SB4239E01

For use in service manual
form SB4239E
SB4240E01
Sep. 2010
SERVICE MANUAL CONTENTS
NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers are listed with mark(*), they are not available for the initial
release of the manual. When items are updated, or supplements are added,
they will be provided separately.
TITLE FORM NUMBER
Service Manual Contents SB4240E01

Safety SB2003E00
Torque Specifications SB2004E00
ENGINE
A2300 Diesel Engine SB4106E01

V2403 Diesel Engine SB4400E00
G420F(E) LP/Gasoline Engine SB4241E01
Delco Remy CS-121 Series Alternator SB2007E02
CS-105D Series Alternator SB4050E00
POWER TRAIN
Power Train SB4243E00

Power Train D & A SB4248E00
VEHICLE SYSTEMS
Vehicle Systems SB4365E00

Vehicle Systems D & A SB4245E01
Mast System SB2143E04
Hydraulic System Schematic SB4246E00
Electric Systems Schematic SB4247E01
OPERATION & MAINTENANCE
Operation & Maintenance Manual SB2353E00

Operation & Maintenance Manual SB2354E00
Models ; D(G)15/18S-5, D(G)20SC-5, GC15/18S-5, GC20S-5

SB2003E00
Dec. 1998
WARNING
SAFETY
WARNING WARNING
The proper and safe lubrication and maintenance Do not operate this machine unless you have
for this machine, recommended by DOOSAN, are read and understand the instructions in the
outlined in the OPERATION & MAINTENANCE OPERATOR'S GUIDE. Improper machine
GUIDE for this machine. operation is dangerous and could result in
Improper performance of lubrication or injury or death.
maintenance procedures is dangerous and could
result in injury or death. Read and understand the
OPERATION & MAINTENANCE GUIDE before 5. Use steps and grab handles (if applicable) when
performing any lubrication or maintenance. mounting or dismounting a machine. Clean any mud or
debris from steps, walkways or work platforms before
using. Always face machine when using steps, ladders
Theserviceman or mechanic maybe unfamiliar with many and walkways. When it is not possible to use the
of the systems on this machine. This makes it important designed access system, provide ladders, scaffolds, or
to use caution when performing service work. A work platforms to perform safe repair operations.
knowledge of the system and/or components is 6. To avoid back injury, use a hoist when lifting
important before the removal or disassembly of any components which weigh 23 kg (50 lb.) or more. Make
component. sure all chains, hooks, slings, etc., are in good
Because of the size of some of the machine condition and are of the correct capacity. Be sure
components, the serviceman or mechanic should check hooks are positioned correctly. Lifting eyes are not to
the weights noted in this Manual, Use proper lifting be side loaded during a lifting operation.
procedures when removing any components. 7. To avoid burns, be alert for hot parts on machines
Following is a list of basic precautions that should always which have just been stopped and hot fluids in lines,
be observed. tubes and compartments.
1. Readand understand all Warning plates and decals on 8. Be careful when removing cover plates. Gradually
the machine before operating, lubricating or repairing back off the last two bolts or nuts located at opposite
the product. ends of the cover or device and pry cover loose to
relieve any spring or other pressure, before removing
2. Always wear protective glasses and protective shoes the last two bolts or nuts completely.
when working around machines. In particular, wear
protective glasses when pounding on any part of the 9. Be careful when removing filler caps, breathers and
machine or its attachments with a hammer or sledge. plugs on the machine. Hold a rag over the cap or plug
Use welders gloves, hood/goggles, apron and other to prevent being sprayed or splashed by liquids under
protective clothing appropriate to the welding job pressure. The danger is even greater if the machine
being performed. Do not wear loose-fitting or torn has just been stopped because fluids can be hot.
clothing. Remove all rings from fingers when working 10. Always use tools that are in good condition and be
on machinery. sure you understand how to use them before
3. Do not work on any machine that is supported only by performing any service work.
lift jacks or a hoist. Always use blocks or jack stands 11. Reinstall all fasteners with same part number. Do not
to support the machine before performing any use a lesser quality fastener if replacements are
disassembly. necessary. Do not mix metric fasteners with
4. Lower the forks or other implements to the ground standard nuts and bolts.
before performing any work on the machine. If this 12. If possible, make all repairs with the machine parked
cannot be done, make sure the forks or other on a level, hard surface. Block machine so it does
implements are blocked correctly to prevent them not roll while working on or under machine.
from dropping unexpectedly.
1 of 2
WARNING
13. Disconnect battery and discharge any capacitors 21. Do not operate a machine if any rotating part is
(electric trucks) before starting to work on machine. damaged or contacts any other part during
Hang "Do Not Operate" tag in the Operator's operation. Any high speed rotating component that
Compartment. has been damaged or altered should be checked
for balance before reusing.
14. Repairs, which require welding, should be
performed only with the benefit of the appropriate 22. On LP equipped lift trucks, be sure to close the
reference information and by personnel adequately valve on the LP tank before service work is
trained and knowledgeable in welding procedures. performed. Always close the valve on the LP tank
Determine type of metal being welded and select when the lift truck is being stored. Do not check for
correct welding procedure and electrodes, rods or LP leaks with an open flame.
wire to provide a weld metal strength equivalent at
23. Caution should be used to avoid breathing dust that
least to that of parent metal.
may be generated when handling components
15. Do not damage wiring during removal operations. containing asbestos fibers. If this dust is inhaled, it
Reinstall the wiring so it is not damaged nor will it can be hazardous to your health. Components in
be damaged in operation by contacting sharp DOOSAN products that may contain asbestos
corners, or by rubbing against some object or hot fibers are brake pads, brake band and lining
surface. Do not connect wiring to a line containing assemblies, clutch plates and some gaskets. The
fluid. asbestos used in these components is usually
bound in a resin or sealed in some way. Normal
16. Be sure all protective devices including guards and
handling is not hazardous as long as airborne dust
shields are properly installed and functioning
which contains asbestos is not generated.
correctly before starting a repair. If a guard or shield
must be removed to perform the repair work, use If dust which may contain asbestos is present, there are
extra caution. several common sense guidelines that should be
followed.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance a. Never use compressed air for cleaning.
or repair work is performed, which requires the
b. Avoid brushing or grinding of asbestos containing
mast in the raised position.
materials.
18. Loose or damaged fuel, lubricant and hydraulic
c. For clean up, use wet methods or a vacuum
lines, tubes and hoses can cause fires. Do not
equipped with a high efficiency particulate air
bend or strike high pressure lines or install ones
(HEPA) filter.
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks d. Use exhaust ventilation on permanent machining
with your hands. Pin hole (very small) leaks can jobs.
result in a high velocity oil stream that will be
e. Wear an approved respirator if there is no other
invisible close to the hose. This oil can penetrate
way to control the dust.
the skin and cause personal injury. Use cardboard
or paper to locate pin hole leaks. f. Comply with applicable rules and regulations for the
work place (for example in the U.S.A., OSHA
19. Tighten connections to the correct torque. Make
requirements as set forth in 29 CFR 1910. 1001).
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibration g. Follow environmental rules and regulations for
or rubbing against other parts during operation. disposal of asbestos.
Shields that protect against oil spray onto hot
h. Avoid areas where asbestos particles may be in the
exhaust components in event of a line, tube or seal
air.
failure must be installed correctly.
20. Relieve all pressure in air, oil or water systems

before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting any
device from a system that utilizes pressure.
2 of 2
SB2004E00
Dec.1998
Specifications
TORQUE
SPECIFICATIONS
STANDARD TORQUE FOR METRIC FASTENERS
NOTE : Take care to avoid mixing metric and inch dimensioned fasteners.
Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or
possible injury. Exceptions to these torques are given in the Service Manual where
needed.
NOTE : Prior to installation of any hardware, be sure components are in near new
condition. Bolt and nut threads must not be worn or damaged. Hardware must be
free of rust and corrosion. Clean hardware with a non-corrosive cleaner and apply
engine oil to threads and bearing face. If thread lock or other compounds are to be
applied, do not apply engine oil.
METRIC NUTS AND BOLTS

THREAD
SIZE STANDARD TORQUE
(mm) (N i m) (lb i ft)
M6 12 3 9 2
M8 28 7 20 5
M10 55 10 40 7
M12 100 20 75 15
M14 160 30 120 22
M16 240 40 175 30
M20 460 60 340 44
M24 800 100 600 75
M30 1600 200 1200 150
M36 2700 300 2000 225
METRIC TAPERLOCK STUDS

THREAD
(mm) (N i m) (lb i ft)
M6 8 3 6 2
M8 17 5 13 4
M10 35 5 26 4
M12 65 10 48 7
M16 110 20 80 15
M20 170 30 125 22
M24 400 60 300 45
M30 650 80 480 60
M36 870 100 640 75
1 of 7
STANDARD TORQUE FOR INCH FASTENERS
Exceptions to these torques are given in the Service

Manual where needed.
INCH NUTS AND BOLTS

THREAD
inch (N i m) (lb i ft)
1/4 12 3 9 2
5/16 25 6 18.0 4.5
3/8 47 9 35 7
7/16 70 15 50 11
1/2 105 20 75 15
9/16 160 30 120 20
5/8 215 40 160 30
3/4 370 50 275 35
7/8 620 80 460 60
1 900 100 660 75
1-1/8 1300 150 950 100
1-1/4 1800 200 1325 150
1-3/8 2400 300 1800 225
1-1/2 3100 350 2300 250
INCH TAPERLOCK STUDS

THREAD
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
1-1/8 500 70 370 50
1-1/4 650 80 480 60
1-3/8 750 90 550 65
1-1/2 870 100 640 75
2 of 7
O-RING FACE SEAL FITTINGS
O-RING FACE SEAL FITTING

O-RING GROOVE
STRAIGHT THREAD O-RING

O-RING FACE SEAL NUT O-RING PORT FITTING END
IDAS001B
STRAIGHT THREAD O-RING

FITTING (FOR O-RING FACE
SEAL FITTING ONLY)
THREAD
5/16-24 5.0 1.5 4515 lb i in
3/8-24 12 2 11020 lb i in
7/16-20 20 4 15 3
1/2-20 30 5 22 4
9/16-18 40 5 30 4
3/4-16 100 15 75 10
7/8-14 135 15 100 10
1 1/16-12 200 25 150 20
1 3/16-12 250 25 185 20
1 5/16-12 300 40 225 30
1 5/8-12 300 40 225 30
1 7/8-12 300 40 225 30
2 1/2-12 300 40 225 30
O-RING FACE SEAL FITTING NUT

THREAD
9/16-18 16 3 12 2
11/16-16 30 4 22 3
13/16-16 50 7 37 5
1-14 90 10 65 7
1 3/16-12 120 15 90 10
1 7/16-12 160 20 120 15
1 11/16-12 190 20 140 15
2-12 215 25 160 20
3 of 7
FITTING INSTALLATION
HYDRAULIC LINE INSTALLATION 1. Put locknut (3), backup washer (4) and O-ring seal
(5) as far back on fitting body (2) as possible. Hold
these components in this position. Turn the fitting
1. For a metal tube to hose installation, install the tube into the part it is used on until backup washer (4) just
and tighten all bolts finger tight. makes contact with the face of the part it is used on.
2. Tighten the bolts at the rigid end. 2.To put the fitting assembly in its correct position, turn
3. Install the hose and tighten all bolts finger tight. the fitting body (2) out (counterclockwise) a
maximum of 359. Tighten locknut (3) to the torque
4. Put the hose in a position so that it does not make shown in the correct chart for the fitting used.
contact with the machine or another hose.
NOTE: If the fitting is a connector (straight fitting), the
5. Tighten the bolts on both connections. hex on the body takes the place of the locknut. To
6. Start the engine. install this type fitting, tighten the hex against the face
of the part it goes into.
7. Move the implement control levers to all positions.
8. Look at the hose during movement of the
implement. Make sure hose is not in contact with TORQUES FOR FLARED AND O-RING FITTINGS
the machine or other hoses.
The torques shown in the charts that follow are to be
9. Shut off the engine.
used on the nut part of 37 Flared, 45 Flared and
10. If necessary, put the hose in a new position where it Inverted Flared fittings (when used with steel tubing),
will not make contact when the implement is moved. O-ring plugs, O-ring fittings and swivel nuts when
used in applications to 3000 psi (20 700 kPa).
ASSEMBLY OF FITTINGS WITH STRAIGHT

THREADS AND O-RING SEALS HOSE CLAMP-BAND TYPE
This type of fitting is used in many applications. The tube

end of the fitting will be different in design so that it can
be used in many different applications. However, the
installation procedure of the fitting is the same. If the tube
end of the fitting body is the same as in the illustration
(either an elbow or a straight body) it will be necessary to
assemble the sleeve on the tube before connecting the
tube to the end.
2
1 IDAS003B
4 CLAMP TORQUE ON RETIGHTENING

3 WIDTH NEW HOSE TORQUE
7.9 mm 0.9 0.2 N i m 0.7 0.2 N i m
(.312 in) 8 2 lb i in 6 2 lb i in
5
13.5 mm 4.5 0.5 N i m 3.0 0.5 N i m
(.531 in) 40 5 lb i in 25 5 lb i in
IDAS002B 6 15.9 mm 7.5 0.5 N i m 4.5 0.5 N i m
ELBOW BODY ASSEMBLY (.625 in) 65 5 lb i in 40 5 lb i in
(1) End of fitting body (connects to tube). (2) Fitting body.
(3) Lock-nut. (4) Backup washer. (5) O-ring seal. (6) End of fitting
that goes into other part.
4 of 7
37 FLARED AND STRAIGHT THREAD O-RING FITTINGS
37 FLARED O-RING SWIVEL NUTS

FITTING-PLUG
IDAS004B
37 FLARED AND STRAIGHT THREAD O-RING FITTINGS

(EXCEPT O-RING FACE SEAL FITTINGS)
NOMINAL TUBE O.D. THREAD STANDARD TORQUE

SIZE
METRIC INCH inch (N i m) (lb i ft)
3.18 .125 5/16 5.0 1.5 4 1
4.76 .188 3/8 11.0 1.5 8 1
6.35 .250 7/16 16 2 12 1
7.94 .312 1/2 20 5 15 4
9.52 .375 9/16 25 5 18 4
9.52 .375 5/8 35 5 26 4
12.70 .500 3/4 50 7 37 5
15.88 .625 7/8 65 7 48 5
19.05 .750 1-1/16 100 10 75 7
22.22 .875 1-3/16 120 10 90 7
25.40 1.000 1-5/16 135 15 100 11
31.75 1.250 1-5/8 180 15 135 11
38.10 1.500 1-7/8 225 15 165 11
50.80 2.000 2-1/2 320 30 240 22
TIGHTENING OTHER FITTINGS

Hi Duty (Shear sleeve) Tube Fittings
After tube has been put through the nut and makes
contact against the tube shoulder in the fitting body,
turn the nut with a wrench until a small decrease in
torque is felt. This is an indication that the sleeve has
been broken off the nut. Hold the tube to prevent IDAS005B
turning and tighten the nut 1-1/2 turns.
Hi Seal Fittings
Put nut and sleeve over the tubing with the short
heavy end of the sleeve facing the end of tubing. Put
the tube end against the counterbore in the body of
the fitting and tighten until nut is over the last thread IDAS006B
on the body. The remainder of space is used
whenever the fitting is removed and installed again.
5 of 7
45 FLARED AND 45 INVERTED FLARE FITTINGS
INVERTED
45 FLARED 45 FLARED
IDAS007B
45 FLARED AND 45 INVERTED FLARE FITTINGS
NOMINAL TUBE O.D. THREAD STANDARD TORQUE

SIZE
METRIC INCH inch (N i m) (lb i ft)
3.18 .125 5/16 5.0 1.5 4 1
4.76 .188 3/8 8.0 1.5 6 1
6.35 .250 7/16 11 2 8 1
7.94 .312 1/2 17 3 13 2
9.52 .375 5/8 30 3 22 2
11.11 .438 11/16 30 3 22 2
12.70 .500 3/4 38 4 28 3
15.88 .625 7/8 50 5 37 4
19.05 .750 1-1/16 90 8 65 6
22.22 .875 1-1/4 100 10 75 7
TIGHTENING OTHER FITTINGS

Ermeto Tube Fittings
Put nut and sleeve over the tube with head or
shoulder end of sleeve next to nut. Push tube into
counterbore of fitting body as far as possible. Turn
nut clockwise until sleeve holds tube and prevents
movement. Tighten the nut 1-1/4 turns more to seat IDAS008B
sleeve and give a locking action. When necessary to
assemble again, put sleeve over tube and tighten nut
until a sudden increase in torque is felt. Then tighten
1/6 to 1/3 turn more to seat the sleeve.
Flex Fittings
Put nut and sleeve over the tubing and push tube in
to counterbore of fitting body as far as possible.
Tighten the nut until it is against the hex part of the
fitting body.
IDAS009B
6 of 7
AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS
O-RING 45 FLARE
IDAS010B
AIR CONDITIONING FITTINGS

O-RING FITTING END 45 FLARE FITTING END
THREAD STEEL TUBES ALUMINUM TUBES

SIZE STANDARD TORQUE STANDARD TORQUE STANDARD TORQUE
inch N im (lb i ft) N im (lb i ft) N im (lb i ft)
5/8-18 18 4 13 3 30 3 22 2 23 3 17 2
3/4-16 37 4 27 3 52 5 38 4 33 4 24 3
7/8-14 40 4 30 3 60 7 44 5 38 4 28 3
1 1/16-14 45 5 33 4 75 8 55 6 50 5 37 4
TAPERED PIPE THREAD FITTINGS

STANDARD TORQUE
PIPE
THREAD THREADS WITH THREADS WITHOUT
SIZE 1E2200E SEALANT SEALANT
inch Nim (lb i ft) Nim (lb i ft)
1/16-27 15 11 20 15
1/8-27 20 15 25 18
1/4-18 25 18 35 26
3/8-18 35 26 45 33
1/2-14 45 33 60 45
3/4-14 60 45 75 55
1-11 1/2 75 55 90 65
1 1/4-11 1/2 95 70 110 80
1 1/2-11 1/2 110 80 130 95
2-11 1/2 130 95 160 120
7 of 7
SB4106E01
Service Manual
A2300 Diesel Engine
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
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. This person should also have the
necessary training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings
in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index
Introduction Air System

About the Manual...................................................... 5 Air System Flow .......................................................98
How to Use the Manual .............................................5 Diagnosing Air System Malfunctions........................99
Generic Symbols....................................................... 6 Air Flow Restriction ..................................................99
Definition of Terms .....................................................7 Damage from Non-Filtered Air ...............................100
Illustrations ................................................................ 8 Pressure Side Air Leaks.........................................100
Exhaust Leaks........................................................101
Malfunctioning Turbocharger..................................101
Oil Consumption and Leaks...................................102
General Engine Information Turbocharger Noise ...............................................103
Rotor Assembly Clearance Measure .....................104
External Engine Components ....................................9
Engine Specifications ...............................................11
Lubricating System
Troubleshooting Logic Lubricating System Flow ........................................113
Lubricating Oil Pump ..............................................113
Engine Diagrams .................................................... 12 Pressure Regulating Valve .....................................113
Problem Isolation and Correction ........................... 12 Oil Coolers..............................................................114
Troubleshooting Logic(List of Symptoms)............... 13 Oil Filters ................................................................114
Oil Filters Bypass Valve..........................................114
Low Oil Pressure ....................................................116
Oil Level .................................................................116
Coolant System Oil Filter ..................................................................117
Oil Gauge ...............................................................117
Cooling System Components and Flow...................53 Oil Suction Tube .....................................................117
Pressure Caps .........................................................56 Bearings and Oil Pump ..........................................117
Water(Coolant) Pump...............................................57 Incorrect Oil Pump..................................................118
Thermostat ...............................................................60 Oil Dilution ..............................................................118
Gauges, Overfueling and Laoding ...........................61 Coolant Diluted Oil .................................................118
Cooling System Replacement Procedures ..............62 Fuel Diluted Oil.......................................................119
Belt Tensioner Replacement ................................... 62 Oil Leaks ................................................................123
Fan Pulley Replacement......................................... 62
Fan Hub Replacement ............................................ 63
Water Pump Replacement .......................................64
Cup Plug Replacement ............................................67 Electrical System
Electrical System Description/Operation................134
Electrical System Spec. .........................................136
Fuel System Starting Motor.........................................................137
Engine Cranking Speed Too Slow .........................139
Fuel System Components and Flow ........................68 Alternator................................................................140
Fuel System Malfunction Diagnosis.........................69 Fuel Shut Off Valve Check.....................................143
Air in the Fuel System..............................................70 Oil Pressure Switch................................................143
Fuel Water Separator/Filter Unit ..............................71
Injection Pump .........................................................72
Governor Malfunctions .............................................72
Fuel Control Lever TRavel and Adjustment .............73
VE Pump Adjustment Screws ..................................73
Manual Shut Down Levers.......................................74
Advance Timing Mechanism ....................................74
Electrical Shut off Valves .........................................75
Injection Pump Timing..............................................77
High Pressure Fuel Line ..........................................78
Injectors....................................................................79
Fuel Drain Manifold ..................................................81
A Series Diesel Engine 3 Index

Base Engine Components Balancer-Remove ..................................................221
Balancer-Install ......................................................222
Operation and Description .....................................148
Cylinder Head and Valve Train ..............................149 Engine Replacement and Testing
Front Gear Housing and Gear Train ......................150
Front Crankshaft Seal ............................................150 Engine Replacement..............................................223
Camshaft, Tappets and Push Rods .......................150 Engine Removal.....................................................224
Flywheel Housing and Flywheel ............................151 Engine Installation..................................................225
Piston and Rod Assemblies ...................................152 Engine Testing........................................................227
Crankshaft and Main Bearings...............................154
Oil Pan ...................................................................156
Base Engine Component .......................................156 Specifications
Air and Fuel System...............................................157
Compression Check...............................................158 General Engine ......................................................228
Piston Ring Seal ....................................................158 Fuel System ...........................................................228
Valce Sealing .........................................................158 Lubricating Oil System ...........................................228
Valve Seal Wear.....................................................160 Cooling System ......................................................229
Front Gear Housing and Gear TRain.....................161 Air Intake System ...................................................229
Rocker Levers ........................................................162 Exhaust System .....................................................229
Piston and Rod Assembly ......................................163 Electrical System....................................................229
Crankshaft and Main Bearings...............................165 Drive Belt Tension ..................................................229
Cylinder Block ........................................................166 Capscrew Markings and Torque Values.................230
Flywheel Housing and Flywheel ............................166 Fraction, Decimal, Millimeter Conversions.............233
Base Engine Componen Specifications.................168 Newton-Meter to Foot-Pound Conversions............234
Gear Train ..............................................................169 Pipe Plug Torque Values ........................................234
Camshaft ................................................................169 Weights and Measures-Conversion Factors..........235
Tappets...................................................................169
Pistons ...................................................................170
Connecting Rod .....................................................171
Crankshaft ..............................................................171 Special Tools
Cylinder Block ........................................................171
Cylinder Bore .........................................................172 Special Tool List .....................................................237
Base Engine Components .....................................173
Rocker Levers ........................................................174
Rocker Levers Assembly .......................................179
Valve Clearance .....................................................179
Four Cylinder Engine .............................................179
Camshaft and Tappet .............................................180
Camshaft Inspection ..............................................181
Camshaft Bushing Inspection ................................182
Tappet Inspection ...................................................183
Gear Housing or Gasket ........................................186
Flywheel Ring Gear and Rear Sel .........................187
Brass Drift Pin ........................................................187
Flywheel .................................................................188
In Chassis Overhaul...............................................189
Cylinder Head Removal .........................................190
Main Bearing Preliminary Inspection .....................191
Main Bearing ..........................................................194
Piston and Rod ......................................................196
Piston, Pin and Connecting Rod ............................197
Piston Ring Gap .....................................................202
Piston Rings ...........................................................202
Piston and Rod Assembly ......................................204
Cylinder Head and Gasket.....................................207
Cylinder Head.........................................................211
Valves.....................................................................214
Valve Seats ............................................................216
Cylinder Head ........................................................220
Hydraulic Pump Drive Gear and Shaft...................221
A Series Diesel Engine 4 Index

Introduction
About the Manual

The procedures in this manual were developed for an in-chassis environment. The information has been grouped
by the main engine systems. The Table of Contents defines the systems. The index at the beginning of each
section subdivides the instructions for the various components of the system. Wrench sizes and special tools are
identified in the procedures as needed.
How to Use the Manual

The organization of this manual is based on the troubleshooting logic presented in Section 2. To fix a problem, find
the logic chart for the particular symptom. Follow the steps specified until the problem is corrected.
The left column of the charts indicates a probable cause. The right column provides a brief description of the
corrective action with a reference to the repair procedure or diagnostic discussion when appropriate.
The logic charts reflect three basic considerations:

1. Assumes the engine has provided satisfactory service prior to the problem.
2. Performing the easiest things first.
3. Most logical cause in descending order.
If the problem occurs with a new engine or after repair of the engine, the diagnostics discussion for each major
system will provide guidance for sorting out the cause of the problem.
A Series Diesel Engine 5 Introduction

Generic Symbols
The following group of symbols has been used in this manual to help communicate the intent of the instructions.
When one of the symbols appears, it conveys the meaning defined below.
Warning Serious personal injury or extensive property damage can result if the warning
instructions are not followed.
Causion Minor personal injury can result or a part, an assembly or the engine can be
damaged if the caution instructions are not followed.
The component weighs 23kg [50lb] or more. To avoid personal injury, use a hoist or get
assistance to lift the component.
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information.

Definition of Terms
The following is a list of guidelines for each procedure in the repair Sections of the Troubleshooting and Repair
Manual. The procedure will be given first; followed by a definition o the step or steps involved.
Check Examine a component or system for damage, excessive wear, accuracy, safety, or
performance.
Inspect Examine a component or dimension to make sure it meets the required specifications.
Test Check or compare the performance of a component or system to established

specifications.
Adjust Complete the necessary steps to set or adjust the component, assemblies, or system in
the required setting or position.
Visually Look for any obvious damage or problem.

Inspect
Remove Take off a component or assembly
Clean Remove dirt, grease or other contamination.
Disassemble Take the component or assembly apart.
Repair Restore a component or assembly to a serviceable condition within the established

specifications.
Note Only the easiest and simplest repairs will be made to a component or assembly. If a
component or assembly must be rebuilt; it must be replaced with a new or Cummins
Diesel Recon, Inc. replacement or be rebuilt at a Cummins authorized repair location.
Replace Install a new, properly rebuilt, or Cummins Diesel Recon, Inc. component or assembly
in place of one which is removed.
Install Place a component or assembly in the correct position.
Star Pattern
Torque
Sequence

Illustrations
The illustrations used in the Diagnosis Sections of this manual are intended to give an example of a problem, show
what to look for and where to look for the problem.
Most of the illustrations are generic and might not look exactly like the engine or parts used in your application.
Some illustrations contain symbols to indicate an action required and an acceptable or unacceptable condition.
Unacceptable
Acceptable
Direction of Movement
(Action)
The illustrations used in the Replacement Sections are intended to show replacement procedures when the engine
is installed in a chassis. The illustration may differ from your application, but the procedure given will be the same.

General Engine Information
External Engine Components

The pictures which follow show the locations of the major external engine components, the filters, and other
service and maintenance points. Some external components will be at different locations for different engine
models. Note: The pictures are only a reference to show a typical engine.
Exhaust Side [Naturally Aspirated] Intake Side [Naturally Aspirated]

1. Exhaust Manifold 5. Crankshaft Pulley 1. Intake Manifold 4. Starting Motor
2. Oil Fill Cap 6. Dip Stick 2. Alternator
3. Fan 7. Oil Filter 3. Thermostat housing
4. Fuel Injection Pump
A Series Diesel Engine 9 General Engine Information

Exhaust Side [Turbocharged] Intake Side [Turbocharged]
1. Fuel Filter 5. Dipstick 1. Turbocharger 5. Starting Motor
2. Crankshaft Pulley 6. Oil Cooler 2. Alternator 6. Turbocharger Oil Tube
3. Cooling Fan 7. Fuel Injection Pump 3. Thermostat Housing 7. Oil Fill Cup
4. Exhaust Manifold 8. Turbocharger Oil Drain Tube 4. Intake Manifold 8. Air Crossover Tube

Engine Specifications
Engine Model A2300

General Engine Data Naturally Aspirated
Engine Weight(Dry) Less Flywheel and Electronics 169 kg [373 lb]
Compression Ratio 21:1
Bore [mm/inch] 88 [3.46]
Stroke [mm/inch] 94 [3.7]
Displacement [/in3] 2.29 [139]
Firing Order 1-3-4-2
Intake 0.3 mm [0.012 in]
Valve Clearance
Exhaust 0.3 mm [0.012 in]
Rotation Viewed from the Front of the Engine Clockwise
Lubrication System Naturally Aspirated

Regulating Valve Opening Pressure 290 390kPa [42-56 psi]
Total System 7.0 [1.85]
Lubricating Oil Capacity [/gal] Standard Oil Pan
6.5 [1.72]
Only
Lubricating Oil Pressure at Idle(Max. Allowable) 69 kPa [10 psi]
Lubricating Oil Pressure at Rated(Min. Allowable) 245 kPa [35 psi]
Oil Filter Differential Pressure to Open Bypass Valve 98 kPa [14 psi]
Number of liters [qt] from Low to High 2.0 [0.53 gal]
Lubrication System Forced Lubrication with Pump
Cooling System Naturally Aspirated

Coolant Capacity (Engine Only) [/gal] 3.0 [0.7]
Standard Modulating Thermostat Start 71 [160]
Range
Pulley Open 8 [185]
[/F]
Cooling System Forced Lubrication with Pump
Air Induction System Naturally Aspirated

Maximum Allowable Intake Restriction at Rated Speed and
6.23 kPa [635 mmAq]
Load with Dirty Filter Element
Exhaust System Naturally Aspirated

Maximum Allowable Exhaust Restriction at Rated Speed
5.88 kPa [600 mmAq]
and Load with Dirty Filter Element
Fuel System Naturally Aspirated

Injection Pressure 150 kPa [22 psi]
Electric starting with Starter Motor
Starting System
(12 V 2.0 kW)

Troubleshooting Logic
Engine Diagrams
A schematic of each of the major engine systems is provided at the beginning of the section of the manual devoted
to troubleshooting and repairing that particular system.
The diagrams depict flow through the various engine systems. The information and configuration of the
components illustrated in the drawings are of a general nature. Some items for specific applications and
installations may be different.
Each Section also contains a discussion regarding diagnosing malfunctions for that specific system.
Knowledge of the systems can help you troubleshoot and repair the engine.
Problem Isolation and Correction

The following Troubleshooting Logic is designed to help you organize your study of a problem and to plan a
procedure to correct it. The series of fault/logic charts given do not provide all the answers, but they should
stimulate a train of thought that will lead you to the source of the trouble.
Be sure to consider any maintenance or repair action that could have caused the problem.
If the engine surges or runs rough initially after not being used for 2 months or more, do not assume that the
engine has a malfunction. Varnish can form on the internal parts of the injection pump and the oil film can drain
from the piston rings. Operate the engine for at least 5 minutes before troubleshooting.
The basic procedure is as follows:

z Study the problem thoroughly.
z Relate the symptoms to your knowledge of the engine components and systems.
z Double-check before beginning the disassembly.
z Solve the problem by deduction starting with the easiest things.
z Determine the cause of the problem and make a thorough repair.
z After making corrections, operate the engine in normal conditions to verify the cause of the problem was
corrected.
A Series Diesel Engine 12 Troubleshooting Logic

Troubleshooting Logic
Page List of Symptoms
52 Alternator Not Charging or Insufficient Charging
36 Coolant Loss
32 Coolant Temperature Above Normal
35 Coolant Temperature Below Normal
46 Compression Knocks
43 Contaminated Coolant
44 Contaminated Lube Oil
15 Engine Cranks But Will Not Start No Smoke From Exhaust
16 Engine Hard to Start Or Will Not Start Smoke From Exhaust
24 Engine RPM Will Not Reach Rated Speed
22 Engine Runs Rough or Misfiring
18 Engine Starts But Will Not Keep Running
14 Engine Will Not Crank Or Cranks Slowly
48 Engine Will Not Shut Off
51 Excessive Engine Noises
30 Excessive Engine Smoke
47 Excessive Fuel Consumption
49 Excessive Vibration
45 Fuel or Oil Leaking From Exhaust Manifold
26 Low Power
41 Lube Oil Loss
38 Lubricating Oil Pressure Low
40 Lubricating Oil Pressure Too High
20 Rough Idle (Irregularly Firing Or Engine Shaking)
19 Surging (Engine Speed Change)

Engine Will Not Crank or Cranks Slowly
Cause Correction
Remove the Starting Motor and Check for
Starting Motor Operating But Not
Broken Teeth on the Flywheel or Broken
Cranking the Engine
Starting Motor Spring. Refer to Page 138
OK
Bar the Engine to Check for Rotational

Crankshaft Rotation Restricted
Resistance. Refer to Page 138
OK
Starting Circuit Connections Loose Clean and Tighten Connections.

Or Corroded Refer to Page 137
OK
Check Battery Voltage.

Battery Charge Low
Refer to Page 137
OK
Check Voltage to Solenoid.

No Voltage to Starter Solenoid
Refer to Page 137
OK
Solenoid or Starting Motor Replace Starting Motor.

Malfunction Refer to Page 144

Engine Cranks But Not Start No Smoke From Exhaust
Cause Correction
No Fuel in Supply Tank Check/Replenish Fuel Supply
OK
Check for Loose Wires and Verify that the

Electrical or Manual Fuel Valve is Functioning. Check to be sure
Shutdown Not Open Manual Shut Off Lever is in the Run
Position. Refer to Page 74
OK
Air Intake or Exhaust Plugged Visually Check: Remove the Obstruction.
OK
Fuel Filter Plugged With Water or Drain Fuel/Water Separator or Replace

Other Contamination Fuel Filter. Refer to Page 71, 83
OK
Injection Pump Not Getting Fuel or Check Fuel Flow/Bleed Fuel System.
Fuel is Aerated Refer to Page 83
OK
Visually Check Fuel Delivery with an

Externally Connected Injector to One of
Worn or Malfunctioning Injection
the Pump Outlets. Replace the Pump if
Pump
Fuel is Not Being Delivered. Refer to Page
94
OK
Verify/Time the Pump.

Internal Pump Timing Incorrect
Refer to Page 77
OK
Check/Correct Gear Train Timing

Camshaft Out of Time
Alignment. Refer to Page 77, 185

Engine Hard To Start Or Will Not Start Smoke From Exhaust
Cause Correction
The Fuel Control Lever on the Bosch VE

Pump Must be Moved to One-Half Travel.
Incorrect Starting Procedure
The Fuel Shut Off Control Must Be in the
Run Position. Refer to O&M Manual.
OK
Verify that the Driven Units are not

Cranking Speed Too Slow
Engaged.
OK
Check the Battery, Starting Motor, and

Look for Loose or Corroded Wiring
Connections. Refer to Page 137
Bar the Engine to Check for Internal

Rotational Resistance.
Cold Starting Aids Not Working or Verify the Aids are Operating. Refer
Are Needed To O&M Manual.
OK
Inspect or Replace Filter and Check for

Insufficient Intake Air Obstructions to the Air Supply Tube.
Refer to Page 98, 112
OK
Check the Flow through the Filter and

Air in the Fuel System or the Fuel
Bleed the System. Locate and Correct the
Supply is Inadequate
Air Source. Refer to Page 83
OK
(Continued)

Engine Hard To Start Or Will Not Start Smoke From Exhaust (Continued)
Cause Correction
Verify by Operating the Engine with Clean

Contaminated Fuel Fuel from a Temporary Tank. Drain and
Flush Fuel Supply Tanks.
OK
Visually Check Fuel Delivery With an

Worn or Malfunctioning Injection Externally Connected Injector to one of the
Pump Pump Outlets. Replace the Pump if Fuel is
Not Being Delivered. Refer to 94
OK
Check/Time the Pump.

Injection Pump Out of Time
OK
Valves Incorrectly Adjusted Adjust Valves. Refer to Page 179
OK
One or More Injectors Worn or Check/Replace Injectors.

Malfunctioning Refer to Page 88
OK
Perform a Compression Check to Identify

Engine Compression Low
the Problem. Refer to Page 158

Engine Starts But Will Not Keep Running
Cause Correction
Engine Starting Under Load Disengage Driven Units.
OK
Idle Speed Too Low For Adjust the Idle Speed.

Accessories Refer to Page 73
OK
Visually Check for Exhaust Restriction and

Intake Air or Exhaust System
Inspect the Air Intake.
Restricted
OK
Check the Flow Through the Filter and

Air in the Fuel System or the Fuel
Supply is Inadequate
OK
Verify by Inspecting the Fuel Filter.

Fuel Waxing Due to Extremely Cold
Clean the System and Use Climatized
Weather
Fuel or Fuel Heaters.
OK
Verify by Operating the Engine With Clean

Contaminated Fuel Fuel from a Temporary Supply Tank. Drain
and Flush the Fuel Supply Tank.
OK
Restricted Fuel Drain Manifold or Check/Correct the Restriction.

Return Line Refer to Page 81

Surging (Speed Change)
Cause Correction
If the Condition Occurs at Idle, the

Idle Speed is Set Too Low for Adjust the Idle. Refer to Page 73
Accessories
OK
Inspect/Correct Leaks in the Pressure

High Pressure Fuel Leak Lines. Fittings, Injector Sealing Washers
or Delivery valves. Refer to Page 78
OK
One or More Injectors Worn or Check/Replace the Injectors.

Malfunctioning Refer to Page 88
OK
Replace Delivery Valves.

Malfunctioning Delivery Valve
Refer to Page 84
OK
Replace the Pump.

Malfunctioning Injection Pump
Refer to Page 94

Rough Idle (Irregularly Firing Or Engine Shaking)
Cause Correction
Refer to Troubleshooting Logic for Engine
Cold Engine
Running Too Cold. Refer to 35
OK
Idle Speed Too Low for the Check/Adjust Low Idle Screw.
Accessories Refer to Page 73
OK
Engine Mounts Over-Tightened, Verify Condition of Mounts. Refer to

Damaged or Loose Equip. Manufactures Service Instructions.
OK
Inspect/Correct Leaks in the High

Pressure Lines, Fittings Injection Sealing
High Pressure Fuel Leak
Washers or Delivery Valve Seals. Refer to
Page 78
OK
Bleed the Fuel System and Correct the

Air in the Fuel System
Source of the Air. Refer to Page 83
OK
Replace the Injector.

Sticking Needle Valve in an Injector
Refer to Page 88
OK
Replace Delivery Valves.

Malfunctioning Delivery Valve
Refer to Page 92
OK
(Continued)

Rough Idle (Irregularly Firing Or Engine Shaking)(Continued)
Cause Correction
Valves Not Sealing Adjust Valves. Refer to Page 179
OK
One or More Cylinders Losing Perform a Compression Check and Repair

Compression as Required. Refer to Page 160

Engine Runs Rough Or Misfiring
Cause Correction

Pressure Lines, Fittings Injector Sealing
Fuel Injection Lines Leaking
Washers, or Delivery Valve. Refer to Page
78
OK
Check the Flow Through the Filter and

Air in the Fuel or the Fuel Supply is
Inadequate
OK
Verify by Operating the Engine with Clean

Contaminated Fuel
Fuel from a Temporary Tank.
OK
Check for a Bent Push Rod and Adjust

Incorrect Valve Adjustment
Valves. Refer to Page 179
OK
Check/Time Pump.
Injection Pump Timing Incorrect
Refer to Page 77
OK
Perform a Compression Check to Isolate

One or More Cylinders Has Low the Cause of Low Compression (Piston
Compression Rings, Head Gasket or Valves). Refer to
Page 158
OK
(Continued)

Engine Runs Rough Or Misfiring (Continued)
Cause Correction
Replace Injectors.
Malfunctioning Injectors
Refer to Page 88
OK
Defective Injection Pump Replace Injection Pump.

(Delivery Valves) Refer to Page 94
OK
Check/Correct Gear Train Timing

Camshaft Out of Time
Alignment. Refer to Page 185
OK
Inspect Camshaft.
Damaged Camshaft or Tappets
Refer to Page 182

Engine RPM will Not Reach Rated Speed
Cause Correction
Verify High Idle Speed Without Load.

Engine Overloaded Investigate Operation to be Sure Correct
Gear is Being Used.
OK
Verify Engine Speed with Hand

Malfunctioning Tachometer
Tachometer - Correct as Required.
OK
Adjust Linkage for Stop-to-Stop Fuel

Throttle Linkage Worn or
Control Lever Travel.
Incorrectly Adjusted
OK
If the Problem Occurs After

Check/Correct Fuel Control Lever
Replacing the Fuel Control Lever
Indexing.
or Pump, Incorrectly Indexed Lever
Refer to Page 74
(Robert Bosch VE Only)
OK
High Speed Stop Screw Incorrectly Check/Set High Speed Stop Screw.
Adjusted Refer to Page 74, 225
OK
Partially Engaged Mechanical Check/Place Shutdown Lever in Run

Shutdown Lever Position. Refer to Page 74, 225
OK
Check the Flow Through and Filter to

Inadequate Fuel Supply Locate the Source of the Restriction.
Refer to Page 68
OK
(Continued)

Engine RPM will Not Reach Rated Speed (Continued)
Cause Correction
If the Condition is Intermittent, Check/Remove Restriction.

