustion chambers for easier
starting.

The amount of time needed to preheat the
pre-combustion chambers is approximately seven
seconds, depending on the surrounding air
temperature. When the light goes OFF the
maximum pre-combustion chamber temperature
has been reached and the key can be turned to the
START position to start the engine.

4. Diesel Engine Water in Fuel Filter
Indicator Light - Indicates when the
engine is running, there is water in the fuel
filter exceeds 100cc.

The light will come ON when the ignition switch is
turned to the ON position. The light should go off
after the engine is started. If the light turns on with
the engine running, park the lift truck and stop the
engine.
Drain some fuel (and any water) until clean fuel
flows from the filter which approximately takes 5 to
6 seconds

5. Fuel Level Gauge - Indicates fuel level
(Gas, Diesel, or Dual Fuel Trucks Only)

6. Engine Coolant Temperature Gauge -
Indicates coolant temperature. If both tenth
& ninth flash out of phase while operating
the lift truck, overheating is indicated. Park the lift
truck and stop the engine.

Check the cooling system for a malfunction. Both
tenth & ninth will flash out of phase when the
coolant temperature reaches approximately 106C
(223F) on all engines.

7. Transmission Oil Temperature Gauge
- Indicates transmission oil temperature. If
both tenth & ninth flash out of phase while
operating the lift truck, excessive transmission oil
temperature is indicated. Park the lift truck and stop
the engine.

8. G420F(E)/G424F(E) Engine
Malfunction Indicator Lamp (MIL)
G420F(E) and G424F(E) engine control systems
are equipped with built-in fault diagnostics. Deteted
system faults can be displayed by the Malfunction
Indicator Lamp (MIL) as Diagnostic Fault Codes
(DFC) or flash codes, and viewed in detail with the
use of service tool software. When the ignition key
is turned ON the MIL will perform a self-test,
illuminate once and then go OFF. If a detected falut
condition exists, the fault or faults will be stored in
the memory of the engine control module (ECM).
Once a fault occurs the MIL will illuminate and
remain ON. This signals the operator that a faults
has been detected by the SECM.

9. Seat Belt Warning Light (If
Equipment)
Indicates when the seat belt dose not fastened by
operator.
The light will come on when the ignition switch is
turned to the on position.
The light should go off after engine is started.

10. Service hour Meter - Indicates the
total number of hours the engine and the
lift truck have operated. The hour meter
will operate when the ignition switch is in the ON
position, whether the engine is running or not. The
hour meter is used to determine lubrication and
maintenance intervals.

11. Parking indicator light- The light will
come ON when the parking lever is applied.

12. Front Floodlights- Push down on the
switch(14), to the first step, to turn the front
floodlights on.
Front and Rear Floodlights Push down on the
switch(14), to the second step, to turn both the front
and rear floodlights on. The floodlights are optional.

13. Transmission Neutral Position Light
- Indicates the neutral position of
transmission.

14. Front and Rear Floodlights Switch The
front floodright is ON when push down switch
to the first step.
The front and rear floodlights are ON when push down
switch to the second step.
Operation Section

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15. Low Level Light of LP GAS Indicates
the low Level of LP GAS (LP or DUAL only)

16. Directional Turning Indicator Light

17. Horn Switch - Push on the horn
button to sound the horn.

17
Operation Section

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Electrical Disconnect Switch (If
Equipped)

1. ON - Connects the battery for electrical
power to all electrical circuits.

2. OFF - Disconnects the battery from all
electrical circuits.

Engine Compartment

1. The engine compartment is accessible by pulling
the latch (GC Series), or pushing down the lever
located at cowl (G.D Series) and raising the hood
and seat assembly (Note: Unlock latch before
pulling-if key equipped)

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.

Operation Section

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Seat Switch System (If Equipped)

The lift truck is equipped with a SEAT SWITCH
SYSTEM. In normal operation if the direction lever
is placed in either forward or reverse, the lift truck
will move at a speed proportional to the accelerator
pedal's position. If the operator leavers the seat
without setting the parking brake, within three
seconds after leaving the seat, the SEAT SWITCH
SYSTEM will automatically disengage the
transmission. The directional lever, however, will
remain in that forward or reverse location although
internally the transmission will have shifted into
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.

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.
To restore the lift truck to normal operation, while
sitting in the operator's seat depress the brake
pedal to hold the lift truck, return the directional
lever to the neutral position, and then reselect a
direction of travel (either forward or reverse). The
transmission will then re-engage.
If seat or seat switch replacement becomes
necessary, be sure to use genuine DOOSAN
Infracore lift truck parts. Lift trucks should never be
operated without an operational SEAT SWITCH
SYSTEM.

Operation Section

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

Circuit Breaker

Circuit Breaker -Protects the main
electrical circuits. To reset the circuit
breaker, push the button in. Located in the
engine compartment.

Seat
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
operators back against seat back.

NOTE: The seat can only be correctly adjusted
with the operator fully seated.
Tilt Steering Column

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

Fuel Selector Switch
(G420F(E)/G424F(E) Dual Fuel
Only)

1. LPG - This position supplies electrical
power to the LP fuelock solenoid, when
the ignition switch is in the ON or the
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 through the fuel filter and fuel
pump to the injector.

Operation Section

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Lift Truck Controls

Direction Control Lever

1. Forward - Push the lever forward for
FORWARD direction travel.

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

3. Reverse - Pull the lever back for
REVERSE direction travel.

Transmission Inching Control
Pedal

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.

Service Brake Pedal

Push DOWN on the brake pedal to slow
or stop the lift truck.

RELEASE the brake pedal to allow the lift
truck to move.

Accelerator Pedal

Push DOWN on the pedal to increase
engine rpm (speed).

RELEASE the pedal to decrease engine
rpm (speed).

Operation Section

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Parking Brake Lever

Pull the lever BACK to engage the parking
brake.

Push the lever FORWARD to release the
parking brake.

Lift Control

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 to lower the load.

2. Hold Position - When the lever is
released it will return to the HOLD or center
position. Lifting or lowering action will stop.

3. Lift Position - Pull the lever BACK
smoothly to lift the load.

Tilt Control

1. Mast Tilt Forward - Push the lever
FORWARD smoothly to tilt the mast
forward.

2. Mast Hold - When the lever is released
it will return to the HOLD or center position.
Tilting action will stop.

3. Mast Tilt Back - Pull the lever BACK
smoothly to tilt the mast backward.

Sideshift Attachment (If Equipped)

1. Sideshift Left - Push the lever
FORWARD to shift the carriage to the left.

2. Sideshift Hold - When the lever is
released it will return to the HOLD or
center position. Sideshifting action will
stop.

3. Sideshift Right - Pull the lever BACK to
shift the carriage to the right.
Operation Section

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Refueling

Gasoline or Diesel Engine
Equipped
WARNING
Explosive fumes may be present during
refueling.
Do not smoke in refueling 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
refueling.

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

Do not fill the tank to the top. Fuel expands when it
gets warm and may overflow.

1. Park the lift truck only at a designated safe
location. Place the transmission in NEUTRAL.
Lower the forks to the ground. Engage the
parking brake. Stop the engine.

2. Open the filter cap.

3. Fill the fuel tank slowly. Close the filter cap.
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.
Operation Section

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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
condition.
Examine all LP containers before filling and
again before reuse, for damage to various
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 areas.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to indoor locations.
Stop the engine and get off the lift truck during
refueling.
The careless handling of LP containers can
result in a serious accident.
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.

2. Close the fuel shut off valve at the LP tank. Run
the engine until it stops, then turn off the ignition
switch and the disconnect switch (if equipped).

3. Disconnect the fuel supply line.

If Swing out type LP-Cradle Equipped

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.

Operation Section

-73-

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

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

7. Check to be sure the replacement tank is of the
correct type.

8. Inspect the replacement tank for damage such
as dents, scrapes or gouges and for indication
of leakage at valves or threaded connections.

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.

11. Position the replacement tank so that the
locating pin (dowel) is in place.

WARNING
The LP tank must not extend past the
counterweight

12. Clamp the tank securely.

13. Connect the fuel supply line.

14. Open the fuel valve by slowly turning it
counterclockwise. If the fuel valve is opened 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 and fittings with a soap
solution after filling the tank or when looking for
leaks.

Operation Section

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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.

1. Inspect the operators compartment for loose
items and 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.

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.

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.

10. Inspect the engine compartment for oil, coolant
and fuel leaks.

Operation Section

-75-

11. Measure the engine crankcase oil level with the
dip stick. Maintain the oil level between the
MAX. and MIN., (or FULL and ADD) notches on
the dip stick.

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.

13. Observe the fuel level gauge after starting the
truck. Add fuel if necessary.

WARNING
Personal injury may occur from accidents
caused by improper seat adjustment. Always
adjust the operators seat before starting the lift
truck engine.
Seat adjustment must be done at the beginning
of each shift and when operators change.

14. To position the seat, PUSH the lever away from
the seat track and move the seat forward or
backward to a comfortable position.

Operation Section

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Starting the Engine

Prestart Conditions
NOTE: The engine will not start unless the
transmission directional control lever is in
the NEUTRAL position.

1. Engage the parking brake, if not already
engaged. Place the transmission directional
control lever in the NEUTRAL position.

2. Lift trucks equipped with electrical disconnect
switches; the engine will not start unless the
disconnect switch is in the ON (closed) position.
Gasoline Engine

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. Dont 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.

4. If engine coolant is cold, engine speed could be
higher than low idle speed. Dont drive forklift
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. Dont
press accelerator pedal and turn the Ignition switch
to the START position to start engine.

Operation Section

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LP Engine
WARNING
LP fuel is flammable and can cause personal
injury.
Inspect LP fuel lines and fitting for leaks.
Inspect tank for secure mounting.

1. Turn the tank fuel valve ON by slowly turning
the valve counterclockwise. Observe the LP
gauge (if equipped).

2. Dont press accelerator pedal, and turn the
ignition switch to the START position.

3. Once the engine starts, release the ignition
switch.

4. If the engine does not start, repeat step 2.

5. If engine coolant is cold, engine speed could be
higher than normal low idle speed. Dont drive
forklift until engine speed becomes normal low
idle speed.
Diesel Engine
Starting a Cold Diesel Engine
1. Turn the key to the ON position. The start pre
heat light will come ON. The preheat light will
stay ON approximately seven seconds,
depending on the surrounding air temperature.

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.

Starting a Warm Diesel Engine
1. Turn the key to the ON position and then to
START position, without waiting for the preheat
light to go OFF. At the same time press the
accelerator.

2. Release the key when the engine starts and
release the accelerator pedal to a low idle
position.
Operation Section

-78-
Starting From a 12 Volt External
Source
WARNING
Sparks occurring near the battery could cause
vapors to explode.
Always connect the external power source
ground cable to a point away from and 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.

Operation Section

-79-
Dual Fuel System

Changing From Gasoline to LP
Gas

NOTE: The Underwriters Laboratory (U.L.)
requires that the gasoline tank must be at
least one - quarter full when operating on
LP. This will allow the lift truck to be
restarted on gasoline and moved to an
approved refueling area, when operating in
a hazardous area.

1. Park the lift truck level in an authorized refueling
area with the forks lowered, the parking brake
applied, the transmission in NEUTRAL and the
engine running.

2. Move lever (1), on the fuel selector switch to the
OFF (2) position. Leave lever (1) in this position
until the engine stops.

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

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

5. Turn the ignition switch key to the OFF position
and then to the START position to start the
engine. Release it when the engine starts.

Changing From LP to Gasoline

1. Park the lift truck level in an authorized
refueling area with the forks lowered, the
parking brake applied, the transmission in
NEUTRAL and the engine running.

2. Close the fuel valve on the LP tank. hood open.
1
2
3 4
Operation Section

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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.

6. Turn the ignition switch key to the START
position and start the engine. Release it when
the engine starts.

1
2
3 4
Operation Section

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After Starting the Engine
Observe all indicator lights and gauges frequently
during operation, to make sure all systems are
working properly. The entire indicator lights will
come ON with the ignition switch in the ON position
before the engine is started.

Diesel (12V)

LPG/GAS (12V)

1. The engine oil pressure indicator light (1), will
not come ON with the engine running, unless
there is low or no oil pressure. Stop the engine
immediately, if the light comes ON.

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.

4. The diesel engine water in fuel filter indicator
light(4), will not come ON with the engine
running, unless water in fuel filter exceeds
100cc. Stop the engine immediately and drain
the water if the light comes ON.

5. Observe the fuel level gauge (5) for fuel level
in the tank.

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.

8. Observe the hour meter (8) to make sure it is
operating properly.
8
3
Operation Section

-82-
Lift Truck Operation

Power Shift Transmission/ Drive
axle

1. Start the engine. See topic Starting the
Engine.

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.

4. Select the direction of travel by pushing the
directional lever FORWARD for forward
direction or by pulling the lever BACK for
reverse direction.

WARNING
A lift truck with the engine running but without
an operator can move slowly (creep) if the
transmission is engaged.
This could result in personal injury.
Always place the transmission control lever in
the NEUTRAL (center) position and apply the
parking brake before dismounting the lift truck.

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.

NOTE: Where conditions permit, directional
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 shifts.
Operation Section

-83-

7. To change the lift truck direction of travel,
release the accelerator pedal.

8. Push down on the service brake pedal to
reduce the lift truck speed as necessary.

9. Move the directional lever to the desired
direction of travel. Slowly push down on the
accelerator pedal as the lift truck changes
direction.

10. When the direction change is completed,
continue to push down on the accelerator pedal
to obtain the desired travel speed.

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 stop.
Inching

NOTE: The purpose of the inching pedal is to
provide precise lift truck inching control at
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
the service brakes fully to stop and hold the lift
truck. This will provide full engine power for fast
hydraulic lift.

WARNING
Do not use inching pedal instead of brake
pedal.
It will give wearing to transmission clutch disc.

Operation Section

-84-
Electronic Controlled Spark-Ignition Engines
G420FE Engine and G424FE Engine

EMS (Engine management system) of G420FE
engine and G424FE engine is a closed loop system
utilizing a 3-way catalytic muffler to reduce the
emission level in the exhaust gas. In order to obtain
maximum effect from the catalyst, an accurate
control of the air fuel ratio is required. A small
engine control module (SECM) uses two heated
exhaust gas oxygen sensors (HEGO) in the
exhaust system to monitor exhaust gas content.
One HEGO is installed in front of the catalytic
muffler and one is installed after the catalytic
muffler.

EMS schematic of G420FE Dual fuel engine

The SECM makes any necessary corrections to the
air fuel ratio by controlling the inlet fuel pressure to
the air/fuel mixer by modulating the dual fuel trim
valves (FTV) connected to the regulator. Reducing
the fuel pressure leans the air/fuel mixture and
increasing the fuel pressure enriches the air/fuel
mixture. To calculate any necessary corrections to
the air fuel ratio, the SECM uses a number of
different sensors to gain information about the
engines performance. Engine speed is monitored
by the SECM through a variable reluctance (VR) or
Hall Effect sensor. Intake manifold air temperature
and absolute pressure are monitored with a TMAP
sensor. MI-07 is a drive-by-wire (DBW) system
connecting the accelerator pedal to the electronic
throttle through the electrical harness; mechanical
cables are not used. A throttle position sensor
(TPS) monitors throttle position in relation to the
accelerator pedal position sensor (APP) command.
Even engine coolant temperature and adequate oil
pressure are monitored by the SECM. The SECM
controller has full adaptive learning capabilities,
allowing it to adapt control function as operating
conditions change. Factors such as ambient
temperature, fuel variations, ignition component
wear, clogged air filter, and other operating
variables are compensated.

MPI (multi-point injection) is used for this system.
Fuel injection pressure and flow rate depend on
engine-specific fuel injection requirements. A
variety of regulators and injectors can be used to fit
individual needs. The gasoline fuel pressure
regulator is a one-way, non-return configuration. All
gasoline specific components are automotive
production parts and validated to strict automotive
standards. Four (4) sequential injection channels
are supported.
Operation Section

-85-
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 this 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 to calculate load. Feedback from the electronic throttle is still provided to the SECM by the throttle
position sensors (TPS).

EMS schematic of G420F Dual Fuel engine

Operation Section

-86-
Basic Troubleshooting(LP)

The MI-07 systems are equipped with built-in fault
diagnostics. Detected system faults can be
displayed by the Malfunction Indicator Lamp (MIL)
and are covered in the Advanced Diagnostics
section. Items such as fuel level, plugged fuel
lines, clogged fuel filters and malfunctioning
pressure regulators may not set a fault code by the
Small Engine Control Module (SECM). Below are

basic checks that should be made before referring
to the Advanced Diagnostics section, if engine or
drivability problems are encountered.

Locating a problem in a propane engine is done
exactly the same way as with a gasoline engine.
Consider all parts of the ignition and mechanical
systems as well as the fuel system.

