SB2349E04 Operation & Maintenance Manual FORKLIFTS 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 G20P-5 Plus, G25P-5 Plus, G30P-5 Plus, G33P-5 Plus, G35C-5 Plus GC20P-5, GC25P-5, GC30P-5, GC33P-5 Original Instruction 1105
Table of Contents Table of Contents Information Section Maintenance Section Foreword ............................................................... 2 Inspection, Maintenance and Repair of Lift Truck Forks ................................................................. 167 Tire Inflation Information .................................... 171 Torque Specifications ........................................ 172 Cooling System Specifications .......................... 174 Fuel Specifications ................
Information Section Foreword Photographs or illustrations guide the operator through correct procedures of checking, operation and maintenance of the DOOSAN operator restraint system. Literature Information This manual should be stored in the operator’s compartment in the literature holder or seat back literature storage area. This manual transportation, information.
Information Section Maintenance The Maintenance Section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by servicing intervals. Items without specific intervals are listed under “When Required” topics. Items in the “Maintenance Intervals” chart are referenced to detailed instructions that follow. Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.
Safety Section Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons must also have the necessary training, skills and tools before attempting to perform these functions.
Safety Section Safety 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.
Safety Section 5. Travel with load as low as possible and tilted back. If load interferes with visibility, travel with load trailing. General Warning to Operator 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.
Safety Section Pressure Warning No Standing On Fork Warning No Standing Under Fork Warning WARNING Contents under pressure may be hot. Allow to cool before opening. 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 radiator top tank by the radiator cap. Located on the lift cylinder.
Safety Section Overhead Guard Must Be In Place Warning Moving Fan Warning WARNING WARNING To avoid personal injury, stay clear of moving fan. Operation without this device in place may be hazardous. This guard conforms to A.N.S.I.B56.1 and F.E.M.Section IV. This design has been tested with an impact of appropriate valve. Located inside the engine compartment cover. Located on the Overhead Guard. No Riders Warning WARNING To avoid personal injury, allow no riders.
Safety Section Parking brake Pull the lever BACK to engage the parking brake. Push the lever FORWARD to release the parking brake. Applying the parking brake puts the transmission in NEUTRAL. The parking brake must be applied when leaving the lift truck and when starting the engine. If the operator leaves the seat without applying the parking brake, an audible alarm will sound. WARNING When leaving machine apply parking brake! Parking brake is not automatically applied.
Safety Section Always use the overhead guard. The overhead guard is intended to protect the lift truck operator from overhead obstructions and from falling objects. General Hazard Information 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.
Safety Section 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. Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully. Clean your shoes and wipe your hands before mounting. Never put maintenance fluids into glass containers. Use all cleaning solutions with care.
Safety Section Make sure the lift truck horn, lights, backup alarm (if equipped) and all other devices are working properly. Operating the Lift Truck Always keep the lift truck under control. Check for proper operation of mast and attachments. Pay particular attention to unusual noises or erratic movement which might indicate a problem. Obey all traffic rules and warning signs. Never leave the lift truck with the engine operating, or with the parking brake disengaged.
Safety Section Loading or Unloading Trucks/Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers. If trailer is not coupled to tractor, make sure the trailer landing gear is properly secured in place. On some trailers, extra supports may be needed to prevent upending or corner dipping.
Safety Section They will throw or cut any object or tool that falls or is pushed into them. Maintenance Information Perform all maintenance unless otherwise specified as follows: z z z z z z z Do not use a kinked or frayed wire rope cable. Wear gloves when handling the wire rope cable. Park the lift truck in authorized areas only. Park the lift truck level, with the forks lowered and the mast tilted forward until the fork tips touch the floor. Place the transmission controls in neutral.
Safety Section Burn Prevention Fire or Explosion Prevention Coolant All fuels, most lubricants and some coolant mixtures are flammable. At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Do not smoke while refueling or in a refueling area. Steam can cause personal injury.
Safety Section Fire Extinguisher z z 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. z z z Ether z Ether is poisonous and flammable. 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.
Safety Section Dry nitrogen (N2) 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. Operator Restraint System(If Equipped) 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.
Safety Section If Optional Suspension Seat (weight adjusting type) Equipped Forward and Backward Adjustment The seat can be adjusted by pushing the lever on the right side of seat. The “Survive in tipover” warning is located on the overhead guard. It shows the proper use of the operator restraint system. Forward and Ba Seat Adjustment Adjust the seat before operating the lift truck. After adjusting, set the seat to make sure it is properly locked. Do not adjust the seat while the truck is in motion .
Safety Section Weight adjustment Seat Belt The Operator Restraint System, Prevents the operator from jumping from the operator’s compartment in the event of a forward or side tipover. The system is designed to keep the operator on the seat and in the operator’s compartment in the event of a tipover. Pull the weight adjustment lever upwards and move right or left side. Adjust to driver’s weight in 7 steps (50 ~ 110 kg) NOTICE Inspection Do not place your hand or fingers under the seat.
Safety Section WARNING If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident. 3. In the event of a tipover, the seat and restraint system should be inspected for damage and replaced, if necessary. NOTE: Operator restraints shall be examined at the regular truck service intervals.
Safety Section Avoiding Lift Truck Tipover Stability and Center of Gravity Lift Truck Stability 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.
Safety Section 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.
Safety Section Safety Rules Do not operate a lift truck unless you are in the operator’s seat. Keep hands and feet inside the operator’s compartment. Do not put any part of the body outside of the operator’s compartment. Never put any part of body into the mast structure or between the mast and the truck 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.
Safety Section 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 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 operate your truck without the load backrest extension and overhead guard.
Safety Section 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. 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. Look out for overhead obstructions when raising or stacking loads. Do not travel with a raised load. Do not travel with the mast raised.
Safety Section 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 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.
Safety Section 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. 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.
Safety Section Do not operate forklifts near flammable or combustible materials. To avoid the discoloration, deformation or combustion of materials (such as lumber, veneer board, paper products and other similar items), always park at least 30 cm (12 inches) away from them. An unloaded forklift may be easier to tip over than a loaded truck. When traveling without a load, the risk of lateral overturn is greater. There are many special attachments available to replace the forks on a lift truck.
Safety Section How to Survive in a Tipover WARNING In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided. Brace your feet and keep them within the operator’s compartment. Always use operator restraint system. Lean away from the direction of fall. Don’t jump. Lean forward. Hold on tight.
General Section Declaration of Conformity We, Manufacturer Doosan Infracore Co., Ltd. 7-11, Hwasu-dong, Dong-gu, Incheon, Korea 401-010 Authorized Representative, Compiler of Technical File According to 2006/42/EC and Keeper of Technical File According to 2000/14/EC Doosan Infracore Europe S.A., Mr. K. S.