Restricted Manifold Drain Line Refer to Page 81
OK
Replace Pump.
Refer to Page 94

Low Power
Cause Correction
If the Condition is Slow Throttle
Response, Leaking Air Fuel Tighten the Fittings. Replace the Pump if
Control Tube or Malfunction the Controls are Not Functioning.
Control in the Pump Refer to Page 87
(Automotive Only)
OK
Fuel Control Lever Not Moving to Check/Correct for Stop-to-Stop Travel.

Full Speed. Refer to Page 73, 225
OK
Mechanical/Shutdown Lever Check/Replace Shutdown Lever in Run

Partially Engaged Position. Refer to Page 74, 225
OK
High Oil Level Check/Correct Oil Level
OK
Check for Added Loading from

Malfunctioning Accessories or Driven
Engine Overloaded
Units, Brakes Dragging and Other
Changes in Vehicle Loading
OK
Incorrect External Injection Pump Verify Pump Timing Marks are Aligned.
Timing Refer to Page 77, 96
OK
(Continued)

Low Power (Continued)
Cause Correction
Inspect/Replace Air Cleaner Element.
Inadequate, or High or Low
Look for Other Restrictions.
Temperature Intake Air
Refer to Page 112
OK
If the vehicle is equipped with a Valve to

Switch the Intake Source from Under the
Hood to Outside, Position the Valve for the
Season.
Coolant Passage in the After Cooler

Plugged.

Pressure Lines, Fittings Injector Sealing
High Pressure Fuel Leak
Washers or Delivery Valve Seals. Refer to
Page 78
OK
Check the Flow Through the Filter to

Inadequate Fuel Supply Locate the Source of the Restriction.
Refer to Page 68
OK
Check for a Restricted Fuel Drain Manifold

High Fuel Temperature
(Robert Bosch VE)
OK
If Low Power is Intermittent, Check/Correct Restriction.

Restricted Fuel Drain Manifold Refer to Page 81
OK
Verify by Operating From a Temporary

Poor Quality Fuel
Tank With Good Fuel.
OK
(Continued)

Cause Correction
Air Leak Between the Check/Correct Leaks in the Air Crossover

Turbocharger and the Intake Tube, Hoses, or Through Holes in the
Manifold. Manifold Cover. Refer to Page 100, 101
OK
Check/Correct Leaks in the Manifold or

Exhaust Leak at the Manifold or
Turbocharger Gaskets. Look for a cracked
Turbocharger
Manifold. Refer to Page 101
OK
Inspect/Replace Turbocharger.
Malfunctioning Turbocharger
Refer to Page 101, 105, 109
OK
Valve Clearances Incorrect Check/Adjust Valves. Refer to Page 179
OK
Injection Pump Internal

Check/Time Pump. Refer to Page 77
Malfunctioning
OK
Perform Compression Check to Identify

Low Engine Compression Malfunction. Correct as Required.
Refer to Page 158
OK
Worn or Malfunctioning Injectors Check Injectors. Refer to Page 79

OK
(Continued)

Cause Correction
Replace Injection Pump.
Refer to Page 94
OK
Check/Correct Exhaust System.

Excessive Exhaust Restriction
Refer to Page 101

Excessive Exhaust Smoke
Cause Correction
Engine Running Too Cold Refer to Troubleshooting Logic for Coolant
(White Smoke) Temperature Below Normal.
OK
Inspect/Change Air Cleaner. Look for

Inadequate Intake Air
Other Restrictions. Refer to Page 112
OK
Air Leak Between the Check/Correct Leaks in the Air Crossover

Turbocharger and the Intake Tube, Hoses, or Through Holes in the
Manifold Manifold Cover. Refer to Page 100, 101
OK
Check/Correct Leaks in the Manifold or

Exhaust leak at the Manifold or
Turbocharger Gaskets. Look for a Cracked
Turbocharger
Manifold. Refer to Page 100, 101
OK
Inspect/Replace Turbocharger.
Refer to Page 101
OK
More than One Sealing Washer Remove Extra Washer.

Under an Injector Refer to Page 89
OK
Replace Injectors.
Refer to Page 88
OK
(Continued)

Excessive Exhaust Smoke (Continued)
Cause Correction
Malfunctioning or Over fueled Replace Injection Pump.
Injection Pump Refer to Page 94
OK
Piston Rings Not Sealing Perform a Compression Check. Correct as

(Blue Smoke) Required. Refer to Page 158

Coolant Temperature Above Normal
Cause Correction
Check/Replenish Coolant.
Low Coolant Level
Refer to Pages 54
OK
Locate and Correct the Source of the

Coolant Leak. Refer to Troubleshooting
Logic for Coolant Loss.
Incorrect/Malfunctioning Pressure Replace Cap with the Correct Rating for

Cap the System. Refer to Page 55
OK
Check/Drain Oil to Correct Level.

High Lube Oil Level
Refer to Page 116
OK
Loose Drive Belt on Water Check/Correct Belt Tension.

Pump/Fan Refer to Page 57, 62
OK
Check/Repair Fan Shroud, Shutters, Fan

Sensors, and Fan Clutch as Required.
Inadequate Air Flow to the Radiator
Refer to the Equipment Manufacturers
Procedures.
OK
Radiator Fins Plugged Blow Debris from Fins.
OK
Check/Replace Hose.
Collapsed Radiator Hose
Refer to Page 58
OK
(Continued)

Coolant Temperature Above Normal (Continued)
Cause Correction
Verify that the Gage and Temperature
Malfunctioning Temperature
Sensor are Accurate.
Sensor/Gage
Refer to Pages 55
OK
Malfunctioning, Incorrect or No Check/Replace the Thermostat.

Thermostat Refer to Page 60, 65
OK
Make Sure the Fill Rate is not Being

Air in the Cooling System Exceeded and the Correct Vented
Thermostat is Installed. Refer to Page 55
OK
If Aeration Continued, Check for a

Compression Leak Through the Head
Gasket. Refer to Page 116
Check/Replace the Water Pump.

Malfunctioning Water Pump
OK
Check/Time the Injection Pump.

Incorrect Injection Pump Timing
Refer to Page 77
OK
Incorrect External Injection Pump Verify Pump Timing Marks are Aligned.
Timing Refer to Page 77, 83
OK
Replace the Injection Pump.

Over fueled Injection Pump
Refer to Page 94
OK
(Continued)

Coolant Temperature Above Normal (Continued)
Cause Correction
Plugged Cooling Passages in

Flush the System and Fill with Clean
Radiator, Head, Head Gasket or
Coolant. Refer to Page 55
Block
OK
Verify that the Engine Load Rating is Not

Engine Overloaded
being Exceeded. Refer to Page 60, 65

Coolant Temperature Below Normal
Cause Correction
Check/Repair Shutters, Fan Clutch,
Too Much Air Flow Across the
Viscous Fan as Required. Refer to the
Radiator
Equip. Manufacturers Procedure.
OK
Incorrect Thermostat, Broken

Check/Replace Thermostats.
Thermostat Jiggle Pin or
Contamination in Thermostat
OK
Verify that the Gage and Sensor are

Temperature Sensor or Gage
Accurate.
Malfunctioning
Refer to Page 61
OK
Coolant Not Flowing by Check/Clean Coolant Passages.

Temperature Sensor Refer to Page 55

Coolant Loss
Cause Correction
Visually Inspect the Radiator Heater,
Radiator or Cab Heater Leaking Hoses and Connections to Locate the
Leak.
OK
If Oil is Present in the Coolant, Check for a

Transmission or Lube Oil Cooler Leak.
Visually Inspect the Engine and

External Engine Leak
Components for Seal or Gasket Leaks.
OK
Overheating or Leaking Review the Operation for Overheating and

Compression Gases Resulting in Low Power. Refer to Troubleshooting
Loss Through the Radiator Logic for Coolant Temperature Above
Overflow Normal.
OK
Check for Mixing of Coolant and

If Equipped, Transmission Cooler
Transmission Flood.
Leak
OK
If Equipped with a Water Cooled Look for Coolant in the Oil. Check/Replace
Air Compressor, Leaking Head or Head or Gasket. Refer to the Equipment
Head Gasket Manufacturers Procedures.
OK
(Continued)

Coolant Loss (Continued)
Cause Correction
Check/Replace the Aftercooler. Look for

If the Engine is Aftercooled, After
Coolant in the Intake Manifold and in the
Cooler Leak
Oil. Refer to Page 119
OK
Check/Replace the Oil Cooler. Look for

Lube Oil Cooler Leak
Coolant in the Oil. Refer to Page 119
OK
Check/Replace the Head Gasket.

Head Gasket Leak
Refer to Page 118
OK
Check/Replace the Head.

Cracked or Porous Head
Refer to Page 157
OK
Leak in Cylinder Block Coolant Check/Replace the Cylinder Block.

Passages Refer to Page 55, 56.

Lubricating Oil Pressure Low
Cause Correction
Check/Replenish Oil.
Low Oil Level
Refer to Page 116
OK
Check for a Severe External Oil Leak that

Could Reduce the Pressure.
Verify the Correct Oil is Being Used.

Oil Viscosity Thin: Diluted or Check for Oil Dilution. Refer to
Wrong Specification Troubleshooting Logic for Contaminated
Lube Oil. Refer to Page 44.
OK
Malfunctioning Pressure Verify the Pressure Switch is Functioning

Switch/Gage Correctly. Refer to Page 143
OK
Check/Replace Valve.
Relief Valve Stuck Open
Refer to Page 116
OK
Change Oil Filter; Review Change Interval.

Plugged Oil Filter
Refer to Page 117
OK
(Continued)

Lubricating Oil Pressure Low (Continued)
Cause Correction
Check/Replace Cup Plugs.

Loose or Missing Cup Plugs
OK
Suction Tube Loose or Seal Check/Replace Seal.

Leaking Refer to Page 117
OK
Check/Replace Lube Pump.

Worn Lube Pump
OK
Check/Install New Bearings (s) and

Loose Main Bearing Cap
Tighten Cap
OK
Inspect/Replace Bearings; also

Worn Bearings Check/Replace Piston Cooling Nozzles.

Lubricating Oil Pressure Too High
Cause Correction
Malfunctioning Pressure Verify the Pressure Switch is Functioning
Switch/Gage Correctly. Refer to Page 143
OK
Refer to Troubleshooting Logic for Coolant

Engine Running Too Cold
Temperature Below Normal.
OK
Make Sure the Correct Oil is Being Used.

Oil Viscosity Too Thick
Refer to O&M Manual.
OK
Check/Replace Valve.
Relief Valve Stuck Closed
Refer to Page 116

Lube Oil Loss
Cause Correction
Visually Inspect for Oil Leaks.
External Leaks
Refer to Pages 55.
OK
Verify that the Dipstick is Correctly

Crankcase Being Overfilled
Marked.
OK
Incorrect Oil
(Specification or Viscosity)
OK
Look for Reduced Viscosity from Dilution

with Fuel. Refer to Page 116
Review/Reduce the Oil Change Intervals.
Oil Cooler Leak Check for Oil in the Coolant.
OK
If Equipped, Air Compressor Check/Replace Air Compressor.

Pumping Oil Refer to Page 94
OK
(Continued)

Lube Oil Loss (Continued)
Cause Correction
Check the Breather Tube Area for Signs of

High Blowby Forcing Oil Out the Oil Loss. Measure the Blowby and
Breather Perform the Required Repairs. Refer to
Page 124
OK
Inspect the Air Crossover Tube for

Turbocharger Leaking Oil to the Air
Evidence of Oil Transfer.
Intake
Refer to Page 124
OK
Inspect/Replace the Valve Seals.

Worn Valve Seals
Refer to Page 160
OK
Piston Rings Not Sealing Oil Perform a Compression Check. Repair as

Being Consumed by the Engine Required. Refer to Page 116

Contaminated Coolant
Cause Correction
Rusty Coolant, Operation Without Drain and Flush the Cooling System. Fill
Correct Mixture of Antifreeze and with Correct Mixture of Antifreeze and
Water Water. Refer to Page 55.
OK
Review the Coolant Change Interval.
If Equipped, Leaking Transmission Check/Replace Oil Cooler. Refer to

Oil Cooler Equipment Manufacturers Procedures.
OK
Oil Leaks from Oil Cooler, Head Refer to Troubleshooting Logic for
Gasket, Head and Cylinder Block Lube Oil Loss.

Contaminated Lube Oil
Cause Correction
Coolant in the Oil, Internal Engine Refer to Troubleshooting Logic for Coolant
Component Leaks Loss
OK
Excessive Oil Sludge Review Oil and Filter Change Intervals
OK
Review the Operation for Excessive Idling

Fuel in the Oil, Engine Operating
Resulting in the Engine Running Below
Too Cold
Normal Temperature.
OK
Replace the Pump.

Fuel Pump Seal Leaking
OK
Locate and Replace malfunctioning

Injector Needle Valves Not Sealing Injector.
Refer to Page 88.

Fuel Or Oil Leaking From Exhaust Manifold
Cause Correction
Check/Replace Filter Element.
Intake Air Restriction
Refer to Page 105
OK
Review Operation for Excessive Idling.
Locate and Replace Malfunctioning

Injector Needle Valve Stuck Open
Injector
OK
Obstructed Turbocharger Drain Check/Clean Line.

Line Refer to Page 102
OK
Check/Replace Turbocharger.
Turbocharger Seals Leaking Oil
Refer to Page 102

Compression Knocks
Cause Correction
Bleed the Fuel System.

Air in the Fuel System
Refer to Page 83.
OK
Verify by Operating from a Temporary

Poor Quality Fuel Tank with Good Fuel; Clean and Flush the
Fuel Supply Tanks.
OK
Verify that Engine Load Rating is Not

Engine Overloaded
Being Exceeded. Refer to Page 61.
OK
Check/Time Injection Pump.

Incorrect Injection Pump Timing
OK
Replace Injectors.
Refer to Page 88.

Excessive Fuel Consumption
Cause Correction
Check/Repair Accessories and Vehicle

Additional Loading form
Components. Refer to the Equipment
Malfunctioning Accessories
Manufacturers Procedures.
OK
Review Operation for Correct Gear Shifts,

Operator Technique
Deceleration, and Idling.
OK
Make Sure Quality No. 2 Fuel is Being

Poor, Quality Fuel
Used.
OK
Inadequate Intake Air or Exhaust Refer to Troubleshooting Logic for

Restriction Excessive Exhaust Smoke.
OK
Check/Time the Pump.

Fuel Pump Timing
OK
Check/Replace Injectors.
Worn or Malfunctioning Injectors
Refer to Page 88.
OK
Check/Adjust Valves.
Valves Not Seating
Refer to Page 179
OK
Check/Repair Power Functions.

Malfunctioning Power Functions
Refer to Page 148
OK
(Continued)

Excessive Fuel Consumption (Continued)
Cause Correction
Stop the Engine Mechanically with Lever

on the Fuel Pump. Check/Replace Sealing
Fuel Shutoff Valve Inoperative
Washer,
Piston and Spring. Refer to Page 75
OK
Engine Running on Fumes Drawn Check the Air Intake Ducts for Source of
into the Air Intake the Fumes.

Excessive Vibration
Cause Correction
Refer to Troubleshooting Logic for Rough
Engine Not Running Smoothly
Running or Misfiring.
OK
Check/Replace Engine Mounts. Refer to

Loose or Broken Engine Mounts the Equipment Manufacturers Service
Instructions.
OK
Check/Replace the Vibrating Component.

Damaged Fan or Malfunctioning
Refer to the Equipment Manufacturers
Accessories
Service Instructions.
OK
Malfunctioning Vibration Damper Inspect/Replace the Vibration Damper.

(Six-Cylinder Only) Refer to Page 164
OK
Inspect/Replace the Fan Hub.

Malfunctioning Fan Hub
OK
Worn or Damaged Alternator Check/Place the Alternator.

Bearing Refer to Page 144
OK
Check/Correct Flywheel Alignment.

Flywheel Housing Misaligned
Refer to Page 167
OK
(Continued)

Excessive Vibration (Continued)
Cause Correction
Inspect the Crankshaft and Rods for

Loose or Broken Power
Damage That Cause and Unbalance.
Component
Refer to Page 199
OK
Worn or Unbalanced Drive Line Check/Repair According to the

Component Equipments Manufacturers Procedures.

Excessive Engine Noises
Cause Correction
Drive Belt Squeal, Insufficient Check the Tensioner and Inspect the Drive
Tension or Abnormally High Belt. Make Sure Water Pump, Tensioner
Loading Pulley, Fan Hub and Alternator Turn Freely.
OK
Check the Tension of Accessory Drive

Belts. Refer to the Equipment
Manufacturers Procedures. Make Sure the
Accessories Turn Freely.
Refer to Troubleshooting Logic for

Intake Air or Exhaust Leaks
Excessive Exhaust Smoke.
OK
Adjust Valves. Make sure the Push rods are

Excessive Valve Lash not Bent or the Rocker Levers are Not
Severely Worn. Refer to Page 162
OK
Check Turbocharger Impeller and Turbine

Turbocharger Noise Wheel for Housing Contact. Refer to Page
101
OK
Visually Inspect and Measure Gear

Gear Train Noise Backlash. Replace Gears as Required.
Refer to Page 161
OK
Check/Replace Rod and Main Bearings.

Power Function Knock
Refer to Page 165

Alternator Not Charging Or Insufficient Charging
Cause Correction
Loose or Corroded Battery Clean/Tighten Battery Connections.
Connections Refer to Page 137
OK
Check/Replace Belt Tensioner.

Alternator Belt Slipping
Refer to Page 62
OK
Alternator Pulley Loose on Shaft Tighten Pulley.
OK
Replace Alternator.
Malfunctioning Alternator
Refer to Page 144

Coolant System
Coolant System Component and
Flow
The following illustration identifies the significant
features of the coolant system.
Coolant is drawn from the radiator by the integrally

mounted water pump. The output from the water
pump empties into the oil cooler cavity of the cylinder
block.
The Coolant then circulates around each cylinder and

crosses the block to the fuel pump side fot the engine.
Coolant then flows up into the cylinder head, crosses

over the bridges and down the exhaust manifold side
of the engine to the integral thermostat housing.
As the coolant flows across the head toward the 1. Radiator. 2. Thermostat. 3. Water Temperature Gauge. 4.
thermostat housing, it provides cooling for the injector Water Pump. 5. Water Manifold. 6. Cylinder Head
nozzle. When the engine is below operating 7. Piston. 8. Cylinder Block. 9. Oil Cooler (Optional).
temperature, the thermostat is closed, and the A. From Oil Pump (Oil)
coolant flow bypasses the radiator and goes to the
water pump inlet via internal drillings in the block and
cylinder head.
When Operating temperature is reached, the

thermostat open, blocking the bypass passage to the
water pump and opening the outlet to the radiator.
Caution: Never operate the engine without a

thermostat. Without a thermostat, the
coolant will not flow to the radiator and the
engine will overheat.
A Series Diesel Engine 53 Coolant System

Cooling System Specifications A2300
Coolant Capacity (Engine Only) - Liter [U.S. Qts.].. 3.0 [3.2]
Standard Modulating Thermostat Range C [F] 71 [160] to 85 [185]
Coolant System Malfunctions - Diagnosis

The function of the coolant system is to maintain a
specified operating temperature of the engine. Some of
the heat generated by the engine is absorbed by the
coolant flowing through the passages in the cylinder block
and head. Then, heat is removed from the coolant as it
flows through the radiator. When you troubleshoot over
heating, remember that too much oil in the oil pan can
cause additional heat from friction when the rod journals
are submerged in oil.
Overfilling with oil raises the oil temperature which is

transferred to the coolant system at the oil cooler.

The system is designed to use a specific quantity of
coolant. If the coolant level is low, the engine will run
hot.
1. The engine or system has a leak if frequent

addition of coolant is necessary. Find and
repair the leak.
Caution : The engine coolant passages must be

completely filled with coolant.
During operation entrapped air mixes with the coolant

which results in cavitation corrosion and poor heat
transfer. Highly aerated coolant can cause localized
overheating of the cylinder head and block which can
result in a cracked head, scored cylinder or blown
head gasket.
During filling, air must be vented from the engine

coolant passages. The air vents through the jiggle
pin opening and the notched vent hole to the top
radiator hose and out the fill opening. Additional
venting is provided for engines equipped with an after
cooler. Open the petcock during filling.
Caution : Never use only water for engine coolant. In

tropical climates where antifreeze
availability may be limited, use a corrosion
inhibitor (Cummins Liquid DCA) to protect
the engine cooling system.
A mixture of 50% ethylene-glycol base antifreeze is

required for operation of the engine in temperature
environments above
-37C [-34F]. A mixture of 40% water and 60%
antifreeze is recommended for temperatures below -
37 C [-34F].

Caution : The small holes in the head gasket are
especially susceptible to plugging.
Water will cause rust formation reducing the flow in

the smaller coolant passages.
Caution : These holes are orifices and their size is

critical. Do not enlarge the size of the
orifices. To do so will disturb the coolant
flow and will not solve an overheating
problem.
Also, water used as a coolant for even a relatively

short period can result in the cup plugs rusting
through allowing the coolant to leak.
Note : A sudden loss of coolant from a heavily loaded

engine can result in severe damage to the
pistons and cylinder bore.
Pressure Caps
The system is designed to use a pressure cap to
prevent boiling of the coolant.
Different caps are specified for the two recommended
systems:
System Cap
A- 104 C [220F] 103kPa [15 PSI]
B- 99 C [210F] 48kPa [7 PSI]
An incorrect or malfunctioning cap can result in the

loss of coolant and the engine running hot.

Air in the coolant can result in loss from the overflow
when the aerated coolant is hot. The heated air
expands, increasing the pressure in the system
causing the cap to open.
Similarly, coolant can be displaced through the
overflow if the head gasket leaks compression
gasses to the coolant system.
The operating pressure of the coolant system and the

lubricating system can result in mixing go the fluids if
there is leak between the systems: head gasket, oil
cooler, etc. (refer to the Lubricating System).
Note: Transmission fluid can also leak into the

coolant through bottom tank oil coolers.
Water (Coolant) Pump

The water pump pulls coolant from the bottom of the
radiator and pumps it through the engine back to the
top of the radiator for cooling. Reduced or interrupted
flow will result in the engine running hot.
The pump is belt driven from the crankshaft pulley.

An belt tensioner is used to prevent the belt from
slipping on the pump pulley.
A malfunction of the tensioner will cause the water
pump impeller to rotate at a slower speed reducing
the amount of coolant flow.

The coolant flow can also be reduced if the inlet hose
to the water pump collapses. A hose will usually not
collapse while the engine is running at low speed.
Check the hose while the engine is running at rated
speed.
Note : Be sure the engine is warm, a minimum of

85C[185F], so the thermostat is open.
A worn or malfunctioning water pump will not produce

the flow required to prevent the engine from running
hot. However, be sure to check the other possibilities
indicated in the Troubleshooting Logic before
checking the flow or replacing the pump.
As stated in the coolant discussion, an obstruction in

the passages can interrupt flow.
Radiator, Fans and Shutters

Air forced through the fins of the radiator by a fan
cools the coolant pumped through the radiator.
Environmental debris (paper, straw, lint, dust, etc.)
can obstruct the fins and stop the flow of air which will
reduce the cooling effect of the radiator.

If the fan is belt driven, a slipping belt will result in a
slower fan speed and reduced cooling. A
malfunctioning belt tensioner can be the problem.
Note : Check the bearings in the fan hub and other

pulleys to make sure they are not causing
excessive blet vibration and slippage.
Interruption of the circuit to an electrically driven fan

can result in insufficient airflow and cause the engine
to run hot.
Note : Make sure that the temperature sensor is

functioning correctly.
Shutters are designed to control air flow across the

radiator. If the shutters fail to open when needed, the
engine can run hot. Failure of the shutters to close
can result in too much air flow and the engine
running cold.
Note : Make sure that the air temperature sensor is

functioning correctly. Check the air operated
shutter controls. Check for air leaks.

An incorrect fan shroud or obstructions can reduce
airflow and cause the engine to run hot.
Note : Check to be sure air is not recirculating.

Check for missing baffles.
Thermostat
The thermostat controls the coolant temperature.
When the coolant temperature is below the operating
range, coolant is bypassed back to the inlet of the
water pump.
When the coolant temperature reaches the operating
range, the thermostat opens, sealing off the bypass,
forcing coolant to flow to the radiator.
Caution : Never operate the engine without a

thermostat. Without a thermostat the path
of least resistance for the coolant is
through the bypass to the pump inlet.
This will cause the engine to overheat.
An incorrect or malfunctioning thermostat can cause

the engine to run too hot or too cold.

Gauges, Overfueling and Loading
Gauges and sensors are used in the system to
measure the coolant temperature. These can
malfunction and provide an incorrect temperature
indication.
Caution : Overfueling can cause the engine to

overheat. Make sure that the fuel pump is
calibrated correctly.
Caution : Constant overloading (lugging) can cause

the engine to run hot.

Cooling System Replacement
Procedures
Drive Belt Replacement
12mm
Lift the tensioner to remove and install the drive belt.
Belt Tensioner Replacement

Preparatory Step:
z Remove the drive belt
12mm
Remove the capscrew and replace the tensioner.
Torque Valve: 25.5 Nm [19ft-lbs]
Fan Pulley Replacement

Preparatory Step:
z Remove the drive belt.

12mm
Remove the four capscrews, fan and spacer.
Replace the fan pulley.
Fan Hub Replacement

Preparatory Steps:
z Remove the fan pulley.
12mm
Remove the four capscrews and replace the fan
hub.
Coolant Draining
The coolant is 50% mixture of water and ethylene-
glycol base antifreeze; a 20 liter (4 U.S. gallons)
drain pan will contain the coolant in most
applications.

Water Pump Replacement
Preparatory Steps:
z Drain the coolant.
12mm
Remove the four capscrews and water pump, and
complete the following steps.
Clean the sealing surface on the cylinder block.
Install the new gasket.

12mm
Install the water pump.
Thermostat - Replacement
Preparatory Steps:
z Disconnect negative battery cable.
z Disconnect the upper radiator hose.
12mm
Note : Loosen the alternator link capscrew and

complete the following steps.
14mm
Remove the alternator mounting capscrew and lower
the alternator.

12mm
Remove the thermostat housing, lifting bracket and
thermostat.
Clean the mating surfaces.
Position the rubber seal as shown for reassembly.

Assemble the removed parts in the reverse order of
removal.
Torque Valve:
(Alternator Link) 25.5 Nm [19 ft-lbs]
(Alternator Mounting) 49Nm [37 ft-lbs]
(Thermostat Mounting) 25.5 Nm [19 ft-lbs]
Cup Plugs Replacement

Remove the cup plugs from the coolant passages as
shown.
Apply a bead of Loctite 277 to the coolant passage

cup plugs.
Drive the plugs in until the outer edge is flush with

the counter sink in the block.

Fuel System
Fuel System Component and Flow

The following illustration identifies the components of
the fuel system.
1. Fuel Injection Pump. 2. Overflow Valve. 3. Fuel Shut-Off

Solenoid. 4. Fuel Injection Nozzle. 5. Fuel Tank.
6. Water in Fuel Sensor (WIF). 7. Fuel Filter. 8. Hand
Priming Pump
Most of the engines will be quipped with a cam

actuated lift pump. Fuel flow begins as the lift pump
pulls fuel from the supply tank. The
pump supplies low-pressure fuel (21-35kPa, [3-5psi])
to the fuel filter head, through the filter and then to the
distributor injection pump.
The engines use distributor-type fuel pumps supplied
by Robert Bosch.
The distributor pump builds the high injection
pressures required for combustion, and routes the
fuel through individual high-pressure fuel lines to
each injector.
When the high-pressure fuel reaches the injector, the
pressure lifts the needle valve against the spring
tension to let the fuel enter the combustion chamber.
A Series Diesel Engine 68 Fuel System

Fuel System Malfunction
Diagnosis
The function of the fuel system is to inject clean,
atomized fuel into the engine cylinders at a precise
time near the end of the compression stroke of each
piston.
The components of the system contribute to the
delivery of fuel to the cylinders.
Normal pressure drop across the filter is 21 kPa [3

psi], maximum.
The pressure drop will increase as the filter removes
contamination form the fuel. Therefore, a worn lit
pump will have reduced capacity to force fuel
through a dirty filter. This can cause low engine
power.
Note : Frequent filter replacement to get full power

from the engine can indicate a worn lift pump.

Air In the Fuel System
A replacement of supply lines, fuel filters, injection
pump, high pressure lines and injectors will let air
enter the fuel system. Follow the specified procedure
to bleed the air from the system.
Since the lift pump provides a positive pressure

through the fuel filter and supply line to the injection
pump, loose connections or defective seals will show
as a fuel leak.
The most usual place for air to enter the fuel system
is between the inlet of the lift pump and the suction
tube in the tank. Fuel tanks that have the outlet fitting
at the top will have a suction tube that extends down
in the tank.
Cracks or pin holes in the weld that joins the tube to
the fitting can let air enter the fuel system.
Air in the system will make the engine: hart to start,

run rough, misfire, produce low power, and can cause
excessive smoke and a fuel knock.

Fuel Water Separator/Filter Unit
Caution : Be sure to use the correct element.
Filtration and separation of water from the fuel is

important for trouble-free operation and long life of the
fuel system. Some of the clearances between the
pump parts are very close. For this reason the parts
can easily be damaged by rust formation and
contaminants.
The element has a valve which can be opened

regularly to drain the collected water.
Regular maintenance, including draining moisture

from the fuel water separator/filter and supply tanks, is
essential to keep water out of the fuel.

Injection Pump
The injection pumps are rotary distributor pumps.
These pumps perform the four basic functions of:
1. Producing the high fuel pressure required
for injection.
2. Metering the exact amount of fuel for each
injection cycle.
3. Distributing the high pressure, metered fuel
to each cylinder at the precise time.
4. Varying the timing relative to engine speed.
A single plunger or rotor is used by the pumps to

develop and distribute the high pressure required for
injection.
A four-cylinder, Robert Bosch VE pump plunger is
shown in this illustration.
Governor Malfunctions
Balance between the flyweight governor and control
lever position controls the metering of the amount of
fuel to be injected.
The pump governor performance and setting can
affect engine power. Special equipment and qualified
personnel are required to verify governor
performance. If the seals are broken on the external
Robert Bosch VE adjustment screw, the fuel rate
may be out of adjustment.

Fuel Control Lever Travel and
Adjustment
The amount of fuel injected and subsequently the
speed and power from the engine is controlled by the
fuel control lever. Restricted travel of the lever can
cause low power. Always check for full travel of the
lever when diagnosing a low power complaint.
A
VE Pump Adjustment Screws
B A Idle Screw
B High Idle Screw
The high speed adjustment screw on both pumps

provides the stop for full speed. The high speed
adjusting screws are sealed. Adjustment of this screw
must be performed only be an authorized pump
service center, and then resealed.
The high speed adjusting screw can be used to
derate engines. The procedure is provided in this
section.

Caution : The fuel control lever on the Robert Bosch
VE pump is indexed to the shaft during pump
calibration. If the lever has been removed and
reinstalled incorrectly, engine speed and
power will be affected.
Manual Shut Down Levers

Injection pumps are equipped with mechanical shut
down levers. These levers are spring-loaded in the run
position. Not all applications will use these manual shut
down controls and there will be no cable or rod
connected to the lever.
Note : Partial actuation of the mechanical shutdown

levers will affect fuel flow and engine power.
Low power or the inability to stop the engine with the

manual shut down control can be corrected by adjusting
the cable/rod length to permit stop-to-stop lever travel.
Advance Timing Mechanism

Regulated pressure produced by a vane supply in both
injection pumps is used to advance the timing as the
engine speed increases.
A return spring is used to retard the timing as the engine
speed is reduced. If a spring should break, the timing
will go to the advance position resulting in torque loss, a
fuel knock and possible engine overheating.
Retarded(late) timing will result in torque loss, high fuel
consumption and white to black smoke.

Electrical Shut Off Valves
The injection pumps are equipped with electrical shut
off valves. These solenoid-operated valves block the
supply of fuel to the high pressure pumping and
distribution components.
The Robert Bosch VE shut off valve is located at the
top, rear of the pump.

The Robert Bosch valve does not make a very
audible sound when actuated, but it can be checked
with an ohmmeter for the following values:
Robert Bosch
Resistance Peak
Shut Down
Ohms Amperes
Values
12 Volt 7.4 + 0.5 2
Caution : Do not connect the electrical wire to the

solenoid when the plunger has been
removed. Without the plunger the valve
can be damaged.
Malfunctioning valves can be diagnosed by removing

the plunger and spring, then reinstall the solenoid.

Injection Pump Timing
Pump to engine timing is extremely critical. Pump timing that is off by only a few crankshaft degrees will cause:
1. Poor performance starting and power
2. Excessive smoke and emission
3. Poor fuel economy
Engine pump timing begins with the timing of the

injection pump drive gear to the camshaft gear.
The first step is the location of TDC for cylinder
Number 1.
After installing each gear, make sure that aligning

marks A, B and C of the idle gear are aligned with
those of the fuel injection pump drive gear, cam shaft
gear and crank shaft gear.

High Pressure Fuel Line
Caution : The high pressure lines must be clamped
securely and routed so they do not contact
each other or any other component.
The high pressure fuel lines are designed and

manufactured to deliver fuel at injection pressure to
the injectors. The high pressure pulses will cause the
lines to expand and contract during the injection
cycle.
Caution : Do not weld or substitute lines; use only

the specified part number for the engine.
The length, internal size and rigidity of the lines is

critical to smooth engine operation.

Warning : The pressure of the fuel in the line is
sufficient to penetrate the skin and cause
serious bodily harm.
Use cardboard to check for cracks and leaks. With

the engine running, move the cardboard over the fuel
lines and look for fuel spray on the cardboard. Fuel
leaks can cause poor engine performance.
It is normal to have entrapped air in the fuel lines

after replacing the pump or the lines. Air in the lines
will cause the engine to run rough or produce a fuel
knock.
Bleed the air from the high pressure line at the fitting
that connects the injector. Bleed one line at a time
until the engine runs smooth.
If the air cannot be removed, check the pump and
supply line for suction leaks.
Injectors
Caution: Use only the specified injector for the
engine.

During the injection cycle, high pressure from the
injection pump rises to the operating (pop) pressure
which causes the needle valve in the injector to lift.
Fuel is then injected into the cylinder. A shimmed
spring is used to force the needle valve closed as the
injection pressure drops belowe the pop pressure to
seal off the nozzle after injection.
Failure of the needle valve to lift and close at the

correct time or needle valve stuck open can cause
the engine to misfire and produce low power.
Fuel leaking from the open nozzle can cause a fuel
knock, poor performance, smoke, poor fuel economy,
and rough running.
Caution : Be sure to tighten the fuel line nut before

proceeding to the next injector.
To find which cylinder is misfiring, operate the engine

and loosen the fuel line nut at one injector and listen
for a change in engine speed.
Note : A drop in engine speed indicates the injector

was delivering fuel to the cylinder.
Check each cylinder until the malfunctioning
injector is found.
Remove the malfunctioning injector to test or replace

it.
If the engine continuous to misfire after replacing the
injector, check for leaks in the high pressure line.
Also check for a defective delivery valve that lets the
fuel drain back into the injection pump.

Carbon build up in the orifices in the nozzle will also
cause low power from the engine.
Remove and check the spray pattern or replace the
injectors.
Fuel Drain Manifold

The fuel system is designed to use fuel to cool and
lubricate the injection pump and injectors.
Fuel is continually vented from the injection pump
and a small amount of fuel leaks by the injector
needle valve during injection. This fuel is returned to
the supply tank by the fuel drain manifold.

Fuel System Replacement Procedure
A certain amount of air will be entrapped in the system during replacement of any of the system components.
After replacement of a component, bleed the system according to the following procedure.
Fuel System Bleeding

Controlled venting is provided at the injection pump
through the fuel drain manifold.
Small amounts of air introduced by changing the
filters or injection pump supply line will be vented
automatically, if the fuel filter is changed in
accordance with the instructions.
However, manual bleeding will be required if:

The fuel filter is not filled prior to installation.
Injection pump is replaced.
High pressure fuel line connections are loosened or
lines replaced.
Initial engine start up or start up after an extended
period of no engine operation.

High Pressure Lines Venting
17mm
Warning : The pressure of the fuel in the line is

sufficient to penetrate the skin and cause
serious bodily harm.
Loosen the fittings at the injector, and crank the

engine to allow entrapped air to bleed from the line.
Tighten the fittings.
Warning : Do not bleed a hot engine as this could

cause fuel to spill onto a hot exhaust
manifold creating a danger of fire.
Fuel Filter Replacement

80 to 95 mm, Filter Wrench
Remove the combination water separator/fuel filter.

Fill the new filter(s) with clean fuel.
Lubricate the seal with clean oil.
Install the filter(s) and tighten it 1/2 turn after its seal
contacts the filter head.

High Pressure Lines Replacement
17mm
Disconnect the high pressure lines from the injectors
and complete the following steps.

10mm
Remove the line clamp capscrew from the intake
cover.
14mm and 17mm

Remove the lines from the injection pump.
Note : Use two wrenches to prevent the delivery

valve holder from turning.
10mm
Assemble the lines in the reverse order of removal.
Torque Value: 11Nm [8 ft-lbs]
Warning : Do not bleed a hot engine as this could

cause fuel to spill onto a hot exhaust
manifold creating a danger of fire.
Start the engine and vent one line at a time until the
engine runs smoothly.

Fuel Drain Manifold Replacement
17mm
Remove the high pressure fuel line.
17mm
Remove the head cap nuts.
17mm
Assemble the high pressure fuel line and fuel drain
manifold in the reverse order of disassembly.

Injector Replacement
Preparatory Steps:
z Disconnect the high pressure fuel supply
lines
z Disconnect the fuel drain manifold.
z Clean around the injectors.
Rust Penetrating Solvent
Caution : When rust has formed on the hold down

nut, the injector can turn in the bore when
the nut is loosed. This will cause severe
damage to the head by the injector
locating ball cutting a groove in the bore.
Brass Drift Pin, Hammer
Hit the injector body with the drift pin to loosen any
rust.
22mm Box Wrench, Adjustable Wrench
Hold the injector body with an adjustable wrench

while you loosen the hold won nut with a 22mm box
wrench.

Injector Bore Brush
Clean the injector nozzle bore.
Assemble the injector and new copper sealing

washer.
Use Only One Copper Washer.
Apply a coat of anti-seize compound to the threads

of the injector hold-down nut and between the top of
the nut and injector body.
22mm Deep Well Socket
Caution : Align the injectors protrusion with the

notch in the bore.
Torque Value: 73 Nm [55 ft-lbs]
Note : The current Bosch injector has an o-ring

located above the hold down nut. After
tightening the injector be sure to push the o-
ring into the groove.

Assemble the fuel drain manifold and high pressure
lines.
Leave the high pressure fittings loose at the
injectors.
17mm
Warning : It is necessary to put the engine in the

run position: Because the engine may
start, be sure to follow all the safety
precautions. Use the normal engine
starting procedure.
Crank the engine to allow entrapped air to bleed from

the lines. Tighten the fittings.
Electrical Fuel Shut Off Valve

Replacement
8mm
Remove the electrical wire and complete the
following steps.
Clean around the valve.

24mm
Remove the valve.
Note : The Bosch VE valve is shown.
Caution : When removing the valve, be careful not

to drop the plunger and spring.
Package the solenoid, o-ring, spring and plunger.
24mm
Tighten the solenoid securely.
Connect the electric wire.

Delivery Valve Holder and Sealing
Washer
(Bosch VE) Replacement
14mm and 17mm
Disconnect the high pressure line.
14mm
Remove the delivery valve holder and sealing
washer.
Insert the sealing washer(1) and the delivery valve(2)

in the pump. Insert the ship(4) and spring(3) in the
holder(5).
Fit the spring(3) over the valve(2) and turn the
holder(5) into the pump.
14mm
Tighten the holder to 49 Nm [37 ft-lbs].

14mm and 17mm
Connect the high pressure lines.
17mm
Start the engine and vent one line at a time until the
engine runs smoothly.

External Pump Leaks
Check for excessive flow in the injection pump and
fuel line due to leakage
Removal (Injection Pump)

Caution : Do not drop the nut and washer inside
gear housing or engine damage can
occur.
12mm
Remove the retaining nuts on the fuel injection pump
mounting on the rear of the gear housing.
Remove the access cover and gasket from the front
of the gear housing.
Rotate the engine to line up the B mark on the fuel
pump gear to the B mark on the idler gear. This can
take a number of crankshaft revolutions to
accomplish
17mm.
Remove the nut from the fuel injection pump shaft
inside the housing.
Remove the fuel injection pump support bracket and
mounting capscrews.
Remove the gear with a gear puller.
If the gear housing is in place, use the arms of the
puller to push against the inside front of the housing
and force the pump shaft rearward out of the gear.
12mm
Remove the fuel injection pump.

Installation (Injection Pump)
The pump shaft is keyed to the gear, and the gear
has timing mark B for alignment to the idler gear
mark B.
In order to make sure that the fuel pump key is
aligned properly to the gear keyway; rotate the
engine opposite engine rotation (counterclockwise)
several degrees to put the keyway in the gear
approximately at 9:00 o'clock position. The B mark
on the fuel pump gear will be on the top edge of the
viewing hole.
Make sure the o-ring seal is installed.
The key on the pump shaft must be approximately in
the 9:00 o'clock position looking at the shaft end.
Hold the fuel pump drive gear to the back of the
housing to prevent disengagement of gear teeth.
12mm
Align the shaft key to the gear keyway and install the
fuel injection pump on the rear of the gear housing.
Hand-tighten the retaining nuts on the mounting

studs.
17mm
Install the gear, washer, and nut on the fuel injection
pump shaft. Tighten the nut.
Torque Value : 88 n.m [65 ft-lb ]
Rotate the engine in the direction of engine rotation.

Check the B timing marks again for proper
alignment.
12mm
Install the access cover. Tighten the cover
capscrews.
Refer to Procedure 1 for fuel injection pump timing.
Tighten the retaining nuts on the fuel injection pump

mounting studs on the rear of the gear housing.
Tighten the supporting bracket on the bottom of the

fuel injection pump.

Timing
Dial Indicator Method
Find number 1 or top dead center (TDC) on
compression for the number 1 cylinder by barring the
engine until the hashmarks on the crank pulley line
up with the indicator mark on the gear cover. This
can be confirmed by removing the front cover access
plate and ensuring that the idler gear and fuel pump
gear timing marks are aligned.
A straight edge can be used to aid lining up the gear
cover pointer and number 1 or top dead center
(TDC) mark.
The flywheel also contains number 1 or top dead

center (TDC) marks. The starter plate or flywheel
contains the alignment mark. The mark is located at
the 3 o'clock position as viewed from the rear of the
engine. The flywheel can be used instead of the
crank pulley if accessible.
12mm
Remove the access plug from the distributor head on

the fuel pump.
Thread the timing tool assembly into the access plug

hole and finger tighten.

Bar the crankshaft in the direction opposite engine
rotation until the indicator needle stops moving.
Adjust the indicator face to read zero.
Rotate the crankshaft in direction of engine rotation

back to the mark on the crank pulley. This is the
number 1 or top dead center (TDC) mark.
If accessible, the flywheel and starter plate can be
used to locate this position more easily.
At this point the dial indicator should read 1 mm [0.04

in] of lift.
If the dial indicator does not read 1 mm [0.04 in],

loosen the fuel pump mounting bolts and rotate the
pump till the correct plunger lift value is attained
12mm
Tighten the fuel pump mounting capscrews.

Re-rating
The pump governor performance and setting can
affect engine power. Special equipment and qualified
personnel are required to verify governor
performance. The fuel rate change is not allowed
Injection pump re-rating must be discuss with

Cummins dealer.

Air System
Air System Flow
The engines are available in naturally aspirated,
turbocharged.
Air is pulled into the engine from an air filter. Clean air
is very important to the life of the engine. Ingested
dust and dirt can damaged the cylinders very quickly.
Caution : Make sure that a quality air cleaner is used

and that it is periodically replaced
according to the manufacturers
recommendations.
Intake air for naturally aspirated engines flows directly

from the filter to the intake manifold. From the intake
manifold, air is pulled into the cylinder and used for
combustion. After combustion it is forced out of the
cylinders through the exhaust manifold.
Air Intake System
On turbocharged engines the flow is from the filter to 1. Filtered air. 2. Turbocharger. 3. Air crossover tube
the turbocharger, and then through the crossover 4. Intake manifold. 5. Intake valve port
tube to the manifold. From the intake manifold, air is
forced into the cylinder and used for combustion. The
exhaust gases flows through the turbocharger to
rotate the turbine and impeller, thereby utilizing
exhaust energy to force more air into the cylinders.
The additional air provided by the turbocharger allows

more fuel to be injected to increase the power output
from the engine. Thus, the power-to-weight ration for
the engine is increased significantly with the addition
of the turbocharger.
Exhaust System
1. Exhaust valve port. 2. Exhaust manifold
3. Turbocharger turbine
A Series Diesel Engine 98 Air System

Intake Air, Exhaust and
A2300
Fuel System
Intake Restriction at Rated Speed and Load with Dirty Air

6.23 [635]
Filter Element kPa [mmAq]
Exhaust Restriction at Rated Speed and Load kPa [mmAq] 7.65 [780]
Diagnosing Air System Malfunctions

The correct amount of clean air to the cylinders is
required for good performance. As discussed earlier
in System Air Flow, ingested dust and dirt will manage
the engine cylinders. Dust and dirt can also damage
the valve stems and guides. Larger debris can
damaged the blades of the turbocharger.
Air Flow Restriction Results in

Excess Smoke and Low Power
Restriction increases as the filter removes
contaminants from the intake air. Restricted air flow
changes the air-to-fuel ratio, reducing power and
increasing smoke from the engine. Verify that the air
cleaner is being maintained correctly.
Measurement of air intake restriction is described in
this Section.

Damage From Non-Filtered Air
Loose connections or cracks in the suction side of the
intake pipe can allow debris to be ingested by the
engine causing rapid wear in the cylinders.
Leaks at the intake manifold, unsealed bolt holes or
manifold cover gasket can also all dust and dir to be
ingested into naturally aspirated engines.
Loose connections or cracks in the suction side of the

intake pipe on turbocharged engines can allow debris
to be ingested into the turbocharger compressor and
forced into the engine.
Debris drawn into the air suction side can damage the
compressor blades causing and imbalance resulting in
a bearing failure.
To verify a bearing failure or damaged compressor,
remove the intake and exhaust piping and check for
contact. The rotor assembly must rotate freely.
Measurement of axial and radial clearance is
described in this Section.
Pressure Side Air Leaks

(Turbocharged Engines)
Excess smoke and low power from a turbocharged
engine can be caused by pressurized air leaking from
loose connections or cracks in the crossover tube or
intake manifold.

In addition to the visual inspection for cracks and loose
fittings, liquid soap can be applied to the crossover
tube, connections and the manifold cover sealing
surfaces to find the leaks.
The leaks will create bubbles that are easier to detect.
Measurement of manifold pressure is described in this
Section.
Exhaust Leaks (Turbocharged

Engines)
Inspect for exhaust leaks at the exhaust manifold and
turbocharger, gasket leaks, or exhaust pipe
restrictions.
Leaks or restrictions will cause the turbine and impeller
to operate at a lower speed and reduce the amount of
air being forced into the cylinders. Again, the symptom
will be excess smoke, low manifold pressure and low
power.
Exhaust leaks can usually be detected audibly or

visually by a discoloration caused by the escaping hot
gases.
Dont overlook exhaust restrictions as a cause of low
power. If the exhaust gasses can not flow freely, the
turbocharger will not operate efficiently.
Failure of the internal components of the turbocharger
can reduce its effectiveness and also cause excess
smoke and low power. A bearing failure can produce
friction which will slow the speed of the rotor assembly.
Failed bearings can also allow the blades of the rotor
assembly to rub the housings, thus reducing the rotor
assembly speed.

Oil Consumption and Leaks
Engine lubricating oil is used to lubricate the bearings
and provide some cooling for the turbocharger.
The oil is supplied to the turbocharger through the
supply line is at engine operating pressure.
IN OUT A return line connected to the bottom of the
turbocharger routes the oil back to the engine oil pan.
Seals are used on each end of the rotor assembly.

The primary function of the seals is to prevent exhaust
gases and compressed air from entering the
turbocharger housing. Oil leakage from the seals is
rare, but it can occur.
A restricted or damaged oil return line will cause the

turbocharger housing to be pressurized causing oil to
migrate by the seals.
Additionally, high intake or exhaust restrictions can

cause a vacuum between the compressor and the
turbocharger housing resulting in oil leaking by the
seals.

To verify oil leakage past the seals, remove the
exhaust pipe and crossover tube and look for oil in the
turbine casing and the crossover tube. Locate and
correct the restriction as previously discussed.
Turbocharger Noise
It is normal for the turbocharger to emit a whine
sound that varies in intensity depending on engine
speed and load. The sound is caused by the very high
rotational speed of the rotor assembly. Consequently,
the sound will be more audible at full speed.
Note: If possible, operate the engine at full speed to
verify the noise level.
Leaks in the air system, both intake and exhaust

components, can produce additional noises.
Check the air intake and crossover tube leaks.
Note : Before removing a turbocharger, make sure

that the noise complaint is not caused by leaks
in the air system components.
Look for loose turbocharger mounting, exhaust

manifold gasket leaks, and cracks in the exhaust
manifold.

Lower pitch sounds or rattles at slower engine speeds
can indicate debris in the system or the rotor assembly
is touching the housings.
Rotor Assembly Clearance

Measure
Measure the shaft end play.
mm End Play (a) Inch

0.03 MIN 0.001
0.06 MAX 0.0024
Measure radial clearance of the shaft.
mm Radial Clearance (B) Inch
0.08 MIN 0.003
0.13 MAX 0.005
The turbocharger should be removed for replacement

or rebuild if the clearances are beyond these limits.

Air System Replacement
Procedures
Air Crossover Tube Replacement
7mm
Loosen the hose clamps and position the hose so the
crossover tube can be remove.
Use a new gasket and new hoses and clamps as

required to install the air crossover tube.
Torque Value:
z Hose Clamps: 39 Nm [29 ft-lbs]
Intake Manifold Cover and Gasket

Replacement
Preparatory Steps:
z Remove the high pressure fuel lines.
z Disconnect the cold starting aid.
z Remove the air crossover tube.

12mm
Remove the manifold cover and complete the following
steps.
Caution : Keep the gasket material and any other

material out of the air intake.
Clean the sealing surface.
12mm
Install the gasket and cover.
Torque Value : 25.5Nm [19 ft-lbs]

Assemble the intake piping and connect the cold
starting aid.
Install and bleed the high pressure fuel lines.

Turbocharger Replacement
Preparatory Steps:
z Disconnect the intake and exhaust piping.
10mm
Remove the oil drain tube capscrews and complete the
following steps.
14mm
Remove the oil supply line.

12mm
Remove the turbocharger.
Caution : If the turbocharger is not to be installed

immediately, cover the opening to prevent
material from falling into the manifold.
Clean and inspect the sealing surface.
Install a new gasket and apply antiseize compound to

the mounting studs.

7mm
Install the turbocharger and connect the air crossover
tube.
Torque Value : 39Nm [29 ft-lbs]
12mm
Use a new gasket and connect drain line.
Caution : New turbochargers must be prelubricated

before start up.
Pour 30 to 40cc of oil into supply fitting.
Note : Rotate the turbine wheel to allow oil to enter

the turbocharger.
14mm
Install the oil supply line.
After installing the air intake and exhaust piping,
operate the engine to check for leaks.

Exhaust Manifold and/or Gasket -
Replacement
Preparatory Steps:
z Disconnect the air intake and exhaust
piping.
z Remove the turbocharger and gasket.
12mm
Remove the manifold and gasket.
Clean the sealing surface.
12mm
Install the manifold and gaskets.
Follow the sequence shown in the illustration.

Install the turbocharger, air crossover tube, oil drain
tube, oil supply line, and the exhaust and intake
piping. Operate the engine to check for leaks.
Intake Air Restriction

Replace the air cleaner element when the restriction
reaches the maximum limit at rated engine RPM.
Naturally Aspirated Turbocharged
6.23 kPa [635 mmAq] 6.23 kPa [635 mmAq]
Measure the restriction just before the turbocharger.

Measure just before the intake manifold for naturally
aspirated engines.

Lubricating System Lubricating Oil Pump
Lubricating System Flow The engine use trochoid type oil pumps (1). The
machined cavity in the block is the same for all
engines.
Pressure Regulating Valve

The pressure regulating valve (2) is designed to keep
the oil pressure from exceeding 343 kPa [50 PSI].
When the oil pressure from the pump is greater than
343 kPa [50 PSI, the valve opens uncovering the
dump port so part of the oil is routed to the oil pan.
Because of manufacturing tolerances of the
components and the oil passages, the oil pressure
can differ as much as 50 kPa [7.2 PSI] between
engines.
1. Oil strainer. 2. Oil pump. 3. Oil cooler (Option).

4. Regulator valve. 5. Oil filter. 6. Safety valve.
7. Crankshaft. 8. Camshaft. 9. Piston.
10. Intake and exhaust valve. 11. Rocker arm
12. Timing gear. 13. Cooling water. 14. Turbocharger
A Series Diesel Engine 113 Lubricating System Flow

Oil Coolers
The engines use full flow, plate type oil coolers. The
oil flows through a cast passage in the cooler cover
and through the element where it is cooled by engine
coolant flowing past the plates of the element.
The use of incorrect components can cause high or
low oil temperature, varnish and sludge build up.
Oil Filters
After the oil is cooled, it flows through the full flow oil filter.
Oil Filter Bypass Valve

The oil cooler cover contains a safety valve that will let the oil flow bypass a plugged filter. The valve is designed
to open when the pressure drop across the filter is more than 138 kPa [20 PSI], as with a plugged filter, and lets
the oil continue on through the engine. When a filter becomes plugged, an oil pressure decrease of 50 kPa [7.2
PSI] or less from the normal operating pressure can be observed on the vehicle oil pressure gauge.

The main bearings and the valve train are lubricated Lubrication for the valve train is supplied through
by pressurized oil directly from the main oil rifle. The separate drillings in the cylinder block. The oil flows
other power components, connecting rods, pistons, through the drillings and across the oil transfer slot in
and camshaft receive pressurized oil indirectly from the cylinder head gasket. From the transfer slot, the
the main oil rifle. oil flows around the outside diameter at the cylinder
The drillings in the crankshaft supply oil to the head capscrew, across a slot in the bottom of the
connecting rod bearing. The oil is supplied to the rocker lever support, and up a vertical drilling in the
camshaft journals through drillings in the main support. From these drillings, oil flows through
bearing saddle. Smaller drillings in the main bearing drillings in the rocker lever support. From these
saddle supply oil to the piston cooling nozzles. The drillings, oil flows through drillings in the rocker lever
spray form the nozzles also provides lubrication for shaft to lubricate the rocker levers. Oil flows through a
the piston pins. drilling in the rocker levers to fill a channel cast into
The number five main bearing saddle does not the top of the levers. The oil from the channel
contain a piston cooling nozzle. Cylinder Number One lubricates the valve stems, push roads and tappets.
receives the lubricating and cooling spray from the
nozzle located in the Number One Bearing Saddle.
Cylinder Number Two receives the spray form the
Number Two Bearing Saddle, etc..

Diagnosing Lubricating System
Malfunctions
Be sure to check items related to oil pressure, such as:
gauges, high and low oil level, excessive oil
contamination, oil viscosity, etc.
High Oil Pressure

High oil pressure usually occurs after the engine is first
started in cold weather. The lubrication system does
not have a cold start relief valve. The pressure
regulating valve components are machined to a size
that will relieve the excessive pressure created by cold
engine oil.
Oil Pressure Regulating Valve

The engine will have high oil pressure if the regulator
sticks in the closed position. Check the regulator for
freedom of movement.
Low Oil Pressure

Low oil pressure can be caused by several lubrication
system related malfunctions. To begin the
investigation, determine the engine operating
conditions when the low pressure was first observed.
Oil Level
Low oil level can cause low oil pressure.
Caution: Never operate the engine with the oil level
below the low (L) mark.

Oil Filter
A plugged filter will cause a gradual loss of pressure
by approximately 69 kPa [10 PSI]. The pressure will
return to normal when the filter bypass valve opens.
Oil Gauge
Check the oil gauge and sending unit to make sure
they are operating correctly by verifying the pressure
with a manual gauge.
Oil Suction Tube

A loose suction tube, damaged gasket or crack in the
suction tube can cause a temporary loss of prime for
oil pump. The engine will have low pressure or no oil
pressure at starting followed by normal oil pressure.
Bearings and Oil Pump

A steady decrease in oil pressure over a long period of
time can be an indication of worn bearings or
excessive oil pump wear.

Incorrect Oil Pump
If low or high pressure occurs after changing the
pump, verify that the correct pump was used.
Oil Dilution
Caution: Diluted oil can cause severe engine damage.
Check the condition of the oil

z Thin, black oil is an indication of fuel in the
oil.
z Milky discoloration is an indication of coolant
in the oil.
Coolant in the oil can be caused by

z Cup plugs leaking.
z Damaged cylinder head gasket.
z Oil cooler element leaking.
Coolant Diluted Oil

Coolant leaking from the oil cup plugs in the cylinder
block water jacket will dilute the oil.
To check for leaks, remove the tappet cover and
pressurize the cooling system.
Coolant in the oil can also be caused by a damaged

cylinder head gasket.
Pressurize the cooling system to check for leaks. It
may be necessary to remove the oil pan to locate
internal leaks.

During operation the oil pressure will be higher than
coolant pressure. A leak in the oil cooler will show as
oil in the coolant.
However, following an engine shutdown, the residual
pressure in the coolant system can cause coolant to
seep through the leak path into the oil.
Fuel Diluted Oil

Fuel dilution is limited to four sources:
1. Injection pump shaft seal
2. Fuel leaking by the rings
3. A crack in the cylinder head from the fuel
filter location to the air intake.

Use the following logic to determine the source of the oil dilution with fuel:
Power Low Increased White Smoke

Power Low Increased Black Smoke
During Start Up -
Verify the Rings are Sealing by

Check/Replace the Injectors
Performing a Compression Check
A worn or damaged injection pump shaft seal will allow

fuel to leak into the gear housing and then into the oil
pan.
The seal is designed to provide increased sealing as

the pump case pressure increases. Pressure forces
the lip (1) tighter around the shaft.
A worn seal is more apt to leak during start up and shut
down when case pressure is low.
Caution : A worn seal can not be detected

pressurizing the pump.

The bushing (2) in the Bosch VE pump can causes a
seal leak. If the bushing is loose in the housing it will
move toward the seal raising the lip (1) and providing a
leak path for fuel.
To check for such a leak remove the fuel drain

manifold connection (1) at the pump and install a plug
(2).
Remove the access cover and rotate the engine so

one of the holes in the fuel pump gear exposes the
back gear housing.
Activate the fuel shut down valve by turning the switch

to the ON position.

Incomplete combustion in the cylinders can result in
unburned fuel draining into the oil pan.
This condition can be caused by a leaking injector or
reduced compression caused by inadequate piston
ring sealing.
An increase in white exhaust smoke during the first

start of the day is a symptom that an injector is leaking.
An injector leak will also cause the engine to run rough
and have low power.
Remove and replace leaking injectors
Perform a compression check to verify piston ring

sealing

Another remote possibility is a crack or porosity in the
head casting could allow fuel to leak to the air intake
and on to the cylinders.
Oil Leaks
Various gaskets, seals and plugs are used to contain
the oil. Most leaks can be identified during routine
inspection of the engine and vehicle.

If the oil cooler element ruptures, the oil pressure will
force oil into the coolant system.
Oil in the coolant should be visible when the radiator
cap is removed.
Worn or damaged seal sin the turbocharger can also

allow oil to leak into the air crossover pipe and be
burned in the engine.
The condition can be verified by removing the air
crossover tube and looking for oil.
Inadequate sealing of the piston rings will result in oil

being blown out the breather tube and/or consumed by
the engine

Lubricating System
Replacement Procedures
Oil Pressure Regulator Valve and/or
Spring Replacement
24mm
Remove the plug and valve.
Clean and inspect the plunger, bore and seat before

assembly.
Note : The plunger must move freely in the valve bore.
Assemble the vale in the reverse order of disassembly.

Oil Cooler Element and/or Gasket

Replacement
Preparatory Step : Drain the coolant.

Fill the coolant system and operate the engine to
check for leaks.
Stop the engine and check the coolant and oil level.
Oil Pan, Suction Tube and/or Gaskets

Replacement
17mm
Drain the oil and remove the pan and gasket.
12mm
Caution : Be sure to connect the support bracket.
If required, remove the suction tube and gasket.

Clean the sealing surfaces.
Install the suction tube and gasket.
Torque Value: 25.5Nm [19 ft-lbs]
Caution : Be sure to fill the joints between the pan

rail, gear housing and rear cover. Use Three
Bond 1207-C.
Clean the pan sealing surfaces.

12mm
Install the pan and gasket.
17mm
Install the drain plug.
Fill the engine with oil. Run the engine and check for
leaks.
Stop the engine and check the oil level with the
dipstick.
Oil Pump Replacement

Preparatory Step:
Note : Removal is easier if the crankshaft pulley is

loosened before removing the belt.

19mm
Remove the crankshaft pulley.
12mm
Remove the front cover.
Remove the Lubricating Oil Pump

5mm Hex Lench
Remove the four mounting capscrews.
Remove the pump from the bore in the cylinder block.
Clean and Inspect

If the pump is to be inspected for reuse, follow these
steps.
Visually inspect the lube pump gears for chips, cracks,
or excessive wear.

Installing the Lubricating Oil Pump
Lubricate the pump with clean engine oil.
Note : Filling the pump with oil during installation will

help to prime the pump at engine start up.

12mm
Install a new gasket.
Tighten in the sequence shown.
Note : Be sure the gear backlash is correct if installing

a new pump.
Measure gear backlash.
Backlash Limits
A
0.11 to 0.19mm
[0.0043 to 0.0075 inch
Note : If the adjusting gear moves when you measure

the backlash, the reading will be incorrect.

Gear Cover Installation
Lubricate the front gear train with clean engine oil.
Caution : The seal lip and the sealing surface on the

crankshaft must be free from all oil residue
to prevent seal leaks.
Thoroughly clean the front seal area of the crankshaft.
12mm
Install the front cover and gasket.
Note : Install the capscrews but do not tighten at this

time.
Torque Value : 25.5 Nm [19 ft-lb]

19mm
Install the crankshaft pulley
19mm
Cup Plugs Replacement

Remove the cup plugs from the oil passages.

To Install the Cup Plugs
Apply a bead of Loctite 277 around the outside
diameter of the oil passage cup plugs.
Drive the cup plugs in until they bottom in the bore.
Fill the engine with oil. Run the engine and check for
leaks.
Stop the engine and check the oil level with the
dipstick.

Electrical System
Densko Poongsung 12V 2.0kw Starting Motor
Electrical System
Description/Operation
The electrical system basically consists of the starting
motor and the alternator.
The injection pump uses an electrical fuel shut off
valve. The function of the valve was discussed in the
fuel system section.
The engine should have temperature and oil pressure
sensors connected to indicators or wired for
automatic shutdown.
The engine may also be fitted with a block heater or
an oil pan heater.
A Series Diesel Engine 134 Electrical System

Injection Pump Fuel Shut Off Valve
Oil Pressure Switch and Temperature Sensors

Electrical System Spec.
z Minimum Recommended Battery : 12 V 75A
z Starter Motor: 12V 2.0kW
z Alternator: 12V 45A

Diagnosing Electrical Malfunctions
Starting Motor
Before you troubleshoot the starting motor, make sure
the battery terminals are not loose or corroded.
Engine Does Not Crank

If the solenoid does not make an audible sound, check
for loose wiring connections.
Check the voltage at the solenoid battery post.

z No voltage Check the condition of the
battery. Check the connections at the batter,
engine and solenoid.
z 12 volts at the solenoid battery post check

the voltage at the S (switch) terminal on the
solenoid. The ignition switch must be in the
start position.
The solenoid is at fault if the check indicates 12 volts

at the S terminal.

z If no voltage is indicated at the S terminal,
check:
z Fuses
z Voltages to the ignition switch
z And, if the vehicle is so equipped, voltage to
clutch switch, neutral safety switch and
engine safety shutoff system.
If the solenoid does make an audible sound, turn the

switch off and attempt to bar the engine in both
directions.
Bar the engine as follows:

1. Direction of engine rotation.
2. Direction of opposite engine rotations.
3. Direction of engine rotation.
If the engine will bar at Step 3, attempt to start the

engine. If the starter cranks the engine, check the
starter pinion gear and flywheel ring gear for damage.
If the engine bars and the starting motor does not

crank, check the voltage between the solenoid and
starting motor. The ignition switch must be in the start
position.
No Voltage: Starter is at fault
Normal Voltage: The solenoid is at fault.
When troubleshooting a 24 volt system, the value is 24

volts.

Engine Cranking Speed Too Slow
Make sure the wiring connections are clean, tight and
not damaged.
Check the battery voltages.
If the engine was not rotated to check the starting

motor (page 7-8), bar the engine in the direction of
engine rotation to make sure the engine is free and
does not have an internal malfunction.
If the engine is free, check the voltage at the starter

during cranking. If the voltage drops more than 2.4
volts, check that all connections are tight. The limit for
24 volt systems is 4.8 volts.
If the cable correct and the voltage drop exceeds the
limit, replace the starter.
If the engine requires more than a normal effort to bar,

check for excessive load from the driven units and
accessories.

Alternator
The terminals on the alternator are shown in this
illustration. The R terminal provides one-half system
voltage and is used to operate accessories such as
the tachometer on generator sets.
Trouble with the charging system may be indicated by

the indicator lamp or ammeter.
Abnormal Indicator Lamp Operation

Check the indicator lamp for normal operation as
shown below.
Engine Switch Lamp Ammeter

Stopped Off Off 0
Stopped On On -
Running On On +
Switch Off, Lamp On, Engine Stopped

Disconnect the lamp lead at the ignition switch. If the
lamp stays on, there is a short to a positive wire on the
ignition side of the lamp.

If the lamp goes out, there is a short in the switch.
Switch On, Lamp Off, Engine Stopped

The condition can be caused by an open in the circuit.
To determine where an open exists. Check for a blown
fuse, a burned out bulb, defective bulb socket, or an
open in No. 1 lead circuit between alternator and
ignition switch.
Switch On, Lamp On, Engine Running

Check the drive belt and alternator pulley to be sure
the alternator is rotating.
Disconnect the lead to Terminals No. 1 and No. 2. If

the lamp stays on, there is a short to ground on the
alternator side of the lamp.

If the lamp goes out, replace the alternator.
Abnormal Charging System Operation

Check the battery and all wiring connections.
Inspect the wiring for defects.
Check all connections for tightness and cleanliness,
including the slip connectors at the alternator and
firewall, and connections at the battery.
With ignition switch on and all wiring harness leads

connected, connect a voltmeter from:
A. Alternator BAT terminal to ground
B. Alternator No. 1 terminal to ground
C. Alternator No. 2 terminal to ground
A zero reading indicates an open between the

voltmeter connection and the battery.
Locate and repair the open circuit.
With all accessories turned off, connect a voltmeter

across the battery.
Operate engine at moderate speed.
If voltage is 15.5 or more, remove the alternator for
repair. The limit for 24 volt system is 25 volts.

Fuel Shutoff Valve Check
Note : Check all connections for loose or corroded
connections for broken wires.
Remove the valve. Ground the valve and connect 12

volts DC to the terminal and observe plunger
movement.
Oil Pressure Switch and Temperature

Sensor
When diagnosing problems with either the pressure
switch or the temperature sensor, check for loose or
corroded connections and for broken wires.
Oil Pressure Switch - Check

Remove the pressure switch, install a gauge, start the
engine and measure oil pressure. Minimum oil
pressure:
Idle 147 kPa [21PSI]

Full Speed 294 kPa [42 PSI]
Note : The pressure switch is set to actuate when oil

pressure drops to 98 kPa [14 PSI].
Temperature Sensor Check

Check for continuity.
Voltage : DC 12 V
Temperature 54.4 110

Resistance 560~716 72.1~81.8

Engine Electrical System
Starting Motor - Replacement
Preparatory Steps:
z Disconnect the ground cable from the
battery terminal.
z Identify each electrical wire with a tag
indicating location.
12mm
Remove the battery cable from the solenoid.
17mm
Remove the starting motor.
Install the starting motor in the reverse order of
removal.
Alternator - Replacement
Preparatory Steps:
z Disconnect the ground cable from the
battery terminal.
z Remove the drive belt from the alternator
pulley.

12mm
Remove the alternator bolts.
14mm
Remove the alternator mounting nuts.
12mm, 14mm
Install the alternator by tightening the 12mm bolts
before the 14mm bolts. Reconnect all wires.
Torque Value : (12mm) 25.5Nm [19 ft-lbs]

. .(14mm) 49Nm [37 ft-lbs]

Electric Fuel Shut Off Valve -
Replacement
8mm
Remove the electrical wire(s) and complete the
following steps.
24mm
Caution : When removing the valve, be careful not to

drop the piston and spring.
Clean around the valve.

Replace the valve and connect the electrical wire.
Oil Pressure Switch Replacement

Disconnect the wire from the sending unit.
Note : The sending units illustrated may differ from

those installed by the equipment manufacturer.
Reconnect the wire to the sending unit.
Torque Value :
(Installed into Cast Iron)
16Nm [12 ft-lbs]

Temperature Sensor Replacement
Preparatory Step:
Drain coolant
Disconnect the temperature sensor wiring.
17mm
Remove the temperature sensor.
17mm
Apply liquid Teflon sealant to the threads when
installing the temperature sensor.
Reconnect the wiring.
Torque Value:
(Installed into Aluminum)
39Nm [29 ft-lbs]

Base Engine Components
Operation and Description
This section of the manual defines the base engine
components, describes the operation of those
components, provides guidelines for diagnosing
malfunctions and gives procedures for component
replacement and in-chassis overhaul.
Definition
For the purpose of this manual, Base Engine
Components are defined as mechanical functions not
included in the other major engine systems. The
components include:
z Valve Train and Cylinder Gear Head
z Front Gear Housing and Gear Train
z Camshaft, Tappets and Push Rods
z Piston and Connecting Rod Assemblies
z Crankshaft and Main Bearings
z Cylinder Block
A Series Diesel Engine 148 Base Engine Components

Cylinder Head and Valve Train
The cylinder head is a one piece, crossflow design
with two valves per cylinder.
The head has integrally steel alloy valve guides and
hardened valve seat surfaces which can be repaired
in a machine shop using the appropriate service parts.
The cylinder head has a cast intake manifold, fuel

filter head, thermostat housing and an internal water
bypass.
The injectors are mounted in the head for direct
injection into the cylinders.
Separate pedestals for each cylinder are used to

support and route oil to the rocker levers.
The cylinder head gasket is a laminated design with

print o-seal on both sides around the water holes.
A fire ring in the gasket seals the cylinder bores.
As discussed in the Cooling System, the gasket also
provides orifices to control coolant flow.

Front Gear Housing and Gear Train
The gear train consists of the crankshaft gear, lube
pump gear idler, the camshaft gear, the fuel pump
gear and the accessory drive gear, if used.
The gear housing provides a support for the injection

pump, and the accessory drive gear, if used.
Front Crankshaft Seal

The front crankshaft seal is mounted in the front gear
cover. A double lipped Teflon seal is used.
The sealing surface on the gearcase must be clean
and free of oil during assembly.
Camshaft, Tappets and Push Rods

The camshaft is gear driven from the crankshaft.
A replaceable bushing is used for the front journal to
carry the side loading from the accessory drive.
The remainder of the journals operate in cast iron
bores in the cylinder block.

The camshaft has lobes to operate the intake and
exhaust valves.
The valve lobes contact mushroom shaped valve
tappets which operate the push rods.
The profile of the cam lobes is the same for all A
series engines.
The tappets are mushroom shaped. The convex

shape of the surface which contacts the camshaft lobe
causes the tappet to rotate as it lifts the push rod.
The ball end of the push rod fits into a ball socket in
the tappet.
The other end of the push rod is fitted with a socket
into which the ball end of the rocker lever adjusting
screw operates.
Flywheel Housing and Flywheel

Several Optional flywheel housing and flywheels are
used depending on the application.

Piston and Rod Assemblies
Piston features include : high swirl combustion bowl
cast aluminum body and 3 ring grooves.
Always check the part number to be sure the correct
configuration is used during piston replacement.
The piston ring sets are also different. While both sets
consist of three rings; two compression rings and one
oil ring.
A free floating, hollow piston pin is used to attach the

piston to the connecting rod.
Lubrication of the pin and journal is accomplished by
residual spray from piston cooling.

The connecting rod is made of high-strength gorged
carbon-steel.
The large end with the special aluminum-ally metal can be
separated into two and the small end has a copper alloy
coil bushing.
Oversize service rod bearings are available for use with re-
ground crankshafts.

Crankshaft and Main Bearings
The crankshaft is a balanced, forged steel unit. Four
cylinder engines have a main bearing.
The lower bearing shells are all the same.
All of the upper bearing shells are all the same.
The two thrust bearings control the end thrust of the
crankshaft.
The upper bearings have two holes in them. The one

side hole receives oil from the main oil rifle.
One of the adjacent holes is aligned with drilling to the
camshaft journal and serves as an orifice for
lubrication flow to the journal and is used for piston
cooling.
The hole does not align perfectly with the cooling
nozzle. The hole is off-set to keep it away from the
highly loaded bearing area.
Note : Oversize service main bearings are available

for reground crankshafts.
Cylinder Block
We have discussed the cylinder block relative to cooling and lubrication in those respective systems. We have also
discussed the interfaces of some of the above power functions with the block. This discussion will cover the
remaining interfaces including the cylinder bores.

The cylinder bores are machined directly into the block
during production.
The size and condition of the bore is critical to engine
performance and life.
During repair, be sure to inspect the bore carefully.
Cylinder liner can be replaced into cylinder block. Both

cylinder and liner have size mark on.
The block and liner marks are identified as follows:
Mark
Cylinder block L
M
S
Cylinder Liner L
M
S

Oil Pan
A front sump, rear sump or center sump pan options
may be used depending on the application.
The mounting of the oil pick up tube will vary with the
pan used.
Rear Crankshaft Seal
The rear crankshaft seal is mounted in a housing that

bolts to the rear of the block.
Double lipped Telflon seals are used. The sealing
surface on the crankshaft must be cleaned and free of
oil during installation of the seal.
Diagnosing Base Engine Component

Malfunctions
Valve Train and Head Assembly
The sound emitted from the overhead can indicate a

valve train problem. Loose rocker levers will chatter. A
squeaking noise can mean lack of lubrication for
adjusting screw and the push rod socket.
Caution : If the end of the individual support

pedestals is removed during inspection or
repair, all head bolts must be retightened
according to the head bolt torque
sequence.

Air and Fuel System Check
When diagnosing a low power problem first
troubleshoot the air and fuel systems to make sure the
engine is receiving adequate intake air and fuel.
Check the intake air system for leaks. Make sure a

sealant is used on the through-hole capscrews wich
secure manifold cover to the head.
Verify the turbocharger is operating correctly.
Check the fuel system for correct timing and fuel

delivery.
Valve Adjustment Check

Verify that the valves are adjusted correctly.

Compression Check
If the air and fuel system are functioning correctly,
perform a compression check to determine whether
the problem is:
z Piston ring sealing
z Valve sealing
z Head gasket sealing or a crack in the
cylinder head
Piston Ring Seal

If the compression is low but can be increased
significantly by squirting oil into the cylinder, the
cause of low compression is inadequate sealing
between the rings and the cylinder walls.
Normal compression is 3430 kPa [497 PSI] at 250

RPM cranking speed. A 26 kPa [383 PSI] difference
between cylinders indicates a compression seal
problem.
Valve Sealing
If the compression is low on one or more non-
adjacent cylinders and the pressure cannot be
increased by oiling the rings, poor valve sealing is
to be suspected.
Valve leakage is often audible from the intake and

exhaust manifold.

Head Gasket Sealing
If the compression was found low on adjacent

cylinders and the pressure cannot be increased by
oiling the rings, the head gasket is probably leaking
between the cylinders.
Low compression on a single cylinder can be caused

by an external leak or a leak to a coolant passage.
A compression leak to the coolant will normally be

detected by loss of coolant as the coolant is blown
from the cooling system.

External head gasket leaks can be detected visually.
Liquid soap can be used to locate external leaks.
Valve Seal Wear

Worn valve seals are typically detected by excessive
smoke at idle or when the engine is unloaded when
the vehicle is going down hill.
Verify the condition by removing the valve spring and
inspecting the seals.
Hardening of the material and wear or damage to the

sealing surface will cause the seal to leak (refer to
page 219 for replacement instructions).

Front Gear Housing and Gear Train
Troubleshooting the front gear housing and gear train
consists of checking for leaks at the gaskets (front
cover, and injection pump) and the front crankshaft oil
seal, inspecting the gears and measuring backlash
when required.
Gear noise emitted from the cover can indicate worn

gear teeth.
Note : Excessive backlash can affect engine timing

and engine performance.

Rocker Lever, Valve Stem, Push Rod,
Tappet, and Camshaft
Excessive valve lash can indicate a worn valve stem
or rocker lever.
Loose rocker levers and the need to re-set the valve

clearance frequently, can also indicate cam lobe or
tappet wear. If an inspection of the levers, valve stems
and push rods does not show wear, then tappet and/or
cam lobe wear can be suspected.
Caution : Anytime a new camshaft is installed, new

tappets must also be installed.
The camshaft lobes can be visually inspected after

removing the pan. Similarly, the face of the tappet can
be inspected after removing the push rods and lifting
the tappet.
A several damaged camshaft journal (s) can generate

metal chips which will be found in the pan and filter. As
the clearance in the journal (s) increases, a small
decrease in oil pressure may be detected.

Piston and Rod Assembly
There are a number of power relate problems
including excessive oil consumption, smoke, blow-by
and poor performance that can be caused by
inadequate sealing between the piston rings and the
cylinder walls.
A blow-by measurement can help detect the problem.
Verification of the damaged or worn component

requires visual/dimensional inspection of rings, pistons
and cylinder bore.
The cause of piston ring wear can range from wear

over a long period of service to a dust-out in a short
period of time because of poor maintenance of the air
intake system.
Refer to Section 5 for troubleshooting the Air System.
During repair it is essential that the cylinder wall be

deglazed so that new rings will seat against the
cylinder wall.
The marks on cylinder block and cylinder liner must be
matched.
The different marks are matched, excessive blow by
gas and excessive oil consumption occur.

However, it is also critical that the cylinder liner walls
be thoroughly cleaned.
Grit left in the cylinder wall will cause rapid wear out of
the new rings leading to the previously discussed
power problems.
Overheating of the engine from a loss of coolant will

cause the cylinder to overheat resulting in seizure of
the piston.
Loss of piston cooling can also lead to piston seizure.
Improper maintenance of the lubrication system is the

primary cause of reduced main bearing life.
Normally, worn bearings can be detected by reduced

oil pressure.
But if this wear goes undetected, the excessive
clearance will cause the rod to strike the crankshaft
causing a distinct knocking sound.

A rod knock occurs when the engine is not loaded.
Verify by first applying load and then unloading and
listening for the knock.
Crankshaft and Main Bearings

Improper maintenance of the lubrication system is also
the primary cause of reduced main bearing life.
A malfunction of the crankshaft/main bearing will
usually be detected by reduced oil pressure. As with
rod bearings, continued operation with low oil pressure
will lead to a rapid deterioration of the bearings and
eventually will produce a knocking sound.
A main bearing will be heard when the engine is

loaded.
A damaged or worn thrust bearing flange of the upper

main bearing shell can be detected by measuring the
end play of the crankshaft .

Failure of driven units at the front or rear of the engine
which increase the end loading can damage the thrust
bearing.
Cylinder Block
Diagnosis of cylinder block malfunctions relative to
cooling and lubrication has been discussed in those
respective systems.
The potential problems with cylinder, the camshaft
bore and the crankshaft main journals have also been
discussed in this Section.
Malfunctions of the block such as leaks.

Require a visual or dimensional inspection to isolate
the problem.
Flywheel Housing and Flywheel

Diagnostics of the flywheel housing and flywheel is
normally limited to a visual inspection of the parts for
damage or wear.

Occasional failure of a starter to engage can be
caused by damaged teeth on the ring gear.
Service ring gears are available for repairing flywheels.
When troubleshooting a transmission vibration

problem, it may be necessary to measure the
concentricity of flywheel housing-to-crankshaft.
Note : The following procedure is for use with an

indicator whose needle rotates clockwise as
the top is depressed.

Specifications
Valve Train
Valve Clearance
z - Intake 0.3mm [0.012 in]
z - Exhaust 0.3mm [0.012 in]
z Valve Guide Diameter

8.025 mm [0.316 in] MAX
8.010 mm [0.3153 in] MIN
z Valve Stem Diameter

7.97 mm [0.3138 in] MAX
7.96 mm [0.3134 in] MIN
z Valve Seat Angle

Intake 30 degrees
Exhaust 45 degrees
z Valve Depth (Installed)

0.6 to 0.8 mm [0.0236 to 0.0315 in]
Wear Limit: 1.0 mm [0.0394 in]

z Cylinder Head Flatness
Total
Maximum Overall
0.15 mm [0.006 in]
Gear Train
z Gear Backlash
Crankshaft, Injection pump drive, camshaft:
0.07 to 0.15mm [0,0027 to 0.006 in]
Oil pump:
0.11 to 0.119mm [0,0043 to 0.0075 in]
Camshaft
z Journal Diameter
44.964 to 44.95 mm [1.7702 to 1.7697 in]
Worn Limit: 44.89 mm [1.767 in]
z Valve Lobes
Standard: 37. 935 to 38.065 mm
[1.4935 to 1.4986 in]
Tappets
z Stem Diameter
Standard: 14.238 to 14.210 mm
[0.5606 to 0.5598 in]

Pistons
z Skirt Diameter (Minimum)
Nominal
87.95 to 87.97 mm
[3.463 to 3.4634 in]
Worn Limit
87.90 mm [3.46 in]
z Pin Bore Diameter (Maximum)

30.008 mm [1.181 in]
Note : Measure the diameter on a vertical axis only.
z Ring Groove (Minimum)

Top Groove
2.006 mm [0.079 in]
Oil Control Groove
3.002 mm [0.118 in]
z Piston Pin Diameter (Minimum)

30 mm [1.181 in]

Connecting Rod
z Pin Bore Diameter
MAX: 30.038 mm [1.1823 in]
Crankshaft
z Main Bearing Journal Diameter
[2.2146 to 2.1240 in]
z Connecting Rod Journal

[1.967 to 1.966 in]
Cylinder Block
z Top Surface Flatness
(Maximum Overall Variation
Standard: 0.03 mm [0.00118 in]

z Main Bearing Bore Diameter
[1.9685 to 1.97 in]
z Camshaft Bore Diameter (Maximum)

[1.773 to 1.774 in]
z Tappet Bore Diameter

[0.561 to 0.562 in]
Cylinder Bore
z Cylinder Bore Diameter
[3.464 to 3.465 in]
z Out of Round
0.34mm [0.0012 in]

Rocker Lever and Push Rods Replacement
Preparatory Step:
17mm
z Remove the valve covers.
Removal
12mm
Loosen the adjusting screw locknuts. Loosen the
adjusting screws until they stop.
19mm
Remove the 19mm nuts from the rocker lever
pedestals. Remove the pedestals. Remove the
pedestals and rocker lever assemblies.
Remove the push rods.

Rocker Levers Disassembly
If the rocker lever and push rods are to be inspected
for reuse, follow these steps.
Remove the retaining rings and thrust washers.
Remove the rocker levers.
Caution : Do not disassemble the rocker lever shaft

and pedestal. The pedestal and shaft must
be replaced as an assembly.
Remove the lock nut and adjusting screw.

Clean all parts in a strong solution of laundry
detergent in hot water.
Use compressed air to dry the parts after rinsing in

clean hot water.
Note : The pedestals are made from powdered metal

and will continue to show wetness after they
have been cleaned and dried.
Inspect for cracks and excessive wear in the bore and

the contact surface for the valve stem.
Measure the rocker lever bore.

[0.748 to 0.749 in]

Inspect the pedestal and shaft.
Measure the shaft diameter.
[0.748 to 0.749 in]
Rocker Levers Assembly

Install the adjusting screw and lock nut.
Lubricate the shaft with engine oil.

Position the levers on the rocker shaft.
Install the snap rings.
Clean the push rods in hot soapy water.

Inspect the push rod ball and socket for signs of
scoring. Check for cracks where the ball and the
socket are pressed into the tube.
Check the push rods for roundness and straightness.
Install the push rods into the sockets of the valve

tappets. Lubricate the push rod sockets with clean
engine oil.
Caution : Make sure the rocker lever adjusting screws

are completely backed out.

Rocker Lever Assembly
Installation
Use clean engine oil to lubricate the threads and
under the heads of the 19mm nuts.
Install the nuts into the pedestals.
Valve Clearance Adjustment

Caution : Adjust the valves when the engine is cold
below 60 [140].
Four-Cylinder Engine
Step A
12mm
Adjust the clearance for the valves shown in the
illustration.
Clearance: 0.3 mm [0.012 in]
Tighten the locknut and check the clearance.
Note : Adjust intake and exhaust clearances in the

following firing order by rotating the crankshaft
180 degrees in the normal direction:
( 1->2->3->4)

Adjust the valve clearances for intake valves No. 1 and
No. 2.
Adjust the valve clearances for exhaust valves No. 1

and No. 3.
Rotate the crankshaft in the normal direction one

revolution.
Adjust the valve clearances for intake valves No. 3 and
No. 4.
Adjust the valve clearances for exhaust valves No. 2

and No. 4.
Tighten the locknut to secure the adjustment screw.
Locknut Torque Value

N.m Ft-lb
23 MIN 17
29 MAX 21
Camshaft and Tappet Replacement

Preparatory Steps:
z Remove the valve covers
z Remove the push rods
z Remove the drive belt
z Remove the crankshaft pulley
z Remove the gear cover
z Remove the oil pan
z Remove the oil pan flange

Rotate the engine to align the crankshaft to camshaft
timing marks.
12mm
Remove the capscrews from the thrust plate.
Remove the camshaft and thrust plate.
Camshaft Inspection
Inspect the lift pump lobe, valve lobes and bearing
journals for wear, cracking, pitting and other damage.

Inspect the gear teeth for wear and damage. Look for
cracks at the root of the teeth.
Measure the bearing journals and valve lobes.

Journal Diameter:
Standard: 44.964 to 44.95 mm [1.7702 to 1.7697 in]
Camshaft Bushing Inspection

Caution : If the bushing is worn beyond the limit,
install a new service bushing.
Inspect the camshaft bore for damage or excessive

wear.
The limit for the bushing in the No. 1 bore is the same
as for the other bores without bushings.
Note : If the bores without a bushing are worn beyond

the limit, the engine must be removed for
machining and installation of service bushings
or replacement of the cylinder block.
Remove the bushing from the Number 1 bore.

Note : Mark the cylinder block so you can align the oil
hole in the cylinder block with the oil hole in the
bushing.
Install the bushing so that it is even with the front face

of the cylinder block.
Measure the installed bushing.

Inside Diameter:
Tappet Inspection
Inspect the socket, stem and face for excessive wear,
cracks and other damage.
Limit
(A) - Normal wear
(B) and (C) - Abnormal wear Do not reuse

Tappet stem specifications
Inside Diameter:
Camshaft Installation
Apply a coat of Lubriplate 105 to the camshaft bores.
Lubricate the camshaft lobes, journals and thrust

washer with Lubriplate 105.
Install the camshaft/thrust washer. Align the timing

marks as illustrated.

Install the thrust washer capscrews and tighten to
25.5Nm [19 ft-lbs].
Verify the camshaft has proper back lash and end play.
A = 0.07 to 0.15 mm [0.0027 to 0.0059 in]

B = 0.05 to 0.25 mm [0.002 to 0.0098 inch]
Complete the installation of the removed parts.

z Gear cover
z Vibration damper
z Rocker levers and valve cover
z Lift pump
Operate the engine at idle for 5 to 10 minutes and

check for leaks and loose parts.

Gear Housing or Gasket
Replacement
Preparatory Step:
z Remove the v-pulley.
z Remove the gear driven accessory drive if
the engine is so equipped.
12mm
Remove the gear housing and gasket.
Clean the gasket material from the cylinder block.
12mm
Caution : If a new housing or other than the original
housing is installed, the timing pin assembly
must be accurately located.
Install a new gasket and gear housing.


Flywheel Ring Gear and Rear Seal
Replacement
Preparatory Step:
z Remove the transmission
Ring Gear Replacement
19mm
Remove the Flywheel.
Brass Drift Pin

Warning : Wear eye protection when you drive the
gear from the flywheel. Do not use a steel
drift pin.
Use the drift pin to drive the ring gear from the
flywheel.
Heat the new ring gear for 20 minutes in an oven

preheated to 127 [260].

Warning : Wear protective glove when you install the
heated gear.
Install the gear. The gear must be installed so the

bevel on the teeth is toward the crankshaft side of the
flywheel.
Flywheel Installation
Caution : Never use the timing pin to hold the crank-
shaft.
Use two capscrews in the front of the crankshaft, or

similar device, to hold the crankshaft when the
flywheel capscrews are being tightened.
17mm Socket, Torque Wrench
Tighten the capscrews in the sequence shown.


In-Chassis Overhaul
The remaining procedures in this manual are
organized for an in-chassis overhaul. An in-chassis
overhaul includes:
z Inspecting the turbocharger
z Replacing piston rings
z Replacing connecting rod bearings
z Replacing crankshaft main bearings
z Grinding valves
z Testing injectors
This manual gives the procedures to replace the

piston rings, rod bearing, main bearings and grinding
the valves. The procedure to test the injectors and
rebuild the turbocharger are given in the Shop
Manual, Bulletin Number 3810206. Refer to pages 5-
3 through 5-9 for inspecting the turbocharger.
Segments of the procedures can also be used to
replace individual components when required.
The condition of the cylinder block and crankshaft is
the limiting criteria for in-chassis overhaul. If there is
reason to believe that either is severely damaged, the
engine should be removed for major overhaul.
Prior to deciding on an in-chassis overhaul, inspect

the air intake for evidence of ingestion of particles
that could have severely damaged the cylinder walls,
Check the oil and oil filter to be sure the lube system
is not thoroughly contaminated with metal. Also check
for rust in the coolant which can indicate build up in
the passages in the cylinder block and require the
block to be removed for cleaning. Also consider the
condition of other components, particularly those that
are more difficult to replace in-chassis; e.g. the
camshaft rear sea, etc. The combination of in-chassis
overhaul and time to repair those components may
exceed the time required to remove the engine and
perform an out of chassis overhaul.
The in-chassis overhaul procedures include

prescribed checks of the hardware to determine if
continued in-chassis work is practical. If the
conditional limits are not met, the engine should be
removed for completion of the overhaul.

Cylinder Head Removal
z Drain the coolant and oil
z Disconnect the radiator and heater hoses
z Remove the turbocharger and air crossover,
if the engine is so equipped
z Remove the exhaust manifold
z Remove the fuel lines and injector nozzles
z Remove the valve covers
z Remove the rocker levers and push rods
z Remove the fuel filter
17 mm
Remove the cylinder head bolts in the sequence
shown.
Remove the cylinder head and gasket from the

cylinder block.
Note : Inspect the coolant passages. A large build up

of rust and lime will require removal of the
cylinder block for cleaning in a hot tank.
Inspect the cylinder bores for damage or excessive

wear. Rotate the crankshaft so the piston is at BDC for
the bores being inspected.
Measure the cylinder bores.
Limits
Diameter: Standard: 88.0 to 88.02
[3.464 to 3.465 in]
Out-of-Roundness: 0.03mm [0.0012 inch]
Refer to page 8-31 for the limits of the oversize
cylinder bores.
Note : Do not proceed with in-chassis overhaul if the

bores are damaged or worn beyond the above
limits.

Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Check the top surface for flatness between each
cylinder.
Limits
Variance: Standard: 0.03 mm [0.0012 in]
Note : Do not proceed with the in-chassis overhaul if

the cylinder block head surface is damaged or
not flat.
Main bearing Preliminary inspection

Remove the pan and suction tube.
Perform a visual inspection of the main bearings and

crankshaft journals. Remove the No. 2 and 3 caps and
check the journals for signs of overheating, deep
scratches or other damage. If there is no damage,
there is no need to pull the other caps at this time.
Inspect the main bearing caps for dents, cracks, or

other damage.

Inspect the journals for deep scratches, indications of
overheating and other damage.
Note : If the journals or main caps are damaged, the

engine will need to be removed to complete the
overhaul.
Piston and Rod Removal
Caution : Make sure the ridge reamer does not make

a deep cut into the bore. Do not remove
more metal than is necessary to remove the
ridge.
If the cylinder bores have edges, use a ridge reamer to

cut the ridge from the top of the cylinder bore.
Hammer, Steel Number Stamps
Mark the cylinder number onto each connecting rod

cap.
Hammer, Steel Number Stamps
Mark the cylinder number onto the top of each piston.

14mm
Remove the capscrews, connecting rod cap and
bearings.
Caution : Use care so that the cylinder bore or

connecting rod is not damaged.
Use a hammer handle or similar object to push the

piston and connecting rod through the cylinder bore.
Put the assemblies in a rack for disassembly later.
Inspect the rod journals for deep scratches,

indications of overheating and other damage.

Caution : Be sure to remove the tape covering the
lube holes after the cleaning process is
complete.
Check the bore cleanliness by wiping with a white, lint

free, lightly oiled cloth. If grit residue is still present,
repeat the cleaning process until all residue is
removed. Wash the bores with solvent and blow the
block dry with shop air.
Caution : Be sure to remove the covering from the

piston cooling nozzles.
Remove the protective tape and cloth, and clean the

crankshaft journals.
Use solvent and a brush to clean any residue that

may have splashed on the camshaft.
Note : Inspect the camshaft lobes and tappet faces

for signs of wear or damage.
Main Bearing Replacement

Remove all main bearing caps except the No.1 and 5
cap for 4 cylinder engine. The 4 cylinder engine is
depicted in the illustration.

Inspect all caps and main bearing crankshaft journals.
(refer to page 171)
Determine the size of the bearing removed and obtain

the same size for installation.
Refer to page 171 for the dimensions of the standard
and undersize main bearing journals.
Caution : Do not lubricate the side that is against the

cylinder block.
Apply a coat of Lubriplate 105 to the new upper

bearings.
Use the pin to push the bearing shell into position. Use
the pin to push against the end of the bearing with the
tang. Push the bearing in slowly being sure it is
aligned with the block. Make sure the tang on the
bearing sets into the notch.
Note : Make sure the tang on the bearing sets into the
notch in the bearing saddle.

Install the lower bearings into the caps. Apply a coat of
Lubricate 105 to the bearings.
19mm
Caution : The crankshaft must rotate freely.
Install a main bearing cap after each upper bearing is

installed to keep the bearing in place while the other
uppers are installed.
Tighten the capscrews evenly and in sequence.

Step Torque Value
1 39Nm [50 ft-lbs]
2 69Nm [52 ft-lbs]
3 98Nm [74 ft-lbs]
Check the bearing installations and the size of the

bearings if the crankshaft does not rotate freely.
Note : The dimensions of the thrust bearings and

crankshaft journal determine end play.
Measure the crankshaft end play

Dim. (A) End Play Limits
Min Max
0.09mm 0.271mm
[0.0035 in] [0.0107 in]
Piston and Rod Disassembly

Remove the retaining rings.

Remove the piston pin.
Note : Heating the piston is not required.
Remove the piston rings.
Piston, Pin and Connecting Rod

Clean
Caution : Do not use bead blast to clean the pistons.
Soak the pistons in cold parts cleaner.

Soaking the pistons overnight will usually loosen the
carbon deposits.
Caution : Do not clean the pistons and rods in an acid

tank.
Wash the pistons and rods in a strong solution of

laundry detergent in hot water.

Caution : Do not use a ring groove cleaner and be
sure not to scratch the ring-sealing surface
in the piston groove.
Clean the remaining deposits from the ring grooves

with the square end of a broken ring.
Wash the pistons again in a detergent solution or

solvent. Rinse the pistons. Use compressed air to dry.
Piston, Pin and Rod Inspection

Inspect the piston for damage and excessive wear.
Check the top, ring grooves, skirt and pin bore.
Measure the piston skirt diameter as illustrated.

[3.463 to 3.4634 in]

Use a new piston ring to measure the clearance in the
ring groove.
Limits
Minimum Clearance
Top groove: 2.006 mm [0.079 in]
Oil Control: 3.002mm [0.1102 in]
Measure the pin bore
Diameter
30.008 mm [1.1814 in]
Inspect the piston pin for nicks, gouges and excessive

wear.
Measure the pin diameter.
Diameter
30.0 mm [1.181 in]
Caution : The I-beam section cannot have dents or

other damage. Damage to this part can
cause stress risers which will progress to
breakage.
Inspect the rod for damage and wear.

Measure the pin bore.
Maximum Diameter
30.038 mm [1.1826 in]
Bearing clearance can also be determined with

Plastigage during engine assembly.
Piston to Connecting Rod

Installation
Caution : Be sure Front marking on piston and the
numbers on the rod and cap are oriented as
illustrated.
Install the retaining ring into the pin groove on the

Front side of the piston.

Lubricate the pin and pin bores with engine oil.
Install the pin.
Note : Pistons do not require heating to install the pin,

however, the piston does need to be at room
temperature or above.
Install the second retaining ring.
Determine the piston diameter and obtain the

appropriate ring set.

Piston Ring Gap Check
Position each ring in the cylinder and use a position to

square it with the bore.
A= 20 mm [0.0787 in]
Use a feeler gauge to measure the gap.
Limits
Ring Minimum Maximum
Top:
0.20 mm [0.0079 in.] 0.35 mm [0.0138 in.]
Intermediate:
0.25mm [0.0100 in.] 0.70 mm [0.0276 in.]
Oil Control:
0.20 mm [0.0079 in.] 0.40mm [0.0157 in.]
Piston Rings Installation

Note : The top surface of all of the rings are identified:
Assemble with the word Top or the supplier
mark up.

Position the oil ring expander in the oil control ring
groove.
Install the oil control ring with the end gap opposite the
ends on the expander.
Install the intermediate ring.
Install the top ring.

Position the rings.
Determine the size of the removed rod bearing and

obtain a set of the same size.
Install the new bearings in the rods and caps and

lubricate them with a light coat of Lubriplate 105.
Piston and Rod Assembly

Installation
Lubricate the cylinder bore with clean engine oil.

Generously lubricate the rings and piston skirts with
clean engine oil.
75 to 125mm Ring Compressor
Caution : If using a strap-type ring compressor, make

sure the inside of the strap does not hook
on a ring gap and break the ring.
Compress the rings.
Bar the crankshaft so the rod journal for the piston to

be installed is at Bottom Dead Center (BDC).
Push the piston into the bore until the top of the piston
is approximately 50mm [2 inches] below the top of the
bore.
Then, pull the connecting rod onto the crankshaft
journal.

Note : The following series of illustrations show the
engine in a vertical position. This is for clarity of
illustration only.
Use clean engine oil to lubricate the threads and under

the heads of the connecting rod capscrews.
Caution : The four digit number stamped on the rod

and cap at the parting line must match and
be installed towards the oil cooler side of
the engine.
Install the rod cap and capscrews to the connecting

rod.
12mm Socket, Torque Wrench
Caution : Tighten the connecting rod and capscrews

evenly.
Torque Value:
Step 1 20 Nm [15 ft-lbs]
Caution : The crankshaft must rotate freely.
Check for freedom of rotation as the caps are installed.

If the crankshaft does not rotate freely, check the
installation of the rod bearings and the bearing size.

Caution : Do not measure clearance between the cap
and crankshaft.
Measure the side clearance between the connecting

rod and crankshaft.
Side Clearance Limits

Min Max
0.15 mm 0.35 mm
[0.006 in] [0.0138 in]
Install the suction tube and oil pan (refer to page 6-19).
Cylinder Head and Gasket

Installation
Caution : Make sure the gasket is correctly aligned
with the holes in the cylinder block.
The cylinder block and head must be clean and dry.

Position the gasket onto the dowels.
Carefully, put the cylinder head onto the gasket and

cylinder block.
Note : Make sure the cylinder head is installed onto

the dowels in the cylinder block.

Install the push rods and rocker levers (refer to page
179).
Lubricate the cylinder head capscrews. Use the
illustrated torque sequence.
17mm
Torque Value:
19mm
Caution: Be sure to lubricate the push rod sockets with

clean engine oil.
Install the rocker lever pedestal capscrews.

Adjust the valve clearance (refer to page 179).

Install the parts previously removed:
z Valve covers
z Injector nozzles
z Fuel lines
z Fuel filters
z Exhaust manifold
z Torbocharger, air crossover and aftercooler, if
the engine is so equipped.
Observe the Following Check List During Final Assembly
OK
z Correct injectors for the engine rating used and only one copper sealing washer
installed?
z Sealant applied to the capscrews that attach the intake manifold cover or aftercooler?
z Turbocharger pre-lubed?
z Engine filled with oil; oil filter filled with oil prior to installation so the engine has an
immediate supply of oil?
z Fuel filter (s) filled with fuel and the injection pump primed using the lever on the lift
pump?
z Aftercooler vent opened during coolant fill?
Caution : It is extremely important that all air is vented prior to operating the engine.

Caution : Stop the engine immediately if any unusual
sounds are heard.
Start the engine. If necessary, bleed the high pressure

lines at the injectors until the engine runs smoothly.

Check the coolant and oil level.
Refer to page 226 through ? for test and performance

requirements.

Cylinder Head Disassembly
The following disassembly and assembly procedures
are provided for inspection purposes only.
Refer to the Shop Manual, Bulletin No. 3810206, for
complete rebuild instructions.
Mark the valve to identify their position.
Compress the valve spring and remove the valve stem

collets. Use a magnet to remove the collets.
Release valve spring and remove the retainer and

spring.
Caution : Keep the valves in a labeled rack.
Remove the remaining collets, retainers, springs and

valves.

Remove the valve stem seals.
Cylinder Head Clean and Inspect

Clean the carbon from the injector nozzle seat with a
nylon brush.
Scrap the gasket material from all gasket surfaces.
Wash the cylinder head in hot soapy water solution.

After rinsing, use compressed air to dry the cylinder
head.

Polish the gasket surface with 400 grit paper.
Use an orbital sander or sanding block to keep a flat
surface.
Inspect the valve guides for scuffing or scoring.

Measure the valve guide bore.
Maximum Diameter
8.025 mm [0.3160 in]
Inspect the head surface for nicks, erosion, or any

other damage.
Check for head distortion as illustrated.
Refer to the Salvage Manual if head distortion exceeds
limits.
Polish the valve stem with crocus cloth.

Mark the valves again for location in the cylinder head.
Inspect for abnormal wear on the heads and stems.

Measure the valve stem diameter.
Maximum Diameter
7.960mm [0.3134 in]
If new valves are required, mark them for location in

the cylinder head.
Valves Grind
Re-face all reused valves. Check/replace bent valves.

Seat Angle
Intake: 30 Degrees
Exhaust: 45 Degrees
Measure rim thickness.

Minimum Thickness (T)
Check the valve stem tip for flatness.
If required, re-surface the valve stem tip.

Valve Seats Grind
Note: The illustrated marks indicate valve seat have
been ground previously.
Previously re-ground seat can be replace with service

seats.
Calculating the Grinding Depth
Install the valves in their designated location and

measure valve depth.
Note : The valve depth is the distance from the valve

face to the head deck.
Record the depth of each valve as (A).
Grind the valve seat to remove scores, scratches and

burns.

Seat Angle
Intake: 30 Degrees
Exhaust: 45 Degrees
Install the valves in their respective bores and

measure depth again.
Note : Make sure the seats are clean before you

measure the depth.
Record the depth of each valve as (B).

Calculate grinding depth (GD) as follows:
GD= (B) (A)
Dimension (GD)
0.20 mm [0.008 in]

Note : Identify re-ground valve seats.
Install the valves in their designated location and

measure the depth.
Caution: Replace the valve if the depth is over the

limit.
Check valve depth (C).
Valve Depth
Apply a light coat of valve lapping compound to each

valve and lap each valve to its companion seat.

Remove the valves and clean lapping compound from
the valves and seats.
Measure the valve seat width indicated by the lapped

surface.
Valve Seat Width Limit

Intake:
Exhaust:
Valve Springs Inspection
Measure the valve spring.
Limits
Approx. Free Length (L): 46.1 mm [1.815 in.]
Check the valve spring tension.

A minimum load of 299.5 N. [67 lb] is required to
compress the spring to a height of 29.85mm [1.175 in].

Cylinder Head Assembly
Note : Clean all cylinder head components before
assembling.
Install the valve stem seals.
Note : The intake and exhaust seals are the same.
Lubricate the stems with SAE 90W engine oil before

installing the valves.
Compress the valve spring after assembling the spring

and retainer.
Install new valve collets and release the spring

tension.

Warning : Wear eye protection. If the collets are not
correctly installed, they can fly out when
the stems are hit with a hammer.
After assembly, hit the valve stems with a plastic

hammer to make sure that the collets are seated.
Hydraulic Pump Drive Gear and Shaft

- Inspect for Reuse
(Just for D15S/18S/20SC-2)
Inspect the hydraulic pump gear for damaged, broken,
or excessively worn teeth.
Rotate the gear, and inspect for rough spots in the

bearing.
Inspect the bearing bore and shaft spline for excessive
wear.
Balancer - Remove
Check the gear backlash before removing balancer.
Refer to Section 1.
Remove the mounting capscrews.
Remove the balancer and shim or shim plate (1).
Remove the o-ring (2) in the oil passage.

Balancer - Install
Align the timing marks on the crankshaft drive gear

and the balancer driven gear.
Install the shim or shim plate (1), balancer, and lightly

lubricate the capscrews with clean 15W-40 engine oil.
Make sure that the oil supply passage is open and the
o-ring (2) is installed..
Tighten the capscrews in a criss-cross pattern.

Rotate the engine to make sure of free movement of
components.
Torque Value: 28 n.m [21 ft-lb ]
Note : Prevent movement of the adjoining gear when

checking backlash or the reading will be the
total of both gears.
Measure the balancer gear backlash.

Balancer Gear Backlash
mm in
Crankshaft Drive 0.06 MIN 0.0024
Gear (A)-to-
Balancer Drive 0.14 MAX 0.0055
Gear (B)
Balancer Drive 0.06 MIN 0.0024
Gear (C)-to-
Balancer Driven 0.14 MAX 0.0055
Gear (D)
.
Measure the balancer end play.
Balancer Shaft End Play
mm in
0.05 MIN 0.002
0.25 MAX 0.0098

Engine Replacement and Testing
Engine Replacement
If the engine cannot be repaired in chassis, use the following guidelines for removal and installation of the engine.
Caution : Use the equipment manufacturers

recommendations and precautions for
removal of chassis parts to gain access
to the engine.
Engine Removal
Preparatory Steps:
z Disconnect the air intake and exhaust pipes.
z Disconnect the throttle linkage from the control lever.
z Do not remove the control lever from the injection pump.
z Disconnect all engine driven accessories.
z Disconnect the drive units from the flywheel.
z Drain the lubricating oil.
z Remove the chassis parts as necessary to lift the engine from the equipment
A Series Diesel Engine 223 Engine Replacement and Testing

Disconnect all electrical connections. Put tags on the
connections to identify their locations.
Disconnect all lines including fuel lines to the lift pump

and fuel return. Use tags to identify the lines.
Put a cover or tape over all engine openings.
Use the lifting eyes to lift the engine. Apply tension to

the hoist to hold the engine while you disconnect the
engine mounts from the chassis.
Lift the engine from the equipment.
Dry Engine Weight: 169 kg
Note : Remove all accessories and brackets not

previously removed to use with the
replacement engine.

Engine Installation
Caution : Do not exceed the torque value for the
engine supports.
Check the data plate to verify that the replacement

engine is the same model and rating as the engine
that was removed.
Note : Install all accessories and brackets that had

been removed form the previous engine.
Use the lifting eyes to lift the engine. Keep tension on

the hoist while you align the engine in the chassis and
tighten the engine mounts.
Connect the engine and chassis parts in the reverse

order of removal.
When connecting the cable/rod to the control lever,

adjust the length so the lever has stop-to-stop
movement.

Adjust the length of the cable/rod to the mechanical
shut down lever so there is stop-to-stop movement.
Note : Make sure the air intake and exhaust pipe

connections are tight and free of leaks.
Fill the engine with the required amount of lubricating

oil.
6.5 Liters [1.85 gal]
Note : Check the oil level after the engine has run for
2 to 3 minutes. Oil held in the oil filter and oil
passages will cause the oil level in the oil pan
to lower.
Fill the cooling system with a mixture of 50% water

and 50% ethylene-glycol base antifreeze.
Refer to the equipment manufactures specifications
for radiator capacity.
Engine Only Coolant Capacity

3.0 Liters [0.7 gal]

Engine Testing
Verify engine performance by performing an in-chassis check.
Operating Conditions for Run-In and Test
Measurement Limit (s)

Coolant Temperature 100 [212] Maximum
Lubricating Oil Temperature 120 [248] Maximum
Lubricating Oil Pressure 294 kPa [42.6 PSI] Minimum
Air Inlet Temperature 25 [77] Maximum
Air Inlet Restriction 250 mmHg Maximum
Boost Pressure 66cm [26 in.] Hg Minimum
Exhaust Temperature 630 [1166] Maximum
Smoke
Bosch Smoke Meter 2.5 Units Maximum
Celsco Smoke Meter 4% Opacity Maximum

Specifications
General Engine
General Engine Data

- A2000, and A2300 Naturally Aspirated
Engine Weight (Dry) Less Flywheel and Electronics
- A2000 and A2300 203 kg [448 lbs]
Compression Ratio 21:1
Bore
- A2000 84 mm [3.31 in]
- A2300 88 mm [3.46 in]
Stroke
- A2000, and A2300 94 mm [3.7 in]
Displacement
- A2000 2.08 liters [127 C.I.D.]
- A2300 2.29 liters [139 C.I.D.]
Firing Order
- A2000, and A2300 1-3-4-2
Valve Clearance
- Intake 0.3 mm [0.012 in]
- Exhaust 0.3 mm [0.012 in]
Engine Rotation (Viewed From the Front of the Engine) Clockwise
Fuel System
Maximum Fuel Inlet Restriction to Injection Pump (Clean FIlter) 76.3 mm-Hg [3 in-Hg]
Maximum Fuel Drain Restriction 381 mm-Hg [15 in-Hg]
Maximum Fuel Inlet Temperature 65C [149F]
Minimum Engine Cranking Speed 180 rpm
Lubricating Oil System

Regulating Valve Opening Pressure 290 - 390 kPa [42 - 56 psi]
Lubricating Oil Capacity (Total System*)
- A2000, and A2300 7 liters [7.5 qt]
Lubricating Oil Capacity (Standard Oil Pan Only*)
- A2000, and A2300 6.5 liters [7.0 qt]
Lubricating Oil Pressure at Idle 69 kPa [10 psi]
(Minimum Allowable)
Lubricating Oil Pressure at Rated 168 kPa [24 psi]
(Minimum Allowable)
* Some applications use different oil pan capacities. Contact your local
Cummins Distributor if you have questions.
A Series Diesel Engine 228 Specifications

Cooling System
Coolant Capacity (Engine Only)
- A2000, and A2300 3 liters [3.2 qt]
Standard Modulating Thermostat - Range 71 - 85C [160 - 185F]
Maximum Allowable Operating Temperature 100C [212F]
Minimum Recommended Operating Temperature 71C [160F]
Minimum Recommended Pressure Cap 48 kPa [7 psi]
Air Intake System

Maximum Intake Air Restriction
- Dirty Filter 635 mm-H2O [25 in-H2O]
- Clean Filter 254 mm-H2O [10 in-H2O]
Minimum Dirt Holding Capacity 25 g/cfm
Exhaust System
Maximum Allowable Exhaust Restriction
- A2000, and A2300 75 mm-Hg [3 in-Hg]
Electrical System
Recommended Battery Capacity
- A2000, and A2300
- 12 Volt Battery with Light Accessories 500 Cold Cranking Amps
- 12 Volt Battery with Heavy Accessories 650 Cold Cranking Amps
- 24 Volt Battery with Light Accessories 250 Cold Cranking Amps
- 24 Volt Battery with Heavy Accessories 325 Cold Cranking Amps
Maximum 12 Volt Starting System Resistance 0.001 ohm
Maximum 24 Volt Starting System Resistance 0.002 ohm
Minimum Cranking Speed 180 rpm
Drive Belt Tension

Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
Note : This chart does not apply to automatic belt tensioners.

* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.

Capscrew Markings and Torque 4. When the ft-lb value is less than 10, convert
the ft-lb value to in-lb to obtain a better
Values
torque with an in-lb torque wrench.
Example: 6 ft-lb equals 72 in-lb.
General information
Caution : When replacing capscrews, always use a

capscrew of the same measurement and
strength as the capscrew being replaced.
Using the wrong capscrews can result in
engine damage.
Metric capscrews and nuts are identified by the grade

number stamped on the head of the capscrew or on
the surface of the nuts. U.S. Customary capscrews
are identified by radial lines stamped on the head of
the capscrew.
The following examples indicate how capscrews are

identified:
NOTES:
1. Always use the torque values listed in the
following tables when specific torque values
are not available.
2. Do not use the torque values in place of
those specified in other sections of this
manual.
3. The torque values in the table are based on
the use of lubricated threads.

Capscrew Markings and Torque Values Metric
Body Size Torque Torque Torque

Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb
6 9 5 7 4 13 10 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 23 17 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 550 400

Capscrew Markings and Torque Values U.S Customary
Capscrew
Cast Iron Aluminum Cast Iron Aluminum
Body Size
Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
1/4 - 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
3/8 - 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480

Fraction, Decimal, Millimeter Conversions
Fraction inch Mm Fraction inch mm

1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
3/64 0.0469 1.191 35/64 0.5469 13.891
1/16 0.0625 1.588 37880 0.5625 14.288
5/64 0.0781 1.984 37/64 0.5781 14.684
3/32 0.0938 2.381 19/32 0.5938 15.081
7/64 0.1094 2.778 39/64 0.6094 15.478
1/8 0.1250 3.175 37749 0.6250 15.875
9/64 0.1406 3.572 41/64 0.6406 16.272
5/32 0.1563 3.969 21/32 0.6563 16.669
11/64 0.1719 4.366 43/64 0.6719 17.066
3/16 0.1875 4.763 37941 0.6875 17.463
13/64 0.2031 5.159 45/64 0.7031 17.859
7/32 0.2188 5.556 23/32 0.7188 18.256
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 37684 0.7500 19.050
17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 37810 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor: 1 inch = 25.4 mm

Newton-Meter to Foot-Pound Conversions
Nm ft-lb Nm ft-lb Nm ft-lb

1 9 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
11 97 in-lb 90 66 190 140
12 106 in-lb 95 70 195 144
14 124 in-lb 100 74 200 148
15 133 in-lb 105 77 205 151
16 142 in-lb 110 81 210 155
18 159 in-lb 115 85 215 159
20 15 ft-lb 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
Note : To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
Pipe Plug Torque Values
Size Torque Torque
In Cast Iron or
Thread Actual Thread O.D. In Aluminum Components
Steel Components
in in Nm ft-lb Nm ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100

Weights and Measures Conversion Factors
From
From U.S.
Metric
Customary
Quantity U.S. Customary Metric To U.S.
To Metric
Customary
Multiply By
Multiply By
Unit Name Abbreviation Unit Name Abbreviation
sq. inch in2 sq. millimeters mm2 645.16 0.001550
Area sq. centimeters cm2 6.452 0.155
sq. foot ft2 sq. meter m2 0.0929 10.764
Fuel pounds per grams per

lb/hp-hr g/kW-hr 608.277 0.001645
Consumption horsepower hour kilowatt hour
kilometers per
miles per gallon mpg km/l 0.4251 2.352
liter
Fuel
Performance
liters per
gallons per mile gpm l/km 2.352 0.4251
kilometer
Force pounds force lbf Newton N 4.4482 0.224809
inch in millimeters mm 25.40 0.039370

Length
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kW 0.746 1.341
pounds force per

psi kilopascal kPa 6.8948 0.145037
sq. inch
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
inches of water in H2O kilopascal kPa 0.2488 4.019299
millimeters of
Pressure inches of mercury in Hg mm Hg 25.40 0.039370
mercury
millimeters of
inches of water in H2O mm H2O 25.40 0.039370
water
bars bars kilopascals kPa 100.001 0.00999
millimeters of
bars bars mm Hg 750.06 0.001333
mercury

From U.S. From Metric
Customary To U.S.
Quantity U.S. Customary Metric
To Metric Customary
Multiply By Multiply By
(1.8 x C)
Temperature fahrenheit F centigrade C (F-32) 1.8
+32
pound force per foot ft-lb Newton-meter Nm 1.35582 0.737562
Torque
pound force per inch in-lb Newton-meter Nm 0.113 8.850756
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
gallon (U.S.) gal. liter l 3.7853 0.264179
Volume: gallon (Imp*) gal. liter l 4.546 0.219976

liquid
displacement cubic inch in3 liter l 0.01639 61.02545
cubic inch in3 cubic centimeter cm3 16.387 0.06102

Weight
pounds (avoir.) lb kilograms kg 0.4536 2.204623
(mass)
British Thermal Unit BTU joules J 1054.5 0.000948
Work British Thermal Unit BTU kilowatt-hour kW-hr 0.000293 3414
horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341

SPECIAL TOOLS
Style Tool No. Tool name
ST 434 Vacuum Gauge
ST 537 Dial Depth Gauge
ST 647 Standard Puller
ST 1111-3 Manometer
ST 1273 Pressure Gauge
A Series Diesel Engine 237 Special Tools

ST 1325 Dial guage attachment
3162745 Injector/Connector Removal tool
3163292 Valve spring compressor
3375072 Dial bore gauge, kit
3375432 Crack Detection Kit

3376579 Tube(Filter) Cutter
3376946 Injector nozzle tester
3377161 Digital multimeter
3377259 Fuel Pump Timing tool
3377462 Digital optical tachometer

3822476 Blow By tool, use with ST1111-3
3822666 Digital Thermometer
3823137 Pistion ring expander

SB4241E00
Apr. 2007
Service Manual
G420FE LP/Dual Fuel Engine
G420F LP/Gasoline Dual Fuel Engine
G15S-5, G18S-5, G20SC-5

GC15S-5, GC18S-5, GC20SC-5
G20E-5, G25E-5, G30E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
publication.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
1
Index Inspect Ignition System................................. 25
Inspection of Ignition Timing ......................... 25
Inspection of Spark Plug ............................... 26
Chapter 1. GENERAL INFORMATION Fuel System Maintenance ................................. 28

Replace LP Fuel Filter Element..................... 28
Testing Fuel Lock-off Operation .................... 29
Precautions before Service ................................. 7
Pressure Regulator/Converter Inspection...... 29
Tightening Torque ............................................. 10
Inspect Air/Fuel Valve Mixer Assembly ......... 30
Recommended Lubricants and Capacities....... 11
Inspect for Intake Leaks................................ 30
Engine Model and Engine Serial Number ......... 12
Inspect Throttle Assembly............................. 30
General Specification ........................................ 13
Checking the TMAP Sensor.......................... 30
Engine Power and Torque ................................. 15
Exhaust System Maintenance........................... 30
Inspect Engine for Exhaust Leaks................. 30
Chapter 2. RECOMMENDED
Maintenance Schedule ...................................... 31
MAINTENANCE
Chapter 3. ENGINE MECHANICAL
General Maintenance......................................... 16
SYSTEM
Test Fuel System for Leaks........................... 16
Inspect Engine for Fluid Leaks ...................... 16
General Information........................................... 33
Inspect Vacuum Lines and Fittings................ 16
Engine Outline.............................................. 33
Inspect Electrical System .............................. 16
Specifications ............................................... 34
Inspect Foot Pedal Operation........................ 16
Specifications ............................................... 35
Engine Oil Classification................................ 17
Torque Specification ..................................... 38
Checking Engine Oil Level ............................ 18
Special Tools................................................ 39
Replacing Engine Oil and Filter ..................... 18
Troubleshooting............................................ 41
Checking Compressed Pressure ................... 19
Timing Belt System ........................................... 42
Adjusting Timing Belt Tension ....................... 20
Components ................................................. 42
Cooling System Maintenance............................ 21
Removal ....................................................... 43
Coolant Recommendation............................. 21
Inspection..................................................... 44
Check Coolant Level ..................................... 21
Assembly...................................................... 46
Inspect Coolant Hoses .................................. 21
PCV Valve .......................................................... 48
Checking coolant leaks ................................. 22
Outline and Operation Principle .................... 48
Specific gravity test ....................................... 22
Service Procedure ........................................ 49
Relation between Coolant concentration and
Intake and Exhaust System............................... 50
Specific Gravity............................................. 22
Intake Manifold ............................................. 50
Checking and Adjusting Drive Belt ................ 23
Exhaust Manifold .......................................... 52
Adjusting....................................................... 24
Cooling System ................................................. 54
Checking Belt for Damage ............................ 24
General Description ...................................... 54
Ignition System Maintenance ............................ 25
Testing and Adjusting ................................... 55
Inspect Battery System ................................. 25
G420F(FE) Service Manual 3 Index

Cooling System Recommendation ................ 58 Troubleshooting...........................................143
Coolant Pipe and Hose ................................. 60 Starter .........................................................144
Water Pump.................................................. 61
Thermostat ................................................... 63 Chapter 5. ENGINE MANAGEMENT
Cylinder Head Assembly ................................... 65
SYSTEM (EMS)
Lubrication System............................................ 74
General Description ...................................... 74
General Information..........................................150
Testing and Adjusting.................................... 75
Specifications ..............................................150
Oil Pressure Switch....................................... 77
Service Standard .........................................155
Front Case and Oil Pump.............................. 78
Component Location....................................156
CAM Shaft, HLA, Timing Chain ......................... 83
Components ................................................. 83
G420FE EMS (Engine Management System)
Removal ....................................................... 84
Overview ...........................................................160
Inspection ..................................................... 85
General Description .....................................160
Crankshaft.......................................................... 90
LPG Fuel System Operation ........................163
Flywheel and Housing ....................................... 94
MPI Gasoline System Operation ..................170
Piston and Connection Rod .............................. 95
Electronic Throttle System ...........................171
Cylinder Block.................................................. 110
Ignition System............................................172
Exhaust System...........................................173
Chapter 4. ENGINE ELECTRICAL SECM..........................................................175
SYSTEM SECM Wiring Diagrams for G420FE ............178
Specifications .................................................. 118 G420F EMS (Engine Management System)

Ignition System ................................................ 119 Overview ...........................................................180
Coil-On-Plug Ignition System ...................... 119 General Description .....................................180
COP Components....................................... 119 LPG Fuel System Operation ........................183
Inspection of Ignition Timing........................ 122 MPI Gasoline System Operation ..................187
Inspection of Ignition Coil Drivers (Power TR) Electronic Throttle System ...........................187
................................................................... 122 Ignition System............................................187
Inspection of Ignition Coil ............................ 123 Exhaust System...........................................187
Inspection of Spark Plug ............................. 124 SECM..........................................................187
Charging System ............................................. 126 SECM Wiring Diagrams for G420F ..............188
General Description .................................... 126
Troubleshooting .......................................... 128 EMS Inspection and Repair..............................189
Disassembly and Installation ....................... 134 Engine Control Module (SECM) ...................189
STARTING SYSTEM......................................... 139 Camshaft Position Sensor ...........................191
General Description .................................... 139 Crank Shaft Position Sensor ........................192
Diagnosis Procedure................................... 140 MAP (Manifold Absolute Pressure) Sensor ..193
Start Relay Tests ........................................ 142 IAT (Intake Air Temperature) .......................194

Sensor ........................................................ 194 N-2001 Regulator Service Testing .225
Oxygen Sensor (Pre-Catalyst)..................... 195 AVV (Air Valve Vacuum) Testing....227
Oxygen Sensor (Post-Catalyst) ................... 196 Connection of the MI-07 Service Tool
ECT (Engine Coolant Temperature) Sensor 197 ......................................................227
LP Fuel Temperature Sensor ...................... 199 Idle Mixture Adjustment .................228
Angle Sensor-Accelerator ........................... 200 Parts Description .........................................230
Transmission Oil Temperature Switch ......... 201 CA100 Mixer for G420F Engine .....230
Ground Speed Limit Switch (optional) ......... 202 N-2001 Regulator for G420F Engine
Electronic Throttle Body .............................. 203 ......................................................234
Chapter 6. LPG FUEL DELIVERY Chapter 7. MPI GASOLINE FUEL

SYSTEM DELIVERY SYSTEM
G420FE LP System Inspection and Repair ..... 204 Specification .....................................................239

Removal and Installation ............................. 204 Special Tools ....................................................239
Hose Connections......................... 205 Components Location......................................240
Removal and Installation of ........... 206 Fuel Pressure Test ...........................................241
N-2007 LP Regulator .................... 206 Injector ..............................................................243
Removal and Installation of CA100 Injector Inspection............................................245
Mixer for G420FE.......................... 207 Fuel Pump.........................................................247
Tests and Adjustments................................ 209
N-2007 Regulator Service Testing. 210
Chapter 8. BASIC TROUBLESHOOTING
AVV (Air Valve Vacuum) Testing... 211
AVV (Air Valve Vacuum) Testing... 212
Preliminary Checks ..........................................248
Connection of the MI-07 Service Tool
Before Starting ............................................248
..................................................... 212
Visual/Physical check ..................................248
Idle Mixture Adjustment................. 213
Basic Troubleshooting Guide ..........................249
Parts Description......................................... 216
Customer Problem Analysis Sheet...............249
CA100 Mixer for G420FE Engine .. 216
Basic Inspection Procedure .........................250
N-2007 Regulator for G420FE Engine
Connector Inspection Procedure..................251
..................................................... 218
Symptom Troubleshooting Guide Chart .......255
Basic Troubleshooting .....................................261
G420F LPG System Inspection and Repair..... 220
Intermittents.................................................261
Removal and Installation ............................. 220
Surges and/or Stumbles ..............................262
G420F Fuel System Connections.. 221
Engine Cranking but Will Not Start / Difficult to
Removal and Installation of N-2001 LP
Start ............................................................263
Regulator/Converter...................... 222
Lack of Power, Slow to Respond / Poor High
Removal and Installation of CA100
Speed Performance / Hesitation During
Mixer for G420F ............................ 223
Acceleration.................................................265
Tests and Adjustments................................ 225

Detonation / Spark Knock............................ 267
Backfire ...................................................... 268
Dieseling, Run-on ....................................... 268
Rough, Unstable, Incorrect Idle, or Stalling.. 269
Cuts Out, Misses......................................... 271
Poor Fuel Economy / Excessive Fuel
Consumption LPG Exhaust Smell ............... 272
High Idle Speed .......................................... 273
Excessive Exhaust Emissions or Odors....... 274
Diagnostic Aids for Rich / Lean Operation ... 275
Chart T-1 Restricted Exhaust System Check276
Chapter 9. ADVANCED DIAGNOSTICS
Reading Diagnostic Fault Codes..................... 277

Displaying Fault Codes (DFC) from SECM
Memory............................................................. 277
Clearing Fault (DFC) Codes............................. 277
Fault Action Descriptions................................ 278
Fault List Definitions........................................ 278
Table 1. Fault List Definitions ...................... 279
Table 2. Diagnostic Fault Codes (Flash Codes)
................................................................... 289
Appendix
Service Tool Software (MotoView) .................. 307

Service Tool Connection to SECM .............. 308
Service Tool Display ................................... 309
SECM field update with Service Tool........... 313
SECM field update with Service Tool........... 314
Ground Speed Limits (Option) ........................ 318
LPG And LPG Fuel Tanks................................ 320
Regulatory Compliance ................................... 324
Special Conditions for Safe Use ..................... 324
Abbreviations................................................... 325

Chapter 1. GENERAL INFORMATION
Precautions before Service Tightening Torque
Removal and Disassembly
Tighten the part properly to specified torque.
For prevention of wrong installation or reassembly Sealant

and for ease of operation, put mating marks to the
parts where no function is adversely affected.
Special Tool
Use specified brand of sealant.