Problem Probable Cause Corrective Action
Fuel container empty Fill fuel container
Do not exceed 80% of liquid
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
the pressure regulator/converter
and the mixer
Check connection
Verify no holes in hose
Clamps must be tight
Look for kinked, pinched and/or
collapsed hose
Fuel Lock-off malfunction Repair/replace Fuel Lock-off
See Engine Service Manual
Pressure regulator/converter
malfunction
Test pressure regulator/converter operation
Incorrect air/fuel or ignition/spark
control
See Advanced Diagnostics
Engine Cranking
but Will Not Start

No VR Sensor Signal Verify the VR signal is present

Operation Section

-87-
Fuel container almost empty LPG Vapor from liquid outlet
Fill fuel container
Do not exceed 80% of liquid capacity
Close liquid valve
Filter replacement
Using caution, disconnect the fuel line
(some propane may escape)
Clear obstruction with compressed air
Slowly open liquid fuel valve
Leak test
and the mixer
Check connection
collapsed hose
Pressure regulator/converter
malfunction
Test pressure regulator/converter operation
Fill fuel container
Air filter clogged Check air filter
Clean/replace as required
Incorrect air/fuel or ignition control See Advanced Diagnostics
Difficult to Start
Engine Mechanical See Engine Service Manual

Operation Section

-88-
Fill fuel container
Close liquid valve
Filter replacement
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
Incorrect idle speed or ignition
problem
Will Not Run
Continuously
Fill fuel container
Will Not
Accelerate/Hesita
tion During
Acceleration
Close liquid valve

Operation Section

-89-
See Maintenance
Section, LP Fuel Filter replacement
and the mixer
Check connection
collapsed hose
Throttle butterfly valve not opening
or sticking
Foot Pedal signal incorrect or
intermittent
Incorrect air/fuel or ignition control
Will Not
Accelerate/Hesita
tion During
Acceleration
Fill fuel container
Close liquid valve
Filter replacement
Engine Stalls
test

Operation Section

-90-
and the mixer
Check connection
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
Verify one pressure hose and one
return hose
Pressure regulator malfunction Test pressure regulator operation
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 Check mixer
Engine Stalls
Engine Mechanical See Engine Manufacturers Service Manual
and the mixer
Check connection
collapsed hose
manifold
head
Rough Idle

Operation Section

-91-
Incorrect Idle speed control
Incorrect timing or spark control
See Advanced Diagnostics & See Engine
Service Manual
Rough Idle
Throttle sticking
Service Manual
High Idle Speed
Foot pedal sticking or incorrect
pedal signal
Check pedal return spring travel for binding
See Maintenance section, Fuel Filter
replacement
test
and the mixer
Check connection
collapsed hose
Restricted exhaust system Check exhaust system
Measure exhaust back pressure
Incorrect ignition control
Incorrect air/fuel control
Poor High Speed
Performance
Incorrect throttle position
Service Manual

Operation Section

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

Operation Section

-93-
Basic Troubleshooting (Gasoline)

Fuel tank empty Fill fuel container
The tank should be at least full to
properly prime the fuel pump.
Fuel select switch is not on GAS
See Maintenance section Primary
and Secondary Fuel Filter replacement
the pressure regulator/ converter
and the mixer (LPG)
Check connection
collapsed hose
Electric Fuel Pump malfunction
(GAS)
Check electrical connection
Check Relay and fuse
Turn key ON and verify pump is operating
Fuel Pressure regulator malfunction Test pressure regulator operation
Fuel Injector malfunction Test Injector operation
Incorrect air/fuel or ignition/ spark
control
Engine Cranking
but Will Not Start
(Gas)

No VR Sensor Signal Verify the VR signal is present

Operation Section

-94-
Fuel tank almost empty Fuel Pump Cavitations
properly prime the fuel pump
Fuel select switch is not on GAS
See Maintenance section, Primary and
Secondary Fuel Filter replacement
(GAS)
Check Relay and fuse Turn key ON
and verify pump is operating
Incorrect air/fuel or ignition control See Advanced Diagnostics
Difficult to Start
(Gas)
Isolate the gasoline system by
running the lift truck on LPG
Verify LPG cylinder is full and valve is open.
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

Will Not Run
Continuously
(Gas)

Operation Section

-95-
(GAS)
Check Relay and fuse Turn key ON
and verify pump is operating

Incorrect idle speed or ignition
problem
Will Not Run
Continuously
(Gas)
below.


Will Not
Accelerate/Hesita
tion During
Acceleration or
Engine Stalls
(Gas)

Operation Section

-96-
Throttle butterfly valve not opening
or sticking
Foot Pedal signal incorrect or
intermittent
Incorrect air/fuel or ignition control
Will Not
Accelerate/Hesita
tion During
Acceleration or
Engine Stalls
(Gas) Engine Mechanical See Engine Service Manual
below.


See Advanced Diagnostics & Service
Manual
Rough Idle (Gas)
manifold
head

Operation Section

-97-
Incorrect timing or spark control
See Advanced Diagnostics & Engine
Service Manual
Rough Idle (Gas)
Throttle sticking
Service Manual
High Idle Speed
(Gas)
Foot pedal sticking or incorrect
pedal signal
Check pedal return spring travel for binding


Operation Section

-98-
below.


See Advanced Diagnostics & Dual Fuel
Engine Service Manual
See Maintenance section, Fuel Filter
replacement
test
and the mixer
Check connection
collapsed hose
Poor High Speed
Performance
(Gas)
See Dual Fuel Engine Service Manual

Restricted exhaust system Check exhaust system
Measure exhaust back pressure
Incorrect ignition control
Incorrect air/fuel control
Poor High Speed
Performance
(Gas)
Incorrect throttle position
Service Manual
Operation Section

-99-
Advanced Diagnostics

MI-07 systems are equipped with built-in fault
diagnostics. Detected system faults can be
displayed by the Malfunction Indicator Lamp (MIL)
as Diagnostic Fault Codes (DFC) or flash codes,
and viewed in detail with the use of the Service Tool
software. When the ignition key is turned on, the MIL
will illuminate and remain on until the engine is
started. Once the engine is started, the MIL lamp will
go out unless one or more fault conditions are
present. If a detected fault condition exists, the fault
or faults will be stored in the memory of the small
engine control module (SECM). Once an active fault
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 (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) has been
detected and the engine has shut down and the MIL
has remained ON. When the codes are displayed
the MIL will flash four times (4), pause, then flash six
times (6), pause, then flash one time (1) This
identifies a four sixty one (461), which is the
ETCSticking fault. If any 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 long
pause then one flash (1), pause, then two flashes
(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.
Displaying Fault Codes (DFC) from
SECM Memory

To enter code display mode you must turn OFF the
ignition key. Now turn ON the key but do not start
the engine. As soon as you turn the key to the ON
position you must cycle the foot pedal by depressing
it to the floor and then fully releasing the pedal
(pedal maneuver). You must fully cycle the foot
pedal three (3) times within five (5) seconds to
enable the display codes feature of the SECM.
Simply turn the key OFF to exit display mode. The
code list will continue to repeat until the key is
turned OFF.

1
Operation Section

-100-
Table 2. MI-07 Diagnostic Fault Codes (Flash Codes)

DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK
12
NONE
Signifies the end of one pass
through the fault list
NONE
None, used as end of the fault list
identification
131
Inj1Open
Gasoline Injector 1 open
circuit, broken injector 1 wire
or defective injector
(1) TurnOnMil
(2) Disable
LiquidO2Ctrl
(3) Delayed
EngineShutdown
Check INJ1 wiring for an open circuit
SECM (Signal) A5 to Injector 1 Pin A
Switched 12V to Injector 1 Pin B
Check Injector 1 Resistance, 12 to14
ohms (cold)
132
Inj2Open
(1) TurnOnMil
(2) Disable
LiquidO2Ctrl
(3) Delayed
EngineShutdown
ohms (cold)
133
Inj3Open
(1) TurnOnMil
(2) Disable
LiquidO2Ctrl
(3) Delayed
EngineShutdown
ohms (cold)
134
Inj4Open
(1) TurnOnMil
(2) Disable
LiquidO2Ctrl
(3) Delayed
EngineShutdown
Check Injector 4 Resistance, 12 to 14
ohms (cold)
141
(14)
ECTRangeLow
Coolant Sensor failure or
shorted to GND
(1) TurnOnMil
(2) DelayedEngine
Shutdown
Check ECT sensor connector and wiring
for a short to GND
SECM (Signal) Pin B15 To ECT Pin 3
SECM (Sensor GND) Pin B1 to ECT Pin 1
SECM (System GND) Pin A16, B17
151
(15)
ECTRangeHigh
Coolant sensor disconnected
or open circuit
(1) TurnOnMil
(2) DelayedEngine
Shutdown
Check if ECT sensor connector is
disconnected or for an open ECT circuit
SECM (Signal) Pin B15 to ECT Pin 3

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

Operation Section

-101-
Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) contd.

161
(16)
ECTOverTempFault
Engine coolant temperature is
high. The sensor has
measured an excessive
coolant temperature typically
due to the engine overheating.
(1) TurnOnMil
(2) DelayedEngine
Shutdown
Check coolant system for radiator
blockage, proper coolant level and for
leaks in the system.
Possible ECT short to GND, check ECT
signal wiring
SECM (Signal) Pin B15 to ECT Pin 3
SECM (System GND) Pin A16, B17
Check regulator for coolant leaks
171
ECT_IR_Fault
Engine coolant temperature
not changing as expected
TurnOnMil
Check for coolant system problems, e.g.
defective or stuck thermostat
181
FuelSelectConflict
Conflict in fuel select signals,
normally set if both of the fuel
select signals are shorted to
ground
(1) TurnOnMil
(2) Delayed
EngineShutdown
Check fuel select switch connection for a
short to GND
SECM (SIGNAL) Pin A12
SECM (SIGNAL) Pin A15
SECM (Sensor GND) Pin B1
191
CamEdgesFault
No CAM signal when engine is
known to be rotating, broken
crankshaft sensor leads or
defective CAM sensor
None
Check CAM sensor connections
SECM (SIGNAL) Pin B10 to CAM sensor
Pin 2
SECM (Sensor GND) Pin B1 to CAM
sensor Pin 3
Switched 12V to CAM sensor Pin 1
Check for defective CAM sensor
192
CamSyncFault
Loss of synchronization on the
CAM sensor, normally due to
noise on the signal or an
intermittent connection on the
CAM sensor
None
Check CAM sensor connections
SECM (SIGNAL) Pin B10 to CAM sensor
Pin 2
SECM (Sensor GND) Pin B1 to CAM
sensor Pin 3
Switched 12V to CAM sensor Pin 1
Check for defective CAM sensor
193
CrankEdgesFault
No crankshaft signal when
engine is known to be rotating,
broken crankshaft sensor
leads or defective crank
sensor
None
Check Crankshaft sensor connections
SECM (SIGNAL) Pin B5 to Crank sensor
Pin 3
SECM (Sensor GND) PIN B1 to Crank
sensor Pin 2
Switched 12V to Crank sensor Pin 1
Check for defective Crank sensor
194
CrankSyncFault
Loss of synchronization on the
crankshaft sensor, normally
due to noise on the signal or
an intermittent connection on
the crankshaft sensor
None
Check Crankshaft sensor connections
SECM (SIGNAL) Pin B5 to Crank sensor
Pin 3
SECM (Sensor GND) Pin B1 to Crank
sensor Pin 2
Switched 12V to Crank sensor Pin 1
Check for defective Crank sensor


Operation Section

-102-
Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) contd.

221
(22)
TPS1RangeLow
TPS1 sensor voltage out of
range low, normally set if the
TPS1 signal has shorted to
ground, circuit has opened or
sensor has failed
(1) TurnOnMil
(2) CutThrottle
Check throttle connector connection and
TPS1 sensor for an open circuit or short to
GND
SECM Pin B23 (signal) to ETC Pin 6
SECM Pin B1 (sensor GND) to ETC Pin 2
SECM (system GND) Pin A16, B17
222
TPS2RangeLow
range low, normally set if the
ground, circuit has opened or
sensor has failed
(1) TurnOnMil
(2) CutThrottle
Check throttle connector connection and
TPS2 sensor for an open circuit or short to
GND
231
(23)
TPS1RangeHigh
range high, normally set if the
power or the ground for the
sensor has opened
(1) TurnOnMil
(2) CutThrottle
Check throttle connector and TPS1 sensor
wiring for a shorted circuit
232
TPS2RangeHigh
range high, normally set if the
power or the ground for the
sensor has opened
(1) TurnOnMil
(2) CutThrottle
Check throttle connector and TPS1 sensor
wiring for a shorted circuit
SECM pin B1 (sensor GND) to ETC Pin 2
241
(24)
TPS1AdaptLoMin
Learned closed throttle end of
TPS1 sensor range lower than
expected
None N/A
242
TPS2AdaptLoMin
TPS2 sensor range lower than
expected
None N/A
251
(25)
TPS1AdaptHiMax
Learned WOT end of TPS1
sensor range higher than
expected
None N/A
252
TPS2AdaptHiMax
sensor range higher than
expected
None N/A
271
TPS1AdaptHiMin
sensor range lower than
expected
None N/A

Operation Section

-103-
Table 2. Diagnostic Fault Codes (Flash Codes) contd.

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


Operation Section

-104-

341
(34)
MAPTimeRangeHigh
Sensor Input is High, normally
signal wire has become
shorted to power, shorted to
the IAT signal, the TMAP has
failed or the SECM has failed.
TurnOnMil
Check TMAP connector and MAP signal wiring
for a shorted circuit
TMAP Pin 3 to SECM Pin B24 (XDRP +5 Vdc)
Check the MAP sensor by disconnect-ing the
TMAP connector and measuring at the sensor:
TMAP Pin 1(GND) to
342
MAPRangeHigh
Sensor Input is High, normally
signal wire has become
shorted to power, shorted to
the IAT signal, the TMAP has
failed or the SECM has failed
(1) TurnOnMil
(2) Engine
Shutdown
Check TMAP connector and MAP signal wiring
TMAP Pin 3 to SECM Pin B24 (XDRP +5 Vdc)
Check the MAP sensor by disconnecting the
TMAP connector and measuring at the sensor:
TMAP Pin 1(GND) to
351
MAP_IR_HI
MAP sensor indicates higher
pressure than expected
TurnOnMil
Check for vacuum leaks. Check that TMAP
sensor is mounted properly. Possible defective
TMAP sensor.
352
MAP_IR_LO
MAP sensor indicates lower
pressure than expected
TurnOnMil Possible defective TMAP sensor.
353
MAP_STICKING
MAP sensor not changing as
expected
TurnOnMil
Check that TMAP sensor is mounted properly.
Possible defective TMAP sensor.
371
(37)
IATRangeLow
Intake Air Temperature
Sensor Input is Low normally
set if the IAT temperature
sensor wire has shorted to
chassis ground or the sensor
has failed.
TurnOnMil
Check TMAP connector and IAT signal wiring
To check the IAT sensor of the TMAP
disconnect the TMAP connector and measure
the IAT resistance
Resistance is approx 2400 ohms at room
temperature.


Operation Section

-105-

381
(38)
IATRangeHigh
Intake Air Temperature
Sensor Input is High normally
set if the IAT temperature
sensor wire has been
disconnected or the circuit has
opened to the SECM.
TurnOnMil
Check TMAP connector and IAT signal wiring
To check the IAT sensor of the TMAP
disconnect the TMAP connector and measure
the IAT resistance
Resistance is approx 2400 ohms at room
temperature.
391
IAT_IR_Fault
Intake Air Temperature not
changing as expected
None
Check connections to TMAP sensor. Check
that TMAP sensor is properly mounted to
manifold.
421
EST1_Open
EST1 output open, possibly
open EST1 signal or defective
spark module
TurnOnMil
Check coil driver wiring and connector for open
circuit
SECM Pin A9 (EST1) to OEM ignition system.
See application note.
Verify GND on ignition module
Pin A (of both connectors)
Verify +12 Vdc on ignition module
Pin B (of both connectors)
Refer to application manual for specific engine
details.
422
EST2_Open
spark module
TurnOnMil
circuit
SECM Pin A10 (EST2) to OEM ignition
system. See application note.
details.
423
EST3_Open
spark module
TurnOnMil
circuit
SECM Pin A3 (EST3) to OEM ignition system.
See application note.
details.


Operation Section

-106-

424
EST4_Open
spark module
TurnOnMil
Check coil driver wiring and connector for
open circuit
SECM Pin A6 (EST4) to OEM ignition
system. See application manual.
Refer to application manual for specific
engine details.
425

EST5_Open
spark module
None N/A
426

EST6_Open
spark module
None N/A
427
EST7_Open
spark module
None N/A
428
EST8_Open
spark module
None N/A
431
EST1_Short
EST1 output shorted high or
low, EST1 signal shorted to
ground or power or defective
spark module
None N/A


Operation Section

-107-

432
EST2_Short
spark module
None N/A
433
EST3_Short
spark module
None N/A
434
EST4_Short
spark module
None N/A
435
EST5_Short
spark module
None N/A
436
EST6_Short
spark module
None N/A


Operation Section

-108-

437
EST7_Short
spark module
None N/A
438
EST8_Short
spark module
None N/A
461
(26)
ETC_Sticking
Electronic Throttle Control is
sticking. This can occur if the
throttle plate (butterfly valve)
inside the throttle bore is
sticking. The plate sticking can
be due to some type of
obstruction, a loose throttle
plate, or worn components shaft
bearings.
NOTE: The throttle assembly
is not a serviceable item and
can only be repaired by
assembly.
(1) TurnOnMil
(2) EngineShutdown
(3) CutThrottle
Check for debris or obstructions inside
the throttle body
Perform the throttle test using the
Service Tool and re-check for fault
Check throttle-plate shaft for bearing
wear
Check the ETC driver wiring for an
open circuit
SECM Pin A17 to ETC + Pin 1
SECM Pin A18 to ETC - Pin 4
Check the ETC internal motor drive by
disconnecting the throttle connector and
measuring the motor drive resistance at
the throttle
TPS Pin 1 (+DRIVER) to
Pin 4 (-DRIVER) ~3.0-4.0
471
ETC_Open_Fault
Electronic Throttle Control Driver
has failed, normally set if driver
signals have failed open or
become disconnected,
electronic throttle or SECM is
defective.
(1) TurnOnMil
(2) CutThrottle

Check the ETC driver wiring for an open
circuit
measuring the motor drive resistance at
the throttle
Pin 4 (-DRIVER) ~3.0-4.0
481
(28)
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
the return spring has lost tension
the throttle will fail the test and
set the fault.
NOTE: The throttle assembly
is not a serviceable item and
can only be repaired by
assembly.
(1) TurnOnMil
(2) EngineShutdown
(3) CutThrottle
Perform throttle spring test by cycling
the ignition key and re-check for fault


Operation Section

-109-

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


Operation Section

-110-

551
(55)
SensVoltRangeLow
Sensor reference voltage
XDRP too low
(1) TurnOnMil
(2) DelayedEngine
Shutdown

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
SECM with a multimeter
SECM Pin B24 +5 Vdc to SECM
Pin B1 XDRG GND
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.
561
(56)
SensVoltRangeHigh
Sensor reference voltage
XDRP too high
(1) TurnOnMil
(2) DelayedEngine
Shutdown

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
SECM with a multimeter
SECM Pin B24 +5 Vdc to
SECM Pin B1 XDRG GND
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.
571
(57)
HardOverspeed
Engine speed has
exceeded the third level (3
of 3) of overspeed
protection
(1) TurnOnMil
(2) HardRevLimit
(3) EngineShutdown
Usually associated with additional ETC faults
Check for ETC Sticking or other ETC faults
Verify if the lift truck was motored down a steep
grade
572
MediumOverspeed
Engine speed has
exceeded the second level
(2 of 3) of overspeed
protection
(1) TurnOnMil
(2) MediumRevLimit
(3) DelayedEngine
Shutdown
grade
573
SoftOverspeed
Engine speed has
exceeded the first level (1
of 3) of overspeed
protection
(1) TurnOnMil
(2) SoftRevLimit
grade
611
(61)
APP1RangeLow
APP1 sensor voltage out
of range low, normally set
if the APP1 signal has
shorted to ground, circuit
has opened or sensor has
failed
TurnOnMil

Check foot pedal connector
Check APP1 signal at SECM PIN B7


Operation Section

-111-

DFC PROBABLE FAULT FAULT ACTION *
CORRECTIVE ACTION FIRST
CHECK
612
(65)
APP2RangeLow
APP2 sensor voltage out of range
low, normally set if the APP2 signal
has shorted to ground, circuit has
opened or sensor has failed
TurnOnMil
Check APP2 signal at SECM PIN
B16
621
(62)
APP1RangeHigh
high, normally set if the APP1 signal
has shorted to power or the ground
for the sensor has opened
TurnOnMil

B7
622
(66)
APP2RangeHigh
high, normally set if the APP2 signal
has shorted to power or the ground
for the sensor has opened
TurnOnMil
B16
631
(63)
APP1AdaptLoMin
Learned idle end of APP1 sensor
range lower than expected
TurnOnMil
Check APP connector and pins for
corrosion
Cycle the pedal several times and
check APP1 signal at SECM Pin
B7
632
(67)
APP2AdaptLoMin
range lower than expected
TurnOnMil
corrosion
B16
641
(64)
APP1AdaptHiMax
Learned full pedal end of APP1
sensor range higher than expected
TurnOnMil
corrosion
check APP1 signal at SECM Pin B7
642
(68)
APP2AdaptHiMax
sensor range higher than expected
TurnOnMil
corrosion
651
APP1AdaptHiMin
sensor range lower than expected
TurnOnMil
corrosion
652
APP2AdaptHiMin
sensor range lower than expected
TurnOnMil
corrosion
661
APP1AdaptLoMax
range higher than expected
TurnOnMil
corrosion
662
APP2AdaptLoMax
range higher than expected
TurnOnMil
corrosion
691
(69)
APP_Sensors_Conflict
APP position sensors do no not track
well, intermittent connections to APP
or defective pedal assembly
(1) TurnOnMil
(2) Cut Throttle
corrosion
B7
B16

Operation Section

-112-

711
(71)
LSDFault_Dither1
Dither Valve 1 Fault, signal
has opened or shorted to
dither 1 valve
(1) TurnOnMil
(2) Disable
GasO2 Ctrl
(3) Disable
GasPost O2Ctrl
Check FTV1 for an open wire or FTV connector
being disconnected
FTV1 Pin 1 (signal) to SECM Pin A1
FTV1 Pin 2 (power) to SECM (DRVP) Pin A23
Check FTV1 for an open coil by disconnecting
the FTV connector and measuring the
resistance (~26 2 )
712
LSDFault_Dither2
Dither Valve 2 Fault, signal
dither 2 valve
(1) TurnOnMil
(2) Disable
GasO2 Ctrl
(3) Disable
GasPost O2Ctrl
Check FTV1 for an open wire or FTV connector
being disconnected or signal shorted to GND
FTV2 Pin 1 (signal) to SECM Pin A2
FTV2 Pin 2 (power) to SECM (DRVP) Pin A23
Check FTV1 for an open coil by disconnecting
the FTV connector and measuring the
resistance (~26 2 )
713 LSDFault_CSValve None N/A
714
LSDFault_CheckEngine
Check Engine Lamp Fault,
signal has opened or shorted
to ground or power or
defective check engine lamp
None
Check Check Engine Lamp for an open wire or
shorted to GND
715
LSDFault_CrankDisable
Crank Disable Fault, signal
crank disable relay
None N/A
716
LSDFault_FuelPump
Fuel pump fault, signal has
opened, shorted to ground or
power, or defective fuel
pump
TurnOnMil
Check fuel pump for an open wire or connector
being disconnected or signal shorted to GND
Fuel Pump Pin B (signal) from SECM Pin A13
Fuel Pump Pin A (power) from main relay 1 Pin
A23
Check Fuel Pump for an open coil by
disconnecting the Fuel Pump connector and
measuring the resistance
(~26 3)
Check for 12V to fuel pump
717
LSDFault_LockOff
Fuel lock off Valve Fault,
signal has opened or shorted
to ground or power or
defective Fuel lock off valve
TurnOnMil
Check fuel lock off valve for an open wire or
connector being disconnected or signal shorted
to GND
Lock off Pin B (signal) from SECM Pin A11
Lock off Pin A (power) from main relay 1 Pin
A23
Check lock off valve for an open coil by
disconnecting the lock off valve connector and
measuring the resistance (~26 3)
Check for 12V to lock off valve
718
LSDFault_MIL
Malfunction Indicator Lamp
Fault, signal has opened or
shorted to ground or power
or defective MIL lamp
None None
721
(72)
GasFuelAdaptRangeLo
In LPG mode, system had to
adapt rich more than
expected
(1) TurnOnMil
(2) Disable
GasO2 Ctrl
(3) Disable
GasPost O2Ctrl
Check for vacuum leaks.
Check fuel trim valves, e.g. leaking valve or
hose
Check for missing orifice(s).
722
GasDesEquivLo
In LPG mode, system had to
adapt rich more than
expected
None N/A
Operation Section

-113-

731
(73)
GasFuelAdaptRangeHi
In LPG mode, system had
to adapt lean more than
expected
(1) TurnOnMil
(2) Disable
GasO2 Ctrl
(3) Disable
GasPost O2Ctrl
Check dual dither valves, e.g. plugged valve or
hose.
Check for plugged orifice(s).
732
GasDesEquivHi
In LPG mode, system had
to adapt rich more than
expected
None N/A
741
(74)
GasO2NotActive
Pre-catalyst O2 sensor
inactive on LPG, open O2
sensor signal or heater
leads, defective O2
sensor
(1) TurnOnMil
(2) DisableGas
O2Ctrl
(3) Disable
GasPost O2Ctrl
Check that Pre-catalyst O2 sensor connections
are OK.
O2 (signal) Pin 3 to SECM Pin B13
O2 Pin 2 (HEATER GND) to SECM (DRVG
GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to SECM (DRVP +
12V) Pin A23
Verify O2 sensor heater circuit is operating by
measuring heater resistance (2.1 0.4)
O2 Pin 2 (HEATER GND) to Pin 1 (HEATER
PWR)
742
GasPostO2NotActive
Post-catalyst O2 sensor
inactive on LPG, open O2
sensor signal or heater
leads, defective O2
sensor.
(1) TurnOnMil
(2) DisableGasPost
O2Ctrl
Check that Post-catalyst O2 sensor
connections are OK.
GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2 Heater
Relay. Relay pin 87. This relay only turns on
after engine has been running for some time
and SECM has calculated that water
condensation in exhaust has been removed by
exhaust heat. Post O2 Heater Relay has
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.
PWR)
743 GasCatInactive None N/A
751
GasO2FailedLean
indicates extended lean
operation on LPG
(1) TurnOnMil
(2) DisableGas
O2Ctrl
(3) Disable
GasPost O2Ctrl
Check dual dither valves, e.g. leaking valve or
hose.
Check for missing orifice(s).
752
GasPostO2FailedLean
operation on LPG
(1) TurnOnMil
(2) DisableGasPost
O2Ctrl
Correct other faults that may contribute to 752
(e.g. faults pertaining to dither valves, Pre-Cat
O2, Post Cat O2 sensor)
Check for vacuum leaks
Check for leaks in exhaust, catalytic converter,
HEGO sensors; repair leaks.
Check all sensor connections (see fault 742
corrective actions).
771
(77)
GasO2FailedRich
indicates extended rich
operation on LPG
(1) TurnOnMil
(2) DisableGas
O2Ctrl
(3) DisableGasPost
O2Ctrl
Check dual dither valves, e.g. plugged valve or
hose.
Check for plugged orifice(s).
Operation Section

-114-

772
GasPostO2FailedRich
operation on LPG
(1) TurnOnMil
(2) DisableGasPost
O2Ctrl
(e.g. faults pertaining to FTVs, Pre-Cat O2,
Post Cat O2 sensor)
Look for leaks in exhaust, catalytic converter,
821
LiqFuelAdaptRangeHi
In Gasoline mode, system
had to adapt lean more
than expected
(1) TurnOnMil
(2) Disable
LiquidO2 Ctrl
(3) Disable LiqPost
O2Ctrl
Low gasoline fuel pressure, perform gasoline
pressure test.
Injector problems, e.g. plugged, defective
injector.
822 LiqDesEquivHi None N/A
831
LiqFuelAdaptRangeLow
In Gasoline mode, system
had to adapt rich more than
expected
(1) TurnOnMil
(2) Disable
LiquidO2 Ctrl
(3) Disable LiqPost
O2Ctrl
pressure test
Injector problems, e.g. leaking, defective
injector.
832 LiqDesEquivLo None N/A
841
LiqO2NotActive
inactive on gasoline, open
O2 sensor signal or heater
leads, defective O2 sensor
(1) TurnOnMil
(2) DisableLiquid
O2Ctrl
Check that Pre-catalyst O2 sensor connections
are OK.
GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to SECM (DRVP +
12V) PIN A23
PWR)
842
LiqPostO2NotActive
inactive on gasoline, open
O2 sensor signal or heater
leads, defective O2 sensor.
(1) TurnOnMil
(2) DisableLiqPost
O2Ctrl
Check that Post-catalyst O2 sensor
connections are OK.
GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2 Heater
Relay. Relay pin 87. This relay only turns on
after engine has been running for some time
and SECM has calculated that water
condensation in exhaust has been removed by
exhaust heat. Post O2 Heater Relay has
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.
PWR)
843 LiqCatInactive None N/A
851
LiqO2FailedLean
operation on gasoline
(1) TurnOnMil
(2) DisableLiquid
O2Ctrl
pressure test.
Injector problems, e.g. plugged, defective
injector

Operation Section

-115-

852
LiqPostO2FailedLean
(1) TurnOnMil
(2) DisableLiqPost
O2Ctrl
(e.g. faults pertaining to Injectors, MAP, IAT,
Pre-Cat O2, Post Cat O2 sensor)
871
LiqO2FailedRich
(1) TurnOnMil
(2) DisableLiquid
O2Ctrl
High gasoline fuel pressure, perform gasoline
pressure test
Injector problems, e.g. leaking, defective injector
872
LiqPostO2FailedRich
(1) TurnOnMil
(2) DisableLiq
PostO2Ctrl
(e.g. faults pertaining to Injectors, MAP, IAT,
Pre-Cat O2, Post Cat O2 sensor)
911
O2RangeLow
voltage out of range low,
sensor signal shorted to
ground
None N/A
912
O2_PostCatRangeLow
ground
None N/A
921
O2RangeHigh
voltage out of range high,
power
(1) TurnOnMil
(2) DisableLiquid O2Ctrl
(3) DisableGas
O2Ctrl
Check if O2 sensor installed before catalyst is
shorted to +5Vdc or battery.
SECM (XDRP + 5V) Pin B24
SECM (DRVP + 12V) Pin A23
922
O2_PostCatRangeHigh
ground
(1) TurnOnMil
(2) Disable asoline
Post-catalyst
O2Ctrl
(3) Disable LPG
Post-catalyst
O2Ctrl
Check if O2 sensor installed after catalyst is
shorted to +5Vdc or battery.
Possible voltage sources: SECM (XDRP + 5V)
Pin B24 and SECM (DRVP + 12V) Pin A23
931
FuelTempRangeLow
Fuel Temperature Sensor
Input is Low normally set if
the fuel temperature
sensor wire has shorted to
chassis ground or the
sensor has failed.
TurnOnMil
Check fuel temp sensor connector and wiring for
a short to GND
SECM (signal) Pin B14 to FTS Pin 1
SECM (sensor GND) Pin B1 to FTS Pin 2
932
FuelTempRangeHigh
Fuel Temperature Sensor
Input is High normally set if
the fuel temperature
sensor wire has been
disconnected or the circuit
has opened to the SECM.
TurnOnMil
Check if fuel temp sensor connector is
disconnected or for an open FTS circuit
SECM (signal) Pin B14 to FTS Pin 1
SECM (sensor GND) Pin B1 to
FTS Pin 2

Operation Section

-116-

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


Operation Section

-117-
Mono-Ped Control System (Option)

Forward-Push the left side (2) of the pedal
for FORWARD direction travel.

Neutral-The lift truck should not move when
the Mono-Ped pedal is released..

Reverse-Push the right side (1) of the pedal
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 in FORWARD.
The speed of the truck increases as the pedal is
depressed

Operation Section

-118-
Auto Shift Controller ASC-100 (If Equipped)

Product Description
The Autoshift controller is an electrical control
system, specially designed for use on forklift trucks
with internal combustion engines.
Its primary purpose is to prevent the operator from
driving the truck outside of the design parameters,
e.g. selecting the reverse gear when traveling in
excess of 5.1 km/h ( 3.17 mph) in a forward
direction, and vice versa.

The Autoshift controller is mounted on a convenient
position away from excessive heat sources and the
trucks electrical system is retrofitted. An inductive
speed sensor is mounted on the differential housing
where it will pick up a pulse from a yoke tooth
pattern. This pulse is used to monitor the truck in
motion and its travel speed. To enable the system
to change gears smoothly, the shift points for offset
speed are adjustable.

The Autoshift controller prevents strain and abuse
to the transmission. It also prevents damage to the
half shaft, excessive tire wear and heat to the
transmission.

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. For
safe operation, carefully read and follow this
Operation and Maintenance Manual.

Adjustments
SW2
(Direction Inhibit Point)
NOTCH Vehicle Speed
0 3.3 km/h ( 2.05 mph )
1 3.6 km/h ( 2.24 mph )
2 3.9 km/h ( 2.42 mph )
3 4.2 km/h ( 2.61 mph )
4 4.5 km/h ( 2.80 mph )
5 4.8 km/h ( 2.98 mph )
6 5.1 km/h ( 3.17 mph )
7 5.4 km/h ( 3.36 mph )
8 5.7 km/h ( 3.54 mph )
9 6.0 km/h ( 3.73 mph )

Direction Inhibit Point
This is accomplished on each machine with a
factory - adjusted controller.

The SW2 is for adjustment of optimal direction
inhibit speed.

Factory - setting value is 5.1 km/h ( 3.17 mph )

SW1 is not used.

Adjustment Switch
Operation Section

-119-
Diagnostics Features
ASC-100 has an internal indicator on the right side
of the controller for displaying the selected gear
and the abnormal condition.

Below is a description applicable for many ASC-
100 implementations.

Display for Operator
This information is given during normal operating
when something special happens.
For example, on ASC-100s with the speed sensor,
one of the indicators is used to indicate a sensor
problem.

Display Description Remark
A Automatic operation
P Speed sensor open Flashing
F Controller fault Flashing
6 Forward Sol. Short Flashing
7 Reverse Sol. Short Flashing

Display for Troubleshooting
This information is input signal for diagnostics.
This test is used to verify an operation of direction
control lever.

Display Description Remark
A Automatic operation
3 Forward s/w input Lever input test
4 Reverse s/w input Lever input test

Operation
This system can basically operate in 2 pre-selected
modes.
Automatic mode (Direction Inhibit mode):
Selected as factory-setting.
Manual mode (Fail-Safe mode): manual
operation in emergency.

Automatic mode (Direction Inhibit
mode)
Start the engine. See topic Starting the engine.
Push down on the service brake pedal to hold the
lift truck until ready to move it.
Release the parking brake.
Check diagnostics display on controller. See
Diagnostics Features.

NOTICE
The parking brake must be released before the
direction control lever can be used.

The gear direction is selected with the direction
control lever.
In automatic mode, if the turbine speed in a for
ward direction is higher than direction inhibit
speed, though the reverse gear is selected by
operator, the direction of travel will not be
changed until the speed is reduced sufficiently by
pushing down on the service brake pedal.

WARNING
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 trucks 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.
Operation Section

-120-
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 Circuit Board).

Fail-Safe mode switch

NOTICE
Direction Inhibit Function is usable in factory-setting
controller. If you dont want to use this function,
make sure to select the manual mode with the
Fail-Safe mode switch on PCB.

Operation Section

-121-
Operating Techniques

Inching into Loads

Typical Example

1. Move the lift truck slowly FORWARD into
position and engage the load. The lift truck
should be square with load, forks spaced
evenly between pallet stringers and as far apart
as load permits.

Typical Example

2. Move the lift truck FORWARD until the load
touches the carriage.
Lifting the Load
1. Lift the load carefully and tilt the mast back a
short distance.

Typical Example

2. Tilt the mast further back to cradle the load.

Typical Example

3. Operate the lift truck in reverse until the load is
clear of the other material.

4. Lower the cradled load to the travel position.

NOTE: Lift and tilt speeds are controlled by engine
rpm.

Operation Section

-122-
Traveling With the Load

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

Typical Example

1. Travel with the load uphill on upgrades and
downgrades.

Typical Example

2. For better vision, travel in reverse with bulky
loads.
Unloading

Typical Example

1. Move the lift truck into the unloading position.

Typical Example

2. Tilt the mast FORWARD only when directly
over the unloading area.

WARNING
Do not tilt the mast forward with the load unless
directly over the unloading area, even if the
power is off.

Operation Section

-123-

Typical Example

3. Deposit the load and BACK away carefully to
disengage the forks.

Typical Example

4. Lower the carriage and forks to the travel
position or to the park position.
Turning

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

2. In narrow aisles, keep away from the stockpile
when turning into the aisle. Allow for counter
weight swing.

Operation Section

-124-
Lifting Drums or Round Objects

1. Block drums or round objects. Tilt the mast
FORWARD and slide the fork tips along the
floor to get under the load.

2. Before lifting, tilt the mast BACK slightly until
the load is cradled on the forks.
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 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
opening engine hood until temperature falls
before shutting off the engine.

Operation Section

-125-
Parking the Lift Truck

NOTE: Park the lift truck level with the fork lowered
and the mast tilted forward until the fork
touches the floor. Block the drive wheels
when parking on an incline.

1. Park in an authorized area only. Do not block
traffic. If LP equipped, do not park near elevator
shafts or any other area where LP could collect
in a pocket (low area), causing a potentially
dangerous condition.

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
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.

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

NOTE: If a LP equipped lift truck is stopped or
parked for an indefinite or prolonged
period of time, shut off the LP fuel tank
valve.

6. Actuate each loading lever several times to
remove the residual pressure in the respective
cylinders and hoses.

If Parking Brake Alarm Equipped

WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied.
Alarm will sound if parking brake is not applied.

Operation Section

-126-
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 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 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.

Operation Section

-127-
Storage Information

Before Storage
Before storing your lift truck, clean and inspect as
the following procedures.

Wipe away grease, oil, etc. adhering to the body
of the truck with waste cloth, and use water, if
needed.
While cleaning the truck, check general condition
of the truck. Especially check the truck body for
dents or damage and tires for wear or nails or
stones in the tread.
Fill the fuel tank with fuel specified.
Check for leakage of hydraulic oil, engine oil, fuel,
or coolant, etc.
Apply grease, where needed.
Check for looseness of nuts and bolts, especially
hub nuts.
Check mast rollers to see that they rotate
smoothly.
Prime the oil into the lift cylinders by actuating the
lift lever all the way several times.
Drain off coolant completely in cold weather, if
antifreeze 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.
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.
Apply antirust to the exposed parts which tend to
rust.
Cover components such as the breather and air
cleaner which may be caught with 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.
To Operate the Lift Truck after a
Long Time Storage
Remove covers and antirust from each of the
components and exposed parts.
Drain the engine crankcase, transmission (clutch
type machine), differential and final reduction
gear, clean the inside of them and add new oil.
Drain off foreign matter and water from the
hydraulic oil tank and fuel tank.
Remove the head cover from the engine cylinder.
Oil valves and rocker shaft and check each valve
for proper operation.
Add cooling water to the specified level.
Charge the battery and mount it on the machine.
Connect the cables.
Perform pre - operational checks carefully. (refer
to Before Starting the Engine)
Warm up the machine.

Operation Section

-128-
Transportation Hints

Lift Truck Shipping
Check travel route for overpass clearances. Make
sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
overhead guard or cab.

To prevent the lift truck from slipping while loading,
or shifting in transit, remove ice, snow or other
slippery material from the loading dock and the
truck bed before loading.

NOTICE
Obey all state and local laws governing the height,
weight, width and length of a load.
Observe all regulations governing wide loads.

NOTICE
Remove ice, snow or other slippery material from
the shipping vehicle and the loading dock.

Always block the trailer or the rail car wheels 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.

Machine Lifting and Tiedown
Information

NOTICE
Improper lifting or tiedowns can allow load to shift
and cause injury and/or damage.

1. Weight and instructions given herein apply to lift
trucks as manufactured by DOOSAN.

2. Use proper rated cables and slings for lifting.
Position the crane for level lift truck lift.

3. Spreader bar widths should be sufficient to
prevent contact with the lift truck.

4. Use the tiedown locations provided for lift truck
tiedown.

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.

Operation Section

-129-
Towing Information

WARNING
Personal injury or death could result when
towing a disabled lift truck incorrectly.
Block the lift truck wheels to prevent movement
before releasing the brakes. The lift 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.

Shield must be provided on the towing lift truck to
protect the operator if the tow line or bar should
break.

Do not allow riders on the lift truck being towed
unless the operator can control the steering and/or
braking.

Before towing, make sure the tow line or bar is in
good condition and has enough strength for the
towing situation involved. Use a towing line or bar
with a strength of at least 1.5 times the gross
weight of the towing lift truck for a disabled lift truck
stuck in the mud or when towing on a grade.

Keep the tow line angle to a minimum. Do not
exceed a 30angle from the straight ahead position.
Connect the tow line as low as possible on the lift
truck that is being towed.

Quick lift truck movement could overload the tow
line or bar and cause it to break. Gradual and
smooth lift truck movement will work better.

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 downhill, 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 conditions.

Consult your DOOSAN Lift Tuck dealer for towing a
disabled lift truck.

1. Release the parking brake.

NOTICE
Release the parking brake to prevent excessive
wear and damage to the parking brake system.

2. Check that the service brake pedal is released.

3. Key switch is in the OFF position.

4. Direction control lever is in neutral.

5. Fasten the tow bar to the lift truck.

6. Remove the wheel blocks. Tow the lift truck
slowly. Do not tow any faster than 2 km/h (1.2
mph).

WARNING
Be sure all necessary repairs and adjustments
have been made before a lift truck that has been
towed to a service area is put back into
operation.

Maintenance Section

-130-
Inspection, Maintenance and Repair of Lift Truck Forks

The following section gives practical guidelines for
inspection, maintenance and repair of lift truck forks.
It also provides general information on the design
and application of forks and the common cause of
fork failures.

Lift truck forks can be dangerously weakened by
improper repair or modification. They can also be
damaged by the cumulative effects of age, abrasion,
corrosion, overloading and misuse.
A fork failure during use can cause damage to the
equipment and the load. A fork failure can also
cause serious injury.

A good fork inspection and maintenance program
along with the proper application can be very
effective in preventing sudden failures on the job.
Repairs and modifications should be done only by
the fork manufacturer or a qualified technician who
knows the material used and the required welding
and heat treatment process.

Users should evaluate the economics of returning
the forks to the manufacturer for repairs or
purchasing new forks. This will vary depending on
many factors including the size and type of fork.

Forks should be properly sized to the weight and
length of the loads, and to the size of the machine
on which they are used. The general practice is to
use a fork size such that the combined rated
capacity of the number of forks used is equal to or
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.

The manufacturer identification and year and date
of manufacture are also usually shown.
Some countries have standards or regulations
which apply specifically to the inspection and repair
of forks.

Users may also refer to the International
Organization For Standardization-ISO Technical
Report 5057- Inspection and Repair of Fork Arms
and ISO Standard 2330 - Fork Arms - Technical
Characteristics and Testing.

While there are no specific standards or regulations
in the United States, users should be familiar with
the requirements for inspection and maintenance of
lift trucks as provided by the 29 Code Federal
Register 1910.178 Powered Industrial Truck, and
ANSI/ASME Safety Standard(s) B56.1, B56.5 or
B56.6 as applicable to the type of machine(s) in
use.

Environment Protection

When servicing this lift truck, use an authorized
servicing area and an approved container to collect
coolant, oil, fuel, grease, electrolyte and any other
potential environmental pollutant before any lines,
fittings or related items are disconnected or
removed. After servicing, dispose of those
materials in an authorized place and container.
When cleaning the lift truck, be sure to use an
authorized area.

Maintenance Section

-131-
Causes of Fork Failure
Improper Modification or Repair
Fork failure can occur as a result of a field
modification involving welding, flame cutting or
other similar processes which affect the heat
treatment and reduces the strength of the fork.

In most cases, specific processes and techniques
are also required to achieve proper welding of the
particular alloy steels involved. Critical areas most
likely to be affected by improper processing are the
heel section, the mounting components and the
fork tip.

Bent or Twisted Forks
Forks can be bent out of shape by extreme
overloading, glancing blows against walls or other
solid objects or using the fork tip as a pry bar.

Bent or twisted forks are much more likely to break
and cause damage or injury. They should be
removed from service immediately.

Fatigue
Parts which are subjected to repeated or fluctuating
loads can fail after a large number of loading cycles
even though the maximum stress was below the
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 in size until it
becomes insufficient to support the load and
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.
Repetitive Overloading

Repetitive cycling of loads which exceeds the
fatigue strength of the material can lead to fatigue
failure. The overload could be caused by loads in
excess of the rated fork capacity and by use of the
forks tips as pry bars. Also, by handling loads in a
manner which causes the fork tips to spread and
the forks to twist laterally about their mountings.

Wear

Forks are constantly subjected to abrasion as they
slide on floors and loads. The thickness of the fork
blade is gradually reduced to the point where it may
not be capable of handling the load for which it was
designed.

Stress Risers

Scratches, nicks and corrosion are points of high
stress concentration where cracks can develop.
These cracks can progress under repetitive loading
in a typical mode of fatigue failure.

Overloading
Extreme overloading can cause permanent bending
or immediate failure of the forks. Using forks of less
capacity than the load or lift truck when lifting loads
and using forks in a manner for which they were not
designed are some common causes of overloading.

Maintenance Section

-132-
Fork Inspection

Establish a daily and 12 month inspection routine
by keeping a record for the forks on each lift truck.
Initial information should include the machine serial
number on each the forks are used, the fork
manufacturer, type, original section size, original
length and capacity. Also list any special
characteristics specified in the fork design.

Record the date and results of each inspection,
making sure the following information is included.

Actual wear conditions, such as percent of
original blade thickness remaining.

Any damage, failure or deformation which might
impair the use of the truck.

Note any repairs or maintenance.

An ongoing record of this information will help in
identifying proper inspection intervals for each
operation, in identifying and solving problem areas
and in anticipating time for replacement of the
forks.
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

3. Make sure positioning lock is in place and
working Lock forks in position before using
truck. See Forks, Step 7, in the 2000 Service
Hours or Yearly in Maintenance Intervals.

Daily Inspection
1. 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.

2. Make sure positioning lock is in place and
working. Lock the forks in position before using
the truck. See 2000 Service Hours or Yearly in
Maintenance Intervals.

3. Remove all defective forks from service.

Maintenance Section

-133-
12 Months Inspection
Forks should be inspected, at a minimum, every 12
months. If the truck is being used in a multi-shift or
heavy duty operation, they should be checked
every six months. See Forks in the 2000 Service
Hours or Yearly in Maintenance Intervals.

Maintenance and Repair
1. Repair forks only in accordance with the
manufacturers recommendations.

Most repairs or modifications should be done
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
manufacturers 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.

With the fork restrained in the same manner as
its mounting on the lift truck, apply the test load
twice, gradually and without shock. Maintain the
test for 30 seconds each time.

Check the fork arm before and after the second
application of the test load. It shall not show any
permanent deformation.

Consult the fork manufacturer for further
information as may be applicable to the specific
fork involved.

Testing is not required for repairs to the positioning
lock or the markings.
Maintenance Section

-134-
Tire Inflation Information

Tire Inflation

WARNING
Personal injury or death could result when tires are
inflated incorrectly.
Use a self - attaching inflation chuck and stand
behind the tread when inflating a tire.
Proper inflation equipment and training in using the
equipment are necessary to avoid over-inflation. A
tire blowout or rim failure can result from improper
or misused equipment.

NOTICE
Set the tire inflation equipment regulator at no more
than 140 kPa (20 psi) over the recommended tire
pressure.

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

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

The operating inflation pressure is based on the
weight of a ready - to - work machine without
attachments, at rated payload, and in average
operating conditions. Pressures for each
application may vary and should always be
obtained from your tire supplier.

NOTE: Fill tires to the recommended pressures
listed 35 kPa (5 psi). Tires can be filled
with nitrogen.

Tire Inflation Pressures
Adjustment
Tire inflation in a warm shop area, 18to 21C (65
to 70F), will be underinflated if the machine works
in freezing temperatures. Low pressure shortens
the life of a tire.

Maintenance Section

-135-
Torque Specifications

Metric Hardware
Most of the nuts, bolts, studs, and threaded holes in
your lift truck are metric. In this manual we provide
specifications in both metric and U.S. customary
measurement. Always replace metric hardware with
metric hardware. See the parts books for proper
replacement.

NOTE: For proper fit, use only metric tools on
metric hardware. Non-metric tools might
slip and cause injury.

Torque for Standard Hose Clamps
- Worm Drive

NOTICE
The chart below gives the torques for initial
installation of hose clamps on new hose and for
reassembly or retightening of hose clamps on
existing hose.

Initial Installation
Torque On New Hose Clamp Width
Nm
1
lbin
16 mm (.625 in) 7.5 0.5 65 5
13.5 mm (.531 in) 4.5 0.5 40 5
8 mm (.312 in) 0.9 0.2 8 2
Reassembly or
Retightening
Torque On Existing Hose
Clamp Width
Nm
1
lbin
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 (Nm) is approximately the same as 0.1 kgm.

Torque for Standard Bolts, Nuts,
and Taperlock Studs

NOTICE
The two charts below give general torques for bolts,
nuts, and taperlock studs of SAE Grade 5 or better
quality.

Torques for Bolts and Nuts with
Standard Threads

Standard Nut and Bolt Torque Thread Size
Inch
Nm lbft
1/4 12 4 9 3
5/16 25 7 18 5
3/8 45 7 33 5
7/16 70 15 50 11
1/2 100 15 75 11
9/16 150 20 110 15
5/8 200 25 150 18
3/4 360 50 270 37
7/8 570 80 420 60
1 875 100 640 75
1 1/8 1100 150 820 110
1 1/4 1350 175 1000 130
1 3/8 1600 200 1180 150
1 1/2 2000 275 1480 200
1
1 Newton meter (Nm) is approximately the same as 0.1 kg m.

Maintenance Section

-136-
Torques for Taperlock Studs

Standard Taperlock Stud Torque Thread Size
Inch
Nm
1
lbft
1/4 8 3 6 2
5/16 17 5 13 4
3/8 35 5 26 4
7/16 45 10 33 7
1/2 65 10 48 7
5/8 110 20 80 15
3/4 170 30 125 22
7/8 260 40 190 30
1 400 60 300 45
1/8 500 700 370 50
1/4 650 80 480 60
3/8 750 90 550 65
1/2 870 100 640 75
1
1 Newton meter (Nm) is approximately the same as 0.1 kgm.

Torque for Metric Fasteners

NOTICE
Be very careful never to mix metric with U.S.
customary (standard) fasteners. Mismatched or
incorrect fasteners will cause lift truck damage or
malfunction and may even result in personal injury.

Original fasteners removed from the lift truck should
be saved for reassembly whenever possible. If new
fasteners are needed, they must be of the same
size and grade as the ones that are being replaced.

The material strength identification is usually shown
on the bolt head by numbers (8.8, 10.9, etc.). This
chart gives standard torques for bolts and nuts with
Grade 8.8.

NOTE: Metric hardware must be replaced with
metric hardware. Check parts book.

Standard Torque Thread Size
Metric
Nm
1
lbft
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 Nm) is approximately the same as 0.1
kgm.
2
ISO - International Standards organization.

Maintenance Section

-137-
Cooling System Specifications

Coolant Information
NOTE: The following information is generic and
valid for lift trucks.

Engine operating temperatures have increased to
improve engine efficiency. This means proper
cooling system maintenance is especially important.
Overheating, overcooling, pitting, cavitation erosion,
cracked heads, piston seizures, and plugged
radiators are classic cooling system failures. In fact,
coolant is as important as the quality of fuel and
lubricating oil.

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
-28C (-20F) with antifreeze, when shipped from
the factory unless special requirements are defined.

Check the specific gravity of the coolant solution
frequently in cold weather to ensure adequate
protection.

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.
Filling at over 20 liters (5 U.S. gallons) per minute
can cause air pockets in the cooling system.

After draining and refilling the cooling system,
operate the engine with the radiator cap removed
until the coolant reaches normal operating
temperature and the coolant level stabilizes. Add
coolant as necessary to fill the system to the proper
level.

Never operate without a thermostat in the cooling
system. Cooling system problems can arise without
a thermostat.
Maintenance Section

-138-
Coolant Water
Hard water, or water with high levels of calcium and
magnesium ions, encourages the formation of
insoluble chemical compounds by combining with
cooling system additives such as silicates and
phosphates.

The tendency of silicates and phosphates to
precipitate out-of-solution increases with increasing
water hardness. Hard water or water with high
levels of calcium and magnesium ions encourages
the formation of insoluble chemicals, especially
after a number of heating and cooling cycles.

DOOSAN prefers the use of distilled water or
deionized water to reduce the potential and severity
of chemical insolubility.

Acceptable Water
Water Content Limits (PPM)
Chlorides (Cl) 50 maximum
Sulfates (SO4) 50 maximum
Total hardness 80mg/l
Total solids 250 maximum
PH 6.0 to 8.0
ppm = parts per million

Using water that meets the minimum acceptable
water requirement may not prevent drop-out of
these chemical compounds totally, but should
minimize the rate to acceptable levels.
Antifreeze

NOTICE
DOOSAN recommends using automotive antifreeze
suitable for gasoline engines having aluminum alloy
parts. Antifreeze of poor quality will cause corrosion
of the cooling system, and thus always use
automotive antifreeze prepared by a reliable maker,
and never use it mixed with antifreeze of different
brand.

DOOSAN recommends that the coolant mix contain
50% commercially available automotive antifreeze,
or equivalent and acceptable water to maintain and
adequate water pump cavitation temperature for
efficient water pump performance.
Premix coolant solution to provide protection to the
lowest expected outside (ambient) temperature.
Pure undiluted antifreeze will freeze at -23C
(-10F).

Use a greater concentration (above 50%) of
commercially available automotive antifreeze only
as needed for anticipated outside (ambient)
temperatures. Do not exceed the recommendations,
provided with the commercially available
automotive antifreezes, regarding the coolant
mixture of antifreeze to water.

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 Concentrations
Protection Temperature Concentrations
Protection to -15C (5F) 30% antifreeze and 70% water
Protection to -23C (-10F) 40% antifreeze and 60% water

Maintenance Section

-139-
Fuel Specifications

General Fuel Information
Use only fuel as recommended in this section.

NOTICE
Fill the fuel tank at the end of each day of operation
to drive out moisture laden air and to prevent
condensation. Maintain a constant level near the
top of the day tank to avoid drawing moisture into
the tank as the level decreases.
Do not fill the tank to the top. Fuel expands as it
gets warm and can overflow.
Do not fill the fuel filters with fuel before installing
them. Contaminated fuel will cause accelerated
wear to the fuel system parts.

Drain the water and sediment from main fuel
storage tank before it is refilled. This will help
prevent water and/or sediment from being pumped
from the fuel storage tank into the engine fuel tank.

Diesel Specifications
Fuel Types
DOOSAN Diesel Engines have the ability to burn a
wide variety of fuels. These fuels are divided into
two general groups, preferred and permissible.

The Preferred Fuels provide maximum engine
service life and performance. They are distillate
fuels. They are commonly called diesel fuel, MDO
diesel, furnace oil, gas oil or kerosene (for cold
weather operation).

Experience has proven that distillate fuels meeting
the following basic specifications will result in
optimum engine performance and durability.

DOOSAN strongly encourages the use of fuels that
meet the Preferred Fuels specification.

The permissible fuels are crude oils or blended
fuels. Use of these fuels can result in higher
maintenance costs and reduced engine service life.
Crude oil is used to describe oils/fuels that are not
refined and are in the original state as when
pumped from the ground. Certain types of crude
oils can be burned in DOOSAN Engines.

PREFERRED DISTILLATE FUEL
FOR DISEL ENGINES
Specifications Requirements*
Aromatics (AST D1319) 35% Max.
Ash (ASTM D482) 0.02% Weight Max.
Cetane Number
(ASTM D613)
35Min. for 45 max.
40 Min. for DI Engines
Could Point (ASTM D287)
Not Above Lowest Expected
Ambient Temperature
Gravity API (ASTM D287) 30 Min. and 45 Max.
Pour Point (ASTM D97)
6C (10F) Below Ambient
Min.
Sulfur (ASTM D2788,
D3605 or D1552)
0.5% Max.
(See Sulfur Topic)
Viscosity, Kinematic @
38C (100F) (ASTM D445)
20.0 cSt Max.
1.4 cSt Min.
Water & Sediment
(ASTM D1796)
0.01% Max.
*As delivered to fuel system

Fuel Sulfur Content
The percentage of sulfur in the fuel will affect the
engine oil recommendations. Fuel sulfur is
chemically changed during combustion to form both
sulfurous and sulfuric acid. These acids chemically
attack metal surfaces and cause corrosive wear.

Certain additives used in lubricating oils contain
alkaline compounds that are formulated to
neutralize these acids. The measure of this reserve
alkalinity in lubricating oil is known as its Total Base
Number (TBN). TBN is essential to neutralize the
acids from combustion gases and to minimize
corrosive wear.

Any API classification performance of oil should
have sufficient TBN for fuels with less than 0.5%
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).
Maintenance Section

-140-
DOOSAN recommends infrared analysis (in
conjunction with wear metal analysis) of used oil in
determining the effectiveness of oil TBN and acid
neutralization.

For fuel with sulfur exceeding 1.5% by weight, use
oil with a TBN of 30 and reduce the oil change
interval by one half. Also, infrared analysis and
wear metal analysis should be used to establish oil
change intervals.

Periodically request fuel sulfur content information
from your fuel supplier. Fuel sulfur content can
change with each bulk delivery.
Gasoline Specifications
Only unleaded gasoline should be used for
DOOSAN forklift trucks.
The gasoline in which methanol is contained is not
recommended. The gasoline in which ethanol is
contained is not recommended, either.

It is recommended to use gasoline fuel that has
octane number 87, to prevent knocking trouble.

LP Specifications
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.

Maintenance Section

-141-
Lubricant Information

Lubricant Information
Certain abbreviations follow Society of Automotive
Engineers (SAE) J754 nomenclature and some
classifications follow SAE J183 abbreviations.

The MIL specifications are U.S.A. Military
Specifications.

The recommended oil viscosities can be found in the
Lubricant Viscosities chart in this publication.

Grease is classified by the National Lubricating
Grease Institute (NLGI) based on ASTM D217-68
Worked Penetration characteristics which are given
a defined consistency number.

Engine Oil (DEO and EO)
The following oil specifications provide guidelines for
the selection of commercial products:

Gasoline/LP Engine : API SJ or higher
Diesel Engine : API CH4, ACEA E5

NOTICE
Failure to follow the oil recommendations can cause
shortened engine lift due to carbon deposits or
excessive wear.

Consult the EMA Lubricating Oils Data Book for a
listing of oil brands.

NOTE: The percentage of sulfur in the fuel will
affect the engine oil recommendations.
For fuel sulfur effects, the Infrared Analysis
or the ASTM D2896 procedure can be used
to evaluate the residual neutralization
properties of engine oil. The sulfur products
formation depends on the fuel sulfur content,
oil formulation, crankcase blow-by, engine
operating conditions and ambient
temperature.
Hydraulic Oil (HYDO)
The following commercial classifications can be
used in the hydraulic system.

ISO 6743/4 HM
AFNOR NFE 48-603 HM
DIN 51524 TEIL 2 H-LP
HAGGLUNDS DENISON HFO-HF2
CINCINNATI P68,69,70

Viscosity: ISO VG32

Industrial premium hydraulic oils that have passed
the Vickers vane pump test (35VQ25).
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
would normally be selected.

NOTICE
Make-up oil added to the hydraulic tanks must mix
with the oil already in the systems. Use only
petroleum products unless the systems are
equipped for use with special products. If the
hydraulic oil becomes cloudy, water or air is entering
the system. Water or air in the system will cause
pump failure. Drain the fluid, retighten all hydraulic
suction line clamps, purge and refill the system.
Consult your DOOSAN Lift Truck dealer for purging
instructions.

Drive Axle Oil
NOTE: Do not use Gear Oil in the final drives or
differentials. Gear Oil can cause seal
material to fail and possibly leak oil.

NOTE: Failure to follow the recommendation will
cause shortened life due to excessive gear
wear.

The API CD/TO-2 specification or MIL-L-2104D, Eor
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.

Maintenance Section

-142-
Lubricating Grease (MPGM)
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
trains only, and should not be used in engines.
Shortened engine life will result.

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.

NOTE: Failure to follow this recommendation can
cause shortened transmission life due to
material incompatibility, inadequate
frictional requirements for disk materials
and/or excessive gear wear.

The API CD/TO - 2 specification or MIL - L 2104D, E
or F oil could be used.

Brake Fluid

Oil Cooled Disc Brake Only
Use heavy duty hydraulic brake fluid certified by oil
supplier to meet the latest version of following
classifications.

ISO 6743/4 HM
AFNOR NFE 48-603 HM
DIN 51524 TEIL 2 H-LP
HAGGLUNDS DENISON HFO-HF2
CINCINNATI P68,69,70

Viscosity : ISO VG32

Brake reservoir oils that have passed the Vickers
vane pump test (35VQ25). 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 would normally
be selected.

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

Maintenance Section

-143-
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities
LUBRICANT VISCOSITIES
FOR AMBIENT (OUTSIDE) TEMPERATURES
C F Compartment
or System
Oil
Viscosities
Min Max Min Max
SAE 10W30 -20 +40 -4 +104
G420F(E)
Engine
Crankcase
(Gasoline and
LP)
API SJ
SAE 5W30 -30 +30 -22 +86
SAE 10W30 -20 +40 -4 +104
G424F(E)
Engine
Crankcase
(Gasoline and
LP)
API SJ
SAE 5W30 -30 +30 -22 +86
Engine
Crankcase
(Diesel)
API CH4,
ACEA E5
SAE 15W40 -15 +50 -5 +122
SAE 10W -20 +22 -4 +72
Power Shift
Transmission
& Drive Axle
Housing
API CD/TO-2
SAE 30 +10 +50 +50 +122
ISO VG 22 -30 +20 -22 +68
ISO VG 32 -20 +30 -4 +86
ISO VG 46 -10 +40 +14 +104
Hydraulic and
Power
Steering
System
ISO 6743/4
HM
ISO VG 68 0 +50 +32 +122
Brake
Reservoir
(Only for
OCDB)
ISO 6743/4HM
ISO VG32 -20 +30 -4 +86

The SAE grade number indicates the viscosity of oil.
A proper SAE grade number should be selected
according to ambient temperature.

Refill Capacities
REFILL CAPACITIES - (APPROXIMATE)
Compartment or System Liters U.S Gal.
Engine Crankcase w/Filter
G420F & G420F(E) 2.0 liter
Gasoline & LP
4.2 1.11
G424F & G424F(E) 2.4 liter
LP
4.5 1.19
4TNV98 Diesel
7.6 2.00
4TNE98 Diesel
9.2 2.43
Cooling System
w/Coolant Recovery Bottle
G420F & G420F(E) 2.0 liter
Gasoline & LP
8.5 2.25
Cooling System
G424F & 424F(E) 2.4 liter
LP
9.0 2.38
Cooling System
4TNV98 &4TNE98 Diesel
10.7 2.83
Fuel Tank - G, D Series
Gasoline or Diesel
51 13.74
Fuel Tank - GC Series
Gasoline
40 10.56
G Series 15.2kg 33.5lb
LP
GC Series 15.2kg 33.5lb
G, D Series 13.0 3.43 Powershift
Transmission
GC Series 11.2 3.0
G, D Series 9.2 2.43
Drive Axle
GC Series 10.0 2.64
Hydraulic & Power Steering System 34 8.98
Brake Reservoir (Only for OCDB) 1.0 0.3

Maintenance Section

-144-

NOTICE
All maintenance and repair, except Every 10
Service Hours or Daily, on the lift truck must be
performed by qualified and authorized personnel
only.

NOTICE
Careless disposal of waste oil can harm the
environment and can be dangerous to persons.
Always dispose of waste oil to authorized personnel
only.

When Required

Fuel Tank Filter Cap and Screen (If Equipped) -
Clean..................................................................... 148
Seat, Hood Latch & Support Cylinder - Check,
Lubricate................................................................ 148
Fuses, Bulbs, Circuit Breaker & Relay - Change,
Reset ..................................................................... 149
Priming the Fuel System(Diesel Engine Only) ... 150
Water Seperator (Diesel Engine Only) - Check,
Drain...................................................................... 152
Tires and Wheels (D, G-Series) - Inspect, Check
............................................................................... 154
Carriage Roller Extrusion Adjust ...................... 154

Every 10 Service Hours or Daily

Inspect Engine for Fluid Leaks............................ 155
Engine Oil Level - Check ..................................... 155
Coolant Level Check......................................... 156
Air Cleaner Indicator-Check................................. 157
Inspect Foot Pedal Operation (G420F(E)/G424F(E)
Only)...................................................................... 157
Inspect Engine for Exhaust Leaks....................... 157
Walk-Around Inspection - Inspect ....................... 157
Mast Channels Lubricate.................................. 158
Transmission Oil Level Check.......................... 159
Parking Brake - Inspect........................................ 159

First 50 - 100 Service Hours or a Week

Engine Oil & Filter (Diesel Engine Only) - Change
............................................................................... 161
Transmission Oil, Oil Filter & Strainer - Check,
Clean, Change...................................................... 162
Drive Axle Oil - Change........................................ 164
Parking Brake - Test, Adjust ................................ 164

First 250 Service Hours or a Month

Hydraulic Return Filter Change ........................ 166

Every 250 Service Hours or Monthly

Air Intake System - Check, Clean........................ 167
Brake Oil Level - Check........................................ 169
Hydraulic Oil Level Check................................. 169
Drive Axle Oil Level - Check................................ 170
Mast, Carriage, Lift Chains & Attachments - Inspect,
Lubricate................................................................ 170
Steering Mechanism - Check, Lubricate............. 170
Battery Terminal - Clean, Inspect ........................ 171
Engine Oil & Filter (LP & Gasoline Engine Only) -
Change.................................................................. 171
PCV Valve System - Inspect, Clean.................... 172
Wheel Bolts & Nuts - Inspect ............................... 173
Inspect Tightness (GC - Series) .......................... 173
Governor Lever and Engine Speed Control (Diesel
Engine Only) - Check ,Adjust............................... 174

Every 500 Service Hours or 3 Months

Belts - Check, Adjust ............................................ 176
Mast Hinge Pin Lubricate.................................. 176
Tilt Cylinders - Check, Adjust, Lubricate............. 176
Crosshead Rollers - Inspect................................. 177
Transmission Oil Filter Change ........................ 178
Overhead Guard Inspect................................... 178
Drive Axle Oil & Strainer - Change, Clean.......... 179
Steer Suspension Inspect ................................. 180
Parking Brake - Test, Adjust ................................ 180
Inching & Braking Control Shaft - Lubricate........ 180
Horn and Lights (If Equipped) - Check................ 180
Inspect Vacuum Lines and Fittings
(G420F(E)/G424F(E) Engine Only)..................... 181
Fuel Trim Valve(FTV) Inspection
Inspect Electrical System (G420F(E)/G424F(E)
Engine Only).......................................................... 181
Fuel Filter (Diesel Engine Only) - Change.......... 182
............................................................................... 183
Water Separator (4TNV98 Diesel Engine Only) -
Clean...................................................................... 184


Hydraulic Return Filter, Breather & Strainer - Check,
Change.................................................................. 185
Clean, Change...................................................... 186
Lift Chains - Test, Check, Adjust ......................... 186
Universal Joint Inspect ...................................... 188
Air Intake System - Change ................................. 188
Maintenance Section

-145-
Inspect Coolant Hoses (LP, Dual Fuel
Engine Only) ......................................................... 189
LP Regulator/Converter Inspection (LP, Dual Fuel
Engine Only) ......................................................... 189
Fuel Lines & Fittings - Check............................... 189
Inspect Mixer Assembly (G420F(E)/G424F(E)
Engine Only) ......................................................... 189
Inspect Throttle Assembly (G420F(E)/G424F(E)
Engine Only) ......................................................... 189
Engine Valve Lash (Diesel Engine Only) - Check,
Adjust..................................................................... 190


Inspect Ignition System (LP, Gasoline & Dual Fuel
Engines Only) ....................................................... 191
Replace Spark Plugs (G424F(E) LP, Dual Fuel
Engine Only) ......................................................... 191
Replace LP Fuel Filter Element (LP, Dual Fuel
Engine Only) ......................................................... 192
Fuel Filter (LP Engine Only) ................................ 192
Testing Fuel Lock-off Operation (LP Engine Only)
............................................................................... 192
Fuel Injectors (Diesel Engine Only) Inspect,
Clean, Test............................................................ 193
Crankcase Breather System (4TNV98 Diesel
Engine Only) - Inspect.......................................... 193

Every 2000 Service Hours or Yearly

Engine Valve Lash (Diesel Engine Only) Check,
Adjust..................................................................... 194
Steer Wheel Bearings - Reassemble.................. 194
Drive Wheel Bearing (Power Shaft and Drive
Wheel) Reassemble.......................................... 196
Cooling System Clean, Change....................... 197
Forks Inspect ..................................................... 199


Hydraulic Oil - Check, Clean, Change................ 201
Inspect Battery System........................................ 201
Replace Oxygen Sensor (G420F(E)/G424F(E)
Engine Only) ......................................................... 202
Replace Spark Plugs (G420F(E) Engine Only).. 202
Checking the TMAP Sensor (G420F(E)/G424F(E)
Engine Only) ......................................................... 203
Inspect for Intake Leaks (G420F(E)/G424F(E)
Engine Only) ......................................................... 203


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

Maintenance Section

-146-
Quick Reference to Maintenance Schedule

FIRST EVERY
ITEMS SERVICES PAGE
W
h
e
n

R
e
q
u
i
r
e
d

5
0
-
1
0
0

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M
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1
0

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H
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D
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2
5
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S
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5
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H
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3

M
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H
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6

M
o
n
t
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s

1
5
0
0

S
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v
i
c
e

H
o
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s

o
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9

M
o
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t
h
s

2
0
0
0

S
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H
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s

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a

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e
a
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2
5
0
0

S
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H
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5

M
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3
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0

S
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i
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H
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o
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1
8

M
o
n
t
h
s

Air Cleaner Indicator Check 157 O
Air Intake System Change 188 O
Air Intake System Check, Clean 167 O
Battery Terminal Clean, Inspect 171 O
Belts Check, Adjust 176 O
Brake Oil Level Check 169 O
Carriage Roller Extrusion Adjust 154 O
Checking the TMAP Sensor (G420F(E)/G424F(E) Engine
Only)
203 O
Coolant Level Check 156 O
Cooling System Clean, Change 197 O
Crankcase Breather System (4TNV98 Diesel Engine Only) Inspect 193 O
Crosshead Rollers Inspect 177 O
Drive Axle Oil Change 164 O
Drive Axle Oil & Strainer Change, Clean 179 O
Drive Axle Oil Level Check 170 O
Drive Wheel Bearing (Power Shaft and Drive Wheel) Reassemble 196 O
Engine Oil & Filter (Diesel Engine Only) Change 161, 183 O O
Engine Oil & Filter (LP & Gasoline Engine Only) Change 171 O
Engine Oil Level Check 155 O
Engine Valve Lash (Diesel Engine Only) Check, Adjust 190, 194 O O
Forks Inspect 199 O
Fuel Filter (Diesel Engine Only) Change 182 O
Fuel Filter (LP Engine Only) 192 O
Fuel Injectors (Diesel Engine Only)
Inspect, Clean,
Test
193 O
Fuel Lines & Fittings Check 189 O
Fuel Tank Filter Cap and Screen (If Equipped) Clean 148 O
Fuel Trim Valve(FTV) Inspection (G420F(E)/G424F(E)
Engine Only)
181 O
Fuses, Bulbs, Circuit Breaker & Relay Change, Reset 149 O
Governor Lever and Engine Speed Control (Diesel Engine
Only)
Check ,Adjust 174 O
Horn and Lights (If Equipped) Check 180 O
Hydraulic Oil
Check, Clean,
Change
201 O
Hydraulic Oil Level Check 169 O
Hydraulic Return Filter Change 166 O
Hydraulic Return Filter, Breather & Strainer Check, Change 185 O
Inching & Braking Control Shaft Lubricate 180 O
Inspect Battery System 201 O
Inspect Coolant Hoses (LP, Dual Fuel Engine Only) 189 O
Inspect Electrical System (G420F(E)/G424F(E) Engine Only) 181 O
Inspect Engine for Exhaust Leaks 157 O
Inspect Engine for Fluid Leaks 155 O
Inspect Foot Pedal Operation (G420F(E)/G424F(E) Only) 157 O
Inspect for Intake Leaks (G420F(E)/G424F(E) Engine Only) 203 O
Maintenance Section

-147-
Quick Reference to Maintenance Schedule

FIRST EVERY
ITEMS SERVICES PAGE
W
h
e
n

R
e
q
u
i
r
e
d

5
0
-
1
0
0

S
e
r
v
i
c
e

H
o
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s

o
r

a

W
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k

2
5
0

S
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e

H
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s

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1
0

S
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H
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a

D
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2
5
0

S
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v
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H
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s

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M
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5
0
0

S
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v
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H
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3

M
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1
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0

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H
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6

M
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s

1
5
0
0

S
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H
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r
s

o
r

9

M
o
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t
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s

2
0
0
0

S
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H
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s

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a

Y
e
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y

2
5
0
0

S
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s

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r
1
5

M
o
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s

3
0
0
0

S
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v
i
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e

H
o
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s

o
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1
8

M
o
n
t
h
s

Inspect Ignition System (LP, Gasoline & Dual Fuel Engines
Only)
191 O
Inspect Mixer Assembly (G420F(E)/G424F(E) Engine Only) 189 O
Inspect Throttle Assembly (G420F(E)/G424F(E) Engine Only) 189 O
Inspect Tightness (GC - Series) 173 O
Inspect Vacuum Lines and Fittings (G420F(E)/G424F(E)
Engine Only)
181 O
Lift Chains
Test, Check,
Adjust
186 O
LP Regulator/Converter Inspection (LP, Dual Fuel Engine
Only)
189 O
Mast Channels Lubricate 158 O
Mast Hinge Pin Lubricate 176 O
Mast, Carriage, Lift Chains & Attachments
Inspect,
Lubricate
170 O
Overhead Guard Inspect 178 O
Parking Brake Inspect 159 O
Parking Brake Test, Adjust 164, 180 O O
PCV Valve System Inspect, Clean 172 O
Priming the Fuel System(Diesel Engine Only) 150 O
Replace LP Fuel Filter Element (LP, Dual Fuel Engine Only) 192 O
Replace Oxygen Sensor (G420F(E)/G424F(E) Engine Only) 202 O
Replace Spark Plugs (G420F(E) Engine Only) 202 O
Replace Spark Plugs (G424F(E) LP, Dual Fuel Engine Only) 191 O
Seat, Hood Latch & Support Cylinder Check, Lubricate 148 O
Steer Suspension Inspect 180 O
Steer Wheel Bearings Reassemble 194 O
Steering Mechanism Check, Lubricate 170 O
Testing Fuel Lock-off Operation (LP Engine Only) 192 O
Tilt Cylinders
Check, Adjust,
Lubricate
176 O
Timing Belt [G420F(E)/G424F(E) LP, Gasoline, Dual Fuel
Engine Only]
Change 204 O
Tires and Wheels (D, G-Series) Inspect, Check 154 O
Transmission Oil Filter Change 178 O
Transmission Oil Level Check 159 O
Transmission Oil, Oil Filter & Strainer
Check, Clean,
Change
162, 186 O O
Universal Joint Inspect 188 O
Walk-Around Inspection Inspect 157 O
Water Separator (4TNV98 Diesel Engine Only) Clean 184 O
Water Seperator (Diesel Engine Only) Check, Drain 152 O
Wheel Bolts & Nuts Inspect 173 O

Maintenance Section

-148-
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
(If Equipped) - Clean
Park the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
engine stopped.

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
required by prevailing conditions.

Seat, Hood Latch & Support
Cylinder - Check, Lubricate

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.

2. Push the lever down to raise the hood and seat
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.
Maintenance Section

-149-
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 checked.

NOTICE
Always replace fuses with ones of the correct
ampere rating.

Typical Example

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. Solenoid, lamp Relay & Back-up
Lamp/alarm - 10 amps.
4. Instrument Panel & Fuel Shutoff - 15 amps.
5. Turn Signal Lamp, Stop/Strobe Lamp & C.S.D.
6. Start Relay - 5 amp.

Check the fuses. Use a flashlight, if necessary.

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:
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)

*Optional lamp or light

Maintenance Section

-150-
Circuit Breaker

1. Raise the hood and seat assembly. Make sure
the support cylinder securely holds the hood
open.

2. The main circuit breaker is located on the rear
of the support for the hydraulic controls.

NOTE: To reset circuit breakers push in on the
button. The button should stay in if the
breaker is reset. If the button will not stay in,
or comes out shortly after reset, have the
circuits checked.

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
After fuel system maintenance such as
changing the fuel filter and draining the
water separator, or replacing a fuel system
component.

To prime the fuel system

1. Turn the key to the ON position for 10 to 15
seconds. This will allow the electric fuel pump
to prime the fuel system.

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

4TNE98 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.
After fuel system maintenance such as
changing the fuel filter and draining the
fuel filter / water separator, or replacing a
fuel system 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 bubbles.
4. Tighten the air bleed port.
Maintenance Section

-151-
5. Wipe up any spills and properly dispose of fuel.
may cause the starter motor to overheat and
damage the coils, pinion and / or ring gear.

To prime the fuel system on engines not equipped
with an electric fuel system:

1. Place an approved container under the air
bleed port.
2. Loosen the air bleed port (Figure 2, (1)) 2 or 3
turns.
3. Operate the fuel priming pump (Figure 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.
may cause the starter motor to overheat and
damage the coils, pinion and / or ring gear.

Figure 2

Maintenance Section

-152-
Water Seperator (Diesel Engine
Only) - Check, Drain

Drain the fuel filter / water separator whenever
there are contaminants, such as water, collected in
the bottom of the cup. NEVER wait until the
scheduled periodic maintenance if contaminants
are discovered.

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
surface of the water to show how much needs to be
drained. Also, some optional fuel filter / water
separators are equipped with a sensor to detect the
amount of contaminants. This sensor sends a
signal to an indicator to alert the operator.

Drain the fuel filter / water separator as follows:

1. Position an approved container under the fuel
filter / water separator (Figure 5-7, (1)) to
collect the contaminants.

Figure 5-7

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

3. Loosen the drain cock (Figure 5-7, (4)) at the
bottom of the fuel filter / water separator. Drain
any water collected inside.

4. Hand-tighten the drain cock.

WARNING
If the fuel filter/water separator is positioned
higher than the fuel level in the fuel tank, water
may not drip out when the fuel filter/water
separator drain cock is opened. If this happens,
turn the air vent screw on the top of the fuel
filter/water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw after the
water has drained out.

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

6. Be sure to prime the diesel fuel system when
you are finished. See topic Priming the Fuel
System When required

7. Check for leaks.

Maintenance Section

-153-
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 as follows:

1. Position an approved container under the fuel
filter / water separator (Figure 5-1, (1)) to
collect the contaminants.

2. Loosen the drain cock (Figure 5-1, (2)) at the
bottom of the fuel filter / water separator. Drain
any water collected inside.

3. Hand tighten the drain cock.

4. Be sure to prime the diesel fuel system when
you are done. See Priming the Fuel System.

Figure 5-1

Test Fuel System for Leaks(LP and Dual Fuel
Engines Only)

1. Obtain a leak check squirt bottle or pump spray
bottle.

2. Fill the bottle with an approved leak check
solution.

3. Spray a generous amount of the solution on the
fuel system fuel lines and connections, starting
at the storage container.

4. Wait approximately 15-60 seconds then
perform a visual inspection of the fuel system.
Leaks will cause the solution to bubble.

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,
Test Fuel System for Leaks.

Check
Points
Maintenance Section

-154-
Tires and Wheels (D, G-Series) -
Inspect, Check
WARNING
Servicing and changing tires and rims can be
dangerous and should be done only by trained
personnel using proper tools and procedures.
If correct procedures are not followed while
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 man or dealer.

Check Inflation and Damage
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
minimum 60 cm (24 inches) length of hose to an
in-line valve and gauge.

Always stand behind the tread of the tire. NOT in
front of the rim.

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 circumstances, attempt to rework,
weld, heat or braze any rim components.
Carriage Roller Extrusion Adjust

1. Set the mast vertical.

2. Lower the carriage completely.

3. On full free lift and full free triple lift models, the
bottom of the inner mast must be flush with the
bottom of the stationary mast.

4. Measure the distance from the bottom of the
inner upright to the bottom of carriage bearing.

5. The measurement (A) must be as follows in
Chart below.

Height of carriage roller extrusion (A)
STD mast FF mast FFT mast
0 41 41

Maintenance Section

-155-
Every 10 Service Hours or Daily


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

Gasoline and LP Engines

1. Maintain oil level between the MAX. and MIN.
marks on the dipstick.

Diesel Engines

1. Maintain oil level between the MAX. and MIN.
marks on the dipstick.
Maintenance Section

-156-
Coolant Level Check
WARNING
At operating temperature, the engine coolant is
hot and under pressure.
Check the coolant level only after the engine
has been stopped and the filter cap is cool
enough to touch with your bare hand.
Remove the filter cap slowly to relieve pressure.
Cooling system conditioner contains alkali.
Avoid contact with the skin and eyes to prevent
personal

4TNV98 Diesel Engine

1. Observe the coolant level 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.

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
radiator cap. Observe coolant level in the
expansion bottle. If necessary, add coolant to
bring the coolant to the appropriate line on the
expansion bottle.

4. Stop the engine.

5. Inspect the cooling system for leaks, hose
cracks or loose connections.

WARNING
Pressure air can cause personal injury.
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.
Maintenance Section

-157-
Air Cleaner Indicator-Check
Checking Service Indicator

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, Clean in
Every 250 Service Hours or Monthly.

NOTE: Service the element more frequently, as
required, in severe dust or lint conditions.
Also, service it more frequently where the
operator is required to wear a respirator.

3. Close hood and seat assembly.

Inspect Foot Pedal Operation
(G420F(E)/G424F(E) Only)
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.
If not, occured malfunction, can cause the
personal injury.

Inspect Engine for Exhaust Leaks
1. Start the engine and allow it to reach operating
temperatures.

2. Perform visual inspection of exhaust system.
Repair any/all leaks found.
Walk-Around Inspection - Inspect
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. Inspect the tires and wheels for cuts, gouges,
foreign objects, inflation pressure and loose or
missing bolts.

2. Inspect the mast and lift chains for wear, broken
links, pins and loose rollers.

3. Inspect the hydraulic system for leaks, worn
hoses or damaged lines.

4. Look for transmission and drive axle leaks on
the lift truck and on the ground.

5. Inspect the operators compartment for loose
items and cleanliness.

6. Inspect the instrument panel for broken gauges
and indicator lights.

7. Test the horn and other safety devices for
proper operation.

Maintenance Section

-158-

8. Inspect the cooling system for leaks, worn
hoses and debris buildup.

9. Inspect engine compartment for oil, coolant and
fuel leaks.

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.

Mast Channels Lubricate

The channels on the roller-type mast require a
break-in period. Apply a light film of lubricant on the
channels where the rollers ride. This will prevent
metal peel until the rollers set a pattern.
Maintenance Section

-159-
Transmission Oil Level Check
WARNING
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
position.

5. Remove the dip stick/filter cap. Observe the oil
level.

6. Maintain the oil level between the Min and Max
marks on the dip stick/filter cap.
When the oil temperature is 40C approximately,
the cold side mark on the dipstick is applicable.
the hot side mark on the dipstick is applicable.

Parking Brake - Inspect
Inspection from Operator's Seat, Engine
OFF

1. Grasp the parking brake lever with your hand
and press down the release button with your
thumb. The lever should move freely forward
and backward.

2. Remove your thumb from the release button.
The lever should resist movement when pulled
fully back and a clicking sound should be heard.
The lever should remain fully back until you
press the release button with your thumb.

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.
Maintenance Section

-160-
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.

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.

Maintenance Section

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


Engine Oil & Filter (Diesel Engine
Only) - Change
The engine oil in a new engine becomes
contaminated from the initial break-in of internal
parts. It is very important that the initial oil and filter
change is performed as scheduled

NOTE: The oil drain plug may be in another
location if an optional oil pan is used..

Drain the engine oil as follows:

1. Make sure the engine is level.

2. Start the engine and bring it up to operating
temperature.

3. Stop the engine.

4. Remove one of the oil filler caps (Figure 5-1,
(1)) to vent the engine crankcase and allow the
engine oil to drain more easily.

5. Position a container under the engine to collect
waste oil.

Figure 5-1
6. Remove the oil drain plug (Figure 5-2, (1)) from
the engine oil pan. Allow oil to drain.

7. After all oil has been drained from the engine,
reinstall the oil drain plug (Figure 5-2, (1)) and
tighten to 139.8 - 47.0 ftlb (53.9 - 63.7 Nm; 5.
5 - 6.5 kgfm).

8. Dispose of used oil properly

Remove the engine oil filter as follows:

1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
wrench.

Figure 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.
Tighten to 14 - 17 ftlb (19.6 - 23.5 Nm; 2.0 -
2.4 kgfm) 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.

Maintenance Section

-162-
WARNING
NEVER overfill the engine with engine oil.
ALWAYS keep the oil level between the upper
and lower lines on the oil cap/dipstick.

5. Warm up the engine by running it for five
minutes and check for any engine oil leaks.

6. After engine is warm, shut it off and let it sit for
10 minutes.

7. Recheck the engine oil level.

8. Add engine oil (Figure 5-3, (5)) as needed until
the level is between the upper (Figure 5-3, (2))
and lower lines (Figure 5-3, (3)) shown on the
dipstick (Figure 5-3, (1)).

Figure 5-3

9. Reinstall the oil filler cap (Figure 5-3, (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.

Transmission Oil, Oil Filter &
Strainer - Check, Clean, Change
WARNING
contact skin.

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

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,
nonflammable solvent and dry it. Install the
strainer assembly.

Maintenance Section

-163-

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.

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 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.

level.

marks on the dip stick/filter cap.
the cold side mark on the dipstick is applicable.
the hot side mark on the dipstick is applicable.

13. Check for oil leaks at the filters and drain plug.

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

Maintenance Section

-164-
Drive Axle Oil - Change
Park the lift truck on a level surface. Apply the
parking brake. Place the directional control lever in
NEUTRAL and stop the engine.

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. 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.

6. Install the dip stick/filter cap.

NOTE: Tighten the dipstick plug fully not to allow
foreign parts(rain, water etc) to enter into
drive axle.

Parking Brake - Test, Adjust
Parking Brake Testing

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.
If the maximum grade in the workplace is less than
its capacity, use the Parking Brake inspection
procedure covered in Inspection from Operators
Seat, Engine On in Every 10 Service Hours or
Daily section.

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

2. Drive forward up the 15% grade. Halfway up
the grade, stop the lift truck with its service
brakes.

3. Engage the parking brake and slowly release
the service brake.

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
the grade with the parking brake engaged, stop
it with the service brakes, disengage the
parking brake and reverse slowly down the
grade controlling your speed with the service
brakes.

Maintenance Section

-165-
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.

2. Chock the lift truck's tires to prevent
unintentional movement.

3. Remove the floor mat and floor plate.

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 and pull downward and turn the clevis
(5) until the pin (3) fits into the brake lever 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).

7. Loosen lock nut (5). Tighten screw (6) to 6 to 7
Nm (50 to 60 lbin). Loosen the screw (6) 1 1/6
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.

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
section.
Maintenance Section

-166-
First 250 Service Hours or a Month


Hydraulic Return Filter Change
WARNING
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 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.

.

Maintenance Section

-167-


Air Intake System - Check, Clean
Precleaner (If Equipped)

NOTICE
Never service precleaner with the engine running.

1. Check the precleaner bowl for dirt build-up.
If the dirt is up to the line, remove the
precleaner bowl and empty it. Periodically wash
the cover and bowl in water.

Servicing Filter Element

NOTICE
Never service filter with the engine running.

Service the air cleaner when the red target in the
service indicator stays locked in the visible position
with the engine stopped.

1. To service the air cleaner, raise the hood and
seat assembly. Make certain the support
cylinder securely holds the hood open. Loosen
the cover latches and remove the cover.

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
new element. See topic, Cleaning Primary
Filter Element.

4. Clean the inside of air cleaner housing and the
cover. Inspect all connections between the air
cleaner and carburetor. Check intake hose for
cracks, damage necessary to prevent leakage.

NOTICE
Do not allow dirty air to enter the intake hose when
cleaning the inside of the air cleaner 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
System-Change in Every 1000 Service Hours
or 6 months section

10. Stop the engine and close the hood and seat
assembly.
Maintenance Section

-168-
Cleaning Primary Filter Elements
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
them.
Inspect filter elements after cleaning. Do not use a
filter with damaged pleats, gaskets or seals.
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.
Air-205 kPa (30 psi) Maximum Pressure

Direct air on the inside and outside of the element
along the length of the pleats. Check the element
for any tears, rips or damage

Water-280kPa (40 psi) Maximum Pressure

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.

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.
Maintenance Section

-169-
Checking Element

1. Insert a light inside the clean dry element and
examine it. Discard the element if tears, rips or
damage are found.

2. Wrap and store good elements in a clean, dry
place.

Brake Oil Level - Check

The brake reservoir is located on the left side of the
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

Hydraulic Oil Level Check
WARNING
At operating temperature, the hydraulic tank is
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
the oil. Park the lift truck on a level surface, with
the forks lowered, mast tilted back, parking
brake engaged, transmission in NEUTRAL and
the engine stopped.

2. Raise the hood and seat assembly. Make sure
the air lift cylinder securely holds the hood
open.

3. Remove the dip stick/filter cap. Maintain the oil
level to the FULL mark on the dip stick/filter
cap.
Maintenance Section

-170-
Drive Axle Oil Level - Check
Park the lift truck on a level surface. Apply the
parking brake. The engine at low idle. Place the
directional control lever in NEUTRAL.

level.

2. Maintain the oil level between the lower mark
and upper marks on the dip stick/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.

2. Inspect for loose bolts and nuts on the carriage.
Remove any debris from the carriage and mast.

3. Inspect the forks and attachments for free
operation and damage. Have repairs made if
necessary.

4. Brush a film of oil on all links of the chain.
5. Raise and lower the carriage a few times to
allow lubricant to enter into the chain links.

NOTICE
Lubricate chains more frequently than normal in
applications where the lift truck is operating in an
atmosphere which could cause corrosion of
components or when lift truck must work in rapid lift
cycles.

6. Inspect the chain anchors and individual links
for wear, loose pins or cracked leaves.

Steering Mechanism - Check,
Lubricate

1. Lubricate the steer axle king pins, total of four
fittings. Two on the right side and two on the left
side.

2. Lubricate the steering link bearings, total of four
fittings. Two on the right side and two on the left
side

3. Check for any worn or loose components of the
steering mechanism. Remove any debris or
trash as

Maintenance Section

-171-
Battery Terminal - Clean, Inspect
WARNING
Batteries give off flammable fumes that can
explode.
Do not smoke when observing the battery
electrolyte levels.
Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes.
Always wear protective glasses when working
with batteries.

1. Clean the top of the battery and terminals.

2. Check terminals for corrosion. Coat terminals
with heavy grease.
Engine Oil & Filter (LP & Gasoline
Engine Only) - Change
Gasoline, LP Engine Crankcase

1. Operate lift truck a few minutes to warm oil.
Park the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
engine stopped.

2. Raise rear of lift truck off ground and block
securely.

WARNING
contact skin.

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 element.

6. Wipe sealing surface of oil filter element
mounting base. Make sure the entire old gasket
is removed.

Maintenance Section

-172-
7. Before installing a new filter element, apply a
small amount of clean engine oil to the filter
element gasket.

8. Install the new filter element. When the gasket
contacts the base, tighten it 3/4 of a turn more.
Do not over-tighten.

9. Raise the lift truck, remove the blocking and
lower the lift truck.

10. Fill the crankcase. See Refill Capacities.

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

12. Check for oil leaks.

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
PCV Valve System - Inspect,
Clean
G420F(E) Gasoline, LP and Dual Fuel
Engines

G424F(E) LP and Duel Fuel Engines

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

Maintenance Section

-173-
Wheel Bolts & Nuts - Inspect
Inspect Tightness (D, G - Series)
Steer Wheels

Typical Example

1. Inspect tightness of wheel bolts in a sequence
opposite each other 110 Nm (75 lbft).

Drive Wheels

Typical Example

2. Inspect tightness of wheel nuts in a sequence
opposite each other to 610 Nm (450 lbft).
Inspect Tightness (GC - Series)
Drive Wheels

Typical Example

1. Inspect tightness of wheel bolts in a sequence
opposite each other to 245 Nm (180 lbft).
Maintenance Section

-174-
Governor Lever and Engine Speed
Control (Diesel Engine Only) -
Check ,Adjust
The governor lever and engine speed control (
throttle lever, pedal, etc.) of the machine are
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.

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

Figure 5-11

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,
(4)) and adjust the cable so the governor lever
makes proper contact with the high / low idle
speed limit screw
WARNING
NEVER attempt to adjust the low or high idle
speed limit screw. This may impair the safety
and performance of the machine and shorten its
life. If the idle speed limit screws require
adjustment, see your authorized Yanmar
industrial engine dealer or distributor..

Maintenance Section

-175-

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 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))
makes uniform contact with the low idle (Figure
5-12, (2)) and high idle (Figure 5-12, (3)) speed
limit screws when the engine speed control is in
the high idle speed or low idle 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.

Figure 5-12
Maintenance Section

-176-


Belts - Check, Adjust

Typical Example

1. Check the condition and adjustment of the belt.
Correct adjustment allows 10 mm (3/8 inch)
deflection under 110 N (25 lb) of force.

NOTICE
Failure to loosen the alternator mounting bolt (2)
will cause excessive stress and break the alternator
mounting ear.

2. To adjust the alternator drive belt, loosen
adjusting bracket bolt (1) and mounting bolt (2).
Move the alternator in or out as required.
Tighten bolts (1) and (2).
Mast Hinge Pin Lubricate

Typical Example

1. Lower the forks and tilt the mast forward.

2. Lubricate the two fittings for the mast hinge pins,
one on each side of the mast.

Tilt Cylinders - Check, Adjust,
Lubricate
Chassis Pivot Eyebolts-Lubricate

Typical Example

1. Remove floor plates. (GC-series only)

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.
Maintenance Section

-177-
Mast Pivot Eyes-Lubricate

Typical Example

1. Lubricate two fittings for the mast pivot eyes,
one on each side of the pin.

2. Check the pivot eye pins for loose retainer bolts
and wear.

Cylinder Rod Extension-Adjust
NOTE: The following description is for forward tilt.
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
be added or removed.

Typical Example

1. Check to make sure the tilt cylinders extend
and retract evenly.

2. If one cylinder continues to move after the other
cylinder has stopped in full forward or backward
tilt, an adjustment must be made to one
cylinder.

Typical Example

3. To adjust the cylinder rod extension, move the
spacer to the rear and loosen the pinch bolt on
the clevis.

4. Turn the cylinder rod in or out of the clevis to
obtain the proper adjustment. Turning the rod
into the clevis shortens the stroke. Turning the
rod out of the clevis lengthens the stroke.

5. Tighten the pinch bolts to a torque of 9515
Name (70 10 abaft). Check the cylinder rods
again for even travel.

Crosshead Rollers - Inspect
Check Operation
1. Operate the mast through a lift cycle. Watch the
chains move over the crosshead rollers. Make
sure the chain is tracking over the rollers
properly.

Typical Example

2. Check for damaged crosshead rollers, guards
and retainer rings.

Maintenance Section

-178-
Transmission Oil Filter Change
WARNING
contact skin.

parking brake engaged, direction control lever in
NEUTRAL and the engine stopped.

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.

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.

level.

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

10. Check for oil leaks at the filters.

11. Stop the engine. Install the floor mat and floor
plate.
Overhead Guard Inspect

1. Check tightness of overhead guard mounting
bolts at 95 Nm (70 lbft).

2. Check overhead guard for bent or cracked
sections. Have repairs made if needed.

Maintenance Section

-179-
Drive Axle Oil & Strainer - Change,
Clean

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.

7. Install the dip stick/filter cap.
Maintenance Section

-180-
Steer Suspension Inspect

1. Inspect the suspension mounting bolts. Tighten
suspension mounting bolts, if necessary, to 240
30 Nm (180 20 lbft).

2. Look for leaks at the power steering hose
connections.

3. Remove any trash buildup on the suspension or
the steer axle.

Parking Brake - Test, Adjust
See topic, Parking Brake - Test, Adjust in First
50-100 Service Hours or a Week.

Inching & Braking Control Shaft -
Lubricate

1. Lubricate three fittings for the inching and brake
pedal control shaft.

Horn and Lights (If Equipped) -
Check

1. Press horn button, to determine if horn is
operational.

2. Check and replace all defective gauges.

3. Check all lights such as warning, directional,
backup, driving and flood lights for correct
operation. Replace all burned out bulbs.
Have repairs made if needed.
Maintenance Section

-181-
(G420F(E)/G424F(E) Engine Only)

1. Visually inspect vacuum lines and fittings for
physical damage such as bittleness, cracks and
kinks. Repair/replace as required.

2. Slovent or oil damage may cause vacuum lines
to become soft resulting in a collapsed line
while the engine is running.

3. If abnormally soft lines are detected, replace as
necessary.

(1) Fuel Trim Valve(FTV)
(2) Vacuum lines

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
converters tee connection.

5. Lightly blow through the vacuum line connected
to the FTV. Air should not pass through the FTV
when de-energized. If air leaks past the FTV
when de-energized replace replace the FTV.

Inspect Electrical System

1. Check for loose, dirty or damaged connectors
and wires on the harness including: Fuel
lock-off, TMAP sensor, O2 sensor, Electronic
throttle, Control Relays, Fuel Trim Valve, Foot
Pedal, and crank sensor.

2. Repair and/or replace as necessary.

2
1
Maintenance Section

-182-
Fuel Filter (Diesel Engine Only) -
Change
Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
diesel fuel flow

1. Stop the engine and allow it to cool.

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)). When
removing the fuel filter, carefully hold it to
prevent the fuel from spilling. Wipe up all spilled
fuel.

Figure5-13

4. Clean the filter mounting surface and apply a
small amount of diesel fuel to the gasket of the
new fuel filter.

5. Install the new fuel filter. Turn to the right
(Figure5-13, (2)) and hand-tighten it only until it
comes in contact with the mounting surface.
Tighten to 14-17 ftlb (19.6-23.5 Nm;
2.0-2.4kgfm) or one additional turn using the
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.
Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
diesel fuel flow.
1. Stop the engine and allow it to cool.
2. Close all fuel cocks in fuel line.
3. Disconnect the fuel filter sensor connector
(Figure 5-14, (1)).

Figure 5-14

4. Place an approved container under fuel filter.
5. Carefully open the drain plug (Figure 5-15, (1))
to drain fuel from the fuel filter.
6. Remove the fuel filter (Figure 5-14, (2)) by
turning it to the left (Figure 5-14, (3)). Wipe up
all spilled fuel.
7. Remove the drain plug (Figure 5-15, (1)) from
the fuel filter (Figure 5-15, (2)) by turning it to
the left (Figure 5-15, (3)).
8. Check the condition of the drain plug O-ring
(Figure 5-15, (4)). Replace the O-ring if
damaged.

Maintenance Section

-183-

Figure 5-15

9. Set the drain plug aside for reinstallation.
10. Remove the fuel filter sensor assembly (Figure
5-15, (5)) by turning it to the left (Figure 5-15,
(3)).
11. Carefully remove the in-line fuel filter (Figure
5-15, (7)) from the output nipple (Figure 5-15,
(8)) that goes to the fuel injection pump.
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 the output nipple (Figure
5-15, (8)).
14. Carefully install the fuel filter sensor assembly
(Figure 5-15, (5)) in the new fuel filter using the
new O-ring supplied with the fuel filter (Figure
5-15, (2)) by turning the fuel filter sensor
assembly to the right (Figure 5-15, (9)).
15. Install the drain plug (Figure 5-15, (1)) on the
new fuel filter (Figure 5-15, (3)) by turning the
drain plug to the right (Figure 5-15, (8)). Hand
tighten only.
16. Clean the fuel filter mounting surface (Figure
5-15, (10)) and apply a small amount of diesel
fuel to the gasket of the new filter.
17. Install the new fuel filter (Figure 5-14, (2)) by
turning it to the right (Figure 5-14, (4)) until it
contacts the mounting surface. Tighten one
additional turn.
18. Open all fuel cocks in the fuel line.
19. Reconnect the fuel filter sensor connector
(Figure 5-14, (1)).
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.
Maintenance Section

-184-
Water Separator (4TNV98 Diesel
Engine Only) - Clean

Periodically clean the fuel filter / water separator
element and inside cup.

1. Position an approved container under the cup
(Figure5-16, (1)) of the fuel filter/water
separator to collect the contaminants.

Figure5-16

2. Close (Figure5-16, (2)) the fuel cock
(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)) to the
left (Figure5-16, (10)) and remove the cup
(Figure5-16, (6)). If equipped, disconnect the
sensor wire (Figure5-16, (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.

6. Remove the float ring (Figure5-16, (8)) from the
cup. Pour the contaminants into the container
and dispose of it properly.

7. Clean the element (Figure5-16, (9)) and inside
cup. Replace the element if it is damaged.

8. Install the element and O-ring in the bracket.

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 a
torque of 11-15 ftlb (15-20 Nm; 1.5-2.0kgfm).

12. Close the drain cock. Reconnect the sensor
wire if equipped.

13. Open the fuel cock (Figure5-16, (3)).

14. Prime the fuel system. See topic, Priming the
Fuel System in When required.

15. Check for leaks

Maintenance Section

-185-


Hydraulic Return Filter, Breather
& Strainer - Check, Change
WARNING
contact skin.


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.

Typical Example

7. Remove and discard the air breather.

8. Install a new air breather.


FULL mark on the dipstick/filter cap assembly.
Maintenance Section

-186-
Transmission Oil, Oil Filter &
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
parts against each other causes wears.
Inspect to be sure that chain link pins do not extend
outside of the link hole. If any single link pin is
extended beyond its connecting corresponding link,
it should be suspected of being broken inside of its
link hole. Lift chains are required to check for wear
about every 1,000 service hours or 6 months.

Chain wear test is a measurement of wear of the
chain links and pins. Take the following steps to
check chain wear.

1. Lift the mast and carriage enough for getting
tension on lift chains.

Typical example

2. Measure precisely ten links of chain distance at
the center of pins in millimeter.

3. Calculate chain wear rate*.

4. If the chain wears rate is 2% or more, replace
the lift chain.

*Chain wear rate (%)

= Actual measurement - Pitch** X 10
Pitch** X 10
**Chain Pitch = 19.05mm (0.75in)

Check for Equal Tension

Typical example

Lift the carriage and the mast high enough for
getting tension on lift chains. Check the chains, and
make sure the tension is the same. Lift chains are
required to check for equal tension about every
1,000 service hours or 6 months.

WARNING
Personal injury can be caused by sudden
movement of the mast and carriage. Keep
hands and feet clear of any parts that can move.

Lift Chain Adjustment

Typical example for carriage equal tension

If the tension is not the same on both chains, take
the procedure as follows.

NOTE: If carriage height is not correct, make
adjustments by following procedures.

X 100
Maintenance Section

-187-
Carriage Chain Adjustment
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
distance from bottom of inner upright to the
bottom of carriage bearing.

Typical example for carriage chain of STD mast

Typical example for carriage chain of FF, FFT mast

3. Make adjustment anchor nut (1), (2) for equal
chain tension.

4. Set the mast vertical and raise the carriage and
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 (1), (2) after the adjustment is
completed.

Mast Chain Adjustment - FF, FFT Mast

Typical example for FF mast

Typical example for FFT 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 from the lift chains.

2. Loosen nut (3) and adjust nut (4) to make inner
mast rail flush with outer mast rail bottom.

3. Make adjustment anchor nuts (3), (4) for equal
chain tension.

4. Raise the inner mast and 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
completed.
Maintenance Section

-188-
Universal Joint Inspect

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.

Air Intake System - Change
Changing Primary Element
See topic, Air Intake System - Check, Clean in

Changing Secondary Element
1. Remove the primary air cleaner element. See
topic Servicing Filter Element. Clean the
inside of the air cleaner housing and cover.

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.
Maintenance Section

-189-
Inspect Coolant Hoses
(LP, Dual Fuel Engine Only)
1. Visually inspect coolant hoses and clamps.
Remember to check the two coolant lines that
connect to the pressure regulator/converter.

2. Replace any hoses that shows signs of swelling,
cracking, abrasion or deterioration.

(1) LP Regulator/Converter
(2) Coolant hoses

LP Regulator/Converter
Inspection (LP, Dual Fuel Engine
Only)

1. Visually inspect the pressure
regulator/converter housing for coolant leaks.
Refer to the pressure regulator/converter
section of the service manual if maintenance is
required.

NOTE: For pressure testing and internal inspection
of the pressure regulator/converter, refer to
the pressure regulator/converter section of
the service manual.

Fuel Lines & Fittings - Check
Visually inspect fuel lines and fittings for physical
damage. Replace as required.

(1) Fuel lines
(2) LP mixer
(3) Throttle Assembly

Inspect Mixer Assembly
Refer to the LP mixer section of the engine service
manual for procedures.

Inspect Throttle Assembly

1. Visually inspect the throttle assembly motor
housing for coking, cracks and missing
cover-retaining clips. Repair and/or replace as
necessary.

NOTE: Refer to the LP mixer and throttle section of
the service manual for procedures on
removing the mixer and inspecting the
throttle plate.
1
2
1
2
3
Maintenance Section

-190-
Engine Valve Lash (Diesel Engine
Only) - Check, Adjust

NOTICE
The valve clearances are to be adjusted at the
times of the following 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
Exhaust Valves 0.2 mm (.0.08 in) 3.3 liter
(4TNV98 &
4TNE98) Diesel
Intake Valves 0.2 mm (.0.08 in)

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

Maintenance Section

-191-

Inspect Ignition System (LP,
Gasoline & Dual Fuel Engines
Only)
1. Disconnect Battery Cables.
2. Remove and inspect the spark plugs. Replace
as required.
3. Test secondary cables with an Ohmmeter. If the
maximum resistance is higher than 25 kOhms,
repair and/or replace(G424F(E) engine only).
4. Inspect the ignition coil for cracks and heat
deterioration. Visually inspect the coil heat sink
fins. If any fins are broken replace as required.

G420F(E) Engine

G424F(E) Engine

(1) Spark Plug Cables
(2) Ignition Coil

Replace Spark Plugs (G424F(E)
LP, Dual Fuel Engine Only)
2. Using a gentle twisting motion remove the high
voltage cables from the spark plugs. Replace
any damaged cables.
3. Remove the spark plugs.
4. Gap the new spark plugs to the proper
specifications.
G424F(E) Engine : 0.9 mm

5. Apply anti-seize compound to the spark plug
threads and install.
G424F(E) Engine : 25 Nm (18 lbft)

WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.

6. Re-install the high voltage cables.

2
1
Maintenance Section

-192-
Replace LP Fuel Filter Element
(LP, Dual Fuel Engine Only)

Park the lift truck in an authorized refueling area
with the forks lowered, parking brake applied and
the transmission in Neutral.

1. Close the fuel shutoff valve on the LP-Fuel tank.
Run the engine until the fuel in the system runs
out and the engine stops.

2. Turn off the ignition switch.

3. Scribe a line across the filter housing covers,
which will be used for alignment purposes when
re-installing the filter cover.

(1) screws

4. Remove the cover retaining screws (1).

Fuel Filter (LP Engine Only)
Disassembly

1. Remove top cover (2), magnet (3), spring (4),
and filter element (7) from bottom cover (5).

2. Replace the filter element (7).

3. Check bottom cover O-ring seal (6) for damage.
Replace if necessary.

4. Re-assemble the filter assembly aligning the
scribe lines on the top and bottom covers.

5. Install the cover retaining screws, tightening the
screws in an opposite sequence across the
cover.

6. Open the fuel valve by slowly turning the valve
counterclockwise.

7. Crank the engine several revolutions to open
the fuel lock-off. DO NOT START THE ENGINE.
Turn the ignition key switch to the off position.

8. Check the filter housing, fuel lines and fittings
for leaks. Repair as necessary.

Testing Fuel Lock-off Operation
(LP Engine Only)

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
within a short period of time.

5. Turn the ignition key switch off and re-connect
the fuel lock-off connector.

NOTE: The length of time the engine runs on
trapped fuel vapor increases with any
increase in distance between the fuel
lock-off and the pressure
regulator/converter.

(1) LP fuel lock-off
(2) Regulator/Converter
(3) Fuel Trim valve (FTV)
Filter
Housing
Scribe
Point
2
1
4
5
6
3
7
1
1
2
3
Maintenance Section

-193-
Fuel Injectors (Diesel Engine Only)
Inspect, Clean, Test

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.
Failure to comply could result in death or
serious injury.

Proper operation of the fuel injectors is required to
obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on
Service Manual

Crankcase Breather System
(4TNV98 Diesel Engine Only) -
Inspect

Proper operation of the crankcase breather system
is required to maintain the emission requirements
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,
(1)) in the valve cover (Figure5-19, (2)). When the
crankcase pressure reaches a predetermined 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)):

1. Remove the bolts retaining the diaphragm
cover (Figure5-19, (4)).

Figure5-19

2. Remove the diaphragm cover, spring,
diaphragm plate (Figure5-19, (5)) and
diaphragm.

3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.

4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.

Failure of the diaphragm and / or spring will cause
the loss of pressure control and allow an excessive
amount of crankcase fumes to be routed to the
intake manifold. This could result in excessive
deposits in the intake system, high engine exhaust
smoke levels, excessive engine oil consumption,
and / or engine run-on due to the burning of the
engine oil

Maintenance Section

-194-
Every 2000 Service Hours or Yearly


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

Steer Wheel Bearings -
Reassemble

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.

Maintenance Section

-195-
3. Straighten the lock washer tangs.

4. Remove the locknut, lock washer and flat
washer.
Remove the outer wheel bearing.

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 bearing cones.

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

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

Typical Example

9. Tighten the locknut to 135 Nm (100 lbft), while
turning wheel hub to seat the bearing.

10. Loosen the locknut. Retorque it to 50 5Nm
(37 4 lbft). 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.
Maintenance Section

-196-
Drive Wheel Bearing (Power Shaft
and Drive Wheel) Reassemble

Consult your DOOSAN lift truck dealer for the
proper wheel bearing reassembling procedure.
Packing of bearings and adjustment procedure
must be made by a trained mechanic or dealer
personnel.

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

D, G-Series Lift Trucks

Torque for single or dual wheel mounting nuts (1) is
644 34 Nm (470 25 lbft).

Torque for adapter assembly bolts (2) is 285 13
Nm (210 10 lbft).

Tighten wheel bearing nut (3) to 135 Nm (100 lbft)
while the wheel is turned in both directions. Loosen
the nut completely and tighten nut again to 50 5
Nm (37 4 lbft). 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 Nm (40 7 lbft).

Apply Loctite No.242 to threads of spindle bolts
(5).Torque for spindle bolts is 115 14 Nm (85
10 lbft).
GC-Series Lift Trucks.

Torque for wheel bolts (1) is 270 25 Nm (200
20 lbft).

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

Torque for bolts (3) that hold cover to drive axle
housing is 55 10 Nm (40 7 lbft).

Apply Loctite No. 242 to threads of spindle bolts (4).
Torque for spindle bolts is 115 14 Nm (85 10
lbft).
Maintenance Section

-197-
Cooling System Clean, Change
WARNING
At operating temperature, the engine coolant is
Check the coolant level only after the engine
has been stopped and the filler cap is cool
enough to touch with your bare hand.
Remove the filler cap slowly to relieve pressure.
Coolant is included antifreeze for forbidding
corrosion. Avoid contact with the skin and eyes
to prevent personal injury.
Use all cleaning solution with care.

The Lift truck must be level, the forks lowered, the
parking brake engaged, the transmission in
NEUTRAL and the engine stopped and cool.

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

2. Remove the drain plug or water hose on engine
block.

4TNE98 3.3L Diesel Engine

4TNV98 3.3L Diesel Engine

G420F(E) 2.0L LPG/Gasoline Engine

G424F(E) 2.4L LPG/Gasoline Engine

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

Maintenance Section

-198-

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
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 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
plug. Fill coolant to top of the filler neck.

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

Maintenance Section

-199-
Forks Inspect

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

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

Forks with cracks should be removed from
service.

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

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

2. Check the angle between the upper face of the
blade and the front face of the shank. The fork
should be withdrawn from service if angle (C)
exceeds 93 degrees or deviates by more than 3
degrees from an original angle other than 90
degrees, as may be found in some special
application forks.

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

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

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 of the load and cause problems with
entering loads.

The maximum recommended difference in fork
tip elevation (F) is 6.5 mm (0.25") for pallet
forks and 3 mm (0.125") for fully tapered forks.
The maximum allowable difference in fork tip
elevation between the two or more forks is 3
percent of blade length (L).
Replace one or both forks when the difference
in fork tip height exceeds the maximum
allowable difference. Contact your local
DOOSAN Lift Truck Dealer for further
information.

Maintenance Section

-200-

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,
especially on tapered forks and platens.
Remove the forks from service when the blade
length is no longer adequate for the intended
loads.

6. Check the fork mountings (K) for wear, crushing
and other local deformation, which can cause
excessive side to side wobble of the forks.
Excessive clearance on hook type forks may
allow them to fall from the carrier. Forks which
show visible signs of such damage should be
removed from service.

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.

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.

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

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

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

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

Maintenance Section

-201-


Hydraulic Oil - Check, Clean,
Change
WARNING
contact skin.


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.


FULL mark on the dipstick/filter cap assembly.

Inspect Battery System
1. Clean battery outer surfaces with a mixture of
baking soda and water.

2. Inspect battery outer surfaces for damage and
replace as necessary.

3. Remove battery cable and clean, repair and/or
replace as necessary.

Maintenance Section

-202-
Replace Oxygen Sensor
G420F(E) Engine

G424F(E) Engine

When indicated by MIL, replace oxygen seasor on
the exhaust manifold and oxygen sensor on muffler
assembly.

1. Stop engine and wait until the exhaust pipe and
exhaust pipe is cooled.

2. Disconnect the electrical connector of oxygen
sensor

3. Remove oxygen sensor

4. Assemble new oxygen sensor
Tightening torque : 45 Nm (32.5 lbft)

5. Connect the electrical connector of oxygen
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)


2. Remove the ignition wiring harness.

3. Remove the ignition coil assy.

4. Remove spark plugs.

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 Nm (18 Ibft)

WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.

(1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug

1
2
3
Maintenance Section

-203-
Checking the TMAP Sensor

1. Verify that the TMAP sensor (F) is mounted
tightly into the manifold adapter (E), with no
leakage.

2. If the TMAP is found to be loose, remove the
TMAP retaining screw and the TMAP sensor
from the manifold adapter.

3. Visually inspect the TMAP O-ring seal for
damage. Replace as necessary.

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.

Inspect for Intake Leaks

1. Visually inspect the intake manifold, throttle
assembly (2), and manifold adapters (3), for
looseness and leaks. Repair as necessary.

Replace PCV Valve and breather
element - Change (LP, Gasoline and
Dual Fuel Engines)
G420F(E) Engine

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

Maintenance Section

-204-

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

Index Section

-205-
Index

#

12 Months Inspection........................................... 133
4TNE98 Diesel Engine Only.......... 150,153,175,182
4TNV98 Diesel Engine Only.......... 150,152,174,182

A

Accelerator Pedal ................................................... 69
Adjustments .......................................................... 118
Advanced Diagnostics............................................ 99
After Starting the Engine........................................ 81
Air Cleaner Indicator-Check................................. 157
Air Intake System - Change................................. 188
Air Intake System - Check, Clean ....................... 167
Antifreeze.............................................................. 138
Attachment Abbreviations (Includes Special Forks)
................................................................................. 61
Auto Shift Controller ASC-100 (If Equipped) ...... 118
Automatic mode (Direction Inhibit mode)............ 119
Avoiding Lift Truck Tipover .................................... 21

B

Basic Troubleshooting (Gasoline) ......................... 93
Basic Troubleshooting(LP) .................................... 86
Battery Terminal - Clean, Inspect........................ 171
Before Operating the Lift Truck ............................. 12
Before Starting the Engine..................................... 74
Before Starting the Lift Truck................................. 11
Before Storage...................................................... 127
Belts - Check, Adjust............................................ 176
Bent or Twisted Forks .......................................... 131
Brake Fluid............................................................ 142
Brake Oil Level - Check ....................................... 169
Bulbs...................................................................... 149
Burn Prevention...................................................... 15

C

..................................................................55,56,57,58
..................................................................47,48,49,50
..................................................................51,52,53,54
..................................................................43,44,45,46
Carriage Roller Extrusion Adjust ...................... 154
Causes of Fork Failure......................................... 131
Center of Gravity (CG) ........................................... 21
Changing From Gasoline to LP Gas.................. 79
Changing From LP to Gasoline............................. 79
Changing LP Tanks................................................ 72
Changing Primary Element ..................................188
Changing Secondary Element .............................188
Chassis Pivot Eyebolts-Lubricate ........................176
Check for Equal Tension ......................................186
Check Inflation and Damage................................154
Check Operation ...................................................177
Checking Service Indicator...................................157
Checking the TMAP Sensor (G420F(E)/G424F(E)
Engine Only)..........................................................203
Circuit Breaker................................................. 68,150
Cleaning Primary Filter Elements ........................168
Coolant Information...............................................137
Coolant Level Check..........................................156
Coolant Water........................................................138
Cooling System Clean, Change........................197
Cooling System Specifications.............................137
Crankcase Breather System (4TNV98 Diesel Engine
Only) - Inspect .......................................................193
Crosshead Rollers - Inspect .................................177
Crushing or Cutting Prevention..............................14
Cylinder Rod Extension-Adjust ............................177

D

D, G-Series Lift Trucks .........................................196
Daily Inspection.....................................................132
Diagnostics Features............................................119
Diesel Engine ..........................................................77
Diesel Engines ......................................................155
Diesel Specifications.............................................139
Direction Control Lever ...........................................69
Direction Inhibit Point............................................118
Disassembly ..........................................................192
Display for Operator..............................................119
Display for Troubleshooting..................................119
Displaying Fault Codes (DFC) from SECM Memory
..................................................................................99
Drive Axle Oil - Change........................................164
Drive Axle Oil & Strainer - Change, Clean ..........179
Drive Axle Oil Level - Check.................................170
Drive Axle Oil.........................................................141
Drive Wheel Bearing (Power Shaft and Drive Wheel)
Reassemble........................................................196
Dual Fuel System....................................................79

E

Electrical Disconnect Switch (If Equipped)............66
Engine Compartment..............................................66
........................................................................ 161,183
Engine Oil & Filter (LP & Gasoline Engine Only) -
Change ..................................................................171
Engine Oil (DEO and EO).....................................141
Engine Oil Level - Check......................................155
Engine Valve Lash (Diesel Engine Only) Check,
Adjust ............................................................. 190,194
Environment Management .......................................3
Index Section

-206-
Environment Protection........................................ 130
Every 10 Service Hours or Daily ......................... 155
Every 1000 Service Hours or 6 Months.............. 185
Every 1500 Service Hours or 9 Months.............. 191
Every 2000 Service Hours or Yearly................... 194
Every 250 Service Hours or Monthly .................. 167
Every 2500 Service Hours or 15 Months............ 201
Every 3000 Service Hours or 18 Months............ 204
Every 500 Service Hours or 3 Months................ 176

F

Fatigue .................................................................. 131
Fire or Explosion Prevention.................................. 15
First 250 Service Hours or a Month .................... 166
First 50 - 100 Service Hours or a Week.............. 161
First Installation..................................................... 132
Fluid Penetration .................................................... 14
Foreword....................................................................2
Fork Inspection..................................................... 132
Forks Inspect ..................................................... 199
Fuel Filter (Diesel Engine Only) - Change.......... 182
Fuel Filter (LP Engine Only) ................................ 192
Fuel Injectors (Diesel Engine Only) Inspect, Clean,
Test........................................................................ 193
Fuel Lines & Fittings - Check............................... 189
Fuel Selector Switch (G420F(E)/G424F(E) Dual
Fuel Only)................................................................ 68
Fuel Specifications ............................................... 139
Fuel Sulfur Content .............................................. 139
Fuel Tank Filter Cap and Screen (If Equipped) -
Clean..................................................................... 148
Fuel Types ............................................................ 139
Fuses..................................................................... 149
Fuses, Bulbs, Circuit Breaker & Relay - Change,
Reset ..................................................................... 149

G

G420F Engine and G424F Engine........................ 85
G420F(E) Engine........................................... 191,202
G420F(E) Gasoline, LP and Dual Fuel Engines . 172
G420FE Engine and G424FE Engine................... 84
G424F(E) Engine........................................... 191,202
G424F(E) LP and Duel Fuel Engines ................. 172
Gasoline and LP Engines .................................... 155
Gasoline Engine ..................................................... 76
Gasoline or Diesel Engine Equipped.................... 71
Gasoline Specifications........................................ 140
Gasoline, LP Engine Crankcase ......................... 171
GC-Series Lift Trucks........................................... 196
General Fuel Information..................................... 139
General Hazard Information .................................. 10
General Warning to Operator ...................................6
Governor Lever and Engine Speed Control (Diesel
Engine Only) - Check ,Adjust .............................. 174
H

Hand Placement Warning.........................................7
Hook-on type Fork.................................................126
Horn and Lights (If Equipped) - Check................180
How to Survive in a Tipover ...................................28
Hydraulic Oil - Check, Clean, Change.................201
Hydraulic Oil (HYDO)............................................141
Hydraulic Oil Level Check.................................169
Hydraulic Return Filter Change.........................166
Hydraulic Return Filter, Breather & Strainer - Check,
Change ..................................................................185

I

Identification, Lift Capacity and Attachment Plate 62
If Convenience Package Equipped........................62
If Optional Suspension Seat (weight adjusting type)
Equipped..................................................................18
If Parking Brake Alarm Equipped.........................125
Important Safety Information....................................4
Improper Modification or Repair...........................131
Inching & Braking Control Shaft - Lubricate........180
Inching into Loads.................................................121
Inching......................................................................83
Index ......................................................................205
Inspect Battery System.........................................201
Inspect Coolant Hoses (LP, Dual Fuel
Engine Only)..........................................................189
Inspect Electrical System (G420F(E)/G424F(E)
Engine Only)..........................................................181
Inspect Engine for Exhaust Leaks .......................157
Inspect Engine for Fluid Leaks.............................155
Inspect Foot Pedal Operation (G420F(E)/G424F(E)
Only).......................................................................157
Inspect for Intake Leaks (G420F(E)/G424F(E)
Engine Only)..........................................................203
Inspect Ignition System (LP, Gasoline & Dual Fuel
Engines Only)........................................................191
Inspect Mixer Assembly (G420F(E)/G424F(E)
Engine Only)..........................................................189
Inspect Throttle Assembly (G420F(E)/G424F(E)
Engine Only)..........................................................189
Inspect Tightness (D, G - Series).........................173
Inspect Tightness (GC - Series)...........................173
(G420F(E)/G424F(E) Engine Only) .....................181
Inspection from Operator's Seat, Engine OFF....159
Inspection from Operator's Seat, Engine ON......159
Inspection, Maintenance and Repair of Lift Truck
Forks ......................................................................130
Instrument Panel .....................................................63

L

Lift Chain Adjustment............................................186
Lift Chain Wear Test .............................................186
Lift Chains - Test, Check, Adjust..........................186
Index Section

-207-
Lift Control............................................................... 70
Lift Fork Adjustment ............................................. 126
Lift Truck Controls .................................................. 69
Lift Truck Operation................................................ 82
Lift Truck Parking.................................................... 13
Lift Truck Shipping................................................ 128
Lift Truck Stability Base.......................................... 22
Lift Truck Stability................................................... 21
Lifting Drums or Round Objects .......................... 124
Lifting the Load..................................................... 121
Literature Information................................................2
Load Backrest Must Be In Place Warning...............7
Long Time Storage............................................... 127
LP Engine................................................................ 77
LP Regulator/Converter Inspection (LP, Dual Fuel
Engine Only) ......................................................... 189
LP Specifications.................................................. 140
Lubricant Information............................................ 141
Lubricant Viscosities and Refill Capacities......... 143
Lubricant Viscosities............................................. 143
Lubricating Grease (MPGM)................................ 142

M

Machine Lifting and Tiedown Information........... 128
Maintenance and Repair...................................... 133
Maintenance Information ....................................... 14
Maintenance Intervals....................................... 3,144
Maintenance ..............................................................3
Make proper antifreeze additions........................ 138
Manual Mode (Fail-Safe mode)........................... 120
Mast Abbreviations................................................. 62
Mast Channels Lubricate.................................. 158
Mast Hinge Pin Lubricate.................................. 176
Mast Pivot Eyes-Lubricate................................... 177
Mast, Carriage, Lift Chains & Attachments - Inspect,
Lubricate................................................................ 170
Metric Hardware ................................................... 135
Mono-Ped Control System (Option).................... 117
Mounting and Dismounting.................................... 11
Moving Fan Warning.................................................8

N

No Riders Warning....................................................8
No Standing On Fork Warning .................................7
No Standing Under Fork Warning............................7
Noise and Vibration................................................ 42

O

Oil Cooled Disc Brake Only................................. 142
Operating in hot weather...................................... 124
Operating Techniques.......................................... 121
Operating the Lift Truck.......................................... 12
Operation Information ............................................ 11
Operation ........................................................... 2,119
Operator's Warning and Identification Plate......... 62
Operator's Warning Plate .......................................62
Operator Restraint System(If Equipped) ............2,17
Operators Station and Monitoring Systems..........63
Overhead Guard Inspect ...................................178
Overhead Guard Must Be In Place Warning...........8
Overloading ...........................................................131

P

Parking Brake - Inspect ........................................159
Parking Brake - Test, Adjust......................... 164,180
Parking Brake Adjusting .......................................165
Parking Brake Lever ...............................................70
Parking Brake Testing ..........................................164
PARKING BRAKE.................................................160
Parking brake ............................................................9
Parking the Lift Truck............................................125
PCV Valve System - Inspect, Clean....................172
Power Shift Transmission/ Drive axle....................82
Precleaner (If Equipped).......................................167
Pressure Air.............................................................14
Pressure Warning .....................................................7
Prestart Conditions..................................................76
Priming the Fuel System(Diesel Engine Only)....150
Product Description...............................................118

R

Reading Diagnostic Fault Codes ...........................99
Refill Capacities.....................................................143
Refueling..................................................................71
Replace LP Fuel Filter Element (LP, Dual Fuel
Engine Only)..........................................................192
Replace Oxygen Sensor (G420F(E)/G424F(E)
Engine Only)..........................................................202
Replace PCV Valve and breather element - Change
(LP, Gasoline and Dual Fuel Engines) ................203
Replace Spark Plugs (G420F(E) Engine Only) ..202
Replace Spark Plugs (G424F(E) LP, Dual Fuel
Engine Only)..........................................................191

S

Safety Rules ............................................................23
Safety......................................................................2,5
Seat Adjustment......................................................18
Seat Switch System (If Equipped) .........................67
Seat ..........................................................................68
Seat, Hood Latch & Support Cylinder - Check,
Lubricate................................................................148
Serial Number Locations ........................................59
Serial Number..........................................................59
Service Brake Pedal ...............................................69
Servicing Filter Element........................................167
Sideshift Attachment (If Equipped) ........................70
Specifications ............................... 30,32,34,36,38,40
Stability and Center of Gravity ...............................21
Starting a Cold Diesel Engine ................................77
Index Section

-208-
Starting a Warm Diesel Engine............................. 77
Starting From a 12 Volt External Source.............. 78
Starting the Engine................................................. 76
Starting the Lift truck .............................................. 12
Steer Suspension Inspect................................. 180
Steer Wheel Bearings - Reassemble.................. 194
Steering Mechanism - Check, Lubricate............. 170
Storage Information.............................................. 127

T

Table of Contents......................................................1
Testing Fuel Lock-off Operation (LP Engine Only)
............................................................................... 192
Tilt Control............................................................... 70
Tilt Cylinders - Check, Adjust, Lubricate............. 176
Tilt Steering Column............................................... 68
Timing Belt [G420F(E)/G424F(E) LP, Gasoline, Dual
Fuel Engine Only] - Change.............................. 204
Tire Inflation Information ...................................... 134
Tire Inflation Pressures Adjustment .................... 134
Tire Inflation .......................................................... 134
Tire Shipping 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 ..................................................................... 135
Torque for Standard Hose Clamps - Worm Drive135
Torque Specifications........................................... 135
Torques for Bolts and Nuts with Standard Threads
............................................................................... 135
Torques for Taperlock Studs............................... 136
Towing Information............................................... 129
Traing Required To Operate or Service Warning ...5
Transmission Inching Control Pedal ..................... 69
Transmission Oil Filter Change........................ 178
Transmission Oil Level Check.......................... 159
Transmission Oil ................................................... 142
Clean, Change............................................... 162,186
Transportation Hints............................................. 128
Traveling With the Load....................................... 122
Turning .................................................................. 123

U

Universal Joint Inspect...................................... 188
Unloading.............................................................. 122

W

Walk-Around Inspection - Inspect ....................... 157
Walk - Around Inspection....................................... 74
Warning Signs and Labels..................................... 17
Warning Signs and Labels........................................5
Water Separator (4TNV98 Diesel Engine Only) -
Clean......................................................................184
Water Seperator (Diesel Engine Only) - Check,
Drain.......................................................................152
Wheel Bolts & Nuts - Inspect................................173
When Required .....................................................148

Doosan D20S-5 Operation

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