General Section Specifications CHARACTERISTICS 1 MANUFACTURER 2 MODEL 3 4 5 6 7 8 CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 a at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear kg mm DOOSAN D25S-5 (YANMAR,TIER2) 2500 500 diesel rider-seated p 2/2 3230 152 II 40x100x1050 275x1035 6/10 2595 1170 217
General Section 1 DOOSAN D30S-5 (YANMAR,TIER2) 3000 500 diesel rider-seated p 2/2 DOOSAN D33S-5 (YANMAR,TIER2) 3250 500 diesel rider-seated p 2/2 DOOSAN D35C-5 (YANMAR,TIER2) 3500 500 diesel rider-seated p 2/2 3 4 5 6 7 8 3230 152 III 45x125x1050 286x1044 6/10 2700 1197 2165 4490 2183 1026 2365 485 2850 2050 3230 152 III 45x125x1050 286x1044 6/10 2730 1197 2165 4490 2183 1026 2395 485 2880 2100 3000 152 III 45x125x1050 286x1044 6/10 2765 1255 2165 4260 2183 1026 2420 495 2915 2170 9 10 11 12 13 14
General Section Specifications CHARACTERISTICS 1 MANUFACTURER 2 MODEL 3 4 5 6 7 8 CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 a at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear kg mm DOOSAN D25S-5 (YANMAR,TIER3) 2500 500 diesel rider-seated p 2/2 3230 152 II 40x100x1050 275x1035 6/10 2595 1170 217
General Section 1 DOOSAN D30S-5 (YANMAR,TIER3) 3000 500 diesel rider-seated p 2/2 DOOSAN D33S-5 (YANMAR,TIER3) 3250 500 diesel rider-seated p 2/2 DOOSAN D35C-5 (YANMAR,TIER3) 3500 500 diesel rider-seated p 2/2 3 4 5 6 7 8 3230 152 III 45x125x1050 286x1044 6/10 2700 1197 2165 4490 2183 1026 2365 485 2850 2050 3230 152 III 45x125x1050 286x1044 6/10 2730 1197 2165 4490 2183 1026 2395 485 2880 2100 3000 152 III 45x125x1050 286x1044 6/10 2765 1255 2165 4260 2183 1026 2420 495 2915 2170 9 10 11 12 13 14
General Section Specifications CHARACTERISTICS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 27 28 29 30 31 32 MANUFACTURER MODEL CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE FORKS TILT OF MAST OVERALL DIMENSIONS at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear kg mm maximum fork height with rated load free lift ISO class
General Section DOOSAN G20E-5 2000 500 LP rider-seated p 2/2 DOOSAN G25E-5 2500 500 LP rider-seated p 2/2 DOOSAN G30E-5 3000 500 LP rider-seated p 2/2 1 2 3 4 5 6 7 8 3230 152 II 40x100x1050 275x1035 6/10 2530 1170 2175 4490 2183 1026 2220 480 2700 1970 3230 152 II 40x100x1050 275x1035 6/10 2595 1170 2175 4490 2183 1026 2265 480 2745 2000 3230 152 III 45x125x1050 286x1044 6/10 2700 1197 2165 4490 2183 1026 2365 485 2850 2050 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 19/20 530/600 510/460 1440
General Section Specifications CHARACTERISTICS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 27 28 29 30 31 32 MANUFACTURER MODEL CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE FORKS TILT OF MAST OVERALL DIMENSIONS at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear kg mm maximum fork height with rated load free lift ISO class
General Section DOOSAN G20E-5 2000 500 LP/Gas rider-seated p 2/2 DOOSAN G25E-5 2500 500 LP/Gas rider-seated p 2/2 DOOSAN G30E-5 3000 500 LP/Gas rider-seated p 2/2 1 2 3 4 5 6 7 8 3230 152 II 40x100x1050 275x1035 6/10 2530 1170 2175 4490 2183 1026 2220 480 2700 1970 3230 152 II 40x100x1050 275x1035 6/10 2595 1170 2175 4490 2183 1026 2265 480 2745 2000 3230 152 III 45x125x1050 286x1044 6/10 2700 1197 2165 4490 2183 1026 2365 485 2850 2050 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 19/20 530/600
General Section Specifications CHARACTERISTICS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 MANUFACTURER MODEL CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear DOOSAN G20P-5 2000 500 lp rider-seated p 2/2 D
General Section DOOSAN G30P-5 3000 500 lp rider-seated p 2/2 DOOSAN G33P-5 3250 500 lp rider-seated p 2/2 DOOSAN G35C-5 3500 500 lp rider-seated p 2/2 1 2 3 4 5 6 7 8 3230 152 III 45x125x1050 286x1044 6/10 2700 1197 2165 4490 2183 1026 2365 485 2850 2050 3230 152 III 45x125x1050 286x1044 6/10 2730 1197 2165 4490 2183 1026 2395 485 2880 2100 3000 152 III 45x125x1050 286x1044 6/10 2765 1255 2165 4260 2183 1026 2420 495 2915 2170 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 18/19 500/600 510/460 18
General Section Specifications CHARACTERISTICS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 MANUFACTURER MODEL CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear DOOSAN G20P-5 Plus 2000 500 lp rider-seated p 2
General Section DOOSAN G30P-5 Plus 3000 500 lp rider-seated p 2/2 DOOSAN G33P-5 Plus 3250 500 lp rider-seated p 2/2 DOOSAN G35C-5 Plus 3500 500 lp rider-seated p 2/2 1 2 3 4 5 6 7 8 3230 152 III 45x125x1050 286x1044 6/10 2700 1197 2165 4490 2183 1026 2365 485 2850 2050 3230 152 III 45x125x1050 286x1044 6/10 2730 1197 2165 4490 2183 1026 2395 485 2880 2100 3000 152 III 45x125x1050 286x1044 6/10 2765 1255 2165 4260 2183 1026 2420 495 2915 2170 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 18/19 510
General Section Specifications 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 CHARACTERISTICS MANUFACTURER MODEL CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear kg mm maximum fork height with rated load free
General Section DOOSAN GC25E-5 2500 500 LP rider-seated C 2/2 DOOSAN GC30E-5 3000 500 LP rider-seated C 2/2 DOOSAN GC33E-5 3000(6500LBS) 600 LP rider-seated C 2/2 1 2 3 4 5 6 7 8 3230 152 II 40x100x1050 297x905 6/8 2268 1110 2130 4480 2150 1038 2045 367 2412 1822 3230 152 III 45x125x1050 282x954 6/8 2333 1110 2130 4480 2150 1038 2105 373 2478 1872 3230 152 III 45x125x1050 282x954 6/8 2368 1110 2130 4480 2150 1038 2135 373 2508 1907 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 16/16 510/600 510/4
General Section Specifications 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 CHARACTERISTICS MANUFACTURER MODEL CAPACITY LOAD CENTER POWER TYPE OPERATOR TYPE TIRES WHEELS(x=driven) DIMENSIONS LIFT WITH STD TWO-STAGE MAST FORK CARRIAGE at rated load center distance electric, diesel, gas, LPG-gas stand-on, ride-seated C=cushion, P=pneumatic number of front/rear kg mm maximum fork height with rated load free
General Section DOOSAN GC25P-5 2500 500 LP rider-seated C 2/2 DOOSAN GC30P-5 3000 500 LP rider-seated C 2/2 DOOSAN GC33P-5 3000(6500LBS) 600 LP rider-seated C 2/2 1 2 3 4 5 6 7 8 3230 152 II 40x100x1050 297x905 6/8 2268 1110 2130 4480 2150 1038 2045 367 2419 1822 3230 152 III 45x125x1050 282x954 6/8 2333 1110 2130 4480 2150 1038 2105 373 2479 1872 3230 152 III 45x125x1050 282x954 6/8 2368 1110 2130 4480 2150 1038 2135 373 2509 1907 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 16/16 510/600 510/4
General Section Noise and Vibration Sound Pressure Level at Operator’s ear (Leq.) according to EN12053 Guaranteed Sound Power level(LWA ) By Noise Directive 2000/14/EC dB(A) dB(A) TIER - II (B3.
D30S-5, G30E-5, G30P-5, G30P-5 Plus D25S-5, G25E-5, G25P-5, G25P-5 Plus D20S-5, G20E-5, G20P-5, G20P-5 Plus General Section Capacity Chart (Without Sideshifter Pneumatic) MODEL STD, FFL SINGLE TIRE FFT -48-
General Section Capacity Chart (Without Sideshifter Pneumatic) SINGLE TIRE STD, FFL FFT D35C-5, G35C-5, G35C-5 Plus D33S-5, G33P-5, G33P-5 Plus MODEL -49-
D30S-5, G30E-5, G30P-5, G30P-5 Plus D25S-5, G25E-5, G25P-5, G25P-5 Plus D20S-5, G20E-5, G20P-5, G20P-5 Plus General Section Capacity Chart (Without Sideshifter Pneumatic) MODEL STD, FFL DOUBLE TIRE FFT -50-
General Section Capacity Chart (Without Sideshifter Pneumatic) DOUBLE TIRE STD, FFL FFT D35C-5, G35C-5, G35C-5 Plus D33S-5, G33P-5, G33P-5 Plus MODEL -51-
D30S-5, G30E-5, G30P-5, G30P-5 Plus D25S-5, G25E-5, G25P-5, G25P-5 Plus D20S-5, G20E-5, G20P-5, G20P-5 Plus General Section Capacity Chart (With Sideshifter Pneumatic) MODEL STD, FFL SINGLE TIRE FFT -52-
General Section Capacity Chart (With Sideshifter Pneumatic) SINGLE TIRE STD, FFL FFT D35C-5, G35C-5, G35C-5 Plus D33S-5, G33P-5, G33P-5 Plus MODEL -53-
D30S-5, G30E-5, G30P-5, G30P-5 Plus D25S-5, G25E-5, G25P-5, G25P-5 Plus D20S-5, G20E-5, G20P-5, G20P-5 Plus General Section Capacity Chart (With Sideshifter Pneumatic) MODEL STD, FFL DOUBLE TIRE FFT -54-
General Section Capacity Chart (With Sideshifter Pneumatic) DOUBLE TIRE STD, FFL FFT D35C-5, G35C-5, G35C-5 Plus D33S-5, G33P-5, G33P-5 Plus MODEL -55-
General Section Capacity Chart (Without Sideshifter cushion) NARROW TIRE STD, FFL FFT GC30E-5, GC30P-5 GC25E-5, GC25P-5 GC20E-5, GC20P-5 MODEL -56-
General Section Capacity Chart (Without Sideshifter cushion) NARROW TIRE STD, FFL FFT GC33E-5, GC33P-5 MODEL -57-
General Section Capacity Chart (Without Sideshifter cushion) WIDE TIRE STD, FFL FFT GC30E-5, GC30P-5 GC25E-5, GC25P-5 GC20E-5, GC20P-5 MODEL -58-
General Section Capacity Chart (Without Sideshifter cushion) WIDE TIRE STD, FFL FFT GC33E-5, GC33P-5 MODEL -59-
General Section Capacity Chart (With Sideshifter cushion) NARROW TIRE STD, FFL FFT GC30E-5, GC30P-5 GC25E-5, GC25P-5 GC20E-5, GC20P-5 MODEL -60-
General Section Capacity Chart (With Sideshifter cushion) NARROW TIRE STD, FFL FFT GC33E-5, GC33P-5 MODEL -61-
General Section Capacity Chart (With Sideshifter cushion) WIDE TIRE STD, FFL FFT GC30E-5, GC30P-5 GC25E-5, GC25P-5 GC20E-5, GC20P-5 MODEL -62-
General Section Capacity Chart (With Sideshifter cushion) WIDE TIRE STD, FFL FFT GC33E-5, GC33P-5 MODEL -63-
General Section Serial Number Serial Number Locations For quick reference, record your lift truck's serial numbers in the spaces provided below the photographs. 2.0 liter Spark-Ignition Engine Serial Number (G420F(E)) •_____________________________ Lift Truck Serial Number •_____________________________ 2.4 liter Spark-Ignition Engine Serial Number (G424F(E)) •_____________________________ 3.3 liter Diesel Engine (4TNV98) Serial Number •_____________________________ 2.
General Section Typical Example 3.
General Section Attachment Abbreviations (Includes Special Forks) SC -Special Carriage-increased width, height or outreach SSS -Shaft-type Sideshift Carriage HSS -Hook-type Sideshift Carriage (ITA) CW -Counterweight SF -Special Forks SWS -Swing Shift, Sideshift RAM -Ram or Boom DBCBH -Double Cube Block Handler HFP -Hydraulic Fork Positioner CR -Crane Arm or Crane Boom TH -Tire Handler CTH -Container Handler LPP -Load Push-Pull Device CC -Carton Clamp RC -Roll Clamp LS -Load S
General Section Operator's Warning and Identification Plate Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES. DO NOT exceed capacity as equipped load ratings. Operator's Warning Plate Identification, Lift Capacity and Attachment Plate Located on the right side of the operator's seat. Located on the cowl to the right side of the steering column.
Operation Section Operator’s Station and Monitoring Systems Instrument Panel Your lift truck may not have the same indicator or warning lights as shown in the illustrations. Due to the various options available, typical instrument panels are shown. However, the symbols on the indicators and lights on your panel identify what those particular items are. Also, the symbol for each of the items is identified and an explanation of their function and location is described on the following pages.
Operation Section 1. Engine Oil Pressure Indicator Light (Except for G430FE) 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. 7. Transmission Oil Temperature Gauge - Indicates transmission oil temperature.
Operation Section 14 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. 15. Low Level Light of LP GAS – Indicates the low Level of LP GAS (LP or DUAL only) 16. Directional Turning Indicator Light 17 17. Horn Switch - Push on the horn button to sound the horn. 18. Brake oil level – Brake oil level Lamp indicates when the brake oil level is low. 19.
Operation Section Electrical Disconnect Switch (If Equipped) 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) 1. ON - Connects the battery for electrical power to all electrical circuits. 2. OFF - Disconnects the battery from all electrical circuits. 2. The hood and seat assembly is held up by a support cylinder.
Operation Section Seat Switch System (If Equipped) NOTICE Prior to operating the lift truck, be sure to understand and check the SEAT SWITCH SYSTEM. While in normal operation and on level ground, select a direction with the derectional lever and with the park brake released. You will note that the truck will move slowly in the selected direction.
Operation Section Tilt Steering Column WARNING When closing the engine hood, be careful not to pinch your hand. Circuit Breaker To adjust the steering column, push down the knob(1), and move the steering column to the desired position, then release the knob(1). Circuit Breaker -Protects the main electrical circuits. To reset the circuit breaker, push the button in. Located in the engine compartment.
Operation Section Lift Truck Controls Direction Control Lever Service Brake Pedal Push DOWN on the brake pedal to slow or stop the lift truck. 1. Forward - Push the lever forward for FORWARD direction travel. RELEASE the brake pedal to allow the lift truck to move. 2. Neutral - Move the lever to center position for NEUTRAL. 3. Reverse - Pull the lever back for REVERSE direction travel. Accelerator Pedal Transmission Inching Control Pedal Push DOWN on the pedal to increase engine rpm (speed).
Operation Section Parking Brake Lever Tilt Control Pull the lever BACK to engage the parking brake. 1. Mast Tilt Forward - Push the lever FORWARD smoothly to tilt the mast forward. Push the lever FORWARD to release the parking brake. 2. Mast Hold - When the lever is released it will return to the HOLD or center position. Tilting action will stop. Lift Control 3. Mast Tilt Back - Pull the lever BACK smoothly to tilt the mast backward.
Operation Section Refueling Gasoline or Diesel Engine Equipped WARNING Explosive refueling. fumes may be present during 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. 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.
Operation Section Changing LP Tanks WARNING Only trained, authorized personnel should fill or exchange LP tanks. Personnel engaged in filling of LP containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves. Do not refuel or store LP powered lift trucks near any underground entrance, elevator shafts or any other place where LP could collect in a pocket causing a potentially dangerous condition. 2. Close the fuel shut off valve at the LP tank.
Operation Section NOTICE If the location pin (dowel) is missing or broken, be sure the pin is replaced. 11. Position the replacement tank so that the locating pin (dowel) is in place. WARNING The LP tank counterweight 6. Check to be sure that the LP warning plate is in position on the lift truck, and is legible. must not extend past the 12. Clamp the tank securely. 7. Check to be sure the replacement tank is of the correct type. 13. Connect the fuel supply line. 8.
Operation Section Before Starting the Engine Walk - Around Inspection Make a thorough walk - around inspection before mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or coolant leaks. Check condition of tires, mast, carriage, forks or attachments. Have repairs made as needed and all debris removed. 7. Inspect the overhead guard for damage and loose or missing mounting bolts. 8. Inspect the hydraulic system for leaks, worn hoses or damaged lines. 9.
Operation Section 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. 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 operator’s seat before starting the lift truck engine. Seat adjustment must be done at the beginning of each shift and when operators change. 12.
Operation Section Starting the Engine Prestart Conditions Gasoline Engine NOTE: The engine will not start unless the transmission directional control lever is in the NEUTRAL position. NOTICE Do not leave the key in ON position when engine is not running. Do not engage the starter more than 10 seconds at any one time. 1. Don’t press accelerator pedal, and turn the ignition switch to the START position. 2. Once the engine starts, release the ignition switch. 3.
Operation Section LP Engine Diesel Engine Starting a Cold Diesel Engine WARNING 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. LP fuel is flammable and can cause personal injury. Inspect LP fuel lines and fitting for leaks. Inspect tank for secure mounting. NOTICE Do not engage the starter for more than 10 seconds. 2.
Operation Section 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( - ).
Operation Section Dual Fuel System Changing From Gasoline to LP – Gas 4. Open the fuel valve, on the LP tank, by slowly turning the valve counterclockwise. NOTE: The Underwriter’s 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. 5.
Operation Section 2 3 4 1 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.
Operation Section After Starting the Engine 4. 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. 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.
Operation Section Lift Truck Operation Power Shift Transmission/ Drive axle WARNING A lift truck with the engine running but without an operator can move slowly (creep) if the transmission is engaged. 1. Start the engine. See topic “Starting the Engine”. 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. 2.
Operation Section Inching 7. To change the lift truck direction of travel, release the accelerator pedal. NOTE: The purpose of the inching pedal is to 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. 8. Push down on the service brake pedal to reduce the lift truck speed as necessary. 1. To inch (creep) in either direction, slowly push down on the inching pedal.
Operation Section Electronic Controlled Spark-Ignition Engines G420FE Engine and G424FE Engine and G424IE Engine EMS (Engine management system) of G420FE engine and G424FE engine and G424IE 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.
Operation Section G420F Engine and G424F Engine and G424I Engine EMS (Engine management system) of G420F engine and G424F engine and G424I 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.
Operation Section 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).
Operation Section Problem Difficult to Start Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet z Fill fuel container z Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve z Wait for a “click” sound Slowly open liquid valve Repair/replace as required z See Maintenance Section, LP Fuel Filter replacement Remove obstruction from the fuel line z Close liquid fuel valve z Using caution, disconnect the fuel line (s
Operation Section Problem Will Not Run Continuously Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet z Fill fuel container z Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve z Wait for a “click” sound Slowly open liquid valve Repair/replace as required z See Maintenance Section, LP Fuel Filter replacement z Clogged fuel filter Plugged fuel line Pressure regulator freezes Fuel Lock-off malfunction Wil
Operation Section Problem Will Not Accelerate/Hesita tion During Acceleration Engine Stalls Probable Cause Corrective Action Clogged fuel filter Repair/replace as required z See Maintenance Section, LP Fuel Filter replacement Faulty vapor connection between the pressure regulator/converter and the mixer Throttle butterfly valve not opening or sticking Foot Pedal signal incorrect or intermittent Incorrect air/fuel or ignition control Engine Mechanical Fuel container almost empty Excess flow valve clo
Operation Section Problem Engine Stalls Probable Cause Corrective Action Fuel Lock-off malfunction Repair/replace Fuel Lock-off z See Engine Service Manual Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or collapsed hose Check level in cooling system z Must be full, check coolant strength z -35F minimum z Check coolant hoses z Watch for kinks and/or pinched hoses z Verify one pressure hose and one return hose Test pressure regulator operation z See Engi
Operation Section Problem Rough Idle High Idle Speed Poor High Speed Performance Probable Cause Corrective Action Incorrect Idle speed control Incorrect timing or spark control Engine Mechanical Incorrect Idle speed control Throttle sticking Foot pedal sticking or incorrect pedal signal Clogged fuel filter See Advanced Diagnostics & See Engine Service Manual See Engine Service Manual See Advanced Diagnostics & See Engine Service Manual Check pedal return spring travel for binding z See Advanced Diagno
Operation Section Problem Probable Cause Corrective Action Air/Fuel Mixer malfunction Check mixer See Engine Service Manual Check air filter z Clean/replace as required Check system vacuum hoses from regulator to FTV and mixer z Repair/replace as necessary Test pressure regulator operation z See Engine Service Manual Check FTV for housing cracks or obstructions z See Advanced Diagnostics FTV operation z Repair and/or replace as necessary See Advanced Diagnostics See Advanced Diagnostics Repair exhaust
Operation Section Basic Troubleshooting (Gasoline) Problem Engine Cranking but Will Not Start (Gas) Probable Cause Corrective Action Fuel tank empty Fill fuel container The tank should be at least ¼ full to properly prime the fuel pump.
Operation Section Problem Difficult to Start (Gas) Probable Cause Corrective Action Fuel tank almost empty Fuel Pump Cavitations z The tank should be at least ¼ full to properly prime the fuel pump z Fuel select switch is not on GAS Repair/replace as required z See Maintenance section, Primary and Secondary Fuel Filter replacement Check electrical connection z Check Relay and fuse Turn key ON and verify pump is operating z See Engine Service Manual Test pressure regulator operation z See Engine Service
Operation Section Problem Will Not Run Continuously (Gas) Probable Cause Corrective Action Electric Fuel Pump malfunction (GAS) Check electrical connection z Check Relay and fuse Turn key ON and verify pump is operating z See Engine Service Manual Pressure regulator malfunction Test pressure regulator operation z See Engine Service Manual Fuel Injector malfunction Test Injector operation See Engine Service Manual z Will Not Accelerate/Hesita tion During Acceleration or Engine Stalls (Gas) Incorr
Operation Section Problem Will Not Accelerate/Hesita tion During Acceleration or Engine Stalls (Gas) Rough Idle (Gas) Probable Cause Corrective Action Throttle butterfly valve not opening or sticking See Advanced Diagnostics Foot Pedal intermittent signal incorrect or Incorrect air/fuel or ignition control Engine Mechanical See Engine Service Manual Isolate the gasoline system by running the lift truck on LPG Verify LPG cylinder is full and valve is open.
Operation Section Problem Probable Cause Corrective Action Rough Idle (Gas) Incorrect Idle speed control Incorrect timing or spark control Engine Mechanical See Advanced Diagnostics Service Manual See Engine Service Manual & Engine Incorrect Idle speed control See Advanced Service Manual & Engine Foot pedal sticking or incorrect pedal signal Check pedal return spring travel for binding High Idle Speed (Gas) Throttle sticking -102- Diagnostics See Advanced Diagnostics
Operation Section Problem Poor High Speed Performance (Gas) Probable Cause Corrective Action 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.
Operation Section Advanced Diagnostics Displaying Fault Codes (DFC) from SECM Memory MI-07 systems are equipped with built-in fault diagnostics. Detected system faults can be 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.
Operation Section Table 2.
Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d. DFC 161 (16) 171 PROBABLE FAULT ECTOverTempFault Engine coolant temperature is high. The sensor has measured an excessive coolant temperature typically due to the engine overheating.
Operation Section Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section 332 MAPRangeLow 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 (1) TurnOnMil (2) EngineShutdown (*) Fault actions shown are default values specified by the OEM.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC 341 (34) 342 351 352 353 371 (37) PROBABLE FAULT MAPTimeRangeHigh Manifold Absolute Pressure Sensor Input is High, normally set if the TMAP pressure signal wire has become shorted to power, shorted to the IAT signal, the TMAP has failed or the SECM has failed.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * 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.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC 437 438 PROBABLE FAULT EST7_Short EST7 output shorted high or low, EST7 signal shorted to ground or power or defective spark module EST8_Short EST8 output shorted high or low, EST8 signal shorted to ground or power or defective spark module 461 (26) ETC_Sticking Electronic Throttle Control is sticking. This can occur if the throttle plate (butterfly valve) inside the throttle bore is sticking.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * 491 (29) HbridgeFault_ETC Electronic Throttle Control Driver has failed. Indeterminate fault on Hbridge driver for electronic throttle control.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section 718 LSDFault_MIL Malfunction Indicator Lamp Fault, signal has opened or shorted to ground or power or defective MIL lamp 721 (72) GasFuelAdaptRangeLo In LPG mode, system had to adapt rich more than expected (1) TurnOnMil (2) Disable GasO2 Ctrl (3) Disable GasPost O2Ctrl (Certified Units Only) 722 GasDesEquivLo In LPG mode, system had to adapt rich more than expected None None None Check for vacuum leaks. Check fuel trim valves, e.g.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section 752 GasPostO2FailedLean Pre-catalyst O2 sensor indicates extended lean operation on LPG (1) TurnOnMil (2) DisableGasPost O2Ctrl (Certified Units Only) 771 (77) GasO2FailedRich Pre-catalyst O2 sensor indicates extended rich operation on LPG (1) TurnOnMil (2) DisableGas O2Ctrl (3) DisableGasPost O2Ctrl (Certified Units Only) Correct other faults that may contribute to 752 (e.g.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK 772 GasPostO2FailedRich Pre-catalyst O2 sensor indicates extended rich operation on LPG (1) TurnOnMil (2) DisableGasPost O2Ctrl (Certified Units Only) 821 LiqFuelAdaptRangeHi In Gasoline mode, system had to adapt lean more than expected (1) TurnOnMil (2) Disable LiquidO2 Ctrl (3) Disable LiqPost O2Ctrl Correct other faults that may contribute to 772 (e.g.
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * (1) TurnOnMil (2) DisableLiqPost O2Ctrl (Certified Units Only) CORRECTIVE ACTION FIRST CHECK Correct other faults that may contribute to 852 (e.g. faults pertaining to Injectors, MAP, IAT, Pre-Cat O2, Post Cat O2 sensor) Look for leaks in exhaust, catalytic converter, HEGO sensors; repair leaks. Check all sensor connections (see fault 842 corrective actions).
Operation Section Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Operation Section Electronic Controlled Spark-Ignition Engines G430FE Engine The primary components of the fuel system are the fuel supply, direct electronic pressure regulator (DEPR), fuel mixer, electronic throttle control (ETC) device, 2-Stage convertor, engine control module (ECM), and a catalytic converter. The system operates on a slightly positive fuel pressure. Primary fuel pressure can be measured at the LD 2-Stage convertor.
Operation Section EMS schematic of G430FE LP engine -126-
Operation Section Basic Troubleshooting(LP) The G430FE fuel 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 Engine Control Module (ECM).
Operation Section INTERMITTENT Checks Action DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code (DTC). Preliminary Checks Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables with this condition may result in the replacement of good parts. Faulty electrical connections or wiring can cause most intermittent problems.
Operation Section NO START Checks Action DEFINITION: The engine cranks OK but does not start. Preliminary Checks ECM Checks Sensor Checks None Use the DST to : • Check for proper communication with both the ECM • Check all system fuses engine fuse holder. Refer to Engine Controls Schematics. • Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity foreach. • • Check the TMAP sensor.
Operation Section NO START Checks Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel system. Engine Mechanical Checks Check for the following: • Vacuum leaks. • Improper valve timing. • Low compression. • Improper valve clearance. • Worn rocker arms. • Broken or weak valve springs. Worn camshaft lobes.
Operation Section HARD START Checks Action DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. Preliminary Checks Make sure the vehicle’s operator is using the correct starting procedure. • Sensor Checks • Check the Engine Coolant Temperature sensor with the DST. Compare the engine coolant temperature with the ambient air temperature on a cold engine.
Operation Section HARD START Checks Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system. Engine Mechanical Checks Check for the following: • Vacuum leaks • Improper valve timing • Low compression • Improper valve clearance. • Worn rocker arms • Broken or weak valve springs • Worn camshaft lobes. Check the intake and exhaust manifolds for casting ash.
Operation Section CUTS OUT, MISSES Checks Action DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks None 1. 2. 3. 4. Start the engine. Check for proper ignition output voltage with spark tester J 26792. Check for a cylinder misfire.
Operation Section HESITATION, SAG, STUMBLE Checks Action DEFINITION: The engine has a momentary lack of response when putting it under load. The condition can occur at any engine speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks None • • Fuel System Checks Ignition System Checks Additional Check • • • • Check the fuel pressure. Refer to LPG Fuel System Diagnosis. Check for low fuel pressure during a moderate or full throttle acceleration.
Operation Section BACKFIRE Checks Action DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Checks None Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire.
Operation Section LACK OF POWER, SLUGGISHNESS, OR SPONGINESS Checks Action DEFINITION: The engine delivers less than expected power. • • Preliminary Checks • • • • • Fuel System Checks • • • • • Sensor Checks • Exhaust System Checks Engine Mechanical Check Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis. Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
Operation Section ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action DEFINITION: The engine runs unevenly at idle. If severe enough, the engine may shake. Preliminary Checks Sensor Checks None. Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance: • Check for silicone contamination from fuel or improperly used sealant. If contaminated, the sensor may have a white powdery coating result in a high but false signal voltage (rich exhaust indication).
Operation Section ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Engine Mechanical Check Action Check the engine for: • Broken motor mounts. • Improper valve timing. • Low compression. • Improper valve clearance. • Worn rocker arms. • Broken or weak valve springs. • Worn camshaft lobes.
Operation Section Advanced Diagnostics The Fuel system has built-in diagnostics for system trouble shooting. The system has a dash mounted malfunction indicator lamp (MIL) that provides indications of engine or fuel system related problem. Most engine control system related problems that affect emissions or driveability of the vehicle will set a (DTC) diagnostic trouble code and illuminate the MIL.
Operation Section BLINK CODE FUNCTION Although the DST is considered a required tool to access the DTC codes, codes may be retrieved without a laptop computer using the blink code function. To enable this function follow the steps below: • Jump pins 1 and 4 at the DLC connector (see illustration below) • Turn the ignition key to the on position • The system will now enter the self diagnostic blink code mode. down any codes that may be stored.
Operation Section Malfunction Indicator Lamp (MIL) Operation How does my MIL work? The emissions control system utilizes a MIL to warn the operator or technician of a possible issue with the engine or emissions control system. The system will keep the MIL illuminated for the entire key cycle in which the trouble code was set.
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (1 of 4) Description DTC 11: Intake cam / distributor position error DTC Set 2 SPN-2 FMI-2 Description DTC Set 2 SPN-2 FMI-2 520800 7 DTC 268: Injector 3 coil shorted 653 636 8 DTC 270: Injector 4 open or short to ground 654 5 520801 7 DTC 271: Injector 4 coil shorted 654 6 DTC 87 Fuel pressure lower than expected 94 1 DTC 273: Injector 5 open or short to ground 655 5 DTC 88 Fuel pressure higher than expected 94
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (2 of 4) DTC Set 2 SPN-2 FMI-2 Description DTC 601: Microprocessor failure - FLASH 628 13 DTC 604: Microprocessor failure - RAM 630 12 DTC 606: Microprocessor failure - COP 629 31 DTC Set 2 SPN-2 FMI-2 Description DTC 1175: MegaJector voltage supply low DTC 1176: MegaJector internal actuator fault detection DTC 1177: MegaJector internal circuitry fault detection DTC 1178: MegaJector internal comm fault 520260 4 520260
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (3 of 4) Description DTC Set 2 SPN-2 FMI-2 Description DTC Set 2 SPN-2 FMI-2 DTC 1546: AUX analog Pull-Up/Down 3 low voltage 520221 4 DTC 1662: PWM6 short to power 925 3 DTC 1547: AUX analog Pull-Up/Down 4 high voltage 713 3 DTC 1663: PWM7 open / ground short 926 5 DTC 1548: AUX analog Pull-Up/Down 4 low voltage 713 4 DTC 1664: PWM7 short to power 926 3 DTC 1551: AUX digital 1 high voltage 520222 3 DTC 1665: PWM
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY DTC # (4 of 4) Description DTC Set 2 SPN-2 FMI-2 DTC 2618: Tach output ground short 645 4 DTC 2619: Tach output short to power 645 3 DTC 8901: UEGO microprocessor internal fault 3221 31 DTC 8902: UEGO heater supply high voltage 3222 3 DTC 8903: UEGO heater supply low voltage 3222 4 DTC 8904: UEGO cal resistor voltage high 3221 3 DTC 8905: UEGO cal resistor voltage low 3221 4 DTC 8906: UEGO return voltage shorted high
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (1 of 4) Description DTC Set 2 Description DTC Set 2 SPN-2 FMI-2 SPN-2 DTC 1561: AUX analog Pull-Down 2 high voltage 0 3 DTC 107: MAP voltage low 106 FMI-2 4 DTC 1561: AUX analog Pull-Down 3 high voltage 0 3 DTC 108: MAP pressure high 106 16 DTC 1561: AUX analog Pull-Down 2 low voltage 0 4 DTC 2229: BP pressure high 108 0 DTC 1561: AUX analog Pull-Down 3 low voltage 0 4 DTC 129: BP pressure low 108 1 DTC
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (2 of 4) Description DTC Set 2 SPN-2 FMI-2 Description DTC Set 2 SPN-2 FMI-2 DTC 16: Crank and/or cam could not synchronize du DTC 1629: J1939 TSC1 message receipt loss 636 639 8 9 DTC 1661: PWM6 open / ground short DTC 1664: PWM7 short to power 925 926 5 3 DTC 1626: CAN-J1939 Tx fault DTC 1627: CAN-J1939 Rx fault DTC 1628: J1939 CAN address / engine-number con 639 639 639 12 12 13 DTC 1663: PWM7 open / ground short DTC 6
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (3 of 4) Description DTC Set 2 SPN-2 FMI-2 Description DTC Set 2 SPN-2 FMI-2 DTC 304: Cylinder 4 emissions/catalyst damaging m 1326 31 DTC 175: Adaptive-learn gasoline bank2 low 520201 1 DTC 1315: Cylinder 5 misfire detected 1327 11 DTC 1161: Adaptive-learn LPG high 520202 0 DTC 305: Cylinder 5 emissions/catalyst damaging m 1327 31 DTC 1162: Adaptive-learn LPG low 520202 1 DTC 1316: Cylinder 6 misfire detected 1
Operation Section DIAGNOSTIC TROUBLE CODE (DTC) CHART – SORTED BY SPN:FMI (4 of 4) Description DTC Set 2 SPN-2 FMI-2 DTC 188: Gaseous fuel temperature sender high vol 520240 3 DTC 187: Gaseous fuel temperature sender low volta 520240 4 DTC 331: Knock2 excessive or erratic signal 520241 2 DTC 332: Knock2 sensor open or not present 520241 4 DTC 2120: FPP1 invalid voltage and FPP2 disagrees 520250 31 DTC 2125: FPP2 invalid voltage and FPP1 disagrees 520250 31 DTC 1122: FPP1/2 do not match
Operation Section 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.
Operation Section Auto Shift Controller ASC-100 (If Equipped) Product Description Adjustments 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.
Operation Section Diagnostics Features Operation ASC-100 has an internal indicator on the right side of the controller for displaying the selected gear and the abnormal condition. This system can basically operate in 2 pre-selected modes. z Automatic mode (Direction Inhibit mode): Selected as factory-setting. z Manual mode (Fail-Safe mode): manual operation in emergency. Below is a description applicable for many ASC100 implementations.
Operation Section Manual Mode (Fail-Safe mode) The system still allows movement of the vehicle in case of controller breakdown by selecting the manual mode with the Fail-Safe mode Switch in the controller. WARNING In the manual mode, direction inhibition function can not be operated normally. The sudden reversal of a loaded lift truck traveling forward can cause the load to fall or the lift truck to tip.
Operation Section Finger Tip (Option) Tilt Control knob Function of Knobs If finger tip control option is equipped, the hall-effect type electric knobs replace conventional control valve levers. Lift Control knob Tilt Forward - Push the knob forward smoothly to tilt the lift forks forward. Hold - Release the tilt knob. The knob will return to the center(hold) position and the forks will remain in the position they are in. Tilt Back - Pull the knob back smoothly to tilt the lift forks back..
Operation Section Sideshift Attachment Control Warning Lamp Sideshift Left - Push the knob forward smoothly to shift the carriage to the left. The state of the finger tip system can be checked by the external warning lamp blinking.. Sideshift Hold - Release the sideshift attachment knob. The knob will return to the center(hold) position and sideshifting action will stop. Sideshift Right - Pull the knob back smoothly to shift the carriage to the right.
Operation Section Auto Tilt Leveling Switch [Aux2] Optional Selector Switch for SAFETY Operating a Rotating Cramp Attachment 1 2 3 In case of auto tilt leveling, push this button. Pushing button makes auto tilt leveling function on and off alternately. When the function is on, the mast stops at a vertical position while tilting forward and backward.
Operation Section Adjustment of Armrest Up and Down Adjustment 1 2 2 By using 2 knobs, adjust the position of the armrest to give the operator the best comfortable position of arm. To move the armrest down, turn the knob(2) counterclockwise knob #1 - Forward and backward adjustment . knob #2 - Up and down adjustment. Forward and Backward Adjustment 2 1 To move the armrest up, turn the knob(2) clockwise. 1. Loosen the knob bolt(1).. 2. Adjust the position of armrest forward or backward. 3.
Operation Section Operating Techniques Inching into Loads Lifting the Load 1. Lift the load carefully and tilt the mast back a short distance. Typical Example 1. Move the lift truck slowly FORWARD into position and engage the load. The lift truck should be square with load, forks spaced evenly between pallet stringers and as far apart as load permits. Typical Example 2. Tilt the mast further back to cradle the load. Typical Example Typical Example 3.
Operation Section Traveling With the Load Unloading NOTICE Travel with the load as low as possible, while still maintaining ground clearance. Typical Example 1. Move the lift truck into the unloading position. Typical Example 1. Travel with the load uphill on upgrades and downgrades. Typical Example 2. Tilt the mast FORWARD only when directly over the unloading area. WARNING Do not tilt the mast forward with the load unless directly over the unloading area, even if the power is off.
Operation Section Turning Typical Example 3. Deposit the load and BACK away carefully to disengage the forks. 1. When turning sharp corners, keep close to the inside corner. Begin the turn when the inside drive wheel meets the corner. Typical Example 4. Lower the carriage and forks to the travel position or to the park position. 2. In narrow aisles, keep away from the stockpile when turning into the aisle. Allow for counter weight swing.
Operation Section Lifting Drums or Round Objects Operating in hot weather Keep the following points in mind when you operate the lift truck in hot weather. 1. Check the radiator. Clogging can cause overheating. Clean them out regularly with a blast of compressed air, also, check for leakage of water. 2. Check the fan belt tension and adjust to proper tension. 3.
Operation Section Parking the Lift Truck 5. Turn the key in the ignition switch to the OFF position and remove the key. NOTE: Park the lift truck level with the fork lowered and the mast tilted forward until the fork touches the floor. Block the drive wheels when parking on an incline. NOTE: 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.
Operation Section Lift Fork Adjustment WARNING When adjusting the fork spread, be careful not to pinch your hand between forks and the carriage slot. Hook-on type Fork 1. Move up the hook pin to the free position. 2. Raise the hook pin in each fork to side the fork on the carriage bar. 3. Adjust the forks in the position 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.
Operation Section Storage Information Before Storage To Operate the Lift Truck after a Long Time Storage Before storing your lift truck, clean and inspect as the following procedures. z z z z z z z z z z 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.
Operation Section Transportation Hints Lift Truck Shipping Machine Lifting and Tiedown Information 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. NOTICE 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.
Operation Section Towing Information Consult your DOOSAN Lift Tuck dealer for towing a disabled lift truck. 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.
Maintenance Section 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.
Maintenance Section Repetitive Overloading Causes of Fork Failure z Improper Modification or Repair 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.
Maintenance Section Fork Inspection First Installation 1. Inspect forks to ensure they are the correct size for the truck on which they will be used. Make sure they are the correct length and type for the loads to be handled. If the forks have been previously used, perform the “12 Month Inspection”. If the forks are rusted, see “Maintenance and Repair”. 2. Make sure fork blades are level to each other within acceptable tolerances.
Maintenance Section 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. 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 Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures. 1 Size Ply Rating or Strength Index 6.5X10 7.0X15 28X9-15 10 12 12 Shipping Pressure kPa 790 825 825 psi 115 120 120 Standard tire, ply rating and inflation pressures.
Maintenance Section Torque Specifications Metric Hardware Torque for Standard Bolts, Nuts, and Taperlock Studs 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. NOTICE The two charts below give general torques for bolts, nuts, and taperlock studs of SAE Grade 5 or better quality.
Maintenance Section Torque for Metric Fasteners Torques for Taperlock Studs Thread Size Inch Standard Taperlock Stud Torque N•m1 NOTICE lb•ft 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 Be very careful never to mix metric with U.S.
Maintenance Section Cooling System Specifications Filling at over 20 liters (5 U.S. gallons) per minute can cause air pockets in the cooling system. 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.
Maintenance Section Coolant Water Antifreeze Hard water, or water with high levels of calcium and magnesium ions, encourages the formation of insoluble chemical compounds by combining with cooling system additives such as silicates and phosphates. NOTICE DOOSAN recommends using automotive antifreeze suitable for gasoline engines having aluminum alloy parts.
Maintenance Section Fuel Specifications fuel should be used. 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.
Maintenance Section Gasoline Specifications These 95 diesel fuels must meet certain requirements. 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. 1. The bio-fuels must meet the minimum specifications for the country in which they are used. z z In Europe, bio-diesel fuels must comply with the European Standard EN14214.
Maintenance Section Lubricant Information Lubricant Information Hydraulic Oil (HYDO) Certain abbreviations follow Society of Automotive Engineers (SAE) J754 nomenclature and some classifications follow SAE J183 abbreviations. The following commercial classifications can be used in the hydraulic system. z The MIL specifications Specifications. are U.S.A. Military z z z The recommended oil viscosities can be found in the Lubricant Viscosities chart in this publication.
Maintenance Section Lubricating Grease (MPGM) Brake Fluid Use Multipurpose Molybdenum Grease (MPGM) for all lubrication points. If MPGM grease can not be used, multipurpose type grease which contains 3% to 5% molybdenum disulfide can be used. NLGI No.2 grade is suitable for most temperatures. Use NLGI No.1 or No.0 grade for extremely low temperature. Transmission Oil NOTICE This oil is formulated for transmissions and drive trains only, and should not be used in engines.
Maintenance Section Lubricant Viscosities and Refill Capacities Lubricant Viscosities Refill Capacities LUBRICANT VISCOSITIES REFILL CAPACITIES - (APPROXIMATE) FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment Oil °C or System Viscosities Min Max Min Max SAE 10W30 -20 +40 -4 +104 SAE 5W30 -30 +30 -22 +86 Compartment or System °F G420F(E) G424F(E) Engine Crankcase (Gasoline and LP) API SJ G424I(E) G430FE SAE 10W30 -20 +40 -4 +104 Engine Crankcase (Gasoline and LP) SAE 5W30 -30
Maintenance Section Maintenance Intervals First 50 - 100 Service Hours or a Week NOTICE Engine Oil & Filter (Diesel Engine Only) - Change .......................................................................... 198 Transmission Oil, Oil Filter & Strainer - Check, Clean, Change .................................................. 199 Drive Axle Oil - Change ..................................... 201 Parking Brake - Test, Adjust ..............................
Maintenance Section Engine Oil & Filter (Diesel Engine Only) - Change .......................................................................... 222 Water Separator (4TNV98 Diesel Engine Only) Clean ................................................................. 223 Every 2500 Service Hours or 15 Months Every 1000 Service Hours or 6 Months Hydraulic Return Filter, Breather & Strainer - Check, Change ..............................................................
Maintenance Section Air Cleaner Indicator Check 194 Air Intake System Change 227 Air Intake System Check, Clean 204 O Battery Terminal Clean, Inspect 208 O Belts Check, Adjust 214 Brake Oil Level Check 206 Carriage Roller Extrusion Adjust 191 Checking the TMAP Sensor (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) Coolant Level O O O O O 244 Check 193 Cooling System Clean, Change 237 Crankcase Breather System (4TNV98 Diesel Engine Only) Inspect 233 Crosshead Rollers Inspe
Maintenance Section Inspect for Intake Leaks (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) 244 Inspect Ignition System (LP, Gasoline & Dual Fuel Engines Only) 230 Inspect Mixer Assembly (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) 229 Inspect Throttle Assembly (G420F(E)/G424F(E)/G424I(E)/G430FE Engine Only) 229 Inspect Tightness (GC - Series) 211 Inspect Vacuum Lines and Fittings (G420F(E)/G424F(E)/G424I(E) Engine Only) 225 Mast Channels Lubricate 195 Mast Hinge Pin Lubricate 214 Mas
Maintenance Section When Required You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Fuel Tank Filter Cap and Screen (If Equipped) - Clean Seat, Hood Latch & Support Cylinder - Check, Lubricate Park the lift truck with the forks lowered, parking brake applied, transmission in neutral and the engine stopped. 1. Check the operation of the seat adjuster rod.
Maintenance Section Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset Fuses NOTE: If a fuse filament separates, use only the same type and size fuses for replacement. If the filament in a new fuse separates, have the circuits and instruments checked. NOTICE Always replace fuses with ones of the correct ampere rating. Remove the front cover from the fuse box located under the cowl. Fuse - Protects an electrical circuit from an overload. Opens (filament separates) if an overload occurs.
Maintenance Section Priming the Fuel System(Diesel Engine Only) Circuit Breaker 4TNV98 Diesel Engine Only The fuel system needs to be primed under certain conditions. 1. Raise the hood and seat assembly. Make sure the support cylinder securely holds the hood open.
Maintenance Section 5. Wipe up any spills and properly dispose of fuel. 6. NEVER use the starter motor to crank the engine in order to prime the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and / or ring gear. 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.
Maintenance Section Water Seperator (Diesel Engine Only) - Check, Drain 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.
Maintenance Section Test Fuel System for Leaks(LP and Dual Fuel Engines Only) 4TNE98 Diesel Engine Only NEVER wait until the scheduled periodic maintenance if the fuel filter indicator comes on. The fuel filter / water separator contains a sensor to detect the amount of water and contaminants. This sensor sends a signal to an indicator to alert the operator. Drain the fuel filter / water separator as follows: Check Points 1.
Maintenance Section Tires and Wheels (D, G-Series) Inspect, Check Carriage Roller Extrusion – Adjust 1. Set the mast vertical. WARNING 2. Lower the carriage completely. 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.
Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspect Engine for Fluid Leaks Gasoline and LP Engines 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.
Maintenance Section 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. Coolant Level – Check WARNING At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. 4. Stop the engine.
Maintenance Section Air Cleaner Indicator-Check Walk-Around Inspection - Inspect Checking Service Indicator For maximum service life of the lift truck, make a thorough walk-around inspection. Look around and under the truck for such items as loose or missing bolts, debris or dirt buildup, fuel, oil or coolant leaks and cut or gouged tires. Have any repairs made and debris removed, as needed. 1. Observe the air cleaner service indicator. 2.
Maintenance Section Mast Channels – Lubricate 8. Inspect the cooling system for leaks, worn hoses and debris buildup. The channels on the roller-type mast require a break-in period. Apply a light film of lubricant on the channels where the rollers ride. This will prevent metal peel until the rollers set a pattern. 9. Inspect engine compartment for oil, coolant and fuel leaks. 10. Inspect the forks.
Maintenance Section Transmission Oil Level – Check Parking Brake - Inspect Inspection from Operator's Seat, Engine OFF WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Start and operate the lift truck until the engine reaches normal operating temperature. 2. Park the lift truck level with the forks lowered, parking brake applied and the transmission controls in NEUTRAL. 3.
Maintenance Section Parking Brake NOTE: The parking brake is required to be adjusted to hold the lift truck with capacity load on a 15% grade. If there is a 15% grade in your workplace, engage a capacity load and drive over to the grade. If the maximum grade in your workplace is less than 15% or if the maximum load carried by the lift truck is less than the lift truck's load capacity, pick up the maximum load and drive to the steepest grade in your workplace. 1.
Maintenance Section First 50 - 100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Oil & Filter (Diesel Engine Only) - Change 6. Remove the oil drain plug (Figure 5-2, (1)) from the engine oil pan. Allow oil to drain. The engine oil in a new engine becomes contaminated from the initial break-in of internal parts.
Maintenance Section Transmission Oil, Oil Filter & Strainer - Check, Clean, Change WARNING NEVER overfill the engine with engine oil. ALWAYS keep the oil level between the upper and lower lines on the oil cap/dipstick. WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 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.
Maintenance Section 12. Maintain the oil level between the Min and Max marks on the dip stick/filter cap. When the oil temperature is 40°C approximately, the cold side mark on the dipstick is applicable. When the oil temperature is 80°C approximately, 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. 3. Remove the floor mat and the floor plate. Remove and discard the oil filter. 4.
Maintenance Section Drive Axle Oil - Change Parking Brake - Test, Adjust Park the lift truck on a level surface. Apply the parking brake. Place the directional control lever in NEUTRAL and stop the engine. 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.
Maintenance Section WARNING To prevent personal injury, the operator MUST be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move. Parking Brake Adjusting 1. Park the lift truck on a level surface, lowered the forks, shift the transmission to NEUTRAL and shut OFF the engine and block the wheels securely. 2. Chock the lift truck's unintentional movement. tires to 7. Loosen lock nut (5). Tighten screw (6) to 6 to 7 N•m (50 to 60 lb•in).
Maintenance Section First 250 Service Hours or a Month You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. . Hydraulic Return Filter – Change WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL and the engine stopped. 1.
Maintenance Section Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. 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.
Maintenance Section Air-205 kPa (30 psi) Maximum Pressure 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 Direct air on the inside and outside of the element along the length of the pleats.
Maintenance Section Hydraulic Oil Level – Check Checking Element WARNING At operating temperature, the hydraulic tank is hot and under pressure. Hot oil can cause burns. Remove the filter cap only when the engine is stopped, and the cap is cool enough to touch with your bare hand. Remove the filter cap slowly to relieve pressure. 1. Operate the lift truck for a few minutes to warm the oil.
Maintenance Section 5. Raise and lower the carriage a few times to allow lubricant to enter into the chain links. 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. 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.
Maintenance Section Battery Terminal - Clean, Inspect Engine Oil & Filter (LP & Gasoline Engine Only) - Change WARNING Gasoline, LP Engine Crankcase Batteries give off flammable fumes that can explode. 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. Do not smoke when observing the battery electrolyte levels.
Maintenance Section 7. Before installing a new filter element, apply a small amount of clean engine oil to the filter element gasket. PCV Valve System - Inspect, Clean 8. Install the new filter element. When the gasket contacts the base, tighten it 3/4 of a turn more. Do not over-tighten. G420F(E) Gasoline, LP and Dual Fuel Engines 9. Raise the lift truck, remove the blocking and lower the lift truck. 10. Fill the crankcase. See “Refill Capacities”. 11.
Maintenance Section G424I(E) LP and Duel Fuel Engines G430FE LP Engine 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.
Maintenance Section Wheel Bolts & Nuts - Inspect Inspect Tightness (GC - Series) Inspect Tightness (D, G - Series) Drive Wheels Steer Wheels Typical Example 1. Inspect tightness of wheel bolts in a sequence opposite each other to 245 N•m (180 lb•ft). Typical Example 1. Inspect tightness of wheel bolts in a sequence opposite each other 110 N•m (75 lb•ft). Drive Wheels Typical Example 2. Inspect tightness of wheel nuts in a sequence opposite each other to 610 N•m (450 lb•ft).
Maintenance Section Governor Lever and Engine Speed Control (Diesel Engine Only) Check ,Adjust 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.. 4TNV98 Diesel Engine Only The governor lever and engine speed control ( throttle lever, pedal, etc.
Maintenance Section 4TNE98 Diesel Engine Only The governor lever and engine speed control(accelerator lever, pedal, etc.) of the machine are connected together by an accelerator cable or rod. If the cable becomes stretched, or the connections loosen, the governor lever may not respond to change of engine speed control position. This may make operation of the machine unsafe. Check the cable periodically and adjust if necessary.
Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Belts - Check, Adjust Mast Hinge Pin – Lubricate Typical Example 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. 1. Lower the forks and tilt the mast forward. 2.
Maintenance Section Mast Pivot Eyes-Lubricate Typical Example 3. To adjust the cylinder rod extension, move the spacer to the rear and loosen the pinch bolt on the clevis. Typical Example 1. Lubricate two fittings for the mast pivot eyes, one on each side of the pin. 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. 2.
Maintenance Section Transmission Oil Filter – Change Overhead Guard – Inspect WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Park the lift truck level, with the forks lowered, parking brake engaged, direction control lever in NEUTRAL and the engine stopped. 1. Check tightness of overhead guard mounting bolts at 95 N•m (70 lb•ft). 2. Check overhead guard for bent or cracked sections. Have repairs made if needed. 1.
Maintenance Section Drive Axle Oil & Strainer - Change, Clean 7. Install the dip stick/filter cap. Park the lift truck level, with the forks lowered, parking brake engaged, transmission in NEUTRAL and engine stopped. 1. Remove drain plug. Allow the oil to drain into a suitable container. Clean the magnetic drain plug. Check O - ring seal and replace if necessary. 2. Install the drain plug. 3. Wash the strainer assembly in clean, non flammable solvent and dry it.
Maintenance Section Steer Suspension – Inspect Inching & Braking Control Shaft Lubricate 1. Inspect the suspension mounting bolts. Tighten suspension mounting bolts, if necessary, to 240 ± 30 N•m (180 ± 20 lb•ft). 1. Lubricate three fittings for the inching and brake pedal control shaft. Horn and Lights (If Equipped) Check 2. Look for leaks at the power steering hose connections. 3. Remove any trash buildup on the suspension or the steer axle. 1.
Maintenance Section Inspect Vacuum Lines and Fittings (G420F(E)/G424F(E)/G424I(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.
Maintenance Section Inspect Electrical System (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) 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.
Maintenance Section Fuel Filter (Diesel Engine Only) Change 4TNE98 Diesel Engine Only Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow. 4TNV98 Diesel Engine Only 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. 1. Stop the engine and allow it to cool. 3. Disconnect the fuel filter sensor connector (Figure 5-14, (1)). 2.
Maintenance Section 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.
Maintenance Section Water Separator (4TNV98 Diesel Engine Only) - Clean 6. Remove the float ring (Figure5-16, (8)) from the cup. Pour the contaminants into the container and dispose of it properly. Periodically clean the fuel filter / water separator element and inside cup. 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. 1.
Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Return Filter, Breather & Strainer - Check, Change WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.
Maintenance Section Transmission Oil, Oil Filter & Strainer - Check, Clean, Change Check for Equal Tension See topic, “Transmission Oil, Oil Filter & StrainerCheck, 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.
Maintenance Section Carriage Chain Adjustment Mast Chain Adjustment - FF, FFT Mast Make sure that carriage height is correct. If correct, adjust the chain for equal tension. If not, adjust the chain for correct carriage height by adjusting anchor nuts (1), (2). NOTE: See the previous section, “Carriage Roller Extrusion” in “When Required” for proper height of carriage. 1.
Maintenance Section Universal Joint – Inspect Air Intake System - Change Changing Primary Element See topic, “Air Intake System - Check, Clean” in “Every 250 Service Hours or Monthly” 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. 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.
Maintenance Section Inspect Coolant Hoses (LP, Dual Fuel Engine Only) Fuel Lines & Fittings - Check Visually inspect fuel lines and fittings for physical damage. Replace as required. 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.
Maintenance Section Inspect Mixer Assembly (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) Engine Valve Lash (Diesel Engine Only) - Check, Adjust Refer to the LP mixer section of the engine service manual for procedures. NOTICE The valve clearances are to be adjusted at the times of the following situations. z When the engine is overhauled and the cylinder heads are disassembled. z When severe noise comes from valve train.
Maintenance Section Every 1500 Service Hours or 9 Months Inspect Ignition System (LP, Gasoline & Dual Fuel Engines Only) G424I(E) Engine 1 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). 2 4. Inspect the ignition coil for cracks and heat deterioration. Visually inspect the coil heat sink fins.
Maintenance Section Replace Spark Plugs (G424F(E) LP, Dual Fuel Engine / G430FE Engine Only) 1. Disconnect Battery Cables. 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)/G430FE Engine : 0.9 mm 5. Apply anti-seize compound to the spark plug threads and install.
Maintenance Section 3. Check bottom cover O-ring seal (6) for damage. Replace if necessary. Replace LP Fuel Filter Element (LP, Dual Fuel Engine Only) 4. Re-assemble the filter assembly aligning the scribe lines on the top and bottom covers. 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.
Maintenance Section 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.
Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures . Engine Valve Lash (Diesel Engine Only) – Check, Adjust Steer Wheel Bearings Reassemble See topic “Engine valve Lash (Diesel Engine Only) – Check, Adjust”. In First 250 Service hours.
Maintenance Section 3. Straighten the lock washer tangs. 8. Install the outer wheel bearing and the out washer. Install a new lock washer and fit the locknut. 4. Remove the locknut, lock washer and flat washer. Remove the outer wheel bearing. Typical Example 9. Tighten the locknut to 135 N•m (100 lb•ft), while turning wheel hub to seat the bearing. 10. Loosen the locknut. Retorque it to 50 ± 5N•m (37 ± 4 lb•ft). Bend the lock washer tang to secure locknut. 11. Install the hub cap. 12.
Maintenance Section Drive Wheel Bearing (Power Shaft and Drive Wheel) – Reassemble GC-Series Lift Trucks. Torque for wheel bolts (1) is 270 ± 25 N•m (200 ± 20 lb•ft). Consult your DOOSAN lift truck dealer for the proper wheel bearing reassembling procedure. Packing of bearings and adjustment procedure must be made by a trained mechanic or dealer personnel. Tighten wheel bearing nut (2) 135 N•m (100 lb•ft) while the wheel is turned in both directions.
Maintenance Section Cooling System – Clean, Change WARNING At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Coolant is included antifreeze for forbidding corrosion. Avoid contact with the skin and eyes to prevent personal injury. 4TNV98 3.
Maintenance Section 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”. G430FE 3.0L LPG Engine 3. Open the radiator drain valve. Allow the coolant to drain into a suitable container.
Maintenance Section Forks – Inspect 3. Check the straightness of the upper face of blade (D) and the front face of shank (E) with a straight edge. 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).
Maintenance Section Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork. They may also use U bolts, pins, or similar devices which engage the fork through the top structure of the carriage. 5. Check the fork blade (J) and shank (H) for wear with special attention to the heel (G). The fork should be withdrawn from service if the thickness is reduced to 90 percent or less of the original thickness.
Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Oil - Check, Clean, Change Inspect Battery System 1. Clean battery outer surfaces with a mixture of baking soda and water. WARNING 2. Inspect battery outer surfaces for damage and replace as necessary. Hot oil and components can cause personal injury.
Maintenance Section Replace Oxygen Sensor (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) G430FE Engine 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. G424I(E) Engine 2. Disconnect the electrical connector of oxygen sensor 3. Remove oxygen sensor 4. Assemble new oxygen sensor Tightening torque : 45 N•m (32.5 lb•ft) 5.
Maintenance Section Replace Spark Plugs (G420F(E)/G424I(E) Engine Only) 1. Disconnect Battery Cables. 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 G424I(E) Engine : 0.8 ~ 0.9 mm 6. Apply anti-seize compound to the spark plug threads and install. G420F(E)/G424I(E) Engine : 25 N•m (18 Ib•ft) WARNING DO NOT OVERTIGHTEN THE SPARK PLUGS.
Maintenance Section Checking the TMAP Sensor (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) Inspect for Intake Leaks (G420F(E)/G424F(E)/G424I(E) /G430FE Engine Only) 1. Verify that the TMAP sensor (F) is mounted tightly into the manifold adapter (E), with no leakage. 1. Visually inspect the intake manifold, throttle assembly (2), and manifold adapters (3), for looseness and leaks. Repair as necessary. 2.
Maintenance Section G424I(E) Engine G430FE Engine 1. Loosen the hose clamps and remove the PCV valve. 2. Assemble new PCV valve and hose. 3.
Maintenance Section Every 3000 Service Hours or 18 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Timing Belt [G420F(E)/G424F(E) LP, Gasoline, 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 Index # 12 Months Inspection ......................................... 170 4TNE98 Diesel Engine Only ......... 187,190,213,221 4TNV98 Diesel Engine Only ......... 187,189,212,221 A [Aux2] Optional Selector Switch for SAFETY Operating a Rotating Cramp Attachment ........... 156 Accelerator Pedal ................................................ 74 Additional Technical Fuel Requirements ............ 176 Adjustment of Armrest ....................................... 157 Adjustments ..............
Index Section E G Electrical Disconnect Switch (If Equipped) ........... 71 Electronic Controlled Spark-Ignition Engines ..... 125 Emergency Switch ............................................. 155 EMS schematic of G430FE LP engine ............... 126 Engine Compartment ........................................... 71 Engine Oil & Filter (Diesel Engine Only) - Change ................................................................... 198,222 Engine Oil & Filter (LP & Gasoline Engine Only) Change ..........
Index Section Inspect Electrical System (G420F(E) /G424F(E) /G424I(E) /G430FE Engine Only) ...................... 220 Inspect Engine for Exhaust Leaks...................... 194 Inspect Engine for Fluid Leaks ........................... 192 Inspect Foot Pedal Operation (G420F(E) /G424F(E) /G424I(E) /G430FE Only) .................................. 194 Inspect for Intake Leaks (G420F(E) /G424F(E) /G424I(E) /G430FE Engine Only) ......................
Index Section Product Description ........................................... 151 R Reading Diagnostic Fault Codes........................ 104 Refill Capacities ................................................. 180 Refueling ............................................................. 76 Replace LP Fuel Filter Element (LP, Dual Fuel Engine Only) ...................................................... 232 Replace Oxygen Sensor (G420F(E) /G424F(E) /G424I(E) /G430FE Engine Only) ......................