Use of sealant other than specified sealant may
cause water or oil leaks.
Be sure to use Special Tools when their use is

specified for the operation.
Use of substitute tools will result in malfunction of
the part or damage it.
G420F(FE) Service Manual 7 Chapter 1. General Information

Replacement Part Genuine Part
When oil seal, O-ring, packing and gasket have When the part is to be replaced, be sure to use
been removed, be sure to replace them with new genuine part.
parts. For selection of appropriate parts, refer to the Parts
However, rocker cover gasket may be reused if it is Catalog.
not damaged.
Electrical System
Rubber Parts
1. Be sure to disconnect the battery cable from the

Do not stain timing belt and V-belt with oil or water.
negative(-) terminal of the battery.
Therefore, do not clean the pulley and sprocket with
detergent.
2. Never pull on the wires when disconnecting
connectors.
Oil and Grease
3. Locking connectors will click when the connector
is secure.
4. Handle sensors and relays carefully. Be careful

not to drop them or hit them against other parts.
Before reassembly, apply specified oil to the rotating

and sliding parts.

Precautions for catalytic Converter
CAUTION
If a large amount of unburned gasoline flows
into the converter, it may overheat and create a
fire hazard. To prevent this, observe the
following precautions and explain them to your
customer.
1. Use only unleaded gasoline.
2. Do net run the engine while the truck is at rest for

a long time. Avoid running the engine at fast idle
for more than 5 minutes and at idle speed for
more than 10 minutes.
3. Avoid spark-jump tests. Do spark-jumps only

when absolutely necessary. Perform this test as
rapidly as possible and, while testing, never race
the engine.
4. Do not measure engine compression for an

extended time. Engine compression tests must be
made as rapidly as possible
5. Do not run the engine when the fuel tank is nearly

empty. This may cause the engine to misfire and
create and extra load on the converter.
6. Avoid coasting with the ignition turned off and

during prolonged braking
7. Do not dispose of a used catalytic converter

together with parts contaminated with gasoline or
oil.

Tightening Torque
Tightening Torque Table of Standard Parts
Bolt nominal Torque (kgm)

Pitch(mm)
diameter(mm) Head mark 4 Head mark 7
M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6

M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1
M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5
M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0
M12 1.25 3.5 ~ 4.5 6~8
M14 1.2 7.5 ~ 8.5 12 ~ 14

M16 1.5 11 ~ 13 18 ~ 21
M18 1.5 16 ~ 18 26 ~ 30
M20 1.5 22 ~ 25 36 ~ 42
M22 1.5 29 ~ 33 48 ~ 55
M24 1.5 37 ~ 42 61 ~ 70
M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6
M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1
M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5
M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0
NOTE: The torques shown in the table are standard 1. When spring washers, toothed washers and the
vales under the following conditions. like are inserted.
1. Nuts and bolt are made of steel bar and 2. If plastic parts are fastened.
galvanized.
3. If oil is applied to threads and surfaces.
2. Galvanized plain steel washers are inserted.
NOTE: If you reduce the torques in the table to the
3. All nuts, bolts, plain washers are dry. percentage indicated below under the following
conditions, it will be the standard value.
NOTE: The torques shown in the table are not
applicable, 1. If spring washers are used : 85%
2. If threads and bearing surfaces are stained with

oil: 85%

Recommended Lubricants and Capacities
Recommended Lubricants
Lubricant Specification Remarks
Engine Oil API Classification SJ or above SAE 10W30 or SAE 5W30

Automotive antifreeze
Concentration level 50%(normal)
Coolant (Antifreeze) suitable for gasoline engines
Concentration level 40%(tropical)
having aluminum alloy parts
Lubricant Capacities
Description G(C)18S-5, G(C)20SC-5 G(C)20/25/30E-5
Oil Pan 3.7 3.7
Engine Oil (liters) Oil Filter 0.3 0.3
Total 4.0 4.0
Engine 3.0 3.0

Coolant (liters) Radiator & Hoses 5.5 5.5
Total 8.5 8.5

Engine Model and Engine Serial Indication of Engine Model and Serial
Number Number
Engine Emission
Fuel Type
Model Regulation
EPA/CARB*
G420FE LP/Dual Fuel 2007
Compliant
LP/Gasoline/Dual
G420F
Fuel
* EPA: Environmental Protection Agency
* CARB: California Air Resources Board
G420FE Engine
Comply with EPA 2007 Emission Regulation Engine Model Engine Serial Number
G420FE/G420F 30700001 to 39999999

Electronic Control by ECM
Certified LP/Dual Fuel System available Features and Benefits of G420FE/G420F Engine
Closed loop LP Carburetion system Al head with valve seat inserts

Closed loop MPI Gasoline system
Aluminum head and valve seat system
3-way Catalytic Muffler is standard
DOHC 16 valve system
G420F Engine
Durable timing belt system
Not comply with EPA 2007 Emission Regulation
Durable timing belt material and rubber-
Electronic Control by ECM sealed cover
Standard LP/Gas/DF/Dual Fuel System available Distributorless Ignition system (coil on plug)
Open loop LP Carburetion system Electronic control system by ECM

(Engine control module)
Closed loop MPI Gasoline system
Drive-by-wire system
Muffler is standard
Higher efficiency and lower fuel consumption
Min./Max. governor control
Automatic engine protection from overheating

and/or low engine oil pressure
Automatic transmission protection from

overheating
Engine diagnostics by service-tool software
Forklift ground speed limit (optional)

General Specification
G420FE Engine G420F Engine
GENERAL DESCRIPTION
ENGINE TYPE: Water-cooled, Inline 4-Cycle, 4-Cylinders
COMBUSTION SYSTEM: Semi-Rent Roof
INTAKE MANIFOLD Cast Aluminum (with injector ports)
EXHAUST MANIFOLD Cast Iron, Dry
VALVE CONFIGURATION: DOHC, 4 Valves per Cylinder
VALVE LIFTER/LASH ADJUSTER Hydraulic Lash Adjuster
VALVE ROTATOR Intake/Exhaust Rotator
CAMSHAFT DRIVE Timing belt system (25.4 mm Toothed Belt)
DISPLACEMENT: 1,975 cc (120.5 cid)
BORE x STROKE 82mm (3.23 in) x 93.5 mm (3.68 in)
BLOCK STRUCTURE Grey Cast Iron
HEAD STRUCTURE Aluminum with seat inserts
COMPRESSION RATIO: 9.4:1
COMPRESSION PRESSURE: 1,450 kPa (210 psi)
Intake Valve: 2 BTDC(Open)/ 16 ABDC(Close)
VALVE TIMING:
Exhaust Valve: 6 BBDC(Open)/ 2 ATDC(Close)
FIRING ORDER: 1-3-4-2
WEIGHT: 170 kg (Dry)
ENGINE ROTATION: Counter-Clockwise (CCW) when viewed from Flywheel End
FUEL TYPE: LPG, Gasoline, Dual Fuel (LPG or Gasoline)
CRANK VENTILATION Foul Air System with PCV
IGNTION SYSTEM
IGNITION TYPE: Distributorless (coil on plug)
IGNITION TIMING: Electronic controlled by ECM
POWER TRANSISTOR Ignition coil driver
IGNITION COIL: 12 V operation volt, 4 coils (coil on plug)
SPARK PLUGS: Platimum Spark Plug (Air Gap: 0.8mm)
LUBRICATION SYSTEM
OIL PRESSURE: 167 kPa (24 psi) @ low Idle (90-100C oil temperature)
Upper Limit: 125C (257F)
OIL TEMPERATURE: Recommended: 99 - 110C (210 - 230F)
Lower Limit:80C (176F)
OIL PAN Cast Aluminum
OIL PAN CAPACITY 3.7 L (EXCLUDES OIL FILTER)
OIL FILTER: 0.3 L
ENGINE OIL SPECIFICATION: API - SJ, SAE 10W30 or SAE 5W30
COOLING SYSTEM
WATER PUMP ROTATION: V-Belt Drive - Clockwise (CW) when viewed from engine front
THERMOSTAT: Opening Temperature: 82C (180F)
Fully Open Temperature: 95C (203F)
COOLING WATER CAPACITY: 3.0 L (block only)

General Specification
G420FE Engine G420F Engine

LP FUEL SYSTEM
Closed loop LP Carburetion
LP FUEL SYSTEM Open loop LP Carburetion System
System
Diaphragm Type Air Valve Diaphragm Type Air Valve
MIXER: Assembly inside, Downdraft Assembly inside, Downdraft
(Model: CA-100) (Model: CA-100)
Two-Stage Negative Pressure Two-Stage Negative Pressure
REGULATOR:
Regulator (Model: N-2007) Regulator (Model: N-2001)
FUEL TRIM VALVE (FTV): Dual Dither System No FTV
FUEL FILTRATION: 40 Microns Maximum 40 Microns Maximum
GASOLINE FUEL SYSTEM
GASOLINE FUEL SYSTEM Closed loop MPI System and In-Tank Fuel Pump System
FUEL PUMP MODULE Electric Fuel Pump (12V)
Fuel Filter & Strainer
Gasoline Pressure Regulator (3.5 bar)
FUEL INJECTOR ASSY Electric Fuel Injector (12V)
ENGINE ELECTRIC
ENGINE CONTROL
12 V operation volt, 48 pins of I/O
MODULE(ECM):
CRANK SENSOR Magnetic Inductive type
CAM SENSOR Hall sensor
TMAP: Intake Air Temp. & Manifold Absolute Press. Sensor
PEDAL ANGLE SENSOR: Two-Output Signals (built in Accelerator Pedal)
Gasoline : One Oxygen sensor
OXYGEN SENSOR: Dual Oxygen Sensor System
LPG: No Oxygen sensor
ECT-ECM: Engine Coolant Temperature Sensor for ECM
ECT-GAUGE Engine Coolant Temp. Sensor for GAUGE on Instrument Panel
TPS: Throttle Position Sensor (built in Throttle Body)
THROTTLE BODY: Electronic Throttle Body
LP FUEL LOCK-OFF: 12 V operation volt
ENGINE OIL PR. S/W: 28.4 kPa (4.1 psi)
STARTING MOTOR: 12 Volts, 1.7 kW
ALTERNATOR: 13.5 Volts, 90 Amp
EXHAUST SYSTEM
Muffler Catalytic Muffler Muffler (without catalyst)

Engine Power and Torque
G420FE Engine Power & Torque
FORKLIFT MODEL G(C)15/18S-5 G(C)20/25/30E-5

G420FE-DF(LP)
ENGINE MODEL G420FE-LP G420FE-DF(Gas)
& G420FE-LP
RATED POWER Kw 33.6 39.5 39.5
hp 45 53 53
PS 46 54 54
rpm 2,400 2,550 2,550
MAX TORQUE N-m 147 157 157
lbf-ft 108 116 116
kgf-m 15,0 16.0 16.0
rpm 1600 1600 1600
GOVERNED SPEED rpm 2450 2600 2600
LOW IDLE rpm 750 750 750
G420F Engine Power & Torque
FORKLIFT MODEL G(C)15/18S-5

G420F-DF(LP)
ENGINE MODEL G420F-DF(Gas) G420F-GAS
& G420F-LP
hp 45 48 49
PS 45.6 48.7 49.7
rpm 2,400 2,400 2,400
lbf-ft 108 112 114
kgf-m 15,0 15.5 15.7
rpm 1600 1600 1600
FORKLIFT MODEL G(C)20/25/30E-5

G420F-DF(LP)
ENGINE MODEL G420F-DF(Gas) G420F-GAS
& G420F-LP
hp 53 53 54
PS 53.7 53.7 54.7
rpm 2,550 2,550 2,550
lbf-ft 116 116 118
kgf-m 16.0 16.0 16.3
rpm 1600 1600 1600

Chapter 2. RECOMMENDED MAINTENANCE
Suggested maintenance requirements for an engine equipped with an MI-07 fuel system are contained in this
section. The operator should, however, develop a customized maintenance schedule using the requirements
listed in this section and any other requirements listed by the engine manufacturer.
General Maintenance Solvent or oil damage may cause vacuum lines to

become soft, resulting in a collapsed line while the
engine is running.
Test Fuel System for Leaks If abnormally soft lines are detected, replace as
necessary.
Inspect Electrical System

Check for loose, dirty or damaged connectors and
wires on the harness including: fuel lock-off, TMAP
sensor, O2 sensors, electronic throttle, control
relays, fuel trim valves, crank position sensor, and
cam position sensor.
Repair and/or replace as necessary.
Inspect Foot Pedal Operation

Verify foot pedal travel is smooth without sticking.
Obtain a leak check squirt bottle or pump spray

bottle.
Fill the bottle with an approved leak check solution.
Spray a generous amount of the solution on the
fuel system fuel lines and connections, starting at
the storage container.
Wait approximately 15-60 seconds, then perform a
visual inspection of the fuel system. Leaks will cause
the solution to bubble.
Listen for leaks
Smell for LPG odor which may indicate a leak
Repair any leaks before continuing.
Crank the engine through several revolutions. This
will energize the fuel lock-off and allow fuel to flow to
the pressure regulator/converter. Apply additional
leak check solution to the regulator/ converter fuel
connections and housing. Repeat leak inspection as
listed above.
Repair any fuel leaks before continuing.
Inspect Engine for Fluid Leaks

Start the engine and allow it to reach operating
temperatures.
Turn the engine off.
Inspect the entire engine for oil and/or coolant
leaks.
Repair as necessary before continuing.
Inspect Vacuum Lines and Fittings

Visually inspect vacuum lines and fittings for
physical damage such as brittleness, cracks and
kinks. Repair/replace as required.
G420F(FE) Service Manual 16 Chapter 2. Recommended Maintenance

Engine Oil Classification
Recommended API classification: Above SJ

Recommended SAE viscosity classification
*1. 10W-30 engine oil is recommended

If 10W-30 is not applicable, proper engine oil will be possible according to temperature ranges.
The following lubricants should be selected for all

engines to enhance excellent performance and
maximum effect.
1. Observe the API classification guide.
2. Proper SAE classification number should be

selected within ambient temperature ranges. Do
not use the lubricant with SAE classification
number and API grade not identified on the
container.

Checking Engine Oil Level Replacing Engine Oil and Filter
CAUTION
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants which may cause skin
cancer.
Exercise caution in order to minimize the length
and frequency of contact of your skin to used oil.
In order to preserve the environment, used oil
and used oil filter must be disposed of only at
designated disposal sites.
1. Drain engine oil.
1) Remove the oil filler cap.
2) Remove the oil drain plug, and drain the oil into
a container.
2. Replace oil filter.
1) Remove the oil filter.
2) Check and clean the oil filter installation

surface.
3) Check the part number of the new oil filter is as

same as old one.
4) Apply clean engine oil to the gasket of a new

oil filter.
5) Lightly screw the oil filter into place, and

tighten it until the gasket contacts the seat.
1. Check that the oil level is between MIN and 6) Tighten it an additional 3/4 turn.
Max marks on the engine oil level gauge.
3. Refill with engine oil filter.
2. If the oil level is below MIN mark, add oil until
the level is within the specified ranges. 1) Clean and install the oil drain plug with a new
gasket.
3. Check the engine for oil contamination and
viscosity and replace if necessary.
39.2~44.1N.m(4.0~4.5kgf.m,
Torque
28.9~32.5lb-ft)
2)Fill with fresh engine oil.
Capacity Drain
4.0L(4.23US qts, 3.52Lmp qts)
and refill
Oil filter 0.3L(0.32US qts, 0.26Lmp qts)

Standard 15kg/
3) Install the oil filler cap. Standard(250~400rpm)
Limit 14kg/
4. Start engine and check for oil leaks.
8. Follow the procedures (no.6-7) to each cylinder
and check that compressed pressure values of all
5. Recheck engine oil level.
cylinders are within the limit.
Checking Compressed Pressure Limit 1.0kg/
9. If any of all cylinders is out of limit, add a small

amount of engine oil to the spark plug hole, and
re-proceed the procedures (no.6-7) to the cylinder.
At this time, if the compressed pressure is increased,

it means that the piston, piston ring or cylinder
surface are worn or damaged, and if the
compressed pressure is decreased, it means that
the valve is clogged, the valve contact is faulty, or
the pressure leaks through gasket.
CAUTION
1. Prior to inspection, check that the engine oil,
If a large amount of incomplete combustion
starter motor and battery are normal.
gaso-line comes into the catalytic converter,
emergency such as a fire can occur due to
2. Start the engine and run it until the engine coolant
overheating. So this job should be done quickly
temperature reaches 80 ~ 95C.
with the engine not operated.
3. Stop the engine and disconnect the ignition coil
and air cleaner element.
4. Remove the spark plug.
5. After opening the throttle valve completely, crank

the engine to remove foreign material from the
cylinder.
CAUTION
At this time, necessarily screen the spark plug
hole with a rag. Because hot coolant, oil, fuel,
and other foreign material, being penetrated in
the cylinder through cracks can come into the
spark hole during checking compressed
pressure.
When cranking the engine to test compressed
pressure, necessarily open the throttle valve be-
fore cranking.
6. Install the compression gauge to the spark plug

hole.
7. With the throttle valve opened, crank the engine

to measure the compressed pressure.

Adjusting Timing Belt Tension
7. Install the timing belt upper cover (A) and tighten
the bolt(B).
Tightening torque 0.8~1.0kgm
Adjust the tension as the following order.
1. Remove the fan drive bracket.
2. Loosen the timing belt upper cover bolt (B) and

disconnect the upper cover (A).
3. As the illustration, insert the hex wrench to the

adjuster groove and turn it counterclockwise to
move the arm indi-cator in the middle of the base
groove.
CAUTION
If it is turned in reverse direction, be sure that
the tensioner may function abnormally.
4. Tighten the tensioner fixing bolt with the arm

indicator fixed.
Tightening torque 2.3~2.9kgfm
5. Rotate the crankshaft 2 turns clockwise and make

sure the auto tensioner arm indicator is placed in
the middle of the base groove.
6. If the arm indicator is out of the middle, loosen the

bolt and repeat the previous procedure.

Cooling System Maintenance Antifreeze
DOOSAN recommends selecting automotive
antifreeze suitable for gasoline engines using
Coolant Recommendation aluminum alloy parts. The antifreeze should meet
ASTM-D3306 standard.
The engine cooling system is provided with a
mixture of 50% ethylene glycol anti-freeze and 50% Check Coolant Level
water (For the vehicles of tropical area, the engine
cooling system is provided with a mixture of 40%
The items below are a general guideline for
ethylene glycol anti-freeze and 60% water at the
system checks. Refer to the engine manufacturers
time of manufacture.)
specific recommendations for proper procedures.
Since the cylinder head and water pump body are
Engine must be off and cold.
made of aluminum alloy casting, be sure to use a 30
to 60% ethylene glycol antifreeze coolant to assure
corrosion protection and freezing prevention. WARNINGPROPER USE
Never remove the pressure cap on a hot engine.
CAUTION
If the concentration of the antifreeze is below The coolant level should be equal to the COLD
30%, the anticorrosion property will be adversely mark on the coolant recovery tank.
affected. In addition, if the concentration is
above 60%, both the antifreeze and engine Add approve coolant to the specified level if the
cooling properties will decrease, adversely system is low.
affecting the engine. For these reasons, be sure
to maintain the concentration level within the Inspect Coolant Hoses
specified range.
Visually inspect coolant hoses and clamps.
Remember to check the two coolant lines that
Coolant Water connect to the pressure regulator/converter.
Hard water, or water with high levels of calcium and
magnesium ions, encourages the formation of Replace any hose that shows signs of leakage,
insoluble chemical compounds by combining with swelling, cracking, abrasion or deterioration.
cooling system additives such as silicates and
phosphates.
The tendency of silicates and phosphates to

precipitate out-of-solution increases with increasing
water hardness. Hard water, or water with high
levels of calcium and magnesium ions encourages
the formation of insoluble chemicals, especially after
a number of heating and cooling cycles.
DOOSAN prefers the use of distilled water or

deionized water to reduce the potential and severity
of chemical insolubility.
Acceptable Water
Water Content Limits (pps)
Chlorides (CI) 40 maximum
Sulfates (SO4) 50 maximum
Total Hardness 80mg/ maximum
Total Solids 250 maximum
pH 6.0 ~ 8.0
ppm = parts per million

Checking coolant leaks
1. After the coolant temperature drops below 38C

loosen the radiator cap.
2. Check that the coolant level reaches filler neck.
3. Install the radiator cap tester to the radiator filler

neck and apply a pressure of 1.4kg/cm2 .
While maintaining it for 2 minutes, check the
radiator, hose, and connecting part for leak.
CAUTION
Because the coolant in the radiator is too hot,
never open the cap when it hot, or injury may
occur due to an outburst of hot water.
Dry out the inspection part.
When removing the tester, take care not to spill
the coolant.
When removing/installing the tester as well as
testing, take care not to deform the filler neck.
4. Replace parts if leak is detected.
Specific gravity test
1. Measure specific gravity of the coolant using a

hydrometer.
2. After measuring the coolant temperature,

calculate specific gravity using the following table.
Relation between Coolant concentration and Specific Gravity
Temperature and Specifiv gravity of coolant (Temp.:) Freezing Coolant Concentration

10 20 30 40 50 temp() (Specific Volume)
1.054 1.050 1.046 1.042 1.036 -16 30%
1.063 1.058 1.054 1.049 1.044 -20 35%
1.071 1.067 1.062 1.057 1.052 -25 40%
1.079 1.074 1.069 1.064 1.058 -30 45%
1.087 1.082 1.076 1.070 1.064 -36 50%
1.095 1.090 1.084 1.077 1.070 -42 55%
1.103 1.098 1.092 1.084 1.076 -50 60%

Checking and Adjusting Drive Belt
1. Checking tension
1) Press the middle of the water pump pulley and

alternator pulley with 10kgf.
2) Inspect the belt deflection by pressing it.
3) If the belt deflection is out of the standard,

adjust it as follows.
Standard
Item
New belt Used belt 1) Type
Drive belt deflection (L) 4.0~4.4mm 5.1~5.7mm
BORROUGHS BT - 33 - 73F
2. Using a tension gauge NIPPONDENSO BTG 2
2) How to use
Insert the belt between the gauge hook and

spindle and press the tension gauge handle.
Leave the handle and read the gauge.
Standard
Tension(T) New belt Used belt
65~75kg 40~50kg
CAUTION
The belt used over 5 minutes should be ad-
justed as used belt of standard
Check that the belt is installed correctly.
When the belt is loosened, slip noise is heard.

Adjusting Checking Belt for Damage
Crank
pulley
1. Loosen the alternator support bolt A nut and Check the following items and replace the belt if
adjusting lock bolt B. defective.
2. Adjust the belt tension by moving the alternator 1. Check the belt surface for damage, wear and
brace adjusting bolt to T direction. crack.
Alternator adjusting lock bolt B 1.2~1.5kgm 2. Check the belt surface for oil or grease
contamination.
Alternator support bolt A 2~2.5kgm
3. Check the rubber part for wear or hardening.
3. Tighten the bolt A and then tighten B to the
4. Check the pulley surface for crack or damage.
specified torque.
CAUTION
If the belt tension is too excessive, noise as well
as early wear of belt occurs and the water pump
bearing and alternator bearing are damaged.
If the belt is too loose, due to early wear of belt
and insufficient power of alternator, battery and
water pump become inefficient and finally en-
gine is overheated or damaged.

Ignition System Maintenance
CAUTION
Inspect Battery System Because ignition timing is fixed by set data
value in ECU, it is impossible to control on
Clean battery outer surfaces with a mixture of
purpose.
baking soda and water.
Fist, check that sensors send output properly to
Inspect battery outer surfaces for damage and help determine ignition timing control.
replace as necessary.
Remove battery cables and clean, repair and/or NOTE: Affective ECU input to lgnition timing control
Coolant temperature sensor
Oxygen sensor
Inspect Ignition System
Battery voltage
MAP sensor (Engine load)
Remove and inspect the spark plugs. Replace as Crankshaft position sensor
required. Throttle position sensor
Intake Air Temperature sensor
Inspect the ignition coil for cracks and heat
deterioration. Visually inspect the coil heat sink 5) Check that actual ignition timing is changed
fins. If any fins are broken replace as required. with engine RPM increased.
Inspection of Ignition Timing
1. Inspection condition
Coolant temperature : 80-90C(At normal

Temperature)
Lamp and all accessories : OFF
Transmission : In neutral position
Parking brake : ON
2. Inspection
1) Connect the timing light.
2) Measure RPM.
RPM
Low Idle 75015rpm
NOTE: If RPM is not normal, it is impossible to

measure the proper ignition timing, so measure it at
a normal RPM.
3) Inspect the standard ignition timing.
BTDC 55
4) If ignition timing is out of the standard, inspect

sensors concerned with ignition timing.

Inspection of Spark Plug
Inspection and clean
3. Check the spark plug as below.
1) Insulator broken
2) Terminal worn
3) Carbon deposit
4) Gasket damaged or broken
5) Porcelain insulator of spark plug clearance
1) Ignition wire Assy

2) Ignition coil Assy
3) Spark plug
1. Disconnect the ignition wire assy from ignition

coil assy.
Remove the ignition coil assy by pulling the ignition
coil hand.
2. Remove all spark plugs from the cylinder head

4. Check the plug clearance using a plug clearance
using a sparkplug wrench.
gauge and if the value is not within the specified
values, adjust it by bending the ground clearance.
CAUTION When installing a new sparkplug, install it after
checking the uniform plug clearance.
Take care not to come foreign materials into
spark-plug mounting hole.
Spark plug clearance 0.7~0.8mm

5. Install the spark plug and tighten it to the specified
torque.
Take care not to over tighten it to prevent cylinder
head threads from damage.
Tightening torque 2~3kgm
SPARK PLUG ANALYSIS
Contact point is Contact point is

State
black white
Density of the
Density of the
Description fuel mixture is
fuel mixture is thin
thick
Lack of air Ignition timing is
intake fast
Spark plug is
tight
Lack of torque

Fuel System Maintenance 8. Re-assemble the filter assembly aligning the
scribe lines on the top and bottom covers.
Replace LP Fuel Filter Element 9. Install the cover retaining screws, tightening the
screws in an opposite sequence across the cover.
Park the lift truck in an authorized refueling area with
the forks lowered, parking brake applied and the 10. Open the fuel valve by slowly turning the valve
transmission in Neutral. counterclockwise.
11. Crank the engine several revolutions to open the

fuel lock-off. DO NOT START THE ENGINE.
Turn the ignition key switch to the off position.
12. Check the filter housing, fuel lines and fittings for
leaks. Repair as necessary.
1. Close the fuel shutoff valve on the LP-fuel tank.

Run the engine until the fuel in the system runs
out and the engine stops.
2. Turn off the ignition switch.
3. Scribe a line across the filter housing covers,

which will be used for alignment purposes when
re-installing the filter cover.
FUEL FILTER DISASSEMBLY (Steps 4-7)
4. Remove the cover retaining screws (1).
5. Remove top cover (2), magnet (3), spring (4), and

filter element (7) from bottom cover (5).
6. Replace the filter element (7).
7. Check bottom cover O-ring seal (6) for damage.

Replace if necessary.

Testing Fuel Lock-off Operation
Start engine. Pressure Regulator/Converter

Inspection
Locate the electrical connector for the fuel lock (A).
Visually inspect the pressure regulator/converter
Disconnect the electrical connector.
(B) housing for coolant leaks.
The engine should run out of fuel and stop within a
Refer to Chapter 5 if the pressure
short period of time.
regulator/converter requires replacement.
Fuel Trim Valve Inspection (FTV)
Visually inspect the fuel trim valves (C) for

NOTE
abrasions or cracking. Replace as necessary.
The length of time the engine runs on trapped fuel To ensure a valve is not leaking a blow-by test can
vapor increases with any increase in distance be performed.
between the fuel lock-off and the pressure
regulator/converter. 1. With the engine off, disconnect the electrical
connector to the FTVs.
Turn the ignition key switch off and re-connect the 2. Disconnect the vacuum line from the FTVs to the
fuel lock-off connector. pressure regulator/converter at the converters
tee connection.
3. Lightly blow through the vacuum line connected to

the FTVs.
Air should not pass through the FTVs when de-
energized.

If air leaks past the FTVs when de-energized, Exhaust System Maintenance
replace the FTVs.
Inspect Engine for Exhaust Leaks
Inspect Air/Fuel Valve Mixer Assembly
Start the engine and allow it to reach operating
Refer to Chapter 5 for procedures regarding the temperatures.
LP mixer (D).
Perform visual inspection of exhaust system from
Inspect for Intake Leaks the engine all the way to the tailpipe. Any leaks,
even after the post-catalyst oxygen sensor, can
Visually inspect the intake throttle assembly (E), cause the sensor output to be effected (due to
and intake manifold for looseness and leaks. exhaust pulsation entraining air upstream).
Repair as necessary. Repair any/all leaks found. Ensure the length
from the post-catalyst sensor to tailpipe is the
Inspect Throttle Assembly same as original factory.
Visually inspect the throttle assembly motor Ensure that wire routing for the oxygen sensors is
housing for coking, cracks, and missing cover- still keeping wires away from the exhaust system.
retaining clips. Repair and/or replace as Visually inspect the oxygen sensors to detect any
necessary. damage.
NOTE: Refer to Chapter 5 for procedures on

removing the mixer and inspecting the throttle plate.
Checking the TMAP Sensor
Verify that the TMAP sensor (F) is mounted tightly

into the manifold or manifold adapter (E), with no
leakage.
If the TMAP is found to be loose, remove the

TMAP retaining screw and the TMAP sensor from
the manifold adapter.
Visually inspect the TMAP O-ring seal for damage.

Replace as necessary.
Apply a thin coat of an approved silicon lubricant

to the TMAP O-ring seal.
Re-install the TMAP sensor into the manifold or

manifold adapter and securely tighten the
retaining screw.

Maintenance Schedule
NOTE: The MI-07 fuel system was designed for use with LPG fuel that complies with HD5 or HD10 LPG fuel
standards. Use of non-compliant LPG fuel may require more frequent service intervals and will disqualify the
user from warranty claims.

Chapter 3. ENGINE MECHANICAL SYSTEM
General Information
Engine Outline
G420F(FE) Service Manual 33 Chapter 3. Engine Mechanical System

Specifications
Description Specification Limit

GENERAL
Type
Cylinder number In-line, DOHC
Bore 4
Stroke 82 mm
Displacement 93.5 mm
Compression ratio 1,975 cc
Firing order 1-3-4-2
Low idle 75015 rpm
Ignition timing @ low idle BTDC 55
Valve timing
Intake
Open BTDC 2
Close ABDC 16
Exhaust
Open BBDC 6
Close ATDC 2
Valve over rap 4
CYLINDER HEAD
Flatness of gasket surface 0.03 mm or less 0.06mm
Flatness of manifold mounting surface 0.15 mm or less 0.3mm
Oversize of valve seat hole
Intake
0.3 mm OS 33.3 ~ 33.325 mm 0.2mm
0.6 mm OS 33.6 ~ 33.625 mm
Exhaust
0.3 mm OS 28.8 ~ 28.821 mm
0.6 mm OS 29.1 ~ 29.121 mm
Oversize of valve guide hole
0.05 mm OS 11.05 ~ 11.068 mm
0.25 mm OS 11.25 ~ 11.268 mm
0.50 mm OS 11.50 ~ 11.518 mm
CAMSHAFT
Cam height
Intake 43 mm
Exhaust 43 mm
Journal O.D 28 mm
Bearing oil clearance 0.02 ~ 0.061 mm
End play 0.1 ~ 0.2 mm

VALVE
Stem O.D
Intake 5.965 ~ 5.980 mm
Exhaust 5.950 ~ 5.965 mm
Thickness of valve head (Margin)
Intake 1.15 mm 0.8 mm
Exhaust 1.35 mm 1.0 mm
Valve stem to guide clearance
Intake 0.02 ~ 0.05 mm 0.1 mm
Exhaust 0.035 ~ 0.065 mm 0.13 mm
VALVE GUIDE
Installed size Intake : 46, Exhaust : 54.5
Over size(O.D) 0.05, 0.25, 0.50 mm
VALVE SEAT
Seat angle 45
Over size 0.3 mm, 0.6 mm
VALVE SPRING
Free length 48.86 mm
Load 18.3kg/39 mm
40.0kg/30.5 mm
Installed height 39 mm
Out-of squareness 1.5 or less 3
CYLINDER BLOCK
Cylinder I.D 82.00 ~ 82.03 mm
Out-of cylindricity of cylinder I.D Less than 0.01 mm
Cylinder block-to-piston clearance 0.02 ~ 0.04 mm
PISTON
O.D 81.97 ~ 82.00 mm
Over size 0.25, 0.50, 0.75, 1.00 mm
PISTON RING
Side clearance
No.1 0.04 ~ 0.08 mm 0.1 mm
No.2 0.03 ~ 0.07mm 0.1 mm
End gap
No.1 0.23 ~ 0.38 mm
No.2 0.33 ~ 0.48 mm 1.0 mm
Oil ring side rail 0.2 ~ 0.6 mm 1.0 mm
Over size 0.25, 0.50, 0.75, 1.00 mm 1.0 mm
CONNECTING ROD
Bend 0.05 mm or less
Twist 0.10 mm or less
Side clearance 0.100 ~ 0.250 mm 0.4 mm

CONNECTING ROD BEARING
Oil clearance 0.024 ~ 0.044 mm
Under size 0.25, 0.50, 0.75 mm
CRANKSHAFT
Pin O.D 45 mm
Journal O.D 57 mm
Bend Less than 0.03 mm
Out-of cylindricity of journal and pin Less than 0.01 mm
End play 0.06 ~ 0.260 mm
Under size of pin
0.25 mm 44.725 ~ 44.740 mm
0.50 mm 44.475 ~ 44.490 mm
0.75 mm 44.225 ~ 44.240 mm
Under size of journal
0.25 mm 56.727 ~ 56.742 mm
0.50 mm 56.477 ~ 56.492 mm
0.75 mm 56.227 ~ 56.242 mm
OIL PUMP
O.D-to-front case clearance
Front side clearance 0.12 ~ 0.185 mm
Tip clearance
Outer gear 0.025 ~ 0.069 mm
Inner gear 0.04 ~ 0.09 mm
Oil pressure (Oil temperature 90C~100C) 0.04 ~ 0.085 mm
at idle (750rpm) 166kpa (1.7kg/cm2)
RELIEF SPRING
Free height 43.8 mm
Load 3.7kg/40.1 mm
Water pump type Centrifugal impeller
THERMOSTAT
Thermostat type Wax pellet type with jiggle valve
Valve open temperature 82C 1.5C
Fully open temperature 95C
WATER TEMPERATURE SENSOR
Type Thermister
Resistance(at 20C) 2.31K ~ 2.59K

Torque Specification
Description Standard (kg.m)

Cylinder block
Engine support bracket bolt and nut 3.5 ~ 5.0
Cylinder head
Cylinder head bolt
M10 2.5+(60~ 65) + (60~ 65)
M12 3.0+(60~ 65) + (60~ 65)
Intake manifold bolt and nut 1.6 ~ 2.3
Exhaust manifold nut 4.3 ~ 5.5
Cylinder head cover bolt 0.8 ~ 1.0
Camshaft bearing cap bolt 1.4 ~ 1.5
Rear plate bolt 0.8 ~ 1.0
Main moving
Connecting rod cap nut 5.0 ~ 5.3
Crankshaft bearing cap bolt 2.7 ~ 3.3+(60~ 65)
Flywheel bolt 12.0 ~ 13.0
Chain guide 0.8 ~ 1.0
Starter bolt 2.7 ~ 3.4
Timing belt
Crankshaft pulley bolt 17 ~ 18
Camshaft sprocket bolt 10 ~ 12
Timing belt tensioner bolt 4.3 ~ 5.5
Timing belt idler bolt 4.3 ~ 5.5
Timing belt cover bolt 0.8 ~ 1.0
Front case bolt 2.0 ~ 2.7
Lubrication System
Oil filter 1.2 ~ 1.6
Oil pan bolt 1.0 ~ 1.2
Oil pan drain plug 3.5 ~ 4.5
Oil screen bolts 1.5 ~ 2.2
Oil pressure switch 1.3 ~ 1.5
Cooling System
Thermostat inlet fitting nut 1.5 ~ 2.0
Thermostat housing mounting nut 1.5 ~ 2.0
Water pump mounting bolt 2.0 ~ 2.7
Alternator brace bolt 2.0 ~ 2.7
Coolant temperature sensor 2.0 ~ 4.0
Alternator support bolt and nut 2.0 ~ 2.5
Water pump pulley 0.8 ~ 1.0
Water pipe bracket bolt 1.2 ~ 1.5
Intake and Exhaust System
Intake manifold to cylinder head bolt 1.6 ~ 2.3
Intake manifold cover to intake manifold bolt 1.8 ~ 2.5
Throttle body and Surge tank nut 1.5 ~ 2.0
Exhaust manifold to cylinder head bolt 4.3 ~ 5.5
Exhaust manifold cover to exhaust manifold bolt 1.5 ~ 2.0
Oxygen sensor to exhaust manifold bolt 5.0 ~ 6.0

Special Tools
Tool (number and name) Illustration Use
Crankshaft front oil seal installer

Installation of front oil seal
(09214-32000)
Crankshaft front oil seal guide

Installation of front oil seal
(09214-32100)
Camshaft oil seal installer

Installation of camshaft oil seal
(09221-21000)
Valve guide installer Removal and installation of valve

(09221-22000(A/B)) guide
Cylinder head bolt wrench Removal and tightening of cylinder

(09221-32001) head bolt
Valve stem oil seal installer

Installation of valve stem oil seal
(09222-22001)
Valve spring compressor holder

Removal and installation of piston
and adaptor
pin (Use with 09234-33003)
(09222-28000, 09222-28100)

Tool (number and name) Illustration Use
Valve stem seal remover

Removal of valve stem seal
(09222-29000)
1. Installation of engine rear oil

Crankshaft rear oil seal installer seal
(09231-21000) 2. Installation of crankshaft rear oil
seal
Removal and installation of intake

Piston pin removal and installation
and exhaust valve
kit (09234-33001)
(Use with 09222-29000)
Piston pin setting tool insert Removal and installation of piston

(09234-33002) pin (Use with 09234-33001)

Troubleshooting
Symptom Possible cause Remedy
Cylinder head gasket damaged Replace gasket
Worn or damaged piston ring Replace ring
Low compression
Worn piston or cylinder Repair or replace piston and cylinder block
Worn or damaged valve seat Repair or replace valve and seat ring
Insufficient engine oil Check engine oil level
Oil pressure switch defective Replace oil pressure switch
Oil filter clogged Install new filter
Low oil pressure Worn oil pump gear or cover Replace
Thin or diluted engine oil Replace engine oil
Oil relief valve clogged(Open) Replace or inspect
Excessive bearing clearance Replace bearing
High oil pressure Oil relief valve clogged(Closed) Repair relief valve
Thin or diluted engine oil Replace engine oil
Noisy valve Faulty HLA Replace HLA
Worn belt stem or valve guide Replace belt stem or valve guide
Insufficient engine oil Check engine oil level
Noisy connecting rod Low oil pressure Refer to too low oil pressure
or timing belt Thin or diluted engine oil Replace engine oil
Excessive bearing clearance Replace bearing
Noisy timing belt Incorrect belt tension Correct belt tension
Coolant leak from
Heater or radiator hose Repair or replace parts
Defective radiator cap Retighten clamp or replace
Low coolant level
Thermostat housing Replace gasket or housing
Radiator Replace
Water pump Replace parts
Radiator clogged Foreign material into coolant Replace coolant
Thermostat defective Replace parts

Radiator cap defective Replace parts
Abnormal flow in cooling system Clean or replace parts
Loose or missing driving belt Correct or replace
Abnormally high
Loose water pump Replace
coolant temperature
Water temperature wiring defective Cooling pan Repair or replace
defective Repair or replace
Radiator or thermostat switch defective Replace
Inefficient coolant Add coolant
Abnormally low coolant Thermostat defective Replace
temperature Water wiring defective Repair or replace
Loose connecting part
Oil cooling system leak Retighten Replace
Cracked or damaged hose, pipe, and oil cooler
Loose connecting part Retighten
Exhaust gas leak
Pipe or muffler damaged Repair or replace
Breakaway exhaust plate in muffler Replace
Rubber hanger damaged Replace
Pipe or muffler with body Interfered Repair
Abnormal noise
Pipe or muffler damaged Repair or replace
Catalytic converter damaged Replace
Each connecting gasket damaged Replace

Timing Belt System
Components
1. Timing belt upper cover. 4. Cylinder head cover 7. Crankshaft sprocket

2. Camshaft sprocket 5. Idler 8. Timing belt lower cover
3. Timing belt 6. Tensioner 9. Flange
10. Crankshaft pulley

Removal
9. Remove the timing belt tensioner pulley.
1. Temporarily loosen the water pump pulley bolts.
2. Loosen the alternator bolt and remove the belt.
3. Remove the water pump pulley.
4. Remove the timing belt upper cover.
10. Remove the timing belt form the camshaft

sprocket.
NOTE: When reusing the timing belt, put an arrow

mark on the rotation direction (or front side of
engine)before removal to help re-install it to
original installation direction.
5. Turn the crankshaft, and align its groove with 11. Remove the idler.
timing mark T
12. Remove the crankshaft sprocket.
13. Remove the cylinder head cover and remove

camshaft sprocket.
6. Remove the crankshaft pulley.
7. Remove the crankshaft flange.
8. Remove the timing belt lower cover.

Inspection
SPROCKET, TENSIONER, IDLER
1. Check the camshaft sprocket, crankshaft sprocket,

tensioner and idler for wear, crack and damage
and replace it if necessary.
2. Check the tensioner and idler pulley for smooth

rotation, check for play and noise, and replace it if
necessary.
3. If grease leak is inspected, replace it.
TIMING BELT
1. Check the belt for oil or dust deposit and replace

it if necessary. In case of small amount of oil or
dust, clean it with a rag or paper instead of a
solvent.
2. After overhauling the engine or readjusting the

belt, inspect the belt in detail and replace it with a
new one if the following defects are detected.
CAUTION
Do not bend or twist the timing belt.
Take care not to contact the timing belt with oil,
water, grease and steam.

Description Specification
Glossy back side. Due to

non-elasticity and hardening,
1. Back side rubber is hardened when pressing it with the tip of
a finger, there is no sign of it.
2. Back side rubber is cracked
3. Canvas is cracked or detached
Tooth loaded from canvas is

worn (elastic canvas fiber rubber
4. Tooth is excessively worn out (initial step) is worn, color is faded in white,
canvas structure is deformed)
Tooth loaded from canvas is

5. Tooth is excessively worn out (final step)
Worn and rubber is worn off
(tooth width is narrowed)
6. Tooth bottom is cracked
7. Tooth is missing
8. The side of belt is severely worn out
NOTE: In case of normal

9. The side of belt is cracked belt, it is cut precisely as
if cut with a sharp cutter

Assembly 4. With no.1 cylinder piston to the dead point of
compression stroke, align the timing mark on the
camshaft sprocket and timing mark on the
crankshaft sprocket.
1) After installing the tensioner, spring and spacer

and tightening the bolt temporarily, tighten the
long hole shaft washer of tensioner and bolt.
2) Install the spring bottom end to the front case

as shown in the illustration.
3) Install the flange and crankshaft sprocket

taking care of installation direction and then
tighten the washer and bolt temporarily.
1. Install the crankshaft sprocket taking care of
installation direction as shown in the illustration. 4) When aligning the timing marks, after turning
the cam-shaft sprocket to place the red timing
mark on the cam cap in the middle of the
knock pin 4.5 bore, align this timing mark with
the timing mark on the front case by rotating
the shaft sprocket.
5) Install the belt with the timing aligned as shown

in the illustration. (When installing, start from
the belt tension side and then install the belt by
pressing the tensioner.
CAUTION
When no.1 piston is at TDC, if the camshaft
sprocket mark is not aligned with head mark,
interference between piston and valve occurs.
So take care of timing aligning.
2. Install the camshaft sprocket and tighten the bolt

to the specified torque.
Camshaft sprocket bolt 10 ~ 12kgm
3. Install the idler and tighten the bolt to the 6) Install the timing belt not to loosen in the
specified torque. following order.
Crankshaft sprocket (A) Idler pulley (B)

Idler fixing bolt 4.3 ~ 5.5kgm
Camshaft sprocket (C) Timing belt tensioner (D).
(After installing timing belt, auto tensioner may be

installed)

13) Install the timing belt lower cover.
Tightening torque 0.8 ~ 1.0kgfm
7) Be sure that timing mark on each sprocket is

placed on the proper position.
8) Remove the tensioner arm fixing pin.
9) Insert a hexagonal wrench to the adjuster 14) Install the crankshaft pulley (A) together with
groove as below, rotate it counterclockwise to the flange, tighten the bolt (B).
place the arm indicator in the middle of base When installing, align the crankshaft key with
groove. the pulley groove.
Crankshaft pulley bolt
CAUTION
Do not rotate the wrench clockwise, or the auto
tensioner is not normally functioned.L4GC144A
15) Install the timing belt upper cover.
16) Install the water pump pulley.
17) Install the alternator driving belt.
18) Tighten the water pump pulley fixing bolt.
10) With the arm indicator fixed not to move,

tighten the tensioner fixing bolt.
11) Rotate the crankshaft to 2 turns clockwise

and then be sure that the auto tensioner arm
indicator is placed in the middle of base
groove.
12) If the arm indicator is out of the middle of

groove, loosen the bolt and repeat the above
procedure.

PCV Valve
Outline and Operation Principle
Engine condition No operating Engine condition At idle or deceleration

PCV valve No operating PCV valve Full operating
Vacuum path Clogged Vacuum path Small
Engine condition Proper operating Engine condition High speed and overload
PCV valve Proper operating PCV valve Light operating
Vacuum path Big Vacuum path Very big

Service Procedure TROUBLESHOOTING
REMOVAL
1. Disconnect the vacuum hose from the PCV valve.

1. After disconnecting the vacuum hose (A), remove Disconnect the PCV valve from the locker cover
the PCV valve (B). and reconnect the vacuum hose.
INSTALLATION 2. With the engine at idle, Check the intake manifold

for vacuum when clogging the opened end of
Install the PCV valve and connect the vacuum hose. PCV valve.
NOTE: The plunger in PCV valve will move back

and forth.
3. If vacuum is not detected, clean or replace PCV

valve and vacuum hose.
INSPECTION
1. Remove the PCV valve.
2. Check the plunger for movement by inserting a

thin stick (A) toward the valve (B) nut.
3. If the plunger is not moved, it means that PCV

valve is clogging, so, clean or replace PCV valve.

Intake and Exhaust System
Intake Manifold
Components
COMPONENTS
MAP sensor

REMOVAL INSTALLATION
1. Disconnect the map sensor and the connector. 1. After replacing the intake manifold gasket, install
it to the cylinder head and then to the intake
2. Remove the P.C.V valve hose. manifold.
3. Disconnect the fuel injector connector and the 2. Install the delivery pipe and injector assembly to
wiring harness. the intake manifold.
4. Remove the delivery pipe with the fuel injector

attached.
CAUTION
Check that the injector is interfered with the
injector hole in the intake manifold.
CAUTION
When removing the delivery pipe, take care not
to drop the injector. 3. Install the fuel injector connector and wiring
harness.
5. Remove the intake manifold stay. 4. Connect the high-pressure fuel hose.
6. Remove the intake manifold and gasket. 5. Connect the P.C.V valve hose.
INSPECTION 6. Check connectors for connection.
1. Intake manifold
Check each component for damage and crack.
2. Air hose
Check each component for damage and crack.

Exhaust Manifold
COMPONENTS
CAUTION
Do not tighten parts excessively, observe the
specified torque.

REMOVAL
1. Remove the heat protector.
2. Detach the exhaust manifold from the cylinder

head.
INSPECTION
1. Check the exhaust manifold for damage and

crack.
2. Exhaust manifold gasket

Check the gasket for tear or damage.
INSTALLATION
1. Installation is the reverse order of removal.
CAUTION
Do not reuse the exhaust manifold nut.

Cooling System
General Description
Cooling System Schematic

(1) Cylinder head. (2) Thermostat. (3) Recovery tank. (5) Radiator top hose. (6) Radiator pressure cap.
(7) Cylinder walls. (8) Radiator. (9) Radiator lower hose. (10) Water pump.
Water pump (10) is installed on the front of the thermostat (2) is open the coolant will go through
cylinder block. The water pump is driven by a single radiator top hose (5) and into the top tank of radiator
V belt from the crankshaft pulley. The inlet opening (8). Coolant then goes through the cores of the
of the water pump is connected to the radiator lower radiator. The air from the fan will make the coolant
hose (9). The outlet flow from the water pump goes cool as the coolant flows to the bottom of the
through passages inside the cylinder block. radiator and out hose (9) where the coolant returns
The coolant from the water pump through the to water pump (10).
cylinder block passages has primary coolant flow to The radiator is equipped with a shroud to increase
and around the seats for the exhaust valves. This the efficiency of the fan and cause the air to be
method gives the coolant with the coolest pushed through the radiator and away from the lift
temperature flow to the hottest area during engine truck.
operation. If the coolant is hot and the cooling system pressure
Cylinder walls (7) are cooled by the coolant flow is too high, some coolant flows to the top of radiator
through the block. After the coolant goes through the (8) through the tube to recovery tank (3). The
cylinder block it flows through cylinder head (1) to cooling system pressure is controlled by cap (6).
the thermostat housing, where the bypass type When the cooling system pressure goes above its
thermostat (2) is installed. The thermostat controls rated pressure, a valve opens in pressure cap (6)
the opening to radiator (8) to control the temperature which releases the cooling system pressure to the
in the cooling system. atmosphere. After the engine is at normal
If the coolant is cold (cool), the thermostat will be temperature for operation, a development of vacuum
closed. The coolant circulates (makes a complete is present in the cooling system. Pressure cap (6)
circuit) from the water pump and through the permits air in the radiator to remove the vacuum at
cylinder block until the temperature of the coolant is the same time coolant from recovery tank (3) is
warm enough to make the thermostat open. When pulled back into the radiator.

Testing and Adjusting 5. Inspect the drive belts for the fan.
Adhere to the following warnings when performing 6. Check for damage to the fan blades.
any tests or adjustments while the engine is running:
7. Look for air or combustion gas in the cooling
system.
WARNING
Work carefully around an engine that is running. 8. Inspect the filler cap and the surface that seals
Engine parts that are hot, or parts that are the cap. This surface must be clean.
moving, can cause personal injury.
9. Look for a large amount of dirt in the radiator core
and on the engine.
WARNING
10. Check for loose or missing fan shrouds that
Exhaust fumes contain carbon monoxide (CO) cause poor flow of cooling air.
which can cause personal injury or death. Start
and operate the engine in a well ventilated area
only. In an enclosed area, vent the exhaust to Cooling System Tests
the outside.
This engine has a pressure type cooling system. A

pressure type cooling system gives two advantages.
The first advantage is that the cooling system can
have safe operation at a temperature that is higher
than the normal boiling (steam) point of water. The
second advantage is that this type system prevents
cavitation (the sudden making of low pressure
bubbles in liquids by mechanical forces ) in the
water pump. With this type system, it is more difficult
for an air or steam pocket to be made in the cooling
system.
The cause for an engine getting too hot is generally

because regular inspections of the cooling system
were not made. Make a visual inspection of the
cooling system before testing with testing equipment.
Cooling System Visual Inspection
WARNING
Do not loosen the filler cap or pressure cap on a
hot engine. Steam or hot coolant can cause
severe burns. Remember that temperature and pressure work
together. When making a diagnosis of a cooling
1. After the engine is cool, loosen the filler cap (on a system problem, temperature and pressure must
radiator with a pressure cap, turn it to the first both be checked. Cooling system pressure will have
stop) to let pressure out of the cooling system. an effect on cooling system temperatures. For an
Then remove filler or pressure cap. example, look at the chart to see the effect of
pressure and height above sea level on the boiling
2. Check coolant level in the cooling system. (steam) point of water.
3. Look for leaks in the system.
4. Look for bent radiator fins. Be sure that air flow

through the radiator does not have a restriction.

Pressure Cap Test Cooling System Leak Check
To test the cooling system for leaks, use the

following procedure:
WARNING
If the engine has been in operation and the
coolant is hot, slowly loosen the pressure cap to
the first stop and let the pressure out of the
cooling system, then remove the pressure cap.
1. Remove pressure cap from the radiator.
Pressure Cap Diagram 2. Make sure the radiator is full (hot) or nearly full
(A) Sealing surface of cap and radiator. (cold) of coolant.
One cause for a pressure loss in the cooling system 3. Attach the Cooling System Pressurizing Pump
can be a bad seal on the pressure cap of the system. Tool to the radiator filler neck.
Inspect the pressure cap carefully. Look for damage
to the seal or the sealing surface. Any foreign 4. Pump the pressure to 20 kPa (3 psi) more than
material or deposits on the cap, seal or seal or the rated pressure of the cap.
sealing surface must be removed.
5. Check the radiator for outside leakage.
To check the pressure cap opening pressure, do the
following procedure. 6. Check all connections and hoses of the cooling
system for outside leakage.
WARNING
7. If there is no outside leakage and the pressure
If the engine has been in operation and the reading on the gauge is still the same after 5
coolant is hot, slowly loosen the pressure cap to minutes, the radiator and cooling system do not
the first stop and let the pressure out of the have leakage. If the reading on the gauge goes
cooling system, then remove the pressure cap. down and there is no outside leakage, there is
leakage on the inside of the cooling system.
Make repairs as necessary
1. Remove pressure cap from the radiator.
2. Put the pressure cap on the Cooling System

Pressurizing Pump Tool.
3. Look at the gauge for the pressure that makes the

pressure cap open. It must be as follows:
A40365876 to 100 kPa (11 to 14.5 psi)
4. If the pressure cap is bad, install a new pressure

cap.

Thermostat Thermostat Test
To test the thermostat opening temperature, use the

following procedure:
WARNING
The pan, water and thermostat will be very hot
and can cause burns. Do not touch the pan,
water or thermostat. Handle the components
with an insulated device for protection.
1. Remove the thermostat from the engine.
2. Hang the thermostat in a pan of water. Put a

thermometer in the water. Put the thermostat
completely under water. Do not let the thermostat
make contact with the pan.
3. Put heat to the pan of water. Make the water in

the pan move around. This keeps all of the water
at the same temperature.
4. The thermostat must start to open when the

temperature is 82C (180F). The thermostat
must be fully open at 96C (205F).
The thermostat is the wax pellet type. A jiggle
valve (which improves air bleeding during water
supply) is provided on the flange part. When the
thermostat is closed, the circulation of coolant is
stopped, thereby making warm-up faster.
Operation
When the temperature of the coolant is low, the

valve is closed by the spring, with the result that the
coolant circulates within the engine, without passing
through the radiator.
When the temperature of the coolant rises and
reaches a certain specified temperature, the valve
opens and the coolant also circulates through the
radiator.
When the temperature increases further and

reaches a certain specified temperature, the valve
opens fully, allowing even more coolant to circulate
Thus, in this way the degree of valve opening is

varied according to the temperature of the coolant,
and the temperature of the coolant is adjusted by
varying the amount of coolant caused to circulate

Cooling System Heat Problems NOTE: Another condition that can cause heat
problems is the ignition timing. Retarded (late)
To check if there is a good reason for heat problems timing causes the engine to send more heat to the
do the checks that follow: cooling system. Advanced (early) timing causes the
engine to send less heat to the cooling system.
1. The indications of a heat problem are as follows:
Cooling System Recommendation
a. High coolant temperature indicator light is on or
needle of coolant temperature gauge is in red Coolant Information
range.
The engine cooling system is provided with a
b. Coolant boils out (comes out because of too mixture of 50% ethylene glycol anti-freeze and 50%
much heat) of the cooling system during water (For the vehicles of tropical area, the engine
operations. cooling system is provided with a mixture of 40%
ethylene glycol anti-freeze and 60% water at the
c. Coolant boils out on the floor when the engine is time of manufacture.)
stopped. Since the cylinder head and water pump body are
made of aluminum alloy casting, be sure to use a 30
d. Coolant must be added at the end of each shift to 60% ethylene glycol antifreeze coolant to assure
but Steps b and c are not present. corrosion protection and freezing prevention.
2. If indication in Step 1 a is only present. It is

possible the problem is only a damaged gauge, WARNING
light or sender. Make a replacement of the If the concentration of the antifreeze is below
defective part. 30%, the anticorrosion property will be adversely
affected. In addition, if the concentration is
3. If indication in Step 1b is present, do the above 60%, both the antifreeze and engine
procedure that follows: cooling properties will decrease, adversely
affecting the engine. For these reasons, be sure
a. Run the engine at medium idle (1200 rpm) for to maintain the concentration level within the
three minutes after high idle operation. This cools specified range.
off the hottest parts of the engine before it is
stopped.
To prevent damage to your engine, never add
b. Install a coolant recovery system on the truck, if coolant to an overheated engine. Allow the engine to
not already equipped. cool first.
If the lift truck is to be stored in, or shipped to, an
4. If indications in Step 1b, 1c or 1d are present, but area with freezing temperatures, the cooling system
Step 1a is not and the high temperature indicator must be protected to the lowest expected outside
light does work, the problem can be a damaged (ambient) temperature.
radiator cap seal or there can be a leak in the
cooling system. Complete the procedure that The engine cooling system is protected with a
follows: commercially available automotive antifreeze, when
shipped from the factory.
a. Do the Pressure Cap Test, Cooling System Leak
Check, Thermostat Test and Belt Adjustment in Check the specific gravity of the coolant solution
the Testing And Adjusting. frequently in cold weather to ensure adequate
protection.
b. Clean the radiator with hot water (steam clean) at
low pressure and use detergent or air according
to the different types of debris that caused the Clean the cooling system if it is contaminated, if the
radiator to be dirty (plugged). engine overheats or if foaming is observed in the
radiator.
c. Check the engine high idle setting.
Old coolant should be drained, system cleaned and
new coolant added as recommended with the
commercially available automotive antifreeze.

Filling at over 20 liters per minute can cause air Antifreeze
pockets in the cooling system. DOOSAN recommends selecting automotive
antifreeze suitable for gasoline engines using
After draining and refilling the cooling system, aluminum alloy parts. The antifreeze should meet
operate the engine with the radiator cap removed ASTM-D3306 standard.
until the coolant reaches normal operating
Make proper antifreeze additions.
temperature and the coolant level stabilizes. Add
coolant as necessary to fill the system to the proper Adding pure antifreeze as a makeup solution for
level. cooling system top-up is an unacceptable practice. It
increases the concentration of antifreeze in the
Operate with a thermostat in the cooling system all cooling system which increases the concentration of
year-round. Cooling system problems can arise dissolved solids and undissolved chemical inhibitors
without a thermostat. in the cooling system. Add antifreeze mixed with
water to the same freeze protection as your cooling
Coolant Water system.
magnesium ions, encourages the formation of
insoluble chemical compounds by combining with
phosphates.
The tendency of silicates and phosphates to

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

deionized water to reduce the potential and severity
of chemical insolubility.
Acceptable Water
Water Content Limits (ppm)
Chlorides (CI) 40 maximum
Sulfates (SO4) 50 maximum
Total Hardness 80mg/ maximum
Total Solids 250 maximum
pH 6.0 ~ 8.0
Using water that meets the minimum acceptable

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

Coolant Pipe and Hose
COMPONENTS
INSPECTION
Check the coolant pipe and hose for crack, damage,
and clogging and replace it if necessary.
INSTALLATION
After getting water around O-ring, insert it the
groove in the coolant intake pipe end and press-fit
the pipe.
CAUTION
Do not apply oil or grease to the O-ring.
Take care not to dirt the coolant pipe connect-
ing part with sand or dust.
Press-fit the coolant intake pipe completely.

Water Pump
COMPONENTS

REMOVAL 2. Check the bearing for damage, abnormal noise
and bad rotation and replace the water pump if
necessary.
3. Check the seal unit from C hole for leak and

replace the water pump assembly if necessary.
INSTALLATION
B
A
B
1. Drain the engine coolant.
CAUTION
A A
System is under high pressure when the engine
is hot. To avoid danger of releasing scalding
engine coolant, remove the cap only when the 1. Clean the gasket surface of the water pump body
engine is cool. and cylinder block.
2. Remove drive belts. 2. After getting water around new O-ring, install it
the groove in the coolant intake pipe front end.
3. Remove the timing belt. Do not apply oil or grease to the O-ring.
4. Remove the timing belt idler. 3. Install a new water pump gasket and water pump
assembly. Tighten it to the specified torque.
5. Remove the water pump.
WATERPUMP AND CYLINDER BLOCK
1) Remove the 4 bolts and pump pulley.
A 2.0 ~ 2.7 kgm
2) Remove the 3 bolts (C), then remove the
alternator brace (A). B 2.0 ~ 2.4 kgm
3) Remove the water pump (B) and gasket. 4. Install the timing belt tensioner and timing belt.
Adjust the timing belt tension and install the timing
INSPECTION belt cover.
5. After installing the water pump pulley and driving

belt, adjust the belt tension.
6. Add the standard coolant.
7. Run the engine and check for leak.
1. Check each part for crack, damage, and wear and

replace the water pump if necessary.

Thermostat
COMPONENTS
INSPECTION INSTALLATION
1. Check that the thermostat flange is correctly

inserted to the thermostat housing socket. At this
time, upward the jiggle valve and make contact to
the hole.
2. Install a new gasket and water inlet fitting.
3. Add coolant.
1. Check the valve closed at room temperature.
2. Check for defect or damage.
3. Heat the thermostat as shown in the illustration

and measure the valve open temperature and full
open temperature.
Valve open temperature
Open 82C
Full open 95C

FAN DRIVE
COMPONENTS
REMOVAL
1. Remove the fan pulley.
2. Remove the fan bracket.
INSPECTION
Check the bearing for damage, abnormal noise and

sluggish rotation, and replace the bracket assembly
if necessary.
INSTALLATION
Installation is the reverse order of removal.

Cylinder Head Assembly
Components
1. Cylinder block 4. Cylinder head bolt

2. Cylinder head gasket 5. Gasket
3. Cylinder head 6. Cylinder head cover

1. HLA(Hydraulic Lash Adjuster) 6. Valve 11. Exhaust camshaft
2. Retainer 7. Key 12. Camshaft bearing cap
3. Valve spring 8. Chain sprocket 13. Timing chain
4. Stem seal 9. Intake camshaft 14. Retainer lock
5. Spring seat 10. Camshaft sprocket

Disassembly
3. Remove the stem seal with pliers.
NOTE: Do not reuse the stem seal.
1. Using the 8mm and 10mm hexagon wrench,

tighten the cylinder head bolts in order by
tightening 2-3 times as shown in the illustration.
Take care not to come the cylinder head gasket

debris into the cylinder.
2. Using the special tool valve spring compressor

(09222-28000, 09222-28100), remove the
retainer lock.
And then, remove the spring retainer, valve spring,
spring seat and valve.
NOTE: Arrange parts in order disassembling not to

make a mistake while reassembling.

Inspection Valve
Cylinder Head
1. Check the cylinder head for crack, damage and

leak.
2. Clean out fur, adhesive and accumulated carbon

and after cleaning the oil passage, bleed the 1. Clean the valve with a wire brush.
passage with compressed air to check it for
clogging. 2. Check each valve for wear and damage and
inspect the head and stem for torsion.
3. Using a square, check the cylinder head gasket If the stem end is cave or worn, trim it.
for flatness from shown in the illustration. If any At this time, trim it least.
flatness is out of the limit, replace the cylinder Also, trim the valve surface.
head or slightly cut the cylinder head gasket If the margin is less than the limit, replace the
surface. valve.
Valve margin
Flatness of cylinder Standard 0.03mm or less
Head gasket surface Limit 0.06mm Intake 1.15mm
Standard
Exhaust 1.35mm
Limit Intake 0.8mm
Exhaust 1.0mm

Valve spring
Free height 48.86mm
Standard Installed load 18.3kg / 39mm
Compressed load 40.0kg / 30.5mm

Out-of-squareness 1.5or less
Limit Free height -1.0mm
Out-of-squareness 3
3. Measure the clearance between the valve stem

and guide and if the measured value exceeds the VALVE SEAT CORRECTION
limit, replace the valve guide and valve.
Valve stem and guide clearance
Standard Intake 0.02 ~ 0.05mm
Exhaust 0.035 ~ 0.065mm
Limit Intake 0.1mm

Check the valve seat for overheat and inspect
Exhaust 0.13mm contact with valve surface. Correct or replace it if
necessary. When correcting, check the valve guide
for wear, if it is worn, replace the guide and correct
VALVE SPRING the seat ring. Using a grinder or a cutter, correct the
valve seat to make the seat contact width to the
1. Measure free height of the valve spring and standard. When correcting the exhaust valve seat,
replace the spring if the measured value exceeds must use the valve seat voce and pilot, after
the limit. correcting, must apply a light coat of compound to
the valve and valve seat.
2. Using a square, measure squareness of each
spring and replace it if the measured value is out
of squareness excessively.

VALVE SEAT RING REPLACEMENT
1. If the valve seat insert is excessively worn, cut the

insert ring wall as shown in the illustration A
using a valve seat cutter at a normal temperature.
2. After removing the seat ring, Cut the seat insert

bore as same size as the following table as
shown in the illustration A using a reamer or
cutter.
3. Heat the cylinder head to 250C and press-fit the

oversize seat.
At this time the oversize seat ring maintains a
normal room temperature.
After installing a new valve seat, correct the valve
seat surface.
Valve seat ring oversize
Cylinder insert height Cylinder head I.D

Item Size(mm) Size mark
H (mm) (mm)
0.3 OS 30 7.5 ~ 7.7 33.330 ~ 33.325
Intake valve seat ring
0.6 OS 60 7.8 ~ 8.0 33.600 ~ 33.625
0.3 OS 30 7.9 ~ 8.1 28.800 ~ 28.821

Exhaust valve seat ring
0.6 OS 60 8.2 ~ 8.4 29.100 ~ 29.121

VALVE GUIDE REPLACEMENT Valve guide oversize
Size Size mark Cylinder head bore size
0.05 OS 5 11.05 ~ 11.068mm
0.25 OS 25 11.25 ~ 11.268mm
0.50 OS 50 11.50 ~ 11.518mm
Because the valve guide is press-fitted, replace the

valve guide as the following procedures using a
valve guide installer or proper tool.
1. Remove the valve guide pressed toward cylinder

block using a push rod of valve guide installer.
2. Cut the valve guide insert bore of the cylinder

head to the valve guide oversize.
3. Press-fit the valve guide using a valve guide

installer or proper tool. When using a valve guide
installer, Use a valve guide installer to press-fit the
valve guide to the specified height.
4. When installing, start from top of valve guide

cylinder head.
Be sure that the intake valve guide is not same
size with the exhaust valve guide. (Intake valve
guide : 46.0mm, ex-haust valve guide : 54.5mm)
5. After installing the valve guide, insert a new valve

and check for perturbation.
6. When replacing the valve guide, check the valve

for con-tact and correct the valve seat if
necessary.

ASSEMBLY
CAUTION
Prior to assembly, clean each component.
Apply a new engine oil to the perturbation part
and rotation part.
Replace a new oil seal.
VALVE
4. Taking care not to press the valve stem seal

down to the retainer bottom, press-fit the spring
with the special tool valve spring compressor
(09222-28000, 09222-28100)and put the retainer
lock in.
Remove spring compressor after pisition retainer
lock exactly.
5. Hit the end of valve two or three times by rubber

malet, so that valve and retainer lock is in position.
6. Assembly the HLA using by hand.
1. After installing the spring seat, insert the stem

seal to the valve guide.
Install the stem seal by tapping on it with the
special tool valve stem oil seal installer (09222-
22001)
Wrong installation of the seal can affect oil leak
from the valve guide, so use the special tool to
install it to exact position and take care not to twist
it. Do not reuse it.
2. After applying engine oil to each valve, insert the

valve into the valve guide.
3. Install the spring and spring retainer. Face the

enamel-plated side toward the valve spring
retainer side.

HEAD
1. Clean out all gasket surfaces of the cylinder block

and cylinder head.
2. Put new cylinder head gaskets on the cylinder

block with the identification marks faced upward.
Do not apply seal-ant to the gasket and do not
reuse the used cylinder head gasket. Take care
not to make a mistake of gasket.
3. Put the cylinder head on the cylinder block.
4. Apply a slight coat of engine oil to the spiral

portion of bolt.
5. Insert the washer to the bolt and insert it to the

cylinder head.
6. Using the 8mm and 10mm hexagon wrench,

install the cylinder head bolt as shown in the
illustration.
Cylinder head bolt
M10 2.5kgm + (60~ 65) + (60~ 65)
M12 3.0kgm + (60~ 65) + (60~ 65)
7. Install the camshafts.
8. Install the camshafts oil seal.
9. Install the camsprocket and timing belt.
10. Install the head cover.

Lubrication System
General Description
Lubricating system is the full-flow filtered pressure- OIl Filter

feed oil system and the oil reserved in the oil pan is
fed with pressure to each part of engine. After the
oil pressure is adjusted through the relief valve, the
oil is fed to the cylinder blocks and cylinder head.
In the cylinder head the oil is forcibly fed to the
camshaft journals, rocker arm pivots and further
cam surfaces.

Testing and Adjusting
Adhere to the following warnings when performing

any tests or adjustments while the engine is running.
WARNING
Work carefully around an engine that is running.
Engine parts that are hot, or parts that are
moving, can cause personal injury.
WARNING
Engine Oil Viscosity Recommendation
Exhaust fumes contain carbon monoxide (CO)
which can cause personal injury or death. Start NOTE: In normal case, the recommended engine oil
and operate the engine in a well ventilated area for G420F(E) engine is SAE 10W - 30.
only. In an enclosed area, vent the exhaust to
the outside.
But, if the excessive valve noise occurs up to five
minutes after a cold start and if the maximum
Engine Oil ambient temperature is lower than 10C (50F), it is
recommended to change engine oil to SAE 5W - 30
Engine Oil Recommendation for that application.
The following oil specifications provide the Synthetic Oils

guidelines for the selection of commercial products :
Use gasoline engine oil. Recommended API service Synthetic engine oils are not recommended for use
classification is class SJ grade. in G420F(E) Engine. Synthetics may offer
advantages in cold-temperature pumpability and
high-temperature oxidation resistance.
NOTICE However, synthetic oils have not proven to provide
operational or economic benefits over conventional
Failure to follow the oil recommendations can cause petroleum-based oils in G420F(E) Engine. Their use
shortened engine life due to carbon deposits or does not permit the extension of oil change intervals.
excessive wear.
Lubrication System Problems
Prior to changing oil, select an oil based on the One of the problems in the list that follows will
prevailing daytime temperature in the area in which
generally be an indication of a problem in the
the engine is operated. The chart in figure is a guide
to selection the proper crankcase oil. lubrication system for the engine.
IMPORTANT: Oils containing solid additives, non- Too much oil consumption.
detergent oils, or low-quality oils are not
Low oil pressure.
recommended for use in G420F(E) Engine.
High oil pressure.
Too much component wear.

Too Much Oil Consumption turn on during operation only when there is
insufficient engine oil pressure to properly lubricate
Engine outside oil leakage the engines internal parts.
Check for leakage at the seals at each end of the If the oil light comes on, indicating the pressure is
crankshaft. Look for leakage at the oil pan gasket low, check for the causes that follow:
and all lubrication system connections. Check to see
if oil comes out of the crankcase breather. This can 1. Low oil level in the crankcase.
be caused by combustion gas leakage around the
pistons. A dirty crankcase breather will cause high 2. Defect in the oil pressure indicator light or oil
pressure in the crankcase, and this will cause pressure sensor unit.
gasket and seal leakage.
3. Restriction to oil pump screen.
Combustion area oil leakage
4. Leakage at the oil line connections.
Oil leakage into the combustion area of the cylinders
can be the cause of blue smoke. There are three 5. Worn connecting rod or main bearings. Worn
possible ways for oil leakage into the combustion gears in the oil pump.
area of the stems.
6. Oil pressure relief valve worn or stuck in the
1. Oil leakage between worn valve guides and valve OPEN position.
stems.
7. Oil filter bypass valve stuck open. Oil filter is
2. Worn or damaged piston rings, or dirty oil return restricted. Replace oil filter.
holes.
High Oil Pressure
3. Compression ring and/or intermediate ring not
installed correctly. Oil pressure will be high if the oil pressure relief
valve in the oil pump cannot move from the closed
NOTE: Too much oil consumption can also be the position.
result if oil with the wrong viscosity is used. Oil with
a thin viscosity can be caused by fuel leakage into Too Much Component Wear
the crankcase, or by increased engine temperature.
When some components of the engine show
Low Oil Pressure bearing wear in a short time, the cause can be a
restriction in an oil passage. A broken oil passage
can also be the cause.
If an oil pressure check is done and the oil pressure
is correct, but a component is worn because it does
not get enough lubrication, look at the passage for
oil supply to that component. A restriction in a
supply passage will not let enough lubrication get to
a component and this will cause early wear.
Instrument Panel
(1) Engine Oil Light
Before starting the engine, the engine oil light(1) on

the instrument panel will turn on when the key
switch is turned to the ON position. The light will turn
off after the engine is started and while the engine is
running, lidicating normal oil pressure. The light will

Oil Pressure Switch Inspection
Oil pressure switch is located on the front right side

of the engine and if oil pressure in the lubrication
system drops less than 0.29kg/cm2, the oil pressure
warning lamp illuminates. Hexagonal width of this
switch is 24mm.
1. Using an ohmmeter, measure an electric current

and re-place the oil pressure switch if an electric
current is not detected.
Removal and Installation
2. When pressing it with a thin stick, if an electric

current is measured between terminal and body,
replace the oil pres-sure switch.
After applying sealant to the spiral portion, install the 3. When applying a negative pressure of 0.3kg/cm2
oil pres-sure switch. through the oil hole, it an electric current is not
measured, the switch is normal. If the switch is not
NOTE: Do not tighten the oil pressure switch too normal, check for air leak. If air is leaked, replace
tight. the switch because it means damage of the
diaphragm.
Oil pressure switch 1.3 ~ 1.5m

Front Case and Oil Pump
COMPONENTS
1. Filter 7.Relief plunger

2. Front case 8.Oil seal
3. Gasket 9.Inner rotor
4. Oil screen 10.Outer rotor
5. Plug 11.Pump cover
6.Relief spring

REMOVAL
5. Remove the oil pan and oil screen.
1. Drain engine oil.
2. Remove the drive belts.
3. Turn the crankshaft and align the white groove on

the crank-shaft pulley with the pointer on the lower
cover.
4. Remove the timing belt.
5. Remove the oil pan and oil screen 6. Remove the front case.
1) Remove the screws (B) from the pump housing,

then separate the housing and cover (A).
2) Remove the inner (A) and outer (B) rotos.

INSPECTION
A 25mm(0.98in)
B 20mm(0.787in)
Body length
C 38mm(1.496in)
D 45mm(7.771in)
19.6~26.5N.m
Tightening torque
(2.0~2.7kgf.m, 14.5~19.5lb-ft)
1. Install oil pump.
1) Place the inner and outer rotors into front case

with the marks facing the oil pump cover side.
2) Install the oil pump cover (A) to front case with

the 7screws (B).
5.9~8.8N.m
Tightening torque 4. Apply a light coat of oil to seal lip.
(0.6~0.9kgf.m, 4.3~6.5lb-ft)
5. Using the SST(09214-32000), install the oil seal.
6. Install the oil screen.
7. Install the oil pan.
NOTE: Clean the oil pan gasket mating surfaces.
2. Check that the oil pump turns freely.
3. Install the oil pump on the cylinder block.

Place a new front case gasket on the cylinder
block. Apply engine oil to the lip of the oil pump
seal. Then, install the oil pump onto the crankshaft.
When the pump is in place, clean any excess
grease off the crankshaft and check that the oil
seal lip is not distorted.

DISASSEMBLY 0.04~0.09mm
Outer gear
Side (0.0016~0.0035in.)
clearance 0.04~0.085mm
Inner gear
(0.0016~0.0033in.)
If the side clearance is greater than maximum,

replace the rotors as a set. If necessary, replace the
front case.
1. Remove the relief plunger.

Remove the plug (A), spring (B) and relief plunger
(A).
INSPECTION
4. Inspect rotor rip clearance.

Using a feeler gauge, measure the tip clearance
between the inner and outer rotor tips.
0.025~0.069mm
Tip clearance
(0.0010~0.0027in.)
If the tip clearance is greater than maximum, replace

1. Inspect relief plunger. the rotor as a set.
Coat the valve with engine oil and check that it
falls smoothly into the plunger hole by its own
weight.
If it does not, replace the relief plunger. If
necessary, replace the front case.
2. Inspect relief valve spring.

Inspect for distorted or broken relief valve spring.
43.8mm
Free height
Standard (1.724in.)
value 3.7kg/40.1mm
Load
(8.14lb/1.579in.)
3. Inspect rotor side clearance.

Using a feeler gauge and precision straight edge,
measure the clearance between the rotos and
precision straight edge.

5. Inspect rotor body clearance.
Using a feeler gauge, measure the clearance
between the outer rotor and body.
0.12~0.185mm
Body clearance
(0.0047~0.0073in.)
If the body clearance is greater than maximum,

replace the rotor as a set. If necessary, replace the
front case.
REASSEMBLY
1. Install relief plunger.

Install relief plunger (A) and spring (B) into the
front case hole, and install the plug(A).
39.2~49.0kgf.m
Tightening torque
(28.9~36.2lb-ft)

CAM Shaft, HLA, Timing Chain
Components
L4GC043A

Removal 8. Loosen the bearing cap bolt and after removing
the bear-ing cap, remove the camshaft.
9. Remove the timing chain.
10. Remove the HLA.
1. Remove the breather hose and P.C.V hose.
2. Remove the center cover.
3. Remove the ignition coil.
4. Remove the timing belt upper cover.
5. Remove the cylinder head cover.
6. Remove the tensioner.
7. Loosen the camshaft sprocket bolt and remove

the cam-shaft sprocket.

Inspection Oil Seal
1. Check the oil seal surface for wear and if the seal
lip portion is worn, replace it.
2. Check the camshaft oil seal lip contact surface for

partial wear and replace it if necessary.
HLA(Hydraulic Lash Adjuster)
1. HLA O.D : 33(-0.025/-0.041)mm
2. How to remove noise when it heard from valve
1) Prior to engine warm-up, check that the engine

Camshaft oil level is normal.
1. Check the camshaft journal for wear and if the 2) Warm-up the engine.
journal is seriously worn, replace the camshaft.
3) If the valve noise is heard at engine warm-up,
2. Check the cam lobe for damage and if the lobe is air-bleed the system.
severely damaged or worn, replace the camshaft.
4) How to air-bleed
Items Standard Limit
a) During remaining it for 10 minutes at
Intake 43 42.9 3,000 rpm and over 5 minutes at idle, check
Cam
that the valve noise is heard.
height Exhaust 43 42.9
b) Repeat the above step(a) only once or twice.
3. Check the cam surface for abnormal wear and
damage and replace it if necessary.
4. Check the cylinder head camshaft journal for

damage and if the surface is severely damaged,
replace the cylinder head assembly.
5. Lightly put the camshaft on the cylinder head as

shown in the illustration and after installing a dial
gauge towards shaft, check the endplay.
Camshaft endplay 0.1 ~ 0.2mm

Timing Chain
5) If the valve noise is still heard after following

the above step 4), replace the hydraulic lash
adjuster(HLA) which makes noise. 1. Check the timing chain bushing and plate portion
for wear and if those are severely worn, replace
6) If the valve noise is heard after replacing parts, those.
necessarily repeat the above step 4).
7) After air-bleeding the system and replacing Installation

parts to remove noise, if the valve noise is re-
heard 2-3 days after, it might be affected from
defective HLA, so replace the defective HLA.
NOTE: In case of the vehicle with HLA, when initially

starting the engine, it is normal if valve noise is
momentarily heard.
CAUTION
Because HAL is precision parts, take care not to
come foreign materials such as a dust from
outside.
Do not disassemble HLA. 1. Install HLA
When cleaning HLA, use clean diesel oil.
Take care not to make scratches and sharp 2. After Installing the intake and exhaust camshaft
edges to O.D of HLA. by aligning it with the timing mark on the timing
With HLA filled with engine oil, grasp A and chain sprocket, install the camshaft to the cylinder
press B by hand as shown in the illustration, if head.
the HLA is moving, replace the HLA.
CAUTION
Apply engine oil to the camshaft journal and
cam.
There a detective pin for TDC sensor in the in-
take camshaft rear end and a dowel pin in the
intake camshaft front end.

3. Install the camshaft cap.
Check the intake and exhaust identification
marks.(Check cap number and arrow and take 5. Using the special tool camshaft oil seal installer
care not to change the bearing cap position and and guide, press the camshaft oil seal.
direction.) Necessarily apply engine oil to the oil seal lip.
Insert the oil seal through the camshaft front end
I: Intake cam shaft and install it by tapping on the installer with a
hammer until the oil seal reaches 8.5mm from the
E: Exhaust camshaft
camshaft front end.
4. Tighten the bearing cap to the specified torque by

tightening bolts 2-3 times as shown in the
6. Install the camshaft sprocket to the specified
illustration.
torque.
Bearing cap bolt 1.4 ~ 1.5kgm

Camshaft sprocket bolt 10 ~ 12kgm
CAUTION
Align the timing marks on the camshaft sprocket
and the crankshaft sprocket. At this time piston
no.1 cylinder should be placed on the
compression dead point.

Cylinder head cover 0.8 ~ 1.0kgm
Apply engine oil to the oil seal lip to help install the
cylinder head cover oil seal to the spark plug pipe
smoothly.
CAUTION
Necessarily tighten the cylinder head cover bolt
If it is tightened too much, the head cover can be
7. Place the cylinder no.1 to the dead point. deformed resulting in oil leaks and the head
cover bolt can be broken resulting in cylinder
head replacement.
1) Rotate the crankshaft pulley so as to align it When installing after head cover removing,
with T mark on the timing belt low cover. necessarily apply sealant to the head cover rear
and front portion.
Because the head cover is made of plastic, take
care not to drop tools on the head cover upper
portion when removing/installing the engine
parts.
When installing after head cover removing, after
checking the head gasket for damage, re-use it if
it is normal.
When applying/draining engine oil, take care not
to spill oil on the head cover upper surface, if oil
is spilled, wipe it out completely with a paper
and a rag.
10. Install the timing belt cover.

2) Check that the camshaft timing pulley hole is
aligned with timing mark on the bearing cap. If it
Timing belt cover 0.8 ~ 1.0kgm
is not aligned, readjust it by rotate the
crankshaft to360.
11. Assembly the ignition coil.
8. Assembly the timing belt.
12. Install the spark plug center cover.
Center cover 0.25 ~ 0.35kgm
9. Install the cylinder head cover. Apply sealant as

shown in the illustration.

Crankshaft
Components

Disassembly 3) Measure the thickness of the crankshaft and
connecting rod bearing.
1. Remove the timing belt train, front case, flywheel,
cylinder head assembly, and oil pan. 4) Calculate clearance by subtracting O.D of the
journal pin and thickness of the bearing from
2. Remove the rear oil seal. diameter of the bore.
3. Disconnect the connecting rod cap. Journal oil clearance 0.028 ~ 0.048mm
4. Remove the main bearing cap. (Arrange it in Pin oil clearance 0.024 ~ 0.044mm
order)
2.7 ~ 3.3kgm+
Main bearing cap bolt
5. Remove the crankshaft. (60~ 65)
Connecting rod cap bolt 5.0 ~ 5.3kgm
6. Disassemble the crankshaft position sensor wheel.
NOTE: Put an identification mark on the main 4. Oil seal

bearing cap to refer to the original position and Check the front and rear oil seal and replace it
direction. with new parts if necessary.
Inspection
1. Crankshaft
1) Check the oil hoe for clogging as well as

crankshaft journal pin for damage, uneven wear
and crack. Repair or replace parts if necessary.
2) Inspect out of circularity of the crankshaft

journal taper and pin.
Crankshaft journal O.D 57mm
Crank pin O.D 45mm

Out of circularity of crankshaft
0.01mm or less
journal pin
2. Main bearing and connecting rod bearing

Visually inspect each bearing for scratch, melting,
sticking, and fault contact and replace the bearing
if necessary.
3. Measuring oil clearance
1) Measure O.D of the crankshaft journal and pin.
2) Measure diameter of the crankshaft bore and

connecting rod bore.

Assembly
5. Install the bearing cap and tighten the cap bolt to

the specified torque from the center in order.
1. After checking the sensor wheel for damage and (Tighten the bearing cap bolts to the specified
crack, replace it if necessary. torque by tightening bolts step by step 2-3 times
equally)
2. Inspect the clearance between the sensor wheel
and crank position sensor. 2.7 ~ 3.3kgm+
Main bearing cap bolt
(60~ 65)
Clearance between sensor wheel Connecting rod cap bolt 5.0 ~ 5.3kgm
0.5 ~ 1.1mm
and crank position sensor
When installing the cap, proper number of cap

If the clearance is out of specified values, check the
should be installed as well as arrow mark should be
sensor wheel for balancing and the crank position
directed to the engine crank pulley.
sensor for installation and replace those if necessary.
CAUTION
Sensor wheel as one of the electronic control
affects performance if deformed or damaged, so
be careful when handling it.
3. Install the upper main bearing to the cylinder

block. When reusing the main bearing, refer to the
identification mark during assembly.
4. Install the bearing shaft and apply engine oil to

the journal and pin. 6. Check that the crankshaft for free rotation and
proper clearance between the center main
bearing thrust flange and connecting rod big-end
bearing.
Crankshaft end-play 0.06 ~ 0.260mm

7. Using the special tool Crankshaft oil seal installer
(09231-21000), fully insert the oil seal into the
crankshaft rear oil seal case.
8. Install the rear oil seal case and gasket and

tighten 5 bolts.
When installing, apply engine oil to the oil seal
round and crankshaft.
9. Install the flywheel, front case, oil pan, and timing

belt train.

Flywheel and Housing
Components
Removal
Inspection
1. Remove the flywheel.
1. Check the ring gear for damage and crack and
2. Remove the flywheel housing. replace it if necessary.
Assembly
1. Install the flywheel housing and tighten the bolt to

the specified torque.
2. Install the flywheel assembly and tighten the bolt

Flywheel bolt 12 ~ 13kgm

Piston and Connection Rod
Components

Disassembly Inspection
Piston and Pistonpin
1. Check the piston for scratch, wear, etc. and

replace it if necessary.
2. Check the piston ring for break, damage and

abnormal wear and replace it if necessary. When
replacing the piston, the ring should be replaced
also.
3. Check that the piston pin is inserted in the piston

hole and replace the piston and pin if necessary.
Piston should be smoothly pressed at normal
room temperature.
Piston Ring
1. When measuring the side clearance of piston ring,

if the measured value is out of the limit, insert a
new ring to the ring groove and re-measure the
side clearance.
Specified
Item Limit
value
1. Remove the cylinder head assembly. Side clearance No.1 0.04 ~ 0.08mm 0.1mm
of piston ring No.2 0.03 ~ 0.07mm 0.1mm
NOTE: Put an identification mark on the connecting
rod and cap before disassembly to refer to the
original position and direction.
2. Remove the oil pan and remove the oil screen.
3. After removing the connecting rod cap, remove

the piston and connecting rod assembly from the
cylinder. Arrange the connecting rod bearing in
cylinder number order.
4. Using the special tool piston pin setting tool

(09234-33001), disassemble the piston from the
connecting rod as below.
1) Remove the piston ring. 2. To measure the end gap of piston ring, insert the
piston ring to the cylinder bore. At this time,
2) When placing the assembly on a press, face smoothly insert the ring to the piston so as to
the front mark on the piston upward. place the ring and cylinder wall to right position.
After this, smoothly insert the ring to the piston.
3) Using the press, remove the piston pin. And then, pull out the piston upward and measure
gap using a feeler gauge. When the gap exceeds
the limit, re-place the piston ring.

Specified
Item Limit
value
No.1 piston ring end gap 0.23 ~ 0.38 1mm
No.2 piston ring end gap 0.33 ~ 0.48 1mm
Oil ring end gap 0.20 ~ 0.60 1mm
When just replacing the ring without correction of

cylinder bore, place the ring to the cylinder lower
part where less worn-out and measure the gap.
When replacing the ring, use the same size of ring.
3. Using a connecting rod aligner, measure bending
Item Mark and torsion of rod and if the measured value is
around the limit, correct the rod with a press.
STD None But when the rod is severely bended or damaged,
0.25mm OS 25 necessarily replace it.
Piston ring over size 0.50mm OS 50 Bending of connecting rod 0.05mm

0.75mm OS 75 Torsion of connecting rod 0.1mm
1.00mm OS 1.00
NOTE: Size mark is placed on the top of the ring.
Connecting Rod
1. When installing the connecting rod cap, refer to

the cylinder numbers on the rod end cap which
are marked during disassembly.
When installing a new connecting rod, align the
bearing with the notch.
2. If both end thrust surfaces of the connecting rod

are damaged, partially worn, or the inside of small
end is too rough, replace the connecting rod.

Assembly 3) Using a press, press-fit the piston pin into the
pin hole with the specified pressure on the pin
end through the push rod.
If the pressure is required more than the
specified value, follow the next step.
Press-fit pressure of piston pin 350 ~ 1350kg
4) Rotate the push rod to a half turn, remove the

piston connecting rod assembly from the
support.
5) After press fitting the piston pin, check that the

connecting rod for smooth slip and free
1. Using the special tool piston pin setting tool movement.
(09234-33001), assemble the piston and
connecting rod as below.
1) Apply engine oil to the outer surface of the

piston pin and small end bore of the connecting
rod.
2. Install the piston ring to the piston in the following

order.
1) Install 3 pieces of oil ring. Install the spacer

lower side rail and upper side rail in order.
When installing the side rail, do not use a piston
ring expander to expand gap as usual because
the side rail is broken. After placing one end of
the side rail between the piston ring groove and
spacer, grasp the lower side securely and press
the side rail to the position by hand as shown in
the illustration. At this time, after installing the
lower side rail, install the upper side rail.
2) With the front mark faced upward, fix the

connecting rod and piston and insert it into the
piston pin assembly.
Front mark
Piston side 0 (engraved)
Connecting rod side Number (embossed)

CAUTION
After installing 3 pieces of oil ring, check the
upper and lower side rails for smooth rotation
The spacer expander gap should be away from
the rail gap to 45 or more.
3. Using a piston ring clamp, insert the piston and

connecting rod assembly as the cylinder number
into the cylinder and face the arrow mark on the
piston head toward the engine crankshaft pulley.
Install a vinyl cover to the cap bolt not to damage
the cylinder bore and crank pin.
2) After installing no.2 piston ring, install no.1

piston ring. CAUTION
Be sure that the piston ring gap is same as
shown in the illustration. If the piston ring gap is
CAUTION normal, gaps are not aligned with direction of
piston and thrust and each gap is away from
Face the size mark and manufacturer mark on gaps as far as possible.
the ring surface upward when installing the Apply enough engine oil to the piston and pis-
piston ring ton ring round.
Take care not to change no.1 and no.2 piston
rings.

4. Install the connecting rod cap and tighten the cap
nut to the specified torque. When installing the
connecting rod cap, align the cylinder number on
the connecting rod big end with cylinder number
on the cap.
5. Inspect clearance of the connecting rod big end.
Clearance of connecting rod big

0.1 ~ 0.25mm
end
6. Install the oil screen.
7. Install the oil pan.
8. Install the cylinder head.

Engine Block
Component
Tightening torque : Nm(kgf.cm , lbfft)

Tightening torque : Nm(kgf.cm , lbfft)

Disassembly
10. Remove oil screen.

Remove the 2bolts (C), oil screen (A) and gasket
1. Remove flywheel. (B).
2. Remove flywheel housing. 11. Check the connecting rod end play.
3. Install engine to engine stand for disassembly. 12. Remove the connecting rod caps and check oil
clearance.
4. Remove timing belt.
13. Remove piston and connecting rod assemblies.
5. Remove cylinder head.
1) Using a ridge reamer, remove all the carbon
6. Remove oil level gauge assembly (A). from the top of the cylinder.
2) Push the piston, connecting rod assembly and

upper bearing through the top of the cylinder
block.
NOTE: Keep the bearings, connecting rod and cap

together. Arrange the piston and connecting rod
assemblies in the correct order.
14. Remove front case.
7. Remove oil pressure sensor (A).
15. Remove rear oil sealcase. Remove the 5bolts

(B) and rear oil sealcase (A).
16. Remove crankshaft bearing cap and check oil

clearance.
8. Remove water pump.
17. Check the crankshaft end play.
9. Remove oil pan (A).

18. Lift the crankshaft (A) out of the engine, being
careful not to damage journals.
NOTE: Arrange the main bearings and trust

washers in the correct order.
19. Check fit between piston and piston pin. Try to

move the piston back and forth on the piston pin.
If any movement is felt, replace the pistonand pin
as a set.
20. Remove piston rings.
1) Using a piston ring expender, remove the

2compressionrings.
2) Remove the 2side rails and oil ring by hand.
NOTE: Arrange the piston rings in the correct order

only.
21. Disconnect connecting rod from piston.

Inspection 4) Clean the crank pin and bearing.
Connecting Rod and Crankshaft 5) Place plastigage across the crank pin.
6) Reinstall the bearing half and cap, and torque

the nuts.
Tightening torque
50~53 Nm(500~530kgf.cm,36.9~39lbf.ft)
NOTE: Do not turn the crankshaft.
1. Check the connecting rod end play. Using feeler 7) Remove the 2 nuts, connecting rod cap and
gauge, measure the end play while moving the bearinghalf.
connecting rod back and forth.
8) Measure the plastigage at its widest point.
Standard oil clearance

Standard end play:
0.1~0.25 mm (0.004~0.010in.)
Maximum end play: 0.4 mm (0.016in.) 0.024 ~ 0.042mm (0.0009 ~ 0.0017in.)
If out-of-tolerance, install a new connecting rod 9) If the plastigage measures too wide or too
narrow, remove the upper half of the bearing,
If still out-of-tolerance, replace the crankshaft. install a new, complete bearing with the same
color mark (select the color as shown in the
next column), and recheck the clearance.
CAUTION
Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
10) If the plastigage shows the clearance is still

incorrect, try the next larger or smaller bearing
(the color listed above or below that one), and
check clearance again.
2. Check the connecting road bearing oil clearance. NOTE: If the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
1) Check the matchmarks on the connecting rod replace the crankshaft and start over.
and cap are aligned to ensure correct
reassembly. CAUTION
2) Remove the 2 connecting rod cap nuts. If the marks are indecipherable because of an
accumulation of dirt and dust, do not scrub them
3) Remove the connecting rod cap and bearing with a wire brush or scraper. Clean them only
half. with solvent or deter gent.

Connecting rod mark location
Discrimination of crankshaft
OUTSIDE
CLASS MARK
DIAMETER OF PIN
44.960~44.966mm
WHITE
(1.7700~1.7703in.)
44.955~44.960mm
NONE
(1.7698~1.7700in.)
44.948~44.955mm
YELLOW
(1.7696~1.7698in.)
Place of identification mark (Connecting rod

bearing)
Discrimination of connecting rod
CLASS MARK INSIDEDIAMETER

48.00~48.006mm
a WHITE
(1.8896~1.8899in.)
48.006~48.012mm
b NONE
(1.8899~1.8902in.)
48.012~48.018mm
c YELLOW
(1.8902~1.8904in.)
Crankshaft pin mark location
Discrimination of connecting rod bearing
CLASS MARK INSIDE DIAMETER

1.514~1.517 mm
AA BLUE
(0.0596~0.0597in.)
A1.511~1.514 mm
A BLACK
(0.0595~0.0596in.)
1.508~1.511 mm
B NONE
(0.0594~0.0595in.)
1.505~1.508 mm
C GREEN
(0.0593~0.0594in.)
1.502~1.505mm
D YELLOW
(0.0591~0.0593in)

11) Selection NOTE: Do not turn the crankshaft.
CONNECTING ASSEMBLING 5) Remove the cap and bearing again, and

CRANKSHAFT
ROD CLASSIFICATI measure the widest part of the plastigage.
INDENTIFICATI
IDENTIFICATI ON OF
ON MARK
ON MARK BEARING
Standard oil clearance : 0.028 ~ 0.046 mm
a (WHITE) D(YELLOW)
(0.0011 ~ 0.0018in.)
I(YELLOW) b (NONE) C (GREEN)
c (YELLOW) B(NONE)
6) If the plastigage measures too wide or too
a (WHITE) C (GREEN) narrow, remove the upper half of the bearing,
install a new, complete bearing with the same
II(NONE) b (NONE) B (NONE) color mark (select the color as shown in the
c (YELLOW) A (BLACK) next column), and recheck the clearance.
a (WHITE) B (NONE)
CAUTION
III(WHITE) b (NONE) A (BLACK) Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
c (YELLOW) AA (BLUE)
3. Check the crankshaft bearing oil clearance. 7) If the plastigage shows the clearance is still
incorrect, try the next larger or smaller bearing
(the color listed above or below that one), and
check clearance again.
NOTE: If the proper clearance cannot be obtained

by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
CAUTION
If the marks are indecipherable because of an
accumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only
with solvent or detergent.
1) To check main bearing-to-journal oil clearance,
remove the main caps and bearing halves.
2) Clean each main journal and bearing half with a

clean shop tower.
3) Place one strip of plastic gage across each

main journal.
4) Reinstall the bearings and caps, then torque

the bolts.
Tightening torque : 30Nm (300kgf.cm, 22lbf.ft) +

60 ~ 65

Connecting rods Discrimination of cylinder block
1. When reinstalling, make sure that cylinder CLASS MARK INSIDE DIAMETER
numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod i 59.000~59.006mm
a A
s installed, make sure that the notches for holding (2.3228~2.3230in.)
the bearing in place are on the same side. 59.006~59.012mm
b B
(2.3230~2.3233in.)
2. Replace the connecting rod if it is damaged on
the thrust faces at either end. Also if step wear or 59.012~59.018mm
c C
a severely rough surface of the inside diameter of (2.3233~2.3235in.)
the small end is apparent, the rod must be
replaced aswell. Crankshaft journal mark location
3. Using a connecting rod aligning tool, check the

rod for bend and twist. If the measured value is
close to the repair limit, correct the rod by a press.
Any connecting rod that has been severely bent or
distorted should be replaced.
Allowable bend of connecting rod : 0.05mm / 100

mm (0.0020in./3.94in.) or less
Allowable twist of connecting rod : 0.1mm / 100mm
(0.0039in./3.94in.) or less
Crankshaft bore mark location
Letters have been stamped on the end of the block Discrimination of crankshaft
as a mark for the size of each of the 5 main journal
bores. OUTSIDE
CLASS MARK DIAMETER OF
Use them, and the numbers or bar stamped on the JOURNAL
crank (marks for main journal size), to choose the 54.956~54.962mm
correct bearings. YELLOW
(2.1636~2.1638in.)
54.950~54.956mm
NONE
(2.1633~2.1636in.)
54.944~54.950mm
WHITE
(2.1631~2.1633in.)
Place of identification mark (Crankshaft bearing)

Discrimination of crankshaft bearing
THICKNESS OF
CLASS MARK
BEARING
2.014~2.017mm
AA BLUE
(0.0793~0.0794in.)
2.011~2.014mm
A BLACK
(0.0791~0.0793in.)
2.008~2.011mm
B NONE
(0.0790~0.0791in.)
2.005~2.008mm
C GREEN
(0.0789~0.0790in.) If the end play is greater than maximum, replace the
2.002~5.005mm thrust bearings as a set.
D YELLOW
(0.0788~0.0789in.)
Selection Thrust bearing thickness : 2.44 ~ 2.47 mm(0.096

~ 0.097in.)
ASSEM-
CRANK-
CRANKSHAFT BLING
SHAFT BORE
INDENTIFICATIO CLASSIFIC 5. Inspect main journals and crank pins Using a
IDENTIFICATI
N MARK ATION OF micrometer, measure the diameter of each main
ON MARK
BEARING journal and crankpin.
a (A) D(YELLOW)
I(YELLOW) b (B) C (GREEN)
c (C) B(NONE)
a (A) C (GREEN)
II(NONE) b (B) B (NONE)
c (C) A (BLACK)
a (A) B (NONE)
III(WHITE) b (B) A (BLACK)
c (C) AA (BLUE)
4. Check crankshaft endplay. Using a dial indicator,

measure the thrust clearance while prying the
crankshaft back and forth with a screwdriver.
Standard end play : 0.06 ~ 0.26mm (0.0023 ~

0.010in.)
Limit : 0.30 mm (0.0118in.)
Main journal diameter : 55 mm (2.165in.)

Crank pin diameter : 45 mm (1.77in.)

Cylinder Block
Standard diameter: 82.00 ~ 82.03 mm (3.2283 ~
3.2295in.)
6. Check the cylinder bore size code on the cylinder

block bottom face.
1. Remove gasket material. Using a gasket scraper,

remove all the gasket material from the top
surface of the cylinder block.
2. Clean cylinder block Using a soft brush and

solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, Cylinder bore inner Size
measure the surface contacting the cylinder head Class
diameter code
gasket for warpage. 82.00~82.01mm
A A
(3.2283~3.2287in.)
82.01~82.02mm
B B
Flatness of cylinder block gasket surface (3.2287~3.2291in.)
Standard : Less than 0.03 mm (0.0012in.) 82.02~82.03mm
C C
Limit : 0.05 mm (0.0020in.) (3.2291~3.2295in.)
7. Check the piston size code (A) on the piston top

face
4. Inspect cylinder bore diameter Visually check the

cylinder for vertical scratchs. If deep scratches are NOTE: Stamp the grade mark of basic diameter with
present, replace the cylinder block. rubber stamp
5. Inspect cylinder bore diameter Using a cylinder

bore gauge, measure the cylinder bore diameter
at position in the thrust and axial directions.

5. Hone the cylinders, finishing them to the proper
Class Piston outer diameter Size code dimension (piston outside diameter + gap with
cylinder).
81.97~81.98mm
A A
(3.2271~3.2275in.) 6. Check the clearance between the piston and
81.98~81.99mm cylinder.
B None
(3.2275~3.2279in.)
81.99~82.00mm
C C Standard: 0.02-0.04 mm (0.0008-0.0016 in.)
(3.2279~3.2283in.
8. Select the piston related to cylinder bore class.

NOTE: When Boring The cylinders, finish all of the
cylinders to the same oversize. Do not bore only one
Clearance cylinder to the oversize.
0.02 ~ 0.04 mm (0.00078 ~ 0.00157in.)
Boring cylinder Piston and Rings
1. Clean piston
1. Oversize pistons should be selected according to 1) Using a gasket scraper, remove the carbon
the largest bore cylinder. from the piston top.
Identification Mark Size 2) Using a groove cleaning tool or broken ring,

clean the piston ring grooves.
0.25 0.25 mm (0.010in.)
3) Using solvent and a brush, thoroughly clean the
0.50 0.50 mm (0.020in.) piston.
NOTE: The size of piston is stamped on top of the NOTE: Do not use a wire brush.
piston.
2. Measure the outside diameter of the piston to be

used.
3. According to the measured O.D., calculate the

new bore size.
New bore size = Piston O.D + 0.02 to 0.04 mm

(0.0008 to 0.0016 in.) (clearance between piston
and cylinder) -0.01 mm (0.0004in.) (honing margin.)
2. The standard measurement of the piston outside
diameter is taken 47 mm (1.85in.) from the top
land of the piston.
4. Bore each of the cylinders to the calculated size.
Standard diameter
CAUTION 81.97 ~ 82.00 mm(3.2272 ~ 3.2283in.)
To prevent distortion that may result from
temperature rise during honing, bore the
cylinder holes in the firing order.

3. Calculate the difference between the cylinder
bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
4. Inspect the piston ring side clearance. Using a

feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
5. Inspect piston ring end gap. To measure the
piston ring end gap, insert a piston ring into the
cylinder bore. Position the ring at right angles to
Piston ring side clearance the cylinder wall by gently pressing it down with a
No.1: 0.04 ~ 0.08 mm (0.0016 ~ 0.0031in.) piston. Measure the gap with a feeler gauge. If the
No.2: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028in.) gap exceeds the service limit, replace the piston
Limit ring. If the gap is too large, recheck the cylinder
No.1: 0.1 mm (0.004in.) bore diameter against the wear limits, If the bore
No.2: 0.1 mm (0.004in.) is over the service limit, the cylinder block must be
rebored.
If the clearance is greater than maximum, replace

the piston. Piston ring end gap
Standard
No.1: 0.23~0.38 mm (0.0091~0.0150in.)
No.2: 0.33~0.48 mm (0.0130~0.0189in.) [2.0L]
Limit
No.1,2,oil ring:1.0mm(0.039in.)

Piston Pins Reassembly
1. Measure the diameter of the piston pin. NOTE: Thoroughly clean all parts to assembled.
Before installing the parts, apply fresh engine oil to
all sliding and rotating surfaces. Replace all gaskets,
O-rings and oil seals with new parts.
Piston pin diameter
20.001~20.006 mm (0.7874 ~ 0.7876in.) 1. Assemble piston and connecting rod.
1) Use a hydraulic press for installation.

2. Measure the piston pin-to-piston clearance.
2) The piston front mark and the connecting rod
front mark must face the timing belt side of the
engine.
Piston pin-to-piston clearance
0.01 ~ 0.02 mm (0.0004 ~ 0.0008in.)
3. Check the difference between the piston pin

diameter and the connecting rod small end
diameter.
Piston pin-to-connecting rod interference

0.016 ~ 0.032 mm (0.00063 ~ 0.00126in.)
2. Install piston rings.
1) Install the oil ring expander and 2 side

rails by hand.
2) Using a piston ring expander, install the

2compression rings with the code mark facing
upward.
3) Position the piston rings so that the

ring ends are as shown.

3. Install connecting rod bearings. 5. Install thrust bearings.
Install the 2 thrust bearings (A) under the
1) Align the bearing claw with the groove of the No.3journal position of the cylinder block with the
connecting rod cap.- oil grooves facing outward.
2) Install the bearings (A) in the 6. Place crankshaft on the cylinder block.
connecting rod and connecting rod cap (B).
7. Place main bearing caps on cylinder block.
4. Install main bearings.

8. Install main bearing cap bolts.
NOTE: Upper1,2,4,5 bearings have an oil groove of
oil holes; Lower bearings do not. NOTE: The main bearing cap bolts are tightened in
2 progressive steps. If any of the bearing cap bolts
1) Align the bearing claw with the claw groove of in broken or deformed, replace it.
the cylinder block, push in the 5 upper bearings
(A). 1) Apply a light coat of engine oil on the threads
and under the bearing cap bolts.
2) Align the bearing claw with the claw groove of
the main bearing cap, and push in the 5 lower 2) Install and uniformly tighten the 10 bearing cap
bearings. bolts (A), in several passes, in the sequence
shown.
Tightening torque
30Nm (300kgf.cm, 22lbf.ft)

3) Retighten the bearing cap bolts by 6065 in the
numerical order shown.
Tightening torque
Main bearing cap bolt:
30Nm (300kgf.cm,22lbf.ft)+60~65
4) Check that the crankshaft turns smoothly.
9. Check crankshaft end play.

11. Install a new gasket and rear oil seal case (A)
with 5 bolts (B).
Tightening torque
10~12Nm (100~120kgf.cm, 7.3~8.8lbf.ft)
NOTE: Check that the mating surfaces are clean

and dry.
10. Install piston and connecting rod

assemblies.
NOTE: Before installing the pistons, apply a coat of

engine oil to the ring grooves and cylinder bores.
1) Remove the connecting rod caps, and slip short

sections of rubber hose over the threaded ends
of the connecting rod bolts.
2) Install the ring compressor, check that the

bearing is securely in place, then position the 12. Install rear oil seal.
piston in the cylinder, and tap it in using the
wooden handle of a hammer. 1) Apply engine oil to a new oil seal lip.
3) Stop after the ring compressor pops free, and 2) Using SST (09231-21000) and a hammer, tap
check the connecting rod-to-check journal in the oil seal until its surface is flush with the
alignment before pushing the piston into place. rear oil seal retainer edge.
4) Apply engine oil to the bolt threads. Install the 13. Install front case.
rod caps with bearings, and torquethenuts:
50~53Nm(500~530kgf.cm,36.9~39lbf.ft)
NOTE: Maintain downward force on The ring

compressor to prevent the rings from expanding
before entering the cylinder bore.

3) Install the oil pan (A) with the 19 bolts.
Uniformly tighten the bolts in several passes.
Tightening torque
10~12Nm (100~120kgf.cm, 7.3~8.8lbf.ft)
16. Install water pump. (see page EM-104)
14. Install oil screen.

Install a new gasket (B) and oil screen (A) with 2
bolts (C).
Tightening torque
12~15Nm (120~150kgf.cm,9~11lbf.ft)
17. Install oil pressure sensor.
1) Apply adhesive to 2 or 3 threads.

Adhesive: MS721-39 (B) or equivalent.
2) Install the oil pressure sensor (A).
Tightening torque
15~22Nm (150~220kgf.cm, 11~16lbf.ft)
15. Install oil pan.
1) Using a razor blade and gasket

scraper, remove all the old packing material from
the gasket surfaces.
NOTE: Check that the mating surfaces are clean

and dry before applying liquid gasket.
2) Apply liquid gasket as an even bead,

centered between the edges of the mating surface.
Use liquid gasket MS721-40A or equivalent.
NOTE: To prevent leakage of oil, apply liquid gasket

to the inner threads of the bolt holes. Do not install
the parts if five minutes or more have elapsed since
applying the liquid gasket. Instead, reapply liquid
gasket after removing the residue. After assembly,
wait at least 30 minutes before filling the engine with
oil.

18. Install oil level gauge assembly.
1) Install a new O-ring on the oil level gauge.
2) Apply engine oil on the O-ring.
3) Install the oil level gauge assembly (A) with

the bolt.
Tightening torque
12~15Nm (120~150kgf.cm, 9~11lbf.ft)
19. Install cylinder head.
19. Install timing belt.
20. Remove engine stand.
21. Install flywheel housing.
22. Install flywheel.
Tightening torque
120~130Nm (1200~1300kgf.cm,89~96lbf.ft)

Chapter 4. ENGINE ELECTRICAL SYSTEM
Specifications
Ignition Coil
Item Specification
1st coil resistance 0.7110%()

2nd coil resistance 18~19.515%(k)
Spark Plug
Item Specification
NGK PFR6N
Type
CHAMPION RC8PYPB
Spark plug gap 0.7 ~ 0.8mm
Starter Motor
Item Specification
Output 12V- 1.7 kW
Pinion tooth number 8
Alternator
Item Specification
Rated output 13.5V - 90A
RPM 1,000 ~ 18,000rpm
Voltage regulator type Electronic, Built-in type
G420F(FE) Service Manual 118 Chapter 4. Engine Electrical System

Ignition System Coil-On-Plug Ignition System
Spark-ignited engines require accurate control of Coil-on-plug (COP) is a type of distributorless

spark timing and spark energy for efficient ignition system where individual ignition coils are
combustion. The MI-07 ignition system provides this mounted directly over each spark plug. No spark
control. The system consists of the following plug wires are used. On most engines, the plugs
components: and coils are located on top of the cylinder head for
easy mounting of the coils. A topside location is best
SECM because it keeps the coils away from the heat of the
exhaust.
Ignition coil drivers *
COP Components
Ignition coil(s) *
In a typical COP ignition system, a crankshaft
Crankshaft position sensor * position sensor generates a basic timing signal by
reading notches on the crankshaft, flywheel, or
Crankshaft timing wheel * harmonic balancer. The crank sensor signal goes to
the small engine control module (SECM), where it is
Cam position sensor * used to determine firing order and turn the individual
(for sequential ignition or fuel injection only) ignition coils on and off.
Cam timing wheel * The operation of the ignition system is essentially

(for sequential ignition or fuel injection only) the same as any other ignition system. Each coil has
a low primary resistance (0.4 to 0.6 ohms) and steps
Spark plugs * up the primary system voltage from 12 volts to as
much as 40,000 volts to produce a spark for the
The SECM, through use of embedded control spark plug.
algorithms and calibration variables, determines the
proper time to start energizing the coil and fire the The primary difference between COP and other
spark plug. This requires accurate crank/camshaft ignition systems is that each COP coil is mounted
position information, an engine speed calculation, directly atop the spark plug so the voltage goes
coil energy information, and target spark timing. The directly to the plug electrodes without having to pass
SECM provides a TTL compatible signal for spark through a distributor or wires. It is a direct
control. The coil must contain the driver circuitry connection that delivers the hottest spark possible.
necessary to energize the primary spark coil Resistor plugs are generally used to suppress
otherwise an intermediary coil driver device must be electromagnetic interference (EMI).
provided. The SECM controls spark energy (dwell
time) and spark discharge timing.
Figure 16. Coil-On-Plug Ignition System

Misfires COP Checks
COP problems can include many of the same Individual ignition coils can be tested with an
ailments as other ignition systems such as misfiring, ohmmeter the same as those on a conventional
hard starting, or a no start. Spark plugs can still be distributor or DIS ignition system. Measure primary
fouled by oil or fuel deposits, as well as pre-ignition and secondary resistance and compare to
and detonation. specifications. If resistance is out of specifications,
the coil is bad and needs to be replaced.
If the crankshaft position sensor fails, the loss of the
basic timing signal will prevent the system from Also, pay close attention to the tube that wraps
generating a spark and the engine will not start or around the spark pug. Cracks can allow voltage to
run. A failed driver circuit within the SECM can kill jump to ground causing a misfire. The spark plug
an individual coil and prevent that cylinder from firing. terminal should also fit tightly.
But with COP, an individual coil failure will only
cause misfiring in one cylinder. If a COP coil tests bad and is replaced, cleaning the
COP connector and wiring harness terminals can
It is important to remember that ignition misfire can often avoid future problems. Corrosion at either
also be caused by other factors such as worn or place can cause intermittent operation and loss of
fouled spark plugs, loose or damaged coil connector continuity, which may contribute to component
or terminals, dirty fuel injectors, low fuel pressure, failure. Applying dielectric grease to these
intake vacuum leaks, loss of compression in a connections can help prevent corrosion and assure
cylinder, even contaminated fuel. These other a good electrical connection.
possibilities should all be ruled out before a COP
unit is replaced. Magnetic crankshaft position sensors can be tested
with an ohmmeter, and the sensor output voltage
A COP engine that cranks but fails to start, in many and waveform can be read with an oscilloscope. The
cases, will often have a problem in the crankshaft or output voltage of a Hall Effect crankshaft position
camshaft position sensor circuits. Loss of sensor sensor can be checked with a voltmeter. On most
signals may prevent the SECM from properly vehicles, a defective crank position sensor will
synchronizing, thereby preventing the engine from usually set a fault code that can be read with the
starting and running. Service Tool.
Figure 17. Ignition Coil and Extension Wire

Assembly for G420F(E) Engiue

Components
Circuit Diagram
SECM

Inspection of Ignition Timing NOTE: Affective ECU input to lgnition timing control
Coolant temperature sensor
1. Inspection condition Oxygen sensor
MAP sensor(Engine load)
Coolant temperature : 80-90C Crankshaft position sensor
(At normal temperature) Throttle position sensor
Intake Air Temperature sensor
Lamp and all accessories : OFF
Transmission : In neutral position 6) Check that actual ignition timing is changed
Parking brake : ON with engine RPM increased.
2. Inspection Inspection of Ignition Coil Drivers

(Power TR)
1) Connect the timing light.
Four Power Transistors are used for G420F(E)
2) After inserting the clip backward the connector, engine. Its function is ignition coil driver, and it is
located near to SECM.
connect the tachometer with the special tool
(09273-24000)
Location of Components
CAUTION
Take care not to disconnect the connector.
3) Measure RPM.
RPM
Low Idle 750 15 rpm
NOTE: If RPM is not normal, it is impossible to

measure the proper ignition timing, so measure it at
a normal RPM.
4) Inspect the standard ignition timing.
BTDC 5 5
5) If ignition timing is out of the standard, inspect (1) Power TRs (2) SECM
sensors concerned with ignition timing.
CAUTION
Because ignition timing is fixed by set data
value in ECU, it is impossible to control on
purpose.
Fisrt, check that sensors send output properly to
help determine ignition timing control.

Circuit Diagram Inspection
1. Connect terminal #2 (Ground) of Power TR to

Battery (-).
2. Connect terminal #3(IB) of Power TR to Battery

(+5V). If the resistance between terminal #2 and
terminal #1(OC) is lower than 10 ohms, it is OK.
3. Disconnect terminal #3(IB) of Power TR to Battery

(+5V). If the resistance between terminal #2 and
terminal #1(OC) is infinite, it is OK.
Inspection of Ignition Coil
Description
The operation of the ignition system is essentially
the same as any other ignition system. Each coil has
up the primary system voltage from 12 volts to as
IB (Terminal #3), OC (Terminal #1), GND (Terminal spark plug.
#2)
The primary difference between COP and other
ignition systems is that each COP coil is mounted
directly atop the spark plug so the voltage goes
directly to the plug electrodes without having to pass
through a distributor or wires. It is a direct
connection that delivers the hottest spark possible.
Resistor plugs are generally used to suppress
electromagnetic interference (EMI).

Component and Circuit Diagram Inspection of Spark Plug
Inspection and clean
Ignition wire Assy Ignition Coil Assy

Spark Plug
1. Disconnect the ignition wire assy from the ignition

coil assy.
2. Remove the ignition coil assy by pulling the

Inspection
ignition coil with hand.
1. 1st Coil Resistance Measurement
Measure resistance between no.1 (Ba+) and no.3 3. Remove all spark plugs from the cylinder head
(ECU) terminals of ignition coil. using a spark plug wrench.
CAUTION
1st Coil Resistance : 0.71 9 % () Take care not to come foreign materials into
spark-plug mounting hole.
2. 2nd Coil Resistance measurement

Measure resistance between high pressure
terminals.
2nd Coil Resistance : 1819.5 14 % (k)

3. Check the spark plug as below. 5. Install the spark plug and tighten it to the specified
torque.
1) Insulator broken Take care not to over tighten it to prevent cylinder
head threads from damage.
2) Terminal worn
Tightening torque 2~3kgm
3) Carbon deposit
Spark Plug Analysis
4) Gasket damaged or broken
Contact point is Contact point is
State
5) Porcelain insulator of spark plug clearance black white
Density of the
Density of the
Description fuel mixture is
fuel mixture is thin
thick
Lack of air Ignition timing is
intake fast
Spark plug is
tight
Lack of torque
4. Check the plug clearance using a plug clearance

gauge and if the value is not within the specified
values, adjust it by bending the ground clearance.
When installing a new sparkplug, install it after
checking the uniform plug clearance.
Spark plug clearance 0.7~0.8mm

Charging System Alternators
The alternators used on these engines have three

General Description phase, full-wave, rectified output. They are the brush
type. Refer to the Alternator Coverage chart for
The alternator is an electrical and mechanical detailed systems operation information
components driven by a belt from engine rotation. It
is used to charge the storage battery during the
engine operation. The alternator is cooled by an ALTERNATOR COVERAGE
external fan mounted behind the pulley. The fan
Alternator Manufacturer/
pulls air through the holes in the back of the
alternator. The air exits the front of the alternator, Part Number Series
cooling it in the process. The valeo alternator also
has an internal fan. This fan is mounted on the rotor. A403795 Valeo
This fan pulls air through the holes in the back of the
D187478 MICO/K1 Sealed
alternator to cool the rectifier bridge and regulator.
The air exits the front of the alternator.
The alternator converts mechanical and magnetic

energy to alternating current (AC) and voltage. This
process is done by rotating a direct current
(DC)electromagnetic field (rotor) inside a three
phase stator. The alternating current and voltage
(generated by the stator) are changed to direct
current by a three phase, full wave rectifier system
using six silicone rectifier diodes. Some alternators
have three exciter diodes or a diode trio. They rectify
the current needed to start the charging process.
Direct current flows to the alternator output terminal. A403795
A solid state regulator is installed in or on the back

of the alternator. Two brushes conduct current,
through two slip rings, to the rotor field. Some
alternators have a capacitor mounted on them. The
capacitor protects the rectifier from high voltages. It
also suppresses electrical noise through a radio, if
equipped.
The alternator is connected to the battery through

the ignition switch for alternator turn on . Therefore,
alternator excitation occurs when the switch is
turned on. D187478

Components

Troubleshooting
1. Faulty battery charging
Charging system defect is almost caused by lack of
pan belt tension and faulty function of wiring, 1) IC regulator fault(Short circuit)
connector, and voltage regulator.
One of most important thing during troubleshooting 2) Field coil fault
of charging system is determining the reason
between overcharging and lack of charging. So, 3) Main diode fault
prior to inspection of alternator, check the battery for
charging. Faulty alternator causes the following 4) Auxiliary diode fault
symptoms.
5) Stator coil fault
6) Brush contact fault
2. Overcharging : IC regulator fault(Short circuit)

Other faults such as voltage adjusting problem
except above symptoms rarely happen.
Refer to the following troubleshooting table
With ignition Fuse cut off Replace

switch ON,
charging Bulb burnt out Replace
warning lamp Loose wiring connection Retighten
does not
Inspect and replace wiring,
illuminate Bad connection of L-S terminals
Replace voltage regulator
With the Loose or worn drive belt Correct or replace

engine started,
warning lamp Fuse cut off Replace
is not turned Fuse link cut off Replace
off (Battery Faulty voltage regulator or alternator Inspect alternator
needs often
Faulty wiring Repair
charging)
Corrosion or wear of battery cable Repair or replace
Faulty voltage regulator (Charging warning lamp illuminates) Replace
Overcharged
Voltage detection wring fault Replace
Loose or worn drive belt Correct or replace
Loose wiring connection Retighten
Short circuit Repair
Battery is
Fusible link cut off Replace
discharged
Ground fault Repair
Faulty voltage regulator (Charging warning lamp illuminates) Inspect alternator
Battery out Replace

Troubleshooting Procedure
Inspection before Starting
1. Charging warning lamp inspection.
2. Alternator and drive belt tension inspection.

3. Alternator and outer terminal connection inspection.
4. Battery outer terminal inspection.

Inspection after Starting
1. Inspection of alternator charging warning lamp operation test.
2. When starting, belt slip and noise inspection
3. Inspection of battery voltage at idling (At this time charge battery only)

Drop of Electric Pressure Test of Alternator Test
Output Wire
1. Start the engine.
This test is to check that wiring is correctly
connected between the alternator B terminal and 2. Repeating ON and OFF of headlight and small
battery (+) terminal. light, adjust the engine speed until an ammeter
reads 20A and at that time measure voltage.
Result
1. If voltmeter reading is within the standard, it is

normal.
Test voltage Maximum 0.2V
2. If voltmeter reading is more than the standard,

mostly wiring is faulty. In this case, inspect wirings
between the alternator and the battery (+) terminal
as well as between the alternator B terminal and
the fusible link.
3. Also prior to re-test, check and repair the

connecting part for looseness and the harness for
discoloration by overheating.
Preparation 4. After test, adjust the engine speed at idle and turn
the light and ignition switch OFF.
1. Turn the ignition switch OFF.
5. Disconnect the battery ground cable.
6. Disconnect the ammeter and voltmeter.
3. Disconnect the alternator output wire from the
alternator B terminal. 7. Connect the alternator output lead wire to the
alternator B terminal.
4. Connect a DC ampere meter (0-100A) between
the terminal and the disconnected output wire. 8. Connect the battery ground cable.
Connect (+) lead wire to the terminal B and (-)
lead wire to the disconnected output wire. Output Current Test
NOTE: In case of using a clamp type ammeter, it is This test is to check that the alternator output
possible to measure current without disconnecting current is identified with the rated current.
the harness.
Preparation
5. Connect a digital voltmeter between the alternator
B terminal and the battery (+) terminal. 1. Prior to test, inspect the following items and repair
Connect (+) lead wire to the terminal and (-) lead if necessary.
wire to the battery (+) terminal.
1) Be sure that the battery installed in the vehicle
6. Connect the battery ground cable. is normal.(See Battery)
7. Be sure that the hood is opened. NOTE: When measuring output current, necessarily
use a slightly discharged battery. Fully charged
battery is not enough to use for correct test owing to
insufficient load.

2) Inspect the drive belt for tension. 2. Turn the headlight ON and start the engine.
(See Engine body )
3. With the engine running at 2,500 rpm, turn ON the
2. Turn the ignition switch OFF. high beam headlights, place the heater blower
switch at HIGH measure the maximum output
3. Disconnect the battery ground cable. current using a ammeter.
4. Disconnect the alternator output wire from the NOTE: This test should be done as soon as
alternator B terminal. possible to measure the exact maximum current
because output current drops rapidly after starting
the engine.
Result
1. Ammeter reading should be higher than the limit.

If the reading is low even though the alternator
output wire is normal, remove the alternator from
the vehicle and inspect it.
Output current limit 70% of rated current
NOTE: The rated output current is represented on

the name plate in the alternator body.
Output current varies according to electrical load or
temperature of the alternator, so during test, lack of
electrical load causes impossibility of measuring the
rated output current. In this case, turn on headlight
to induce the battery discharging or turn on other
lights to increase the electrical load. If alternator
temperature or ambient temperature is too high, it is
5. Connect a DC ampere meter (0-100V) between impossible to measure the rated output current, so
B terminal and the disconnected output wire. prior to re-test, necessarily drop the temperature.
Connect (+) lead wire to the terminal B and (-)
lead wire to the disconnected output wire.
Ambient temperature
Voltage adjust(V)
NOTE: Do not use clips or equivalent owing to high of voltage regulator()
current and Use bolts and nuts to tighten each
-20 14.2 ~ 15.4
connecting part securely.
20 13.8 ~ 15.0
6. Connect a volt meter(0-20V) between B terminal
and the ground. 60 13.4 ~ 14.6
Connect (+) lead wire to the alternator B terminal
and (-) lead wire to the proper position. 80 13.2 ~ 14.4
7. Connect the engine tachometer and then battery 2. After test, adjust the engine speed at idle and turn
ground cable. the light and ignition switch OFF.
8. Be sure that the hood is opened. 3. Disconnect the battery ground cable.
Test 4. Disconnect the ammeter and voltmeter.
1. Be sure that voltmeter reading is identified with 5. Connect the alternator output lead wire to the
battery voltage. alternator B terminal.
If voltmeter reading is 0V, it means short circuit of
wire between B terminal and the battery (-) 6. Connect the battery ground cable.
terminal, fusible link cut off or ground fault.

Disassembly and Installation
1. Nut 8. Rotor coil 15. Rectifier assembly

2. Pulley 9. Rear bearing 16. Stud bolt
3. Bushing 10. Bearing cover 17. Brush holder assembly
4. Front cover assembly 11. Stator coil 18. Brush holder bolt
5. Front bearing 12. Rear cover 19. Slip ring guide
6. Bearing cover 13. Through bolt 20. Cover
7. Bearing cover bolt 14. Seal

Removal and Installation Disassembly
1. Disconnect the battery (A) terminal. 1. After removing the mounting nuts (B), remove the
generator cover (A) using a screwdriver.
2. Disconnect the alternator B terminal and then

the connector (A). Loosen the clip (B). 2. Loosen 3 mounting bolts (A) and disconnect the
brush holder assembly (B).
3. Loosen the alternator tension adjusting bolt (A)

and the alternator fixing bolt (B). 3. Remove the slip ring guide (A).
4. Remove the belt by pressing inward the alternator.
5. Remove the alternator brocket.
6. Loosen the mounting and remove the alternator

assembly.
7. Installation is reverse order of removal.

Inspection
Rotor
4. Remove the nut, pulley and spacer.
1. Inspect the rotor coil for continuity and check for

continuity between slip rings.
If resistance is too low, circuit is short and if the
resistance is too high, circuit is opened. So
replace the rotor assembly in both cases.
Resistance value 2.5 ~ 3.0(20)
5. Loosen 4 through bolts.
2. Inspect the rotor coil ground and check continuity

between the slip ring and the core, If there is
continuity, replace the rotor assembly.
6. Separate the rotor and cover.

Stator
2. (-) rectifier
When inspecting continuity between (-) rectifier
1. Inspect the stator coil for continuity and check and stator coil lead connecting terminal using an
continuity between the coil leads. If there is no ohmmeter, there must have only one direction
continuity, replace the stator assembly. continuity. If there is both direction continuity,
replace the rectifier assembly owing to short
circuit of diode.
Brush Replacemement
2. Inspect the coil ground and check continuity

between the coil and the core. If there is continuity,
replace the stator assembly.
Rectifier If the brush is worn out to the limit, replace the brush
as the following order.
1. (+) rectifier
When inspecting continuity between (+) rectifier
and stator coil lead connecting terminal using an
ohmmeter, there must have only one direction
continuity. If there is both direction continuity,
replace the rectifier assembly owing to short
circuit of diode.

Installation
Installation is the reverse order of disassembly.

Take care of the following items.
1. Before installing the rotor to the bracket, insert the

wire into the small bore of rear bracket and fix the
brush.
2. After installing the rotor, remove the wire.
Installation
1. After placing the alternator, insert the support bolt.

(At this time do not insert the nut.)
2. After pressing forward the alternator, Contact the

alternator front bracket with front case (A) as
shown in the illustration.
3. Insert and install the nut by tightening it to the

specified torque.

STARTING SYSTEM
General Description
The starting motor is used to turn the engine

flywheel lfast enough to make the engine run. The
starting motor has a solenoid. When the ignition
switch is activated, voltage from the electrical
system will cause the solenoid to move the pinion
toward the flywheel ring gear of the engine. The
electrical contacts in the solenoid close the circuit
between the battery and the starting motor just
before the pinion engages the ring gear. This
causes the starting motor to rotate. This type of
motor "turn on" is a positive shift starting motor.
When the engine begins to run, the overrunning
clutch portion of the pinion drive prevents damage to
the armature caused by excessive speeds. The
clutch does this by breaking the mechanical
connection. The pinion will stay meshed with the
ring gear until the ignition switch is released. A
return spring in the overrunning clutch returns the
clutch to its rest position.
Components

Diagnosis Procedure
2. Is a high current switch rated about 1000 amps
The following simplified procedure is intended to that actually turns on the starting motor.
help the serviceman determine if a starting motor
needs to be removed and replaced or repaired. It is The starting motor solenoid has two coils. Pull-in
not intended to cover all possible problems and coil(W) draws about 40 amps and hold-in coil (X)
conditions, but to serve only as a guide. The most requires about 5 amps. The instant the start relay
common 12 volt circuit is shown and discussed. closes, both coils (W) and (X) receive power. Battery
voltage is applied to the high end of both coils, at
General Information test point (3)which is the start (S) terminal. The low
end of hold-in coil (X) is permanently grounded to
All starting systems are made up of four elements. the ground post or motor housing of the starting
They are the ignition switch, start relay, the starting motor. Grounding for the low end, test point (4), of
motor solenoid and starting motor. pull-in coil (W) is momentary, and takes place
through the DC resistance of the starting motor. As
Start switches are relatively low current devices. soon as magnetic force builds in both coils, the
They are rated to switch approximately 5 to 20 amps. pinion moves toward the flywheel ring gear. The
Because the coil of a start relay [between test point pinion will stop short of engagement of the flywheel
(1)and (2)] draws about 1 amp, the start switch can ring gear. Only then will the solenoid contacts close
easily turn on the start relay and have long life. to power the starting motor. This temporarily
removes the ground from pull-in coil (W), and puts
The switch contacts of a typical start relay are rated battery voltage on both ends of it while the starting
to switch 30 amps. Because the solenoid requires 5 motor cranks. During this period, the pull-in coil is
to 20amps the start relay can easily switch this load. out of the circuit. Cranking continues until power to
the solenoid is broken by releasing the ignition
The starting motor solenoid has two functions: switch.
1. Engages the pinion with flywheel.

The result of these switches and relays is to permit a
5 amp dash-mounted switch to turn on a 500 to
1000amp motor used to crank an engine. Battery
voltage (power) available during cranking varies NOTICE
according to the temperature of the batteries. The
following chart is a guide as to what to expect from a Do not operate the starting motor for more than
normal system. 30seconds at a time. After 30 seconds, the cranking
must be stopped for two minutes to allow the
TYPICALSYSTEM VOLTAGE DURING starting motor to cool. This will prevent damage to
CRANKING AT VARIOUS AMBIENT the starting motor due to excessive heat buildup.
TEMPERATURES
Temperature 12V System
If the starting motor cranks real slow or does not
-23 to -7 C (-10 to 20 F) 6 to 8 Volts crank at all, do the following procedure:
-7 to 10 C (20 to 50 F) 7 to 9 Volts
1. Measure battery voltage at the battery posts with
10 to 27 C (50 to 80 F) 8 to 10 Volts the multimeter while cranking or attempting to
crank the engine. Make sure to measure the
battery posts. Do not measure the cable post
Figure 1
clamps.
The next chart shows maximum acceptable voltage
loss in the high current battery circuit feeding the
2. Is battery voltage equal to or greater than shown
starting motor. These values are maximums for
in Figure 1?
machines of approximately 2000 SMH and up.
Newer machines would be less than those shown.
If the battery voltage is correct, go to Step 3.
MAXIMUM ACCEPTABLE SYSTEM VOLTAGE If the battery voltage is too low, Charge or replace
DROPS DURING CRANKING the battery.
Circuit
12V System NOTE: Alow battery can be caused by battery
Battery(-) post to starting motor (-) condition or a shorted starting motor.
terminal 0.7 Volts
3. Measure current draw on the (+) battery cable
Battery (+) post to solenoid (+) between the battery and the starting motor
terminal 0.5 Volts solenoid with the clamp-on ammeter. The
maximum current draw allowed is 350 Amp. At
Solenoid Bat terminal to solenoid temperatures below27C (80F), the voltage will
Mtr terminal 0.4 Volts be less and the current draw will be higer. If
current draw is too much, the starting motor has a
problem and must be removed for repair or
Figure 2 replacement.
Voltages greater than those shown are most often
caused by loose and/or corroded connections or NOTE: If voltage at the battery post is within
defective switch contacts. approximately 2 volts of the lowest value in the
applicable temperature range of Figure1 and if the
Diagnosis Procedure large starting motor cables get hot, then the starting
motor has a problem and the Ammeter test is not
needed.
TOOLS NEEDED
Digital Multimeter or Equivalent
1 4. Measure starting motor voltage from test point (4)
to (5) with the multimeter while cranking or
DC Clamp-On Ammeter or Equivalent attempting to crank the engine.
1
5. Is voltage equal to or greater than shown in
Figure1?

If the starting motor voltage is correct, the Start Relay Tests
battery and starting motor cables down to the
motor are within specifications. Go to Step 8. Relay
If the starting motor voltage is low, the voltage 1. Put the multimeter on the 200 ohm scale.
drop between the battery and the starting motor
is too great. Go to Step 6. 2. Put the multimeter lead to the 85 and 86 terminals.
6. Measure the voltage drops in the cranking circuits 3. The indication on the meter must be 82 5 ohms. If
with the multimeter. Compare the results with the indication is not correct, the start relay must
maximum voltage drops allowed in Figure 2. be replaced.
7. Are all the voltages within specifications ? 4. Put the multimeter leads to the 30 and 87
terminals.
If the voltage drops are correct, go to Step 8, to
check the engine. 5. The indication must be "OL"(Over Load). If the
indication is not correct, the start relay must be
If the voltage drops are too high, repair and/ or replaced.
replace the faulty electrical component.
6. Connect WH wire to 86 and BK wire to 85
8. Rotate the crankshaft by hand to make sure it is terminal with the ignition switch to start position.
not locked up. Check oil viscosity and any Put the meter lead to 30 and 87 terminal.
external loads that would affect engine rotation.
7. The indication must be Zero ohm. If the indication
9. Is the engine locked up or hard to turn ? is not correct the start relay must be replaced.
If it is, repair the engine as required. If the

engine is not hard to turn, go to Step 10.
10. Does the starting motor crank?
If it does crank, remove the starting motor for

repair and/or replacement.
If it does not crank, check for blocked

engagement of the pinion and flywheel ring
gear.
NOTE: Blocked engagement and open solenoid

contacts will give the same electrical symptoms.

Troubleshooting
Starting system problem can be classified into Start

motor is not operating, Start motor is operating but
engine is not starting , and There is a lot of time
taken to start engine.
When the starting system has problems, before

removing the start motor, find where the problem
happens. Generally if it is difficult to start, there are
problems in ignition system, fuel system, and
electrical system. In this case, necessarily inspect
and repair step by step, or the same problem will
happen.
Low battery charging voltage Charge or replace
Loose, corroded or worn battery cable Repair or replace
Impossible cranking Inhibitor switch fault (With A/T) Adjust or replace
Short circuit of fusible link Replace
Start motor fault Repair
Ignition switch fault Replace
Low battery charging voltage Charge or replace
Slow cranking Loose, corroded or worn battery cable Repair or replace
Start motor fault Repair
Continuous rotating of start Start motor fault Repair

motor Ignition switch fault Replace
Short circuit of wiring Repair

Start motor is rotating but Worn or broken pinion gear tooth or motor fault Repair
engine is not cranking
Replace flywheel ring gear
Worn or broken ring gear tooth
or torque converter

Starter
Components
11
8
7 9
14
15
13
12
19
10
3
2
20
18
17
16
L4GC343A
1. Screw 6. Lever 11. Magnetic switch 16. Yoke assembly

2. Front bracket 7. Plate 12. Planetary gear holder 17. Armature
3. Stop ring 8. Packing B 13. Planetary gear 18. Brush holder
4. Stopper 9. Shim 14. Ball 19. Through bolt
5. Overrunning clutch 10. Internal gear 15. Packing A 20. Rear bracket

CAUTION
This test should be done as soon as possible
not to damage the coil (in 10 seconds).
2. Remove the speedometer cable.
3. Separate the start motor connector and terminal. 4. Measure clearance between the pinion and
stopper using a feeler gauge. If the measured
4. Remove the start motor assembly. value is out of the standard, adjust clearance by
adding or removing the washer between the
5. Installation is the reverse of removal. magnetic switch and front bracket.
Inspection (After Removal)

Pinion clearance 0.5 ~ 2.0
Insection of Pinion Clearance
Pull in Test of Magnetic Switch
1. Disconnect the wire from M terminal.

1. Disconnect the connector from M terminal.
2. Connect a 12V battery between S terminal and
M terminal. 2. Connect a 12V battery between S terminal and
M terminal.
3. If the switch is turned ON, the pinion is moving.
CAUTION
This test should be done as soon as possible
not to damage the coil (in 10 seconds).
3. If the pinion is moving outward, the coil is normal,

if or not, replace the magnetic switch.

Hold in Test of Solenoid Performance Test (with NO-LOAD)
1. Disconnect the connector from M terminal. 1. Connect a 12V battery to the start motor.
2. Connect a 12V battery between S terminal and 2. To operate the start motor with no load, turn the
M terminal. switch ON. If the operating speed and current
measured are identified with the standard, the
start motor is normal. If the operating speed is
CAUTION insufficient or the current is excessive, it is
This test should be done as soon as possible not to because of excessive friction resistance. And the
damage the coil (in 10 seconds). low current or lack of operating speed is because
of faulty contact or open circuit between the brush
and the rectifier or between the welding points.
3. If the pinion is moving outward, the coil is normal,
if the pinion is moving inward, replace the
magnetic switch owing to open-circuit. Speed Minimum 3,000rpm
Current Maximum 60A or less

Return Test of Solenoid
1. Connect the connector from M terminal.
2. Connect a 12V battery between S terminal and

M terminal.
CAUTION
This test should be done as soon as possible not to
damage the coil (in 10 seconds).
3. When releasing after pulling the pinion outward, if

the pinion is returned to native position, it is
normal, if or not, replace the solenoid valve.

Disassembly
2. Short Circuit Test of Armature Coil.

To remove the overrunning clutch from the armature Inspect the armature coil in the growler and if
shaft, remove the stop ring. Remove the stop ring by there is short circuit, replace the coil. During core
moving it to the pinion side, and then remove the rotation, if the blade attached in the core is
stop ring from the shaft. vibrated, the armature is short.
Inspection (After Disassembly)
3. Open Circuit Test of Armature Coil.

Check continuity between the commutator
1. Ground Test of Armature Coil. segments using a circuit tester. If there is no
Check continuity between the commutator and the continuity, replace the armature assembly owing
armature coil using a circuit tester. If there is to open circuit of commutator segment.
continuity, replace the rotor assembly.

4. Open Circuit Test of Field Coil. 7. Brush Holder
Check continuity of the field coil using a circuit Check continuity between the (+) side brush
tester. If there is no continuity, replace the field holder and the base. If there is continuity, replace
coil assembly owing to open circuit of the field coil. the brush holder assembly.
5. Ground Test of Field Coil. 8. Overrunning Glutch.

With the yoke field coil installed, inspect continuity
between the field coil and the yoke, if there is 1) Check the pinion and spline teeth for wear
continuity, replace the field coil. and damage and replace it if necessary. Also,
inspect the flywheel for wear and damage.
2) Rotate the pinion. The pinion must be rotated

clockwise but counterclockwise.
6. Brush.
If the brush is worn out to the limit, replace the
brush.

Assembly
9. Bruch Replacement
1) Remove the worn brush taking care not to 1. Install the overrunning clutch to the armature
damage the pigtail. shaft front end.
2) For better welding, correct the pigtail end with a 2. Install the stop ring and snap ring to the armature
sand paper. shaft front end and completely press the stop ring
toward the snap ring.
3) Weld the pigtail end.
3. When installing the lever to the front bracket, take

10. Installation of Rear Bracker. care of the direction. If the installation direction is
in reverse, the pinion will move outward only.
1) Before removing the bushing, measure the
bushing press-fit depth.
2) Remove the bushing as shown in the

illustration.
3) Press-fit a new bushing as the depth measured

procedure 1).

Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)
General Information
Specifications
SECM and Sensor/Switch Inputs
Qty
Components Items Specifications
G420FE G420F
Environmental / Ambient Operating -20 F to 221F [-29 C to 105 C]
Electrical Temperature
None None
Specifications 8-16 Vdc
Operating Voltage
Engine Control Module Operating Temperature -20 F to 221F [-29 C to 105 C]
(SECM 48)
8-16 Vdc
Operating Voltage SECM microprocessor may reset at
1 1
voltages below 6.3 Vdc
On-engine mounting, underhood

Operating Environment automotive
Camshaft Position Type Hall effect sensor
1 1
Sensor Output Voltage 58X
Crankshaft Position Type Hall effect sensor
1 1
Sensor Tooth wheel 0 5 Volts
TMAP Sensor MAP sensor Piezo- Resistivity type
0-5V output
1 1 Intake Air Temp Sensor Thermistor type
(built in MAP sensor)
2.0-3.0kohms at 20C
LP Fuel Temperature Type Thermister
Sensor 1 None Resistance 2.5k@20
243@90
Oxygen Sensor 0(LP) Type Zirconia Sensor (Heated)
2
1(Gas) Output Voltage 0 - 1V
Coolant Temperature Type Thermistor Type
1 1
Sensor Resistance 1.0-4.0 kohms at 20C
Acceleration Pedal Type Hall IC
Angle Sensor APP1(Low idle) 0.4 0.1 V
1 1 APP2(Low idle) 4.5 0.1 V
APP1(Hi idle) 3.6 0.15 V
APP2(Hi idle) 1.39 0.15 V
Engine Oil Pressure Actuation Pressure 0.3 +/- 0.1 kgf/cm^2
1 1
Switch
Transmission Oil Actuation Temperature 125C
1 1
Temperature Switch
G420F(FE) Service Manual 150 Chapter 5. Engine Management System (EMS)

Qty
G420FE G420F
Ground speed limit Type Normal Open
option option
switch Actuation Pressure 145 28 kPa
Electronic Throttle System
Qty
G420FE G420F
Electronic Throttle Minimum Electrical 1.5 ohms

System 1 1 Resistance of Throttle
Actuator
Ignition System Components Specification
Qty
G420FE G420F
Power TR 4 4 Operating Voltage 5-16V
Ignition Coil Assy Coil Type Inductive

4 4 Coil Supply Voltage 8-16 Vdc
Primary Resistance 0.71 ohm +/- 9%
Spark Plug Material Platinum spark plug

4 4
Air Gap 0.7-0.8 mm

LP Fuel Components Specification
Qty
G420FE G420F
LP Fuel System Operating Temperature -20 F to 221F [-29 C to 105 C]
Requirements
LPG Composition HD5 / HD10 LPG. Failure to use fuel
- -
Requirements compliant with
HD5 or HD10 standards will void the
user warranty.
LP Fuel Filter 1 1 Fuel Filter Micron Size 40 micron
LP Fuel Lock-off 1 1 Electrical Resistance 20~25
N-2007 LP Regulator Fuel Supply Pressure 10 psi to 250 psi (68.95 kPa to
For G420FE 1723.69 kPa)
Fuel Inlet Fitting 1/4 NPT
Fuel Outlet Fitting Two 3/4 NPT fittings with one plugged
and one 1/8 NPT fitting with plug
Fuel Supply -20 F to 120 F [-29 C to 49 C]

Temperature at Tank Outlet
Primary Pressure Tap 1/8 NPT with plug
Max Flow 50 lbm/hr LPG
Coolant Flow to Vaporizer > 1.0 gpm/100bhp, equipped with

1 None
140 F (60 C) thermostat
Fuel Outlet Pressure -0.7 0.2 inH2O @ 1.7 lbm/hr LPG

Setpoints (-1.744 0.498 mbar) @ 1.7 lbm/hr
LPG)
-2.0 0.2 inH2O @ 50 lbm/hr LPG
(-4.982 0.498 mbar) @ 50 lbm/hr
LPG)
Mounting Regulator should be installed with

centerline of outlet at least 15 below
horizontal to permit drainage of any
liquid precipitates from LPG fuel.
Diaphragm should be vertically

oriented.

Qty
G420FE G420F
N-2001 LP Regulator Fuel Supply Pressure 10 psi to 250 psi (69 kPa to 1724 kPa)
For G420F
Fuel Outlet Fitting One 3/4 NPT and one 1/8 NPT fitting
with plug
Fuel Supply -20 F to 120 F [-29 C to 49 C]

Temperature
At Tank Outlet
None 1 Primary Pressure Tap 1/8 NPT with plug
Max Flow 50 lbm/hr LPG
Coolant Flow to Vaporizer >1.0 gpm/100bhp, equipped with

140 F (60C) thermostat
Fuel Outlet Pressure -0.5 0.35 inH2O@1.7 lbm/hr LPG

Setpoints (-1.25 0.87 mbar)@1.7 lbm/hr LPG)
-1.35 0.5 inH2O@32.1 lbm/hr LPG
(-3.36 1.25 mbar)@32.1 lbm/hr
LPG)
CA100 Mixer Fuel LPG
For G420FE
Fuel Inlet Fitting 1/2 NPT Fuel inlet fitted with Delphi
temperature sensor
Air Intake Flange 2.25 (57.15mm) ID inlet, four #10-

24 screws in
1.94 (49.28mm) square pattern
Mixer Mounting Flange 1.87 (47.49mm ID outlet, four #12-

24 screws arranged in a rectangular
pattern
1 None Reference Pressure Ports Two 1/8-NPT ports. Pressure

readings must be identical within
0.25 inH2O (0.623 mbar) at all
airflows.
Air Valve Vacuum (AVV) 1/4-28 UNF

Port Size
Fuel Inlet Adjustments None
Idle Air Adjustment None
Mounting Suitable for on-engine mounting in

vertical orientation

Qty
G420FE G420F
CA100 Mixer Fuel LPG
For G420F
Fuel inlet fitted with Delphi
temperature sensor
Air Intake Flange 2.25 (57.15mm) ID inlet, four #10-

24 screws in 1.94 (49.28mm)
square pattern
Mixer Mounting Flange 1.87 (47.49mm ID outlet, four #12-

24 screws arranged in a rectangular
pattern
None 1
Reference Pressure 1/4-1/8 NPT ports. Pressure
Ports readings must be identical within
0.25 inH2O (0.623 mbar) at all
airflows.
Air Valve Vacuum (AVV) 1/4-28 UNF

Port Size
Fuel Inlet Adjustments Power valve
Idle Air Adjustment Idle adjustment screw
Mounting Suitable for on-engine mounting in

vertical orientation
Fuel Trim Valve (FTV) Actuator Type On/off two-position valve compatible
2 None
Operating Voltage with LPG 8-16 Vdc
Gasoline Fuel Components Specification
Qty
G420FE G420F
Gasoline System Gasoline Unleaded gasoline of 87 octane or
None None
Requirements Requirements higher is recommended
Gasoline Fuel Pump 1 1 Type Electrical, In-Tank
Gasoline Fuel Filter Type High pressure type (built in Fuel Pump
1 1
Assembly)
Gasoline Pressure Pressure 350 kPa (49.8 psi)
1 1
Regulator built in Fuel Pump Assembly
Fuel Injector Type Electric-magnetic
4 4
Coil resistance 14.5 +/- 0.35 ohms

Service Standard
Basic Idle rpm (After warm up) No Load 75015 rpm

Ignition Timing (After warm up, at idle) BTDC 55
Sealants
Engine Coolant Temperature Sensor (ECTS) assembly LOCTITE 962T or equivalent
Tightening Torques
Items Nm kgfm 1bfft
Heated Oxygen Sensor (HO2S, Sensor 1) 50 ~ 60 50 ~ 60 36. 2 ~ 43.4
Heated Oxygen Sensor (HO2S, Sensor 2) 50 ~ 60 5.0 ~ 6.0 36.2 ~ 43.4
Crankshaft Position Sensor (CKPS) 4~6 0.4 ~ 0.6 2.9 ~ 4.3
CKPS target wheel installation screw 10.8 ~ 11.8 1.1 ~ 1.2 8.0 ~ 8.7
Camshaft Position Sensor (CMPS) 4~6 0.4 ~ 0.6 2.9 ~ 4.3
Engine Coolant Temperature Sensor (ECTS) 15 ~ 20 1.5 ~ 2.0 10.8 ~ 14.5
Delivery pipe installation 19 ~ 28 1.9 ~ 2.8 13.7 ~ 20.3

Component Location
Engine Control Module (SECM48) Camshaft Position Sensor
Crankshaft Position Sensor TMAP Sensor
LP Fuel Temperature Sensor Coolant Temperature Sensor

Pre-Catalyst Oxygen Sensor Electronic Throttle Body
Pedal Angle Sensor Post-Catalyst Oxygen Sensor
Transmission Oil Temperature Switch Engine Oil Pressure Switch

Ground speed limit switch (option) Fuel Trim Valve (FTV)
Power TR Gasoline Injectors and fuel rall
N-2007 LP Regulator LP Fuel Lock-off

CA100 Mixer
Gasoline Fuel Pump Ass`y

G420FE EMS (Engine Management System) Overview
General Description
MI-07 control system provides a complete, fully MI-07 is a closed loop system utilizing a catalytic
integrated engine management system that meets muffler to reduce the emission level in the exhaust
or exceeds 2007 emission standards for Large gas. In order to obtain maximum effect from the
Spark Ignited (LSI) engines established by the catalyst, an accurate control of the air fuel ratio is
California Air Resources Board (CARB) and the required. A small engine control module (SECM)
Environmental Protection Agency (EPA). uses two heated exhaust gas oxygen sensors
(HEGO) in the exhaust system to monitor exhaust
The control system is applicable to naturally gas content. One HEGO is installed in front of the
aspirated engines running on LPG and/or gasoline. catalytic muffler and one is installed after the
It provides accurate, reliable, and durable control of catalytic muffler.
fuel, spark, and air over the service life of the engine
in the extreme operating environment found in
heavy-duty, under hood, on-engine electronic
controls.
[Figure 1] MI-07 Dual Fuel System for G420FE Engine on Certified Systems
The SECM makes any necessary corrections to the wire (DBW) system connecting the accelerator pedal
air fuel ratio by controlling the inlet fuel pressure to to the electronic throttle through the electrical
the air/fuel mixer by modulating the dual fuel trim harness; mechanical cables are not used. A throttle
valves (FTV) connected to the regulator. Reducing position sensor (TPS) monitors throttle position in
the fuel pressure leans the air/fuel mixture and relation to the accelerator pedal position sensor
increasing the fuel pressure enriches the air/fuel (APP) command. Even engine coolant temperature
mixture. To calculate any necessary corrections to and adequate oil pressure are monitored by the
the air fuel ratio, the SECM uses a number of SECM. The SECM controller has full adaptive
different sensors to gain information about the learning capabilities, allowing it to adapt control
engines performance. Engine speed is monitored function as operating conditions change. Factors
by the SECM through a Hall Effect sensor. Intake such as ambient temperature, fuel variations,
manifold air temperature and absolute pressure are ignition component wear, clogged air filter, and other
monitored with a TMAP sensor. MI-07 is a drive-by- operating variables are compensated.

Dual Fuel System of G420FE (certified engine system)
INPUT OUTPUT
Crank Sensor Throttle body
CAM sensor 4 Power TRs

4 Ignition coils
TMAP sensorv
2 Fuel trim valves
Coolant Temp
LP fuelock valve
EG oil pressure switchv

4 Injectors
T/M Temp switch SECM

Fuel Pump
Accel pedal angle sensor

CAN communication
Throttle position sensor
Pre Oxygen sensor

Post Oxygen sensor
LP fuel temp sensor
T/M Inching pressure

switch
A dual fuel system operates on either LPG or MPI (multi-point injection) system is used for
gasoline. The fuel type can be switched while the G420FE dual fuel engine and G420F gasoline/dual
engine is stopped or running at low speeds and low fuel engine. On gasoline, the camshaft sensor along
loads. The fuel selection switch is a three-position with the crankshaft sensor is used to control the fuel
type where the center position is fuel off. injectors and feedback from oxygen sensor is used
by the SECM to adjust the gasoline delivery based
on the exhaust emissions.

MI-07 System Components LPG mixer
LPG pressure regulator
Fuel trim valves
The MI-07 control system provides electronic control
Fuel trim orifices
to the following subsystems on mobile industrial
Small engine control module (SECM), firmware
engines:
and calibration
Fuel system sensors and actuators
Fuel delivery system
Ignition system including spark plugs, cables, coils
Spark-ignition control system
and drivers
Air throttle
Gasoline injectors and fuel pressure regulator
Sensors/Switches/Speed inputs
(dual-fuel systems only)
The chart below lists the MI-07 components required
for a G420F (E) engine operating on LP fuel. MI-07 System Features
Qty DESCRIPTION The MI-07 system uses an advanced speed-density

G420FE G420F-LP control strategy for fuel, spark, and air throttle
1 1 Engine Control Module control. Key features include the following.
(SECM 48-pin) Closed-loop fuel control with fuel specific controls
1 1 Camshaft Position for LPG, and gasoline (MPI) fuels
Sensor Speed-load spark control with tables for dwell,
1 1 Crankshaft Position timing, and fuel type
Sensor Speed-load throttle control with table for maximum
1 1 TMAP Sensor TPS limiting
1 None Fuel Temperature Closed-loop fuel control with two oxygen sensors
Sensor (one installed pre catalyst and one installed post
1 1 Transmission Oil catalyst). The pre-catalyst oxygen sensor includes
Temperature Switch adaptive learn to compensate for fuel or
2 None Oxygen Sensors component drift. The post-catalyst oxygen sensor
includes adaptive learn to compensate the pre-
1 1 Coolant Temperature
catalyst oxygen sensor setting for pre-catalyst
Sensor
oxygen sensor drift and catalyst aging. The pre-
1 1 Engine Oil Pressure
catalyst oxygen sensor function includes
Switch
parameters for transport delay, O2 set point,
2 None Fuel Trim Valve
excursion rich/lean, jump back rich/lean, and
4 4 Ignition Coils
perturbation.
4 4 Power TR LPG fuel temperature compensation
1 1 Fuel Lock Off Solenoid Min/max governing
N-2007 N-2001 LP Regulator All-speed isochronous governing
CA-100 CA-100 LP Mixer Fixed-speed isochronous governing with three
(Certified) switch-selectable speeds
1 1 Electronic Throttle Body Fuel enrichment and spark timing modifiers for
temperature and fuel type
Transient fuel enrichment based on rate of change
of TPS
Key Components Transient wall wetting compensation for gasoline
Input sensor selection and calibration
The MI-07 system functions primarily on engine Auxiliary device control for fuel pump, fuel lock-off
components that affect engine emissions and solenoid, tachometer, MIL, interlocks, vehicle
performance. These key components include the speed limiting, etc.
following: CANBus data transfer for speed, torque, etc.
Engine/Combustion chamber design

Intake/Exhaust valve configuration, timing and lift
Intake/Exhaust manifold design
Catalytic converter and exhaust system
Throttle body
Air intake and air filter

Other system features include: LPG Fuel System Operation
The principles outlined below describe the operation

Tamper-Resistance
of MI-07 on an LPG fuel system.
Special tools, equipment, knowledge, and
authorization are required to effect any changes to
An LPG fuel system consists of the following
the MI-07 system, thereby preventing unauthorized
components:
personnel from making adjustments that will affect
Fuel filter
performance or emissions.
Electric fuel lock-off solenoid valve
Fuel pressure regulator/vaporizer
Diagnostics
Two orificed fuel trim valves
MI-07 is capable of monitoring and diagnosing
Gas/Air mixer with fixed orifice for trim system and
problems and faults within the system. These
fuel temperature sensor
include all sensor input hardware, control output
Miscellaneous customer-supplied hoses and
hardware, and control functions such as closed-loop
fittings
fuel control limits and adaptive learn limits. Upon
detecting a fault condition, the system notifies the
Fuel is stored in the customer-supplied LPG tank in
operator by illuminating the MIL and activating the
saturated liquid phase and enters the fuel system
appropriate fault action. The action required by each
from the tank as a liquid and at tank pressure. Fuel
fault shall be programmable by the OEM customer
passes through a high-pressure fuel filter and lock-
at the time the engine is calibrated.
off solenoid, and is then vaporized and regulated
down to the appropriate pressure to supply the
Diagnostic information can be communicated
mixer. The regulator controls the fuel pressure to the
through both the service tool interface and the MIL
gas/air mixer.
lamp. With the MIL lamp, it is possible to generate a
string of flashing codes that correspond to the fault
type. These diagnostics are generated only when Dual Dither Valve
the engine is not running and the operator initiates a The key to meeting emissions requirements when
diagnostic request sequence such as repeated operating in LPG is the dual dither valve hardware in
actuations of the pedal within a short period of time the fuel system. Similar to the MI-04 system, the
following reset. dual dither system modulates the fuel pressure
regulator outlet pressure by providing an offset to
Limp Home Mode the regulator secondary stage reference pressure.
The system is capable of "limp-home" mode in the By adding a second dither valve, or fuel trim valve
event of particular faults or failures in the system. In (FTV), to the MI-07 system, smoother, more
limp-home mode the engine speed is approximately accurate control of supply pressure is achieved,
1000 rpm at no load. A variety of fault conditions can resulting in better control of air fuel ratio and
initiate limp-home mode. These fault conditions and emissions. This smoother control also minimizes
resulting actions are determined during calibration wear on fuel system components such as the
and are OEM customer specific. regulator diaphragm and lever by significantly
reducing the pressure pulsations observed with a
Service Tool single FTV.
A scan tool/monitoring device is available to monitor
system operation and assist in diagnosis of system Regulator Pressure Offset
faults This device monitors all sensor inputs, control
Regulator pressure offset is achieved through the
outputs, and diagnostic functions in sufficient detail
use of a fixed orifice and a variable orifice in series.
through a single access point to the SECM to allow
The inlet to the fixed orifice is connected to the
a qualified service technician to maintain the system.
mixer inlet pressure (roughly equal to ambient
This Mototune software (licensed by Mototron
pressure). The outlet of the fixed orifice is connected
Communication) is secure and requires a crypt-
to both the pressure regulator reference port and the
token USB device to allow access to information.
inlet to the two FTVs (the variable orifice) that act in
parallel. The outlets of the FTVs are connected to
the mixer outlet, referred to as Air Valve Vacuum
(AVV). Thus, by modulating the FTVs, the pressure
regulator reference pressure can be varied between
mixer inlet pressure and AVV. For a given change in
the pressure regulator reference pressure, the

pressure regulator outlet pressure changes by the MI-07 Fuel Lock-Off (Electric)
same amount and in the same direction. The end
The fuel lock-off is a safety shutoff valve, normally
result is that a change in FTV modulation changes
held closed by spring pressure, which is operated by
the outlet pressure of the regulator/fuel inlet
an electric solenoid and prevents fuel flow to the
pressure of the mixer, and thus the AFR. A major
regulator/ converter when the engine is not in
benefit of this trim system results from the use of
operation. This is the first of three safety locks in the
mixer inlet pressure and AVV as the reference
MI-07 system.
pressure extremes. The pressure differential across
the mixer fuel valve is related to these same two
pressures, and thus so is fuel flow. Given this
arrangement, the bias pressure delta scales with the
fuel cone delta pressure. The result is that the trim
system control authority and resolution on AFR
stays relatively constant for the entire speed and
load range of the engine.
SECM
The Small Engine Control Module (SECM) controls
the LPG lock-off solenoid valve and the FTVs. The
lock-off solenoid is energized when fueling with LPG
and the engine is turning. FTV modulation frequency Figure 4. Electric Fuel Lock Assembly
will be varied as a function of rpm by the SECM in
order to avoid resonance phenomena in the fuel In the MI-07 design, power is supplied to the fuel
system. FTV commands will be altered by the lock-off via the main power relay with the SECM
SECM in order to maintain a stoichiometric air-fuel controlling the lock-off ground (earth) connection.
ratio. Commands are based primarily on feedback The lock-off remains in a normally closed (NC)
from the exhaust gas oxygen sensor, with an offset position until the key switch is activated.
for fuel temperature. This supplies power to the lock-off and the SECM,
but will not open the lock-off via the main power
MI-07 LP Fuel Filter relay until the SECM provides the lock-off ground
connection. This design gives the SECM full control
After exiting the fuel tank, liquid propane passes
of the lock-off while providing additