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Doosan G20E-5, Operation & Maintenance Manual, Page: 96 / 210

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Doosan G20E-5 Operation & Maintenance Manual Download Page 96

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Operation Section

Operation Section

Problem 

Problem 

Probable 

Probable Cause 

Cause 

Corrective 

Corrective Action

Action

Fuel 

Fuel tank 

tank almost 

almost empty 

empty 

Fuel 

Fuel Pump 

Pump Cavitations

Cavitations

  

The  tank  should  be  at  least  ¼  full  to

The  tank  should  be  at  least  ¼  full  to

properly prime the fuel pump

properly prime the fuel pump

  

Fuel select switch is not on 

Fuel select switch is not on GAS

GAS

Clogged 

Clogged fuel 

fuel filter 

filter 

Repair/replace 

Repair/replace as 

as required

required

  

See Maintenance section, Primary and

See Maintenance section, Primary and

Secondary Fuel Filter re

Secondary Fuel Filter replacement

placement

Electric  Fuel  Pump  malfunction

Electric  Fuel  Pump  malfunction
(GAS)

(GAS)

Check electrical connection

Check electrical connection

  

Check  Relay  and  fuse  Turn  key  ON

Check  Relay  and  fuse  Turn  key  ON

and verify pump is operating

and verify pump is operating

  

See Engine Service Manual

See Engine Service Manual

Pressure 

Pressure regulator 

regulator malfunction 

malfunction 

Test 

Test pressure 

pressure regulator 

regulator operation

operation

  

See Engine Service Manual

See Engine Service Manual

Fuel 

Fuel Injector 

Injector malfunction 

malfunction 

Test 

Test Injector 

Injector operation

operation

  

See Engine Service Manual

See Engine Service Manual

Air 

Air filter 

filter clogged 

clogged 

Check 

Check air 

air filter

filter

  

Clean/replace as required

Clean/replace as required

Incorrect 

Incorrect air/fuel 

air/fuel or 

or ignition 

ignition control 

control 

See 

See Advanced 

Advanced Diagnostics

Diagnostics

Difficult to Start

Difficult to Start
(Gas)

(Gas)

Engine 

Engine Mechanical 

Mechanical 

See 

See Engine 

Engine Service 

Service Manual

Manual

Isolate  the  gasoline  system  by

Isolate  the  gasoline  system  by
running the lift truck on LPG

running the lift truck on LPG

Verify LPG cylinder is full and valve is open.

Verify LPG cylinder is full and valve is open.
If the problem does not exist in LPG mode

If the problem does not exist in LPG mode
proceed  with  the  corrective  action  steps

proceed  with  the  corrective  action  steps
below.

below.

If the problem 

If the problem also exists in LPG mode then

also exists in LPG mode then

the  root  cause  is  most  likely  to  be

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

something other than the fuel system

  

See Advanced Diagnostics

See Advanced Diagnostics

Fuel 

Fuel tank 

tank almost 

almost empty 

empty 

Fuel 

Fuel Pump 

Pump Cavitations

Cavitations

  

The  tank  should  be  at  least  ¼  full  to

The  tank  should  be  at  least  ¼  full  to

properly prime the fuel pump

properly prime the fuel pump

Will Not Run

Will Not Run
Continuously

Continuously

(Gas)

(Gas)

Clogged 

Clogged fuel 

fuel filter 

filter 

Repair/replace 

Repair/replace as 

as required

required

  

See Maintenance section, Primary and

See Maintenance section, Primary and

Secondary Fuel Filter re

Secondary Fuel Filter replacement

placement

Summary of Contents for G20E-5

Page 1: ...25S 5 D30S 5 D33S 5 D35C 5 D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 G20E 5 G25E 5 G30E 5 G20E 5 G25E 5 G30E 5 GC20E 5 GC25E 5 GC30E 5 GC33E 5 GC20E 5 GC25E 5 GC30E 5 GC33E 5 G20P 5 G25P 5 G30P 5 G33P 5 G35C 5 G20P 5 G25P 5 G30P 5 G33P 5 G35C 5 GC20P 5 GC25P 5 GC30P 5 GC33P 5 GC20P 5 GC25P 5 GC30P 5 GC33P 5 0712 0712 ...

Page 2: ......

Page 3: ...uck Truck Opera Operation tion 82 82 Mono Ped Control System O Mono Ped Control System Option ption 117 117 Auto Shift Auto Shift Controller ASC 1 Controller ASC 100 If Equipped 00 If Equipped 118 118 Opera Operating ting Technique Techniques s 121 121 Parking Parking the the Lift Lift Truck Truck 125 125 Lift Lift Fork Fork Adjustment Adjustment 126 126 Storage Storage Informa Information tion 12...

Page 4: ...r restraint system Photographs or illustrations guide the operator Photographs or illustrations guide the operator through correct procedures of checking operation through correct procedures of checking operation and maintenance of the DOOSAN operator and maintenance of the DOOSAN operator restraint system restraint system SAFE and EFFICIENT OPERATION of a lift truck SAFE and EFFICIENT OPERATION o...

Page 5: ...l requirement For example at Every 500 Service requirement For example at Every 500 Service Hours or 3 Months also service those items listed Hours or 3 Months also service those items listed under Every 250 Service Hours or Monthly and under Every 250 Service Hours or Monthly and Every 10 Service Hours or Every 10 Service Hours or Daily Daily Environment Management Environment Management Note tha...

Page 6: ...ert Your Safety is Attention Become Alert Your Safety is involved involved The message that appears under the warning explaining the hazard can be either written or pictorially The message that appears under the warning explaining the hazard can be either written or pictorially presented presented Operations that may cause product damage are identified by NOTICE labels on the product and in this O...

Page 7: ...ions which can result in an avoid actions or conditions which can result in an accident accident Do not operate a lift truck if in need of repair Do not operate a lift truck if in need of repair defective or in any way unsafe Report all defects defective or in any way unsafe Report all defects and unsafe conditions immediately Do not attempt and unsafe conditions immediately Do not attempt any adj...

Page 8: ...g load trailing 6 6 On grade operations travel with load up grade On grade operations travel with load up grade 7 7 Watch out for pedestrians and obstructions Watch out for pedestrians and obstructions Check overhead clearances Check overhead clearances 8 8 Do not permit riders on forks or machine at any Do not permit riders on forks or machine at any time time 9 9 Do not allow anyone to stand or ...

Page 9: ...o do so permit others to do so Located on the mast Located on the mast No Standing On Fork Warning No Standing On Fork Warning No Standing Under Fork Warning No Standing Under Fork Warning WARNING WARNING Do not stand or ride on the forks Do not stand Do not stand or ride on the forks Do not stand or ride on a load or pallet on the forks Do not or ride on a load or pallet on the forks Do not stand...

Page 10: ...d on the Overhead Guard Overhead Guard No Riders Warning No Riders Warning WARNING WARNING To avoid personal injury allow no riders A lift To avoid personal injury allow no riders A lift truck is designed for only one operator and no truck is designed for only one operator and no riders riders Located beside the operator s station STD or on Located beside the operator s station STD or on front of ...

Page 11: ... audible alarm will sound sound WARNING WARNING When leaving machine apply parking brake When leaving machine apply parking brake Parking brake is Parking brake is not automatically applied not automatically applied Alarm will sound if parking brake is Alarm will sound if parking brake is not applied not applied WARNING WARNING Correct adjustment is necessary to provide Correct adjustment is neces...

Page 12: ...place due to low overhead clearance use extreme care Make sure there i clearance use extreme care Make sure there is no s no possibility of falling objects from any adjacent possibility of falling objects from any adjacent storage or work area Make sure the load is stable storage or work area Make sure the load is stable and fully supported by the carriage and the load and fully supported by the c...

Page 13: ...attention to the fact that any secondary damages due to improper handling secondary damages due to improper handling insufficient maintenance wrong repairs or the use insufficient maintenance wrong repairs or the use of other than original DOOSAN spare parts waive of other than original DOOSAN spare parts waive any liability by any liability by DOOSAN DOOSAN Operation Information Operation Informa...

Page 14: ...ments work Before devices Know how the attachments work Before moving the lift truck look around Start turn and moving the lift truck look around Start turn and brake smoothly brake smoothly An operator must constantly observe his lift truck An operator must constantly observe his lift truck for proper operation for proper operation Operating the Lift Truck Operating the Lift Truck Always keep the...

Page 15: ...he Refer to the topic Operation Techniques in the Operation Section of this Operation Section of this manual manual Loading or Unloading Trucks Trailers Loading or Unloading Trucks Trailers Do not operate lift trucks on trucks or trailers which Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose Be are not designed or intended for that purpose Be ce...

Page 16: ...cut any object or tool that falls or is pushed into them is pushed into them Do not use a kinked or frayed wire rope cable Do not use a kinked or frayed wire rope cable Wear gloves when handling the wire rope cable Wear gloves when handling the wire rope cable Retainer pins when struck with force can fly out Retainer pins when struck with force can fly out and injure nearby persons Make sure the a...

Page 17: ...e flammable mixtures are flammable Fuel leaked or spilled onto hot su Fuel leaked or spilled onto hot surfaces or electrical rfaces or electrical components can cause a fire components can cause a fire Do not smoke while refueling or in a refueling area Do not smoke while refueling or in a refueling area Do not smoke in Do not smoke in areas where ba areas where batteries are charged tteries are c...

Page 18: ...oard or cardboard to check for leaks See Fluid Penetration cardboard to check for leaks See Fluid Penetration in the Safety Section for more details Tighten all in the Safety Section for more details Tighten all connections to the recommended torque Replace if connections to the recommended torque Replace if any of the following conditions are found any of the following conditions are found End fi...

Page 19: ...rsonal injury explosive force and cause serious personal injury or death Follow carefully the specific information or death Follow carefully the specific information provided by your tire or rim servicing personnel or provided by your tire or rim servicing personnel or dealer dealer Operator Restraint System If Operator Restraint System If Equipped Equipped Warning Signs and Labels Warning Signs a...

Page 20: ...ile the truck is in motion motion WARNING WARNING Do not place your hand or fingers under the Do not place your hand or fingers under the seat Injury may occur as the seat moves up seat Injury may occur as the seat moves up and down and down If Optional Suspension Seat weight If Optional Suspension Seat weight adjusting type Equipped adjusting type Equipped Forward and Backward Adjustment Forward ...

Page 21: ...t belt is torn if pulling motion is If the seat belt is torn if pulling motion is interrupted during extension of the belt or if the interrupted during extension of the belt or if the belt cannot be inserted into the buckle properly belt cannot be inserted into the buckle properly replace the seat bel replace the seat belt assembly t assembly 2 2 Belt Maintenance Every 500 service hours Belt Maint...

Page 22: ...plate connector of the belt and pull the belt from the retractor Then insert the plate into belt from the retractor Then insert the plate into the slot of the buckle until a snap is heard Pull the slot of the buckle until a snap is heard Pull on the belt to confirm it i on the belt to confirm it is latched s latched 2 2 Make sure the belt is not twisted Make sure the belt is not twisted WARNING WA...

Page 23: ...nd load have a lift truck picks up a load the truck and load have a new combined CG new combined CG Stability and Center of Gravity Stability and Center of Gravity The The stability of the lift truck is determined by the stability of the lift truck is determined by the location of its CG or if the truck is loaded the location of its CG or if the truck is loaded the combined CG of the truck and loa...

Page 24: ... the CG in the vertical direction load The location of the CG in the vertical direction is the same as is the same as the horizontal dimensi the horizontal dimension on Remember that unless otherwise indicated the Remember that unless otherwise indicated the capacity load shown on the nameplate is for a capacity load shown on the nameplate is for a standard lift truck with standard backrest forks ...

Page 25: ...te a lift truck unless you are in the Do not operate a lift truck unless you are in the operator s s operator s seat eat Keep hands Keep hands and feet and feet inside the inside the operator s operator s compartment compartment Do not Do not put a put any part ny part of of the body outside of the operator s compartment the body outside of the operator s compartment Never put any part of body int...

Page 26: ...e under the Position the forks as wide as possible under the load Position loads evenly on the forks for proper load Position loads evenly on the forks for proper balance Do not lift a load with one balance Do not lift a load with one fork fork Do not overload Always handle loads within the Do not overload Always handle loads within the rated capacity shown on the rated capacity shown on the capac...

Page 27: ...forks as low Travel with the load tilted back and the forks as low as as possib possible le This will increase stability to the truck and load and This will increase stability to the truck and load and permit better visibility for you permit better visibility for you Do not elevate the load with the mast tilted for Do not elevate the load with the mast tilted forward ward Do not tilt the elevated ...

Page 28: ... path of travel An operator must be in full control of his lift truck at An operator must be in full control of his lift truck at all times all times Do not drive in forward direction when loads restrict Do not drive in forward direction when loads restrict your visibility Operate your lift truck in reverse to your visibility Operate your lift truck in reverse to improve visibility except when mov...

Page 29: ...t forget to close the fuel tank before restarting the engine tank before restarting the engine Park your lift truck in authorized areas only Fully Park your lift truck in authorized areas only Fully lower the forks to the floor put direction lever in lower the forks to the floor put direction lever in NEUTRAL position engage the parking brake and NEUTRAL position engage the parking brake and turn ...

Page 30: ... injury or death will be reduced if the operator is using the operator restraint system and follows using the operator restraint system and follows the instructions provided the instructions provided Always use operator restraint system Always use operator restraint system Don t jump Don t jump Hold on tight Hold on tight Brace your feet and keep them Brace your feet and keep them within the opera...

Page 31: ...Safety Section Safety Section 29 29 Lean away from the direction of fall Lean away from the direction of fall Lean forward Lean forward ...

Page 32: ...50 520 550 520 550 26 26 SPEED SPEED lowering lowering loaded unl loaded unloaded oaded mm s mm s 510 460 510 460 510 460 510 460 27 27 DRAWBA DRAWBAR R PULL at PULL at 1 6km hr 1 6km hr loaded u loaded unloaded nloaded kg kg 1765 1765 1740 1740 28 28 GRADEA GRADEABILITY BILITY at at 1 6km hr 1 6km hr loaded u loaded unloaded nloaded 33 33 28 28 29 ACCELERATION 29 ACCELERATION time reached at max ...

Page 33: ...490 550 490 550 480 550 480 550 25 25 510 460 510 460 510 460 510 460 510 460 510 460 26 26 1830 1830 1820 1820 1750 1750 27 27 25 25 23 5 23 5 21 5 21 5 28 28 29 29 4450 4450 4630 4630 4810 4810 30 30 6580 870 6580 870 6940 940 6940 940 7340 970 7340 970 31 31 1840 2610 1840 2610 1800 2830 1800 2830 1780 3030 1780 3030 32 32 2 2 2 2 2 2 2 2 2 2 2 2 33 33 28x9x15 12 28x9x15 12 28x9x15 1 28x9x15 12...

Page 34: ...50 520 550 520 550 26 26 SPEED SPEED lowering lowering loaded unl loaded unloaded oaded mm s mm s 510 460 510 460 510 460 510 460 27 27 DRAWBA DRAWBAR R PULL at PULL at 1 6km hr 1 6km hr loaded u loaded unloaded nloaded kg kg 1765 1765 1740 1740 28 28 GRADEA GRADEABILITY BILITY at at 1 6km hr 1 6km hr loaded u loaded unloaded nloaded 33 33 28 28 29 ACCELERATION 29 ACCELERATION time reached at max ...

Page 35: ...490 550 490 550 420 550 420 550 25 25 510 460 510 460 510 460 510 460 510 460 510 460 26 26 1830 1830 1820 1820 1750 1750 27 27 25 25 23 5 23 5 21 5 21 5 28 28 29 29 4450 4450 4630 4630 4810 4810 30 30 6580 870 6580 870 6940 940 6940 940 7340 970 7340 970 31 31 1840 2610 1840 2610 1800 2830 1800 2830 1780 3030 1780 3030 32 32 2 2 2 2 2 2 2 2 2 2 2 2 33 33 28x9x15 12 28x9x15 12 28x9x15 1 28x9x15 12...

Page 36: ...km hr km hr 25 25 lift lift loaded unloade loaded unloaded d mm s mm s 26 26 SPEED SPEED lowering lowering loaded unl loaded unloaded oaded mm s mm s 27 27 DRAWBAR DRAWBAR PULL PULL at at 1 6km hr 1 6km hr loaded un loaded unloaded loaded kg kg 28 28 GRADEABILI GRADEABILITY TY at at 1 6km hr 1 6km hr loaded un loaded unloaded loaded 29 ACCELERATION 29 ACCELERATION time reached at max speed time re...

Page 37: ... 25 510 460 510 460 510 460 510 460 510 460 510 460 26 26 1440 1440 1415 1415 1485 1485 27 27 27 27 22 5 22 5 20 5 20 5 28 28 29 29 3570 3570 3940 3940 4380 4380 30 30 4940 630 4940 630 5670 770 5670 770 6310 1050 6310 1050 31 31 1730 1840 1730 1840 1660 2280 1660 2280 1800 2580 1800 2580 32 32 2 2 2 2 2 2 2 2 2 2 2 2 33 33 7 00x15 12 7 00x15 12 7 00x15 12 7 00x15 12 28x9x15 12 28x9x15 12 34 34 6 ...

Page 38: ...0 26 26 SPEED SPEED lowering lowering loaded loaded unloaded unloaded mm s mm s 510 460 510 460 510 460 510 460 27 27 DRAWBA DRAWBAR R PULL PULL at at 1 6km hr 1 6km hr loaded unloade loaded unloaded d kg kg 1750 1750 1725 1725 28 28 GRADEA GRADEABILITY BILITY at at 1 6km hr 1 6km hr loaded unloade loaded unloaded d 33 33 28 28 29 ACCELERATION 29 ACCELERATION time reached at max time reached at ma...

Page 39: ...420 600 25 25 510 460 510 460 510 460 510 460 510 460 510 460 26 26 1815 1815 1805 1805 1735 1735 27 27 25 5 25 5 24 24 21 5 21 5 28 28 29 29 4380 4380 4560 4560 4750 4750 30 30 6310 1050 6310 1050 6890 920 6890 920 7300 950 7300 950 31 31 1800 2780 1800 2780 1760 2800 1760 2800 1750 3000 1750 3000 32 32 2 2 2 2 2 2 2 2 2 2 2 2 33 33 28x9x15 12 28x9x15 12 28x9x15 12 28x9x15 12 250x15 18 250x15 18 ...

Page 40: ...ded loaded mm s mm s 530 600 530 600 26 26 SPEED SPEED lowering lowering loaded u loaded unloaded nloaded mm s mm s 510 460 510 460 27 27 DRAWBA DRAWBAR R PULL PULL at at 1 6km hr 1 6km hr loaded u loaded unloaded nloaded kg kg 1795 1795 28 28 GRADEABILITY GRADEABILITY at at 1 6km hr 1 6km hr loaded unload loaded unloaded ed 35 5 35 5 29 ACCELERATION 29 ACCELERATION time reached at max time reache...

Page 41: ...0 600 500 600 500 600 25 25 510 460 510 460 510 460 510 460 510 460 510 460 26 26 1775 1775 1750 1750 1740 1740 27 27 30 30 25 5 25 5 23 5 23 5 28 28 29 29 3710 3710 4180 4180 4350 4350 30 30 5500 710 5500 710 6330 850 6330 850 6490 860 6490 860 31 31 1460 2250 1460 2250 1470 2710 1470 2710 1420 2930 1420 2930 32 32 2 2 2 2 2 2 2 2 2 2 2 2 33 33 21x7 15 21x7 15 21x8 15 21x8 15 21x8 15 21x8 15 34 3...

Page 42: ... unloaded loaded mm s mm s 530 600 530 600 26 26 SPEED SPEED lowering lowering loaded u loaded unloaded nloaded mm s mm s 510 460 510 460 27 27 DRAWBA DRAWBAR R PULL PULL at at 1 6km hr 1 6km hr loaded u loaded unloaded nloaded kg kg 2170 2170 28 28 GRADEABILITY GRADEABILITY at at 1 6km hr 1 6km hr loaded unload loaded unloaded ed 44 44 29 ACCELERATION 29 ACCELERATION time reached at max time reac...

Page 43: ...500 600 500 600 500 600 500 600 25 25 510 460 510 460 510 460 510 460 510 460 510 460 26 26 2050 2050 2125 2125 2115 2115 27 27 37 37 31 31 29 29 28 28 29 29 3730 3730 4200 4200 4370 4370 30 30 5510 720 5510 720 6340 860 6340 860 6500 870 6500 870 31 31 1470 2260 1470 2260 1490 2710 1490 2710 1430 2940 1430 2940 32 32 2 2 2 2 2 2 2 2 2 2 2 2 33 33 21x7 15 21x7 15 21x8 15 21x8 15 21x8 15 21x8 15 34...

Page 44: ...5 D33S 5 D35C 5 W O Cabin W O Cabin 82 104 82 104 TIER III 4TNE98 E G TIER III 4TNE98 E G D20S 5 D25S 5 D30S 5 D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 D33S 5 D35C 5 W O Cabin W O Cabin 82 104 82 104 TIER III G420F E E G TIER III G420F E E G G20E 5 G25E 5 G30E 5 G20E 5 G25E 5 G30E 5 W O Cabin W O Cabin 82 104 82 104 TIER III G424F E E G TIER III G424F E E G G20P 5 G25P 5 G30P 5 G20P 5 G25P 5 G30P 5 G33P...

Page 45: ...Capacity Chart Without Sideshifter Pneumatic SINGLE TIRE SINGLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 2 2 0 0 S S 5 5 G G 2 2 0 0 E E 5 5 G G 2 2 0 0 P P 5 5 D D 2 2 5 5 S S 5 5 G G 2 2 5 5 E E 5 5 G G 2 2 5 5 P P 5 5 D D 3 3 0 0 S S 5 5 G G 3 3 0 0 E E 5 5 G G 3 3 0 0 P P 5 5 ...

Page 46: ...tion Capacity Chart Without Sideshifter Pneumatic Capacity Chart Without Sideshifter Pneumatic SINGLE TIRE SINGLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 3 3 3 3 S S 5 5 G G 3 3 3 3 P P 5 5 D D 3 3 5 5 C C 5 5 G G 3 3 5 5 C C 5 5 ...

Page 47: ...Capacity Chart Without Sideshifter Pneumatic DOUBLE TIRE DOUBLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 2 2 0 0 S S 5 5 G G 2 2 0 0 E E 5 5 G G 2 2 0 0 P P 5 5 D D 2 2 5 5 S S 5 5 G G 2 2 5 5 E E 5 5 G G 2 2 5 5 P P 5 5 D D 3 3 0 0 S S 5 5 G G 3 3 0 0 E E 5 5 G G 3 3 0 0 P P 5 5 ...

Page 48: ...ction Capacity Chart Without Sideshifter Pneumatic Capacity Chart Without Sideshifter Pneumatic DOUBLE TIRE DOUBLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 3 3 3 3 S S 5 5 G G 3 3 3 3 P P 5 5 D D 3 3 5 5 C C 5 5 G G 3 3 5 5 C C 5 5 ...

Page 49: ... Capacity Chart With Sideshifter Pneumatic SINGLE TIRE SINGLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 2 2 0 0 S S 5 5 G G 2 2 0 0 E E 5 5 G G 2 2 0 0 P P 5 5 D D 2 2 5 5 S S 5 5 G G 2 2 5 5 E E 5 5 G G 2 2 5 5 P P 5 5 D D 3 3 0 0 S S 5 5 G G 3 3 0 0 E E 5 5 G G 3 3 0 0 P P 5 5 ...

Page 50: ... Section Capacity Chart With Sideshifter Pneumatic Capacity Chart With Sideshifter Pneumatic SINGLE TIRE SINGLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 3 3 3 3 S S 5 5 G G 3 3 3 3 P P 5 5 D D 3 3 5 5 C C 5 5 G G 3 3 5 5 C C 5 5 ...

Page 51: ... Capacity Chart With Sideshifter Pneumatic DOUBLE TIRE DOUBLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 2 2 0 0 S S 5 5 G G 2 2 0 0 E E 5 5 G G 2 2 0 0 P P 5 5 D D 2 2 5 5 S S 5 5 G G 2 2 5 5 E E 5 5 G G 2 2 5 5 P P 5 5 D D 3 3 0 0 S S 5 5 G G 3 3 0 0 E E 5 5 G G 3 3 0 0 P P 5 5 ...

Page 52: ... Section Capacity Chart With Sideshifter Pneumatic Capacity Chart With Sideshifter Pneumatic DOUBLE TIRE DOUBLE TIRE MODEL MODEL STD FFL STD FFL FFT FFT D D 3 3 3 3 S S 5 5 G G 3 3 3 3 P P 5 5 D D 3 3 5 5 C C 5 5 G G 3 3 5 5 C C 5 5 ...

Page 53: ...ideshifter cushion Capacity Chart Without Sideshifter cushion NARROW TIRE NARROW TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 2 2 0 0 E E 5 5 G G C C 2 2 0 0 P P 5 5 G G C C 2 2 5 5 E E 5 5 G G C C 2 2 5 5 P P 5 5 G G C C 3 3 0 0 E E 5 5 G G C C 3 3 0 0 P P 5 5 ...

Page 54: ...Section General Section Capacity Chart Without Sideshifter cushion Capacity Chart Without Sideshifter cushion NARROW TIRE NARROW TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 3 3 3 3 E E 5 5 G G C C 3 3 3 3 P P 5 5 ...

Page 55: ... Sideshifter cushion Capacity Chart Without Sideshifter cushion WIDE TIRE WIDE TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 2 2 0 0 E E 5 5 G G C C 2 2 0 0 P P 5 5 G G C C 2 2 5 5 E E 5 5 G G C C 2 2 5 5 P P 5 5 G G C C 3 3 0 0 E E 5 5 G G C C 3 3 0 0 P P 5 5 ...

Page 56: ...l Section General Section Capacity Chart Without Sideshifter cushion Capacity Chart Without Sideshifter cushion WIDE TIRE WIDE TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 3 3 3 3 E E 5 5 G G C C 3 3 3 3 P P 5 5 ...

Page 57: ...ideshifter cushion Capacity Chart With Sideshifter cushion NARROW TIRE NARROW TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 2 2 0 0 E E 5 5 G G C C 2 2 0 0 P P 5 5 G G C C 2 2 5 5 E E 5 5 G G C C 2 2 5 5 P P 5 5 G G C C 3 3 0 0 E E 5 5 G G C C 3 3 0 0 P P 5 5 ...

Page 58: ...al Section General Section Capacity Chart With Sideshifter cushion Capacity Chart With Sideshifter cushion NARROW TIRE NARROW TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 3 3 3 3 E E 5 5 G G C C 3 3 3 3 P P 5 5 ...

Page 59: ... Sideshifter cushion Capacity Chart With Sideshifter cushion WIDE TIRE WIDE TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 2 2 0 0 E E 5 5 G G C C 2 2 0 0 P P 5 5 G G C C 2 2 5 5 E E 5 5 G G C C 2 2 5 5 P P 5 5 G G C C 3 3 0 0 E E 5 5 G G C C 3 3 0 0 P P 5 5 ...

Page 60: ...eral Section General Section Capacity Chart With Sideshifter cushion Capacity Chart With Sideshifter cushion WIDE TIRE WIDE TIRE MODEL MODEL STD FFL STD FFL FFT FFT G G C C 3 3 3 3 E E 5 5 G G C C 3 3 3 3 P P 5 5 ...

Page 61: ... 3 liter Diesel Engine 4 3 3 liter Diesel Engine 4TNV9 TNV98 Serial Number 8 Serial Number _____________________________ _____________________________ 3 3 liter Diesel Engine 4 3 3 liter Diesel Engine 4TNE9 TNE98 Serial Number 8 Serial Number _____________________________ _____________________________ 2 0 liter Spark Ignition Engine Serial Number 2 0 liter Spark Ignition Engine Serial Number G420F...

Page 62: ...___________________ _____________________________ Drive Axle Serial Number Drive Axle Serial Number _____________________________ _____________________________ Typical Example Typical Example Side Shifter Serial Number If Equipped Side Shifter Serial Number If Equipped _____________________________ _____________________________ ...

Page 63: ...Special Forks Special Forks SWS SWS Swing Shift Sideshift Swing Shift Sideshift RAM RAM Ram or Boom Ram or Boom DBCBH DBCBH Double Cube Block Handler Double Cube Block Handler HFP HFP Hydraulic Fork Positioner Hydraulic Fork Positioner CR CR Crane Arm or Crane Boom Crane Arm or Crane Boom TH TH Tire Handler Tire Handler CTH CTH Container Handler Container Handler LPP LPP Load Push Pull Device Load...

Page 64: ...he cowl to the right side of the steering column column Below are abbreviations that may appear on the Below are abbreviations that may appear on the IDENTIFICATION LIFT CAPACITY and IDENTIFICATION LIFT CAPACITY and ATTACH ATTACHMENT PLATES and MENT PLATES and their meanings their meanings Mast Abbreviations Mast Abbreviations STD STD Standard Standard Mast Mast single single inner inner member me...

Page 65: ...s are shown 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 However the symbols on the indicators and lights on your panel identify what those particular items are Also the symbol for each of Also the symbol for each of the items is identified and a the items is identifi...

Page 66: ...k the cooling system for a malfunction Both tenth ninth will flash out of phase when the tenth ninth will flash out of phase when the coolant temperature reaches approximately 106 C coolant temperature reaches approximately 106 C 223 F on all engines 223 F on all engines 7 Transmission Oil Temperature Gauge 7 Transmission Oil Temperature Gauge Indicates transmission oil temperature If Indicates tr...

Page 67: ...AS Indicates Indicates the low Level of LP GAS LP or the low Level of LP GAS LP or DUAL only DUAL only 16 Directional Turning Indicator Light 16 Directional Turning Indicator Light 17 Horn Switch 17 Horn Switch Push on the horn Push on the horn button to sound the horn button to sound the horn 17 17 ...

Page 68: ...e by pulling the latch GC Series or pushing down the lever the latch GC Series or pushing down the lever located at cowl G D Series and located at cowl G D Series and raising the hood raising the hood and seat assembly Note Unlock latch before and seat assembly Note Unlock latch before pulling if key equipped pulling if key equipped 2 2 The hood and seat assembly is held up by a The hood and seat ...

Page 69: ...f the parking brake is not applied when leaving the not applied when leaving the machine machine NOTICE NOTICE Prior to operating the lift truck be sure to Prior to operating the lift truck be sure to understand and check the SEAT SWITCH understand and check the SEAT SWITCH SYSTEM SYSTEM While in normal operation and on level ground While in normal operation and on level ground select a direction ...

Page 70: ...perator fully seated with the operator fully seated Tilt Steering Column Tilt Steering Column To adjust the steering column push down the To adjust the steering column push down the knob 1 and move the steering column to the knob 1 and move the steering column to the desired position then release the knob 1 desired position then release the knob 1 Fuel Selector Switch Fuel Selector Switch G420F E ...

Page 71: ...completely relieves clutch pack pressure and applies the service clutch pack pressure and applies the service brakes to stop and hold the lift truck brakes to stop and hold the lift truck NOTE NOTE The purpose of the inching control pedal is The purpose of the inching control pedal is to provide precise inching control at slow to provide precise inching control at slow travel speed with high engin...

Page 72: ...othly to lift the load smoothly to lift the load Tilt Control Tilt Control 1 1 Mast Tilt Forward Push the lever Mast Tilt Forward Push the lever FORWARD smoot FORWARD smoothly to tilt hly to tilt the mast the mast forward forward 2 2 Mast Hold When the lever i Mast Hold When the lever is released s released it will return to the H it will return to the HOLD or center position OLD or center positio...

Page 73: ... cold weather the moisture condensation can In the cold weather the moisture condensation can cause rust in the fuel system and hard starting due cause rust in the fuel system and hard starting due to its freezing to its freezing Do not fill the tank to the top Fuel expands when it Do not fill the tank to the top Fuel expands when it gets warm and may gets warm and may overflow overflow 1 1 Park t...

Page 74: ...uck should be refueled only at designated Lift truck should be refueled only at designated safe locations Safe outdoor locations are safe locations Safe outdoor locations are preferable to indoor loc preferable to indoor locations ations Stop the engine and get off the lift truck during Stop the engine and get off the lift truck during refueling refueling The careless handling of LP containers can...

Page 75: ...t couplings for deterioration damage or missing flexible seals deterioration damage or missing flexible seals 11 11 Position the replacement tank so that the Position the replacement tank so that the locating pin dowel is in place locating pin dowel is in place WARNING WARNING The LP tank must not extend past the The LP tank must not extend past the counterweight counterweight 12 12 Clamp the tank...

Page 76: ... safety devices for Test the horn and other safety devices for proper operation proper operation 4 4 Inspect the mast and lift chains for wear Inspect the mast and lift chains for wear broken broken links pins and loose rollers links pins and loose rollers 5 5 Inspect the carriage forks or attachments for Inspect the carriage forks or attachments for wear damage and loose or missing bolts wear dam...

Page 77: ...he top tank tank 13 13 Observe the fuel level gauge after starting the Observe the fuel level gauge after starting the truck Add fuel if necessary truck Add fuel if necessary WARNING WARNING Personal injury may occur from accidents Personal injury may occur from accidents caused by improper seat adjustment Always caused by improper seat adjustment Always adjust the operator s seat before starting ...

Page 78: ...d turn the Don t press accelerator pedal and turn the ignition switch to the ignition switch to the START position START position 2 2 Once the engine starts release the ignition Once the engine starts release the ignition switch switch 3 3 If the engine does not start repeat If the engine does not start repeat step 1 step 1 4 4 If engine coolant is cold engine speed could be If engine coolant is c...

Page 79: ...he key to the ON position The start pre heat light will come ON The preheat light will heat light will come ON The preheat light will stay ON approximately seven seconds stay ON approximately seven seconds depending on the surrounding air temperature depending on the surrounding air temperature NOTICE NOTICE Do not engage the starter for more than 10 Do not engage the starter for more than 10 seco...

Page 80: ...ystem components components NOTICE NOTICE Do not reverse battery cables It can Do not reverse battery cables It can cause damage cause damage to the alternator to the alternator Always connect the external power source cables Always connect the external power source cables in parallel with the lift truck battery cables in parallel with the lift truck battery cables POSITIVE to POSITIVE and NEGATIV...

Page 81: ... selector switch to the Move lever 1 on the fuel selector switch to the OFF 2 position Leave lever 1 in this position OFF 2 position Leave lever 1 in this position until the engine stops until the engine stops 3 3 Move lever 1 to the LPG 3 position Move lever 1 to the LPG 3 position 4 4 Open the fuel valve on the LP tank by slowly Open the fuel valve on the LP tank by slowly turning the turning th...

Page 82: ...runs out and engine stops stops 4 4 Move lever 1 from the LPG 3 position to the Move lever 1 from the LPG 3 position to the GAS 4 position GAS 4 position 5 5 Turn the ignition switch key to the OFF po Turn the ignition switch key to the OFF position sition 6 6 Turn the ignition switch key to the START Turn the ignition switch key to the START position and start the engine Release it when position ...

Page 83: ... engine running unless the fault or faults are stored in the memory of the fault or faults are stored in the memory of the engine control module ECM Stop the engine engine control module ECM Stop the engine and check the electric engine control system if and check the electric engine control system if the light comes the light comes ON Refer G420F E G424F E ON Refer G420F E G424F E Engines of this...

Page 84: ...RAL center position and apply the parking brake before dismounting the lift truc parking brake before dismounting the lift truck k 5 5 Release the service brake Release the service brake 6 6 Push down on the accelerator pedal to obtain Push down on the accelerator pedal to obtain the desired travel speed Release the pedal to the desired travel speed Release the pedal to decrease travel speed decre...

Page 85: ...s to provide precise lift truck inching control at provide precise lift truck inching control at very slow travel speed and high engine very slow travel speed and high engine rpm This is used for fast hydraulic lift rpm This is used for fast hydraulic lift during load approach during load approach pick up or load pick up or load positioning positioning 1 1 To inch creep in either direction slowly ...

Page 86: ... is monitored by the SECM through a variable reluctance VR or by the SECM through a variable reluctance VR or Hall Effect sensor Intake manifold air temperature Hall Effect sensor Intake manifold air temperature and absolute pressure are monitored with a TMAP and absolute pressure are monitored with a TMAP sensor MI 07 is a drive by wire DBW system sensor MI 07 is a drive by wire DBW system connec...

Page 87: ...pen loop as no mixture adjustments are made by the SECM 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 Manifold pressure from the TMAP rpm from the crank position sensor and throttle position is used by the SECM to calculate load Feedback fro...

Page 88: ...e liquid valve Close liquid valve Wait for a click sound Wait for a click sound Slowly open liquid valve Slowly open liquid valve Plugged Plugged fuel fuel line line Remove Remove obstruction obstruction from from the the fuel fuel line line Close liquid fuel valve Close liquid fuel valve Using caution disconnect the fuel Using caution disconnect the fuel line some propane may escape line some pro...

Page 89: ...ssed air Re connect fuel line Re connect fuel line Slowly open liquid fuel valve Slowly open liquid fuel valve Leak test Leak test Faulty vapor connection between Faulty vapor connection between the pressure regulator converter the pressure regulator converter and the mixer and the mixer Check connection Check connection Verify no holes in hose Verify no holes in hose Clamps must be tight Clamps m...

Page 90: ...d fuel valve Leak test test Pressure Pressure regulator regulator freezes freezes Check Check level level in in cooling cooling system system Must be full check coolant strength Must be full check coolant strength 35F minimum 35F minimum Check coolant hoses Check coolant hoses Watch for kinks and or pinched hoses Watch for kinks and or pinched hoses Verify one pressure hose and one Verify one pres...

Page 91: ...ring Acceleration Acceleration Engine Engine Mecha Mechanical nical See See Engine Engine Service Service Manual Manual Fuel Fuel container container almost almost empty empty LPG LPG Vapor Vapor from from liquid liquid outlet outlet Fill fuel container Fill fuel container Do not exceed 80 of liquid Do not exceed 80 of liquid capacity capacity Excess Excess flow flow valve valve closed closed Rese...

Page 92: ...leaks Between mixer and throttle body Between mixer and throttle body Between throttle body and intake Between throttle body and intake manifold manifold Between intake manifold and cylinder Between intake manifold and cylinder head head Air Fuel Air Fuel Mixer Mixer malfunctio malfunction n Check Check mixer mixer See Engine Service Manual See Engine Service Manual Engine Stalls Engine Stalls Eng...

Page 93: ... fuel line some propane may escape some propane may escape Clear obstruction with compressed air Clear obstruction with compressed air Re connect fuel line Re connect fuel line Slowly open liquid fuel valve Leak Slowly open liquid fuel valve Leak test test Air Air filter filter clogged clogged Check Check air air filter filter Clean replace as required Clean replace as required Faulty vapor connec...

Page 94: ...gulator operation Test pressure regulator operation See Engine Service Manual See Engine Service Manual Faulty Faulty FTV FTV Check Check FTV FTV for for housing housing cracks cracks or or obstructions obstructions See See Advanced Advanced Diagnostics Diagnostics FTV FTV operation operation Repair and or replace as Repair and or replace as necessary necessary Weak ignition and or spark control W...

Page 95: ...fy no holes in hose Clamps must be tight Clamps must be tight Look for kinked pinched and or Look for kinked pinched and or collapsed hose collapsed hose Electric Fuel Pump malfunction Electric Fuel Pump malfunction GAS GAS Check electrical connection Check electrical connection Check Relay and fuse Check Relay and fuse Turn key ON and verify pump is operating Turn key ON and verify pump is operat...

Page 96: ...eck air air filter filter Clean replace as required Clean replace as required Incorrect Incorrect air fuel air fuel or or ignition ignition control control See See Advanced Advanced Diagnostics Diagnostics Difficult to Start Difficult to Start Gas Gas Engine Engine Mechanical Mechanical See See Engine Engine Service Service Manual Manual Isolate the gasoline system by Isolate the gasoline system b...

Page 97: ...e is open Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode If the problem does not exist in LPG mode proceed with the corrective action steps proceed with the corrective action steps below below If the problem If the problem also exists in LPG mode then also exists in LPG mode then the root cause is most likely to be the root cause is most likely to be someth...

Page 98: ...xists in LPG mode then the root cause is most likely to be the root cause is most likely to be something other than the fuel system something other than the fuel system See Advanced Diagnostics Service See Advanced Diagnostics Service Manual Manual Pressure Pressure regulator regulator malfunction malfunction Test Test pressure pressure regulator regulator operation operation See Engine Service Ma...

Page 99: ...Rough Idle Gas Engine Engine Mechanical Mechanical See See Engine Engine Service Service Manual Manual Incorrect Idle speed control Incorrect Idle speed control Throttle sticking Throttle sticking See Advanced Diagnostics Engine See Advanced Diagnostics Engine Service Manual Service Manual High Idle Speed High Idle Speed Gas Gas Foot pedal sticking or incorrect Foot pedal sticking or incorrect ped...

Page 100: ...on with compressed air Re connect fuel line Re connect fuel line Slowly open liquid fuel valve Leak Slowly open liquid fuel valve Leak test test Air Air filter filter clogged clogged Check Check air air filter filter Clean replace as required Clean replace as required Faulty vapor connection between Faulty vapor connection between the pressure regulator converter the pressure regulator converter a...

Page 101: ... as been been detected and the engine has shut down and the M detected and the engine has shut down and the MIL IL has remained ON When the codes are displayed has remained ON When the codes are displayed the MIL will flash four times 4 pause then flash si the MIL will flash four times 4 pause then flash six x times 6 pause then flash one time 1 This times 6 pause then flash one time 1 This identi...

Page 102: ... Disable 2 Disable LiquidO2Ctrl LiquidO2Ctrl 3 Delayed 3 Delayed EngineShutdown EngineShutdown Check INJ3 wiring for an open circuit Check INJ3 wiring for an open circuit SECM Signal A4 to Injector 3 Pin A SECM Signal A4 to Injector 3 Pin A Switched 12V to Injector 3 Pin B Switched 12V to Injector 3 Pin B Check Injector 3 Resistance 12 to14 Check Injector 3 Resistance 12 to14 ohms cold ohms cold 1...

Page 103: ...e CAM sensor None None Check CAM sensor connections Check CAM sensor connections SECM SIGNAL Pin B10 to CAM sensor SECM SIGNAL Pin B10 to CAM sensor Pin 2 Pin 2 SECM Sensor GND Pin B1 to CAM SECM Sensor GND Pin B1 to CAM sensor Pin 3 sensor Pin 3 Switched Switched 12V 12V to to CAM CAM sensor sensor Pin Pin 1 1 Check for defective CAM Check for defective CAM sensor sensor 192 192 CamSyncFault CamS...

Page 104: ...rted to TPS1 signal has shorted to power or the ground for the power or the ground for the sensor has opened sensor has opened 1 TurnOnMil 1 TurnOnMil 2 CutThrottle 2 CutThrottle Check throttle connector and TPS1 sensor Check throttle connector and TPS1 sensor wiring for a shorted ci wiring for a shorted circuit rcuit SECM Pin B23 signal to ETC Pin 6 SECM Pin B23 signal to ETC Pin 6 SECM Pin B1 se...

Page 105: ...horted to shorted to ground or the circuit has ground or the circuit has opened to the SECM opened to the SECM TurnOnMil TurnOnMil Check TMAP connector and MAP signal Check TMAP connector and MAP signal wiring for an open circuit wiring for an open circuit TMAP Pin 4 to TMAP Pin 4 to SECM Pin B18 signal SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 1 to SECM Pin B1 sensor GND T...

Page 106: ...sensor GND TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor Check the MAP sensor by disconnecting the by disconnecting the TMAP connector and measuring at the TMAP connector and measuring at the sensor sensor TMAP Pin 1 GND to TMAP Pin 1 GND to Pin 4 pressure signal KPA 2 4k Pin 4 pressure signal KPA 2 4kΩ Ω 8 2k ...

Page 107: ...9 EST1 to OEM ignition system EM ignition system See application note See application note Verify GND on ignition module Verify GND on ignition module Pin A of both connectors Pin A of both connectors Verify 12 Vdc on ignition module Verify 12 Vdc on ignition module Pin B of both connectors Pin B of both connectors Refer to application manual for s Refer to application manual for specific engine p...

Page 108: ...ecific Refer to application manual for specific engine details engine details 425 425 EST5_Open EST5_Open EST5 output open possibly EST5 output open possibly open EST5 signal or defective open EST5 signal or defective spark module spark module None N A None N A 426 426 EST6_Open EST6_Open EST6 output open possibly EST6 output open possibly open EST6 signal or defective open EST6 signal or defectiv...

Page 109: ... defective spark module spark module None N A None N A 434 434 EST4_Short EST4_Short EST4 output shorted high or EST4 output shorted high or low EST4 signal shorted to low EST4 signal shorted to ground or power or defective ground or power or defective spark module spark module None N A None N A 435 435 EST5_Short EST5_Short EST5 output shorted high or EST5 output shorted high or low EST5 signal s...

Page 110: ...rive by disconnect disconnecting the ing the throttle connector and throttle connector and measuring the motor drive resistance at measuring the motor drive resistance at the throttle the throttle TPS Pin 1 TPS Pin 1 DRIVE DRIVER to R to Pin 4 Pin 4 DRIVER 3 0 4 0 DRIVER 3 0 4 0Ω Ω 471 471 ETC_Open_Fault ETC_Open_Fault Electronic Throttle Control Driver Electronic Throttle Control Driver has faile...

Page 111: ...pressure switch pressure switch SECM Pin B9 to Oil Pressure Switch SECM Pin B9 to Oil Pressure Switch 531 531 53 53 SysVoltRangeLow SysVoltRangeLow System voltage too low System voltage too low TurnOnMil TurnOnMil Check battery voltage Check battery voltage Perform maintenance check on Perform maintenance check on electrical electrical connections to the battery and chassis connections to the batt...

Page 112: ...th a multimeter multimeter 571 571 57 57 HardOverspeed HardOverspeed Engine speed has Engine speed has exceeded the third level 3 exceeded the third level 3 of 3 of overspeed of 3 of overspeed protection protection 1 TurnOnMil 1 TurnOnMil 2 H 2 HardRevLimit ardRevLimit 3 3 EngineShutdow EngineShutdown n Usually associated with additional ETC faults Usually associated with additional ETC faults Che...

Page 113: ...and Cycle the pedal several times and check APP1 signal at SECM Pin B7 check APP1 signal at SECM Pin B7 642 642 68 68 APP2AdaptHiMax APP2AdaptHiMax Learned full pedal end of APP2 Learned full pedal end of APP2 sensor range higher than e sensor range higher than expected xpected TurnOnMil TurnOnMil Check APP connector and pins for Check APP connector and pins for corrosion corrosion Cycle the pedal...

Page 114: ...e ground or power or defective crank disable relay crank disable relay None N A None N A 716 716 LSDFault_FuelPump LSDFault_FuelPump Fuel pump fault signal has Fuel pump fault signal has opened shorted to ground or opened shorted to ground or power or defective fuel power or defective fuel pump pump TurnOnMil TurnOnMil Check fuel pump for an open wire or connector Check fuel pump for an open wire ...

Page 115: ...R PWR to Post O2 Heater Relay Relay pin 87 This relay only turns on Relay Relay pin 87 This relay only turns on after engine has been running for some time after engine has been running for some time and SECM has calculated that water and SECM has calculated that water condensation in exhaust has been re condensation in exhaust has been removed by moved by exhaust heat Post O2 Heater Relay has exh...

Page 116: ...lyst O2 sensor connections Check that Pre catalyst O2 sensor connections are OK are OK O2 signal Pin 3 to SECM Pin B13 O2 signal Pin 3 to SECM Pin B13 O2 Pin 2 O2 Pin 2 HEATER GND to SECM DRVG HEATER GND to SECM DRVG GNG Pins A16 B17 GNG Pins A16 B17 O2 Pin 1 O2 Pin 1 HEATER PWR to SECM DRVP HEATER PWR to SECM DRVP 12V PIN A23 12V PIN A23 Verify O2 sensor heater circuit is operating by Verify O2 s...

Page 117: ...w Post c Post catalyst O2 atalyst O2 sensor sensor voltage out of range low voltage out of range low sensor signal shorted to sensor signal shorted to ground ground None N A None N A 921 921 O2RangeHigh O2RangeHigh Pre catalyst O2 sensor Pre catalyst O2 sensor voltage out of range high voltage out of range high sensor signal shorted to sensor signal shorted to power power 1 TurnOnMil 1 TurnOnMil 2...

Page 118: ...92 992 ServiceFault2 ServiceFault2 Service Interval 2 has been Service Interval 2 has been reached reached None None Perform service procedure related to Perform service procedure related to Service Interval 2 Service Interval 2 determined by OEM determined by OEM 993 993 ServiceFault3 ServiceFault3 Service Interval 3 has been Service Interval 3 has been reached reached None None Perform service p...

Page 119: ...ED pedal controls the speed and The MONO PED pedal controls the speed and direction of the lift truck Pushing on the right side of direction of the lift truck Pushing on the right side of the pedal 1 causes the lift truck to move in the pedal 1 causes the lift truck to move in REVERSE The optional reverse lights and optional REVERSE The optional reverse lights and optional back up alarm will be ON...

Page 120: ...ars smoothly the shift points for offset speed are adjustable speed are adjustable The Autoshift controller prevents strain and abuse The Autoshift controller prevents strain and abuse to the transmission It also prevents damage to the to the transmission It also prevents damage to the half shaft excessive tire wear and heat to the half shaft excessive tire wear and heat to the transmission transm...

Page 121: ...ctory setting ing Manual mode Fail Safe mode manual Manual mode Fail Safe mode manual operation in emergency operation in emergency Automatic mode Direction Inhibit Automatic mode Direction Inhibit mode mode Start the engine See topi Start the engine See topic Starting the engine c Starting the engine Push down on the service brake pedal Push down on the service brake pedal to hold the to hold the...

Page 122: ...t truck traveling forward can cause the load to fall or the lift forward can cause the load to fall or the lift truck to tip truck to tip If the controller fails If the controller fails An operator can operate the truck manually by An operator can operate the truck manually by selecting the Manual mode with the Fail Safe mode selecting the Manual mode with the Fail Safe mode switch on the PCB swit...

Page 123: ...ARD until the load Move the lift truck FORWARD until the load touches the carriage touches the carriage Lifting the Load Lifting the Load 1 1 Lift the load carefully and tilt the mast back a Lift the load carefully and tilt the mast back a short distance short distance Typical Example Typical Example 2 2 Tilt the mast further ba Tilt the mast further back to cradle the load ck to cradle the load T...

Page 124: ...r better vision travel in reverse with bulky For better vision travel in reverse with bulky loads loads Unloading Unloading Typical Example Typical Example 1 1 Move the lift truck into the u Move the lift truck into the unloading position nloading position Typical Example Typical Example 2 2 Tilt the mast FORWARD only when directly Tilt the mast FORWARD only when directly over the unloading area o...

Page 125: ...ition or to the pa position or to the park position rk position Turning Turning 1 1 When turning sharp corners keep close to the When turning sharp corners keep close to the inside corner Begin the turn when the inside inside corner Begin the turn when the inside drive wheel meets the corner drive wheel meets the corner 2 2 In narrow aisles keep away from the stockpile In narrow aisles keep away f...

Page 126: ...points in mind when you operate the lift truck in hot weather the lift truck in hot weather 1 1 Check the radiator Clogging can cause Check the radiator Clogging can cause overheating Clean them out regularly with a overheating Clean them out regularly with a blast of compressed air also check fo blast of compressed air also check for leakage r leakage of water of water 2 2 Check the fan belt tens...

Page 127: ...rward and lower the fork to the ground ground WARNING WARNING Blocking the wheels will prevent unexpected lift Blocking the wheels will prevent unexpected lift truck movement which could cause personal truck movement which could cause personal injury injury 5 5 Turn the key in the ignition switch to the OFF Turn the key in the ignition switch to the OFF position and remove the key position and rem...

Page 128: ...ork to side the fork on the carriage bar on the carriage bar 3 3 Adjust the forks in the posi Adjust the forks in the position most appropriate tion most appropriate for the load and as wide as possible for load for the load and as wide as possible for load stability stability 4 4 When adjusting the forks make sure that the When adjusting the forks make sure that the weight of the load is cente we...

Page 129: ...ough the machine is parked indoors if the though the machine is parked indoors if the place is hot or humid the battery should be kept place is hot or humid the battery should be kept in a dry cool place Charge the battery once a in a dry cool place Charge the battery once a month month Apply antirust to the exposed parts which tend to Apply antirust to the exposed parts which tend to rust rust Co...

Page 130: ... brake and place the transmission Apply the parking brake and place the transmission control in control in NEUTRAL NEUTRAL Tilt the mast forward and lower forks to the Tilt the mast forward and lower forks to the floor floor Turn the ignition switch to the OFF position and Turn the ignition switch to the OFF position and remove the key If LP equipped shut off the LP fuel remove the key If LP equip...

Page 131: ...ruck that is being towed truck that is being towed Quick lift truck movement could overload the tow Quick lift truck movement could overload the tow line or bar and cause it to break Gradual and line or bar and cause it to break Gradual and smooth lift truck movement will work b smooth lift truck movement will work better etter Normally the towing lift truck should be as large as Normally the towi...

Page 132: ...ted Capacity of greater than the Standard or rated Capacity of the lift truck the lift truck The individual load rating in most cases will be The individual load rating in most cases will be stamped on the fork in a readily visible area This is stamped on the fork in a readily visible area This is generally on the top or generally on the top or side of the fork shank side of the fork shank A fork ...

Page 133: ...ize until it remaining metal is decreased in size until it becomes insufficient to support the load and becomes insufficient to support the load and complete failure occurs complete failure occurs Fatigue failure is the most common mode of fork Fatigue failure is the most common mode of fork failure It is also one which can be anticipated and failure It is also one which can be anticipated and pre...

Page 134: ...rect size Inspect forks to ensure they are the correct size for the truck on which they will be used Make for the truck on which they will be used Make sure they are the correct length and type for the sure they are the correct length and type for the loads to be handled loads to be handled If the forks have been previously used perform If the forks have been previously used perform the 12 the 12 ...

Page 135: ...efects Polish the inside radius of the heel defects Polish the inside radius of the heel section to increase the fatigue life of the section to increase the fatigue life of the fork Always grind or polish in the direction fork Always grind or polish in the direction of the blade and shank length of the blade and shank length Repair or replace the positioning locks on Repair or replace the position...

Page 136: ...ipping pressures Shipping Pressure Shipping Pressure Size Size Ply Rating or Ply Rating or Strength Index Strength Index kPa kPa psi psi 6 6 5 5X X1 10 0 1 10 0 7 79 90 0 1 11 15 5 7 7 0 0X X1 15 5 1 12 2 8 82 25 5 1 12 20 0 2 28 8X X9 9 1 15 5 1 12 2 8 82 25 5 1 12 20 0 1 1 Standard tire p Standard tire ply rating and inflation pressures ly rating and inflation pressures The operating inflation p...

Page 137: ...0 5 5 4 40 0 5 5 8 8 m mm m 3 31 12 2 i in n 0 0 9 9 0 0 2 2 8 8 2 2 Reassembly or Reassembly or Retightening Retightening Torque On Existing Hose Torque On Existing Hose Clamp Width Clamp Width N N m m 1 1 lb lb in in 1 16 6 m mm m 6 62 25 5 i in n 4 4 5 5 0 0 5 5 4 40 0 5 5 1 13 3 5 5 m mm m 5 53 31 1 i in n 3 3 0 0 0 0 5 5 2 25 5 5 5 8 8 m mm m 3 31 12 2 i in n 0 0 7 7 0 0 2 2 6 6 2 2 1 1 1 New...

Page 138: ...uld Original fasteners removed from the lift truck should be saved for reassembly whenever possible If new be saved for reassembly whenever possible If new fasteners are needed they must be of the same fasteners are needed they must be of the same size and grade as the ones that a size and grade as the ones that are being replaced re being replaced The material strength identification is u The mat...

Page 139: ... temperatures the cooling system must be protected to the lowest expected outside must be protected to the lowest expected outside ambient temperature ambient temperature The engine cooling system is normally protected to The engine cooling system is normally protected to 28 28 C C 20 20 F F with antifreeze when shipped from with antifreeze when shipped from the factory unless special requirements...

Page 140: ...N recommends ends that the coolant mix c that the coolant mix contain ontain 50 commercially available automotive antifreeze 50 commercially available automotive antifreeze or equivalent and acceptable water to maintain and or equivalent and acceptable water to maintain and adequate water pump cavitation temperature for adequate water pump cavitation temperature for efficient water pump efficient ...

Page 141: ...re not Crude oil is used to describe oils fuels that are not refined and are in the original state as when refined and are in the original state as when pumped from the ground Certain types of crude pumped from the ground Certain types of crude oils can be burned oils can be burned in DOOSAN Engines in DOOSAN Engines PREFERRED DISTILLATE FUEL PREFERRED DISTILLATE FUEL FOR DISEL ENGINES FOR DISEL E...

Page 142: ...The gasoline in which methanol is contained is not The gasoline in which methanol is contained is not recommended The gasoline in which ethanol is recommended The gasoline in which ethanol is contained is not recommended either contained is not recommended either It is recommended to use gasoline fuel that has It is recommended to use gasoline fuel that has octane number 87 to p octane number 87 t...

Page 143: ... system ISO ISO 6743 4 6743 4 HM HM AFNOR AFNOR NFE NFE 48 603 48 603 HM HM DIN DIN 51524 51524 TEIL TEIL 2 2 H LP H LP HAGGLUNDS HAGGLUNDS DENISON DENISON HFO HF2 HFO HF2 CINCINNATI P68 69 70 CINCINNATI P68 69 70 Viscosity ISO VG32 Viscosity ISO VG32 Industrial premium hydraulic oils that have passed Industrial premium hydraulic oils that have passed the Vickers vane pump test 35VQ25 the Vickers ...

Page 144: ...follow this recommendation can Failure to follow this recommendation can cause shortened transmission life due to cause shortened transmission life due to material incompatibility inadequate material incompatibility inadequate frictional requirements for disk materials frictional requirements for disk materials and or excessive gear wear and or excessive gear wear The API CD TO 2 spe The API CD TO...

Page 145: ...ber should be selected A proper SAE grade number should be selected according to ambient temperature according to ambient temperature Refill Capacities Refill Capacities REFILL CAPACITIES APPROXIMATE REFILL CAPACITIES APPROXIMATE Co Comp mpar art tme ment nt or or Sy Syst stem em Li Lite ters rs U U S S Gal Gal Engine Crankcase w Filter Engine Crankcase w Filter G420F G420F E 2 0liter G420F G420F ...

Page 146: ...hly Every 250 Service Hours or Monthly Air In Air Intake take System System Check Check Clean Clean 167 167 Brake Oil Level Brake Oil Level Che Check ck 169 169 Hydraulic Oil Hydraulic Oil Level Level Check Check 169 169 Drive Axle Drive Axle Oil Level Oil Level Check Check 170 170 Mast Carriage Lift Chains Mast Carriage Lift Chains Attachments Inspect Attachments Inspect Lubric Lubricate ate 170 ...

Page 147: ...k off Operation LP Engine Only 192 192 Fuel Injectors Diesel Engine Only Inspect Fuel Injectors Diesel Engine Only Inspect Clean Clean Test Test 193 193 Crankcase Breather System 4TNV98 Diesel Crankcase Breather System 4TNV98 Diesel Engine Only Engine Only Inspe Inspect ct 193 193 Every 2000 Service Hours or Yearly Every 2000 Service Hours or Yearly Engine Valve Lash Diesel Engine Only Check Engin...

Page 148: ... Be Bear arin ing g P Pow ower er Sh Shaf aft t an and d Dr Driv ive e Whe Wheel el Re Reas asse semb mble le 19 196 6 O O E En ng gi in ne e O Oi il l F Fi il lt te er r D Di ie es se el l E En ng gi in ne e O On nl ly y C Ch ha an ng ge e 1 16 61 1 1 18 83 3 O O O O E En ng gi in ne e O Oi il l F Fi il lt te er r L LP P G Ga as so ol li in ne e E En ng gi in ne e O On nl ly y C Ch ha an ng ge e ...

Page 149: ...cate 1 17 70 0 O O O Ov ve er rh he ea ad d G Gu ua ar rd d I In ns sp pe ec ct t 1 17 78 8 O O P Pa ar rk ki in ng g B Br ra ak ke e I In ns sp pe ec ct t 1 15 59 9 O O P Pa ar rk ki in ng g B Br ra ak ke e T Te es st t A Ad dj ju us st t 1 16 64 4 1 18 80 0 O O O O P PC CV V V Va al lv ve e S Sy ys st te em m I In ns sp pe ec ct t C Cl le ea an n 1 17 72 2 O O P Pr ri im mi in ng g t th he e F F...

Page 150: ...ly Install filter cap assembly WARNING WARNING Fuel leaked or spilled onto hot surfaces or Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire electrical components can cause a fire 4 4 Drain moisture and sediment from fuel tank as Drain moisture and sediment from fuel tank as required by p required by prevailin revailing conditions g conditions Seat Hood Latch Suppo...

Page 151: ...identified as Fuses are identified as follows follows 1 1 Horn Horn 10 amps 10 amps 2 2 Head Rear Lamp Head Rear Lamp 15 amps 15 amps 3 3 Fwd R Fwd Rev Solenoid lamp R ev Solenoid lamp Relay Back up elay Back up Lamp alarm 10 amps Lamp alarm 10 amps 4 4 Instrument Panel Fu Instrument Panel Fuel Shutoff 15 amps el Shutoff 15 amps 5 5 Turn Signal Lamp Sto Turn Signal Lamp Stop Strobe Lamp C S p Stro...

Page 152: ...r separator or replacing a fuel system system component component To prime the fuel To prime the fuel system system 1 1 Turn the key to the Turn the key to the ON ON position for 10 to 15 position for 10 to 15 seconds This will allow the electric fuel pump seconds This will allow the electric fuel pump to prime the fuel s to prime the fuel system ystem 2 2 NEVER NEVER use the starter motor to cran...

Page 153: ...h an electric fuel with an electric fuel system system 1 1 Place an approved container under the air Place an approved container under the air bleed port bleed port 2 2 Loosen the air bleed port Loosen the air bleed port Figure 2 1 Figure 2 1 2 or 3 2 or 3 turns turns 3 3 Operate the fuel priming pump Operate the fuel priming pump Figure 2 2 Figure 2 2 until the fuel coming out of the air bleed po...

Page 154: ...iner under the fuel Position an approved container under the fuel filter water separator filter water separator Figure 5 7 1 Figure 5 7 1 to to collect the c collect the contaminants ontaminants Fig Fig ure 5 ure 5 7 7 2 2 Close Close Figure 5 7 2 Figure 5 7 2 the fuel cock the fuel cock Figure Figure 5 7 3 5 7 3 3 3 Loosen the drain cock Loosen the drain cock Figure 5 7 4 Figure 5 7 4 at the at t...

Page 155: ...uel System for Leaks LP and Dual Fuel Engines Only Engines Only 1 1 Obtain a leak check squirt bottle or pump spray Obtain a leak check squirt bottle or pump spray bottle bottle 2 2 Fill the bottle with an approved leak check Fill the bottle with an approved leak check solution solution 3 3 Spray a generous amount of the solution on the Spray a generous amount of the solution on the fuel system fu...

Page 156: ...e flat Do not re inflate a tire that has been run while flat or underinflated without first checking to make sure or underinflated without first checking to make sure the locking ring on the rim is not damaged and is in the locking ring on the rim is not damaged and is in the correct position the correct position When tires are changed be sure to clean all rim When tires are changed be sure to cle...

Page 157: ...allow it to reach dperating temperatures temperatures 2 2 Turn the engine off Turn the engine off 3 3 Inspect the entire for oil and or Inspect the entire for oil and or coolant leaks coolant leaks 4 4 Repair as necessary before continuing Repair as necessary before continuing Engine Oil Level Check Engine Oil Level Check 1 1 Raise the hood Raise the hood and seat assembly and seat assembly WARNIN...

Page 158: ...the top Remove the radiator cap Fill radiator to the top of the filter neck Inspect radiator cap Replace of the filter neck Inspect radiator cap Replace if damaged Install the radiator cap if damaged Install the radiator cap 3 3 Start and run the engine to stabilize the coolant Start and run the engine to stabilize the coolant level in the filter neck If low add coolant until it level in the filte...

Page 159: ...t to reach operating temperatures temperatures 2 2 Perform visual inspection of exhaust system Perform visual inspection of exhaust system Repair any all leaks found Repair any all leaks found Walk Around Inspection Inspect Walk Around Inspection Inspect For maximum service life of the lift truck make a For maximum service life of the lift truck make a thorough walk around inspection Look around a...

Page 160: ...blades and shanks twisted blades and shanks Make sure positioning lock is in place and Make sure positioning lock is in place and working working Lock the forks in position before using the truck Lock the forks in position before using the truck See Step 7 of Forks in Every 2000 Service See Step 7 of Forks in Every 2000 Service Hours or Yearly Hours or Yearly Remove all defective forks from servic...

Page 161: ...erator s Seat Engine Inspection from Operator s Seat Engine OFF OFF 1 1 Grasp the parking brake lever with your hand Grasp the parking brake lever with your hand and press down the release button with your and press down the release button with your thumb The lever should move freely forward thumb The lever should move freely forward and backward and backward 2 2 Remove your thumb from the release...

Page 162: ...ard up the grade or in reverse down Drive forward up the grade or in reverse down the grade and stop the lift truck with the service the grade and stop the lift truck with the service brakes brakes 3 3 Engage the parking brake and release the Engage the parking brake and release the service brakes service brakes 4 4 If the lift truck moves down the grade control its If the lift truck moves down th...

Page 163: ...he engine crankcase and allow the engine oil to drain more easily engine oil to drain more easily 5 5 Position a container under the engine to collect Position a container under the engine to collect waste oil waste oil 6 6 Remove the oil drain plug Remove the oil drain plug Figure 5 2 1 Figure 5 2 1 from from the engine oil pan Allow oil to drain the engine oil pan Allow oil to drain 7 7 After al...

Page 164: ...f If any engine oil is spilled wipe it away with a any engine oil is spilled wipe it away with a clean cloth clean cloth NOTICE NOTICE Servicing of the engine oil and oil filter element will Servicing of the engine oil and oil filter element will largely affect the engine performance as well as the largely affect the engine performance as well as the Transmission Oil Oil Filter Transmission Oil Oi...

Page 165: ...engine 9 9 With the service brake applied and engine at With the service brake applied and engine at low idle shift the direction control lever to low idle shift the direction control lever to forward and reverse to fill the clutches forward and reverse to fill the clutches 10 10 Shift the direction control lever into NEUTRAL Shift the direction control lever into NEUTRAL Engage the parking brake ...

Page 166: ...oad on a 15 grade Testing requires a test load equal to the capacity of Testing requires a test load equal to the capacity of the truck and a 15 g the truck and a 15 grade rade If the maximum grade in the workplace is less than If the maximum grade in the workplace is less than its capacity use the Parking Brake inspection its capacity use the Parking Brake inspection procedure covered in Inspecti...

Page 167: ... the stop pin 2 go to step 7 If the brake lever the stop pin 2 go to step 7 If the brake lever 1 is NOT held against the stop pin 2 go to 1 is NOT held against the stop pin 2 go to step 6 step 6 6 6 Remove the pin 3 and the cotter pin 4 Remove the pin 3 and the cotter pin 4 Tighten the nut 6 to compress the spring 7 Tighten the nut 6 to compress the spring 7 7 7 Loosen lock nut 5 Tighten screw 6 t...

Page 168: ...nts to injury Do not allow hot oil or components to contact skin contact skin Park the lift truck level with the forks lowered Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL parking brake engaged transmission in NEUTRAL and the engine stopped and the engine stopped 1 1 Loosen the bolts of the hydraulic tank top plate Loosen the bolts of the hydraulic...

Page 169: ... from Rotate the element slightly to separate it from its base and remove it from the air cleaner its base and remove it from the air cleaner housing housing 3 3 Clean and inspect the element or replace with a Clean and inspect the element or replace with a new element See topic Cleaning Primary new element See topic Cleaning Primary Filter Filter Element Element 4 4 Clean the inside of air cleane...

Page 170: ...ning with pressure water use 280 kPa When cleaning with pressure water use 280 kPa 40 psi maximum pressure to prevent filter element 40 psi maximum pressure to prevent filter element damage damage Have spare elements on hand to Have spare elements on hand to use while cleaning use while cleaning used elements used elements The primary element should be replaced after 6 The primary element should b...

Page 171: ... hydraulic tank is hot and under pressure hot and under pressure Hot oil can cause burns Hot oil can cause burns Remove the filter cap only when the engine is Remove the filter cap only when the engine is stopped and the cap is cool enough to touch stopped and the cap is cool enough to touch with your bare hand Remove the filter cap with your bare hand Remove the filter cap slowly to relieve press...

Page 172: ...ecessary 4 4 Brush a film of oil on all Brush a film of oil on all links of the chain links of the chain 5 5 Raise and lower the carriage a few times to Raise and lower the carriage a few times to allow lubricant to enter into the chain links allow lubricant to enter into the chain links NOTICE NOTICE Lubricate chains more frequently than normal in Lubricate chains more frequently than normal in a...

Page 173: ... Engine Crankcase Gasoline LP Engine Crankcase 1 1 Operate lift truck a few minutes to warm o Operate lift truck a few minutes to warm oil il Park the lift truck with the Park the lift truck with the forks lowered parking forks lowered parking brake applied transmission in neutral and the brake applied transmission in neutral and the engine stopped engine stopped 2 2 Raise rear of lift truck off g...

Page 174: ... e Refill Capacities Capacities 11 11 Start the engine and allow the oil to fill the filter Start the engine and allow the oil to fill the filter and passages and passages 12 12 Check for oil leaks Check for oil leaks 13 13 Stop the engine and measure the oil level Stop the engine and measure the oil level Maintain the oil level to the FULL mark on the Maintain the oil level to the FULL mark on th...

Page 175: ...110 N m 75 lb ft N m 75 lb ft Drive Wheels Drive Wheels Typical Example Typical Example 2 2 Inspect tightness of wheel nuts in a sequence Inspect tightness of wheel nuts in a sequence opposite each other to 610 N m 450 lb ft opposite each other to 610 N m 450 lb ft Inspect Tightness GC Series Inspect Tightness GC Series Drive Wheels Drive Wheels Typical Example Typical Example 1 1 Inspect tightnes...

Page 176: ...e engine speed control speed control Checking and adjusting the governor lever Checking and adjusting the governor lever 1 1 Check that the governor lever Check that the governor lever Figure 5 11 1 Figure 5 11 1 makes uniform contact with the high idle makes uniform contact with the high idle Figure 5 11 2 Figure 5 11 2 and low idle and low idle Figure 5 11 Figure 5 11 3 3 speed limit screws when...

Page 177: ...procedure adjustment procedure NEVER force the accelerator cable or pedal to NEVER force the accelerator cable or pedal to move This may deform the governor lever or move This may deform the governor lever or stretch the cable and cause irregular operation of stretch the cable and cause irregular operation of the engine speed control the engine speed control Checking and adjusting the governor lev...

Page 178: ...ak the alternator mounting ear mounting ear 2 2 To adjust the alternator drive belt loosen To adjust the alternator drive belt loosen adjusting bracket bolt 1 and mounting bolt 2 adjusting bracket bolt 1 and mounting bolt 2 Move the alternator in or out as required Move the alternator in or out as required Tighten bolts 1 and 2 Tighten bolts 1 and 2 Mast Hinge Pin Lubricate Mast Hinge Pin Lubricat...

Page 179: ...rward or backward backward tilt an adjustment must be made to one tilt an adjustment must be made to one cylinder cylinder Typical Example Typical Example 3 3 To adjust the cylinder rod extension move the To adjust the cylinder rod extension move the spacer to the rear and loosen the pinch bolt on spacer to the rear and loosen the pinch bolt on the clevis the clevis 4 4 Turn the cylinder rod in or...

Page 180: ...art the engine 6 6 With the service brake applied and engine at With the service brake applied and engine at low idle shift the direction control lever to low idle shift the direction control lever to forward and reverse to fill the clutches forward and reverse to fill the clutches 7 7 Shift the direction control lever into NEUTRAL Shift the direction control lever into NEUTRAL Engage the parking ...

Page 181: ...heck O ring seal and replace if necessary necessary 2 2 Install the drain plug Install the drain plug 3 3 Wash the strainer assembly in clean non Wash the strainer assembly in clean non flammable solvent and dry it Install the strainer flammable solvent and dry it Install the strainer assembly and reconnect the hose assembly and reconnect the hose 4 4 Remove the dip stick filter cap Fill the drive...

Page 182: ...Test Adjust in First 50 100 Service Hours or a 50 100 Service Hours or a Week Week Inching Braking Control Shaft Inching Braking Control Shaft Lubricate Lubricate 1 1 Lubricate three fittings for the inching and b Lubricate three fittings for the inching and brake rake pedal control shaft pedal control shaft Horn and Lights If Equipped Horn and Lights If Equipped Check Check 1 1 Press horn button ...

Page 183: ... by To ensure the valve is not leaking a blow by test can be performed test can be performed 3 3 With the engine off disconnect the electrical With the engine off disconnect the electrical connector to the FTV connector to the FTV 4 4 Disconnect the vacuum lines form the FTV to Disconnect the vacuum lines form the FTV to the pressure regulator converter at the the pressure regulator converter at t...

Page 184: ...2 0 2 4kgf m or one additional turn using the filter wrench filter wrench 6 6 Open the fuel cock of the fuel filter water Open the fuel cock of the fuel filter water separator separator 7 7 Prime the fuel system See topic Priming the Prime the fuel system See topic Priming the Fuel System in When Required Fuel System in When Required 8 8 Check for leaks Check for leaks 4TNE98 Diesel Engine Only 4T...

Page 185: ... new O ring supplied with the fuel filter new O ring supplied with the fuel filter Figure Figure 5 15 2 5 15 2 by turning the fuel filter sensor by turning the fuel filter sensor assembly to the right assembly to the right Figure 5 15 9 Figure 5 15 9 15 15 Install the drain plug Install the drain plug Figure 5 15 1 Figure 5 15 1 on the on the new fuel filter new fuel filter Figure 5 15 3 Figure 5 ...

Page 186: ...onnect the If equipped disconnect the sensor wire sensor wire Figure5 16 7 Figure5 16 7 from the cup from the cup before removing the cup before removing the cup 6 6 Remove the float ring Remove the float ring Figure5 16 8 Figure5 16 8 from the from the cup Pour the contaminants into the container cup Pour the contaminants into the container and dispose of it properly and dispose of it properly 7 ...

Page 187: ... in NEUTRAL and the engine stopped and the engine stopped 1 1 Loosen the bolts of the hydraulic tank top plate Loosen the bolts of the hydraulic tank top plate assembly assembly 2 2 Remove the return filter from tank top plate Remove the return filter from tank top plate assembly assembly 3 3 Install new return filter by hand Install new return filter by hand 4 4 Remove the suction strainer from t...

Page 188: ...Lift the mast and carriage enough for getting tension on lift chains tension on lift chains Typical example Typical example 2 2 Measure precisely ten links of chain distance at Measure precisely ten links of chain distance at the center of pins in the center of pins in millimeter millimeter 3 3 Calculate chain wear rate Calculate chain wear rate 4 4 If the chain wears rate is 2 or more replace If ...

Page 189: ...s step 1 through step 3 the same procedure as step 1 through step 3 5 5 Put LOCTITE No 242 Tread lock on the threads Put LOCTITE No 242 Tread lock on the threads of the anchor nuts 1 2 after the adjustment is of the anchor nuts 1 2 after the adjustment is Mast Chain Adjustment FF FFT Mast Mast Chain Adjustment FF FFT Mast Typical example for FF mast Typical example for FF mast Typical example for ...

Page 190: ...ove the secondary element Inspect the Remove the secondary element Inspect the gasket between the air cleaner housing and the gasket between the air cleaner housing and the engine inlet Replace the gasket if it is engine inlet Replace the gasket if it is damaged damaged NOTICE NOTICE Always replace the secondary element Do not Always replace the secondary element Do not attempt to reuse it by clea...

Page 191: ...e pressure regulator converter refer to ressure regulator converter refer to the pressure regulator converter section of the pressure regulator converter section of the service manual the service manual Fuel Lines Fittings Check Fuel Lines Fittings Check Visually inspect fuel lines and fittings for physical Visually inspect fuel lines and fittings for physical damage Replace as re damage Replace a...

Page 192: ...l before additional time for the engine to cool before measuring valve clearance measuring valve clearance NOTICE NOTICE Measure the valve lash with the engine stopped To Measure the valve lash with the engine stopped To obtain an accurate measurement allow at least 20 obtain an accurate measurement allow at least 20 minutes to cool the engine cylinder head and block minutes to cool the engine cyl...

Page 193: ...e as required re broken replace as required G420F E Engine G420F E Engine G424F E Engine G424F E Engine 1 Spark Plug Cables 1 Spark Plug Cables 2 Ignition Coil 2 Ignition Coil Replace Spark Plugs G424F E Replace Spark Plugs G424F E LP Dual Fuel Engine Only LP Dual Fuel Engine Only 1 1 Disconnect Battery Cables Disconnect Battery Cables 2 2 Using a gentle twisting motion remove the high Using a gen...

Page 194: ... covers 5 5 Install the cover retaining screws tightening the Install the cover retaining screws tightening the screws in an opposite sequence across the screws in an opposite sequence across the cover cover 6 6 Open the fuel valve by slowly turning the valve Open the fuel valve by slowly turning the valve counterclockwise counterclockwise 7 7 Crank the engine several revolutions to open Crank the...

Page 195: ...r operation of the crankcase breather system Proper operation of the crankcase breather system is required to maintain the emission requirements is required to maintain the emission requirements of the engine The EPA ARB requires that the of the engine The EPA ARB requires that the crankcase breather system is inspected every crankcase breather system is inspected every 1500 1500 hours hours 4TNV9...

Page 196: ...esel Engine Only Diesel Engine Only Check Ad Check Adjust In First 250 Servi just In First 250 Service hours ce hours Steer Wheel Bearings Steer Wheel Bearings Reassemble Reassemble Park the lift truck level with the forks lowered Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL parking brake engaged transmission in NEUTRAL and the engine stopped and t...

Page 197: ...l and Install the inner bearing Lubricate the seal and install the wheel assembly on the knuckle install the wheel assembly on the knuckle 8 8 Install the outer wheel bearing and the out Install the outer wheel bearing and the out washer Install a new lock washer and fit the washer Install a new lock washer and fit the locknut locknut Typical Example Typical Example 9 9 Tighten the locknut to 135 ...

Page 198: ...rections Loosen while the wheel is turned in both directions Loosen the nut completely and tighten nut again to 50 5 the nut completely and tighten nut again to 50 5 N m 37 4 lb ft Bend the lock washer tab into a N m 37 4 lb ft Bend the lock washer tab into a groove of the nut groove of the nut Torque for bolts 4 that hold cover to drive axle Torque for bolts 4 that hold cover to drive axle housin...

Page 199: ...bidding corrosion Avoid contact with the skin and eyes corrosion Avoid contact with the skin and eyes to prevent personal injury to prevent personal injury Use all cleaning solution with care Use all cleaning solution with care The Lift truck must be level the forks lowered the The Lift truck must be level the forks lowered the parking brake engaged the transmission in parking brake engaged the tr...

Page 200: ...d the radiator cleaner and clean the engine and the radiator 5 5 Start and run the engine fo Start and run the engine for 30 minutes r 30 minutes 6 6 Stop the engine and drain the cleaning solution Stop the engine and drain the cleaning solution into a suitable container into a suitable container 7 7 Flush the system with clean water until draining Flush the system with clean water until draining ...

Page 201: ...nk The fork blade and the front face of the shank The fork should be withdrawn from service if angle C should be withdrawn from service if angle C 3 3 Check the straightness of the upper face of Check the straightness of the upper face of blade D and the front face of shank E with a blade D and the front face of shank E with a straight edge straight edge The fork should be withdrawn from service i...

Page 202: ...aded pin M located in the top hook to engage notches in the located in the top hook to engage notches in the top carriage bar to hold the fork top carriage bar to hold the fork in place in place When adjusting the fork spacing the forks are When adjusting the fork spacing the forks are Shaft mounted forks may use set collars or spacers Shaft mounted forks may use set collars or spacers on the shaf...

Page 203: ...n in NEUTRAL and the engine stopped and the engine stopped 1 1 Remove the hydraulic tank drain plug Allow the Remove the hydraulic tank drain plug Allow the oil to drain into a suitable container Clean and oil to drain into a suitable container Clean and install the plug install the plug 2 2 Remove the dipstick filter cap assembly Remove the dipstick filter cap assembly 3 3 Fill the hydraulic tank...

Page 204: ...hen assembling the filters check the arrow When assembling the filters check the arrow mark on the filter surface mark on the filter surface The arrow mark position is same as fuel flow The arrow mark position is same as fuel flow direction direction Replace Spark Plugs G420F E Replace Spark Plugs G420F E Engine Only Engine Only 1 1 Disconnect Battery Cables Disconnect Battery Cables 2 2 Remove th...

Page 205: ... as necessary necessary 4 4 Apply a thin coat of an approved silicon Apply a thin coat of an approved silicon lubricant to the TMAP o ring seal lubricant to the TMAP o ring seal 5 5 Re install the TMAP sensor into the manifold Re install the TMAP sensor into the manifold adapter and securely tighten the retaining adapter and securely tighten the retaining screw screw Inspect for Intake Leaks Inspe...

Page 206: ...eration before performing any operation or maintenance procedures or maintenance procedures Timing Belt G420F E G424F E Timing Belt G420F E G424F E LP Gasoline Dual Fuel Engine LP Gasoline Dual Fuel Engine Only Only Change Change See the Service manual for the procedure and See the Service manual for the procedure and specification specification WARNING WARNING G420F E is dual over head CAM engine...

Page 207: ...econdary Element Element 188 188 Chassis Chassis Pivot Pivot Eyebolts Lu Eyebolts Lubricate bricate 176 176 Check for Check for Equal Tension Equal Tension 186 186 Check Inflation and Damage 154 Check Inflation and Damage 154 Check Check Operation Operation 177 177 Checking Service Indicator 157 Checking Service Indicator 157 Checking the TMAP Sensor G420F E G424F E Checking the TMAP Sensor G420F ...

Page 208: ...nes l Engines 172 172 Gasoline and Gasoline and LP LP Engines Engines 155 155 Gasoline Gasoline Engine Engine 76 76 Gasoline or Diesel Engine Equipped Gasoline or Diesel Engine Equipped 71 71 Gasoline Gasoline Speci Specifications fications 140 140 Gasoline LP Engine Crankcase Gasoline LP Engine Crankcase 171 171 GC Series GC Series Lift Lift Trucks Trucks 196 196 H H Hand Placement Warning 7 Hand...

Page 209: ... Mounting and and Dismounti Dismounting ng 11 11 Moving Fan Warning Moving Fan Warning 8 8 N N No Riders Warning No Riders Warning 8 8 No Standing On No Standing On Fork Warning Fork Warning 7 7 No Standing Under No Standing Under Fork Warning Fork Warning 7 7 Noise Noise and and Vibration Vibration 42 42 O O Oil Oil Cooled Disc Brake Cooled Disc Brake Only Only 142 142 Ope Operator s rator s Warn...

Page 210: ...lation Information Information 134 134 Tire Inflation Pressures Adjustment Tire Inflation Pressures Adjustment 134 134 Tire Tire Inflatio Inflation n 134 134 Tire Tire Shipping Shipping Pressure Pressure 134 134 Tires and Wheels D G Series Tires and Wheels D G Series Inspect Check154 Inspect Check154 To Operate the Lift Truck after a Long Time Storage To Operate the Lift Truck after a Long Time St...

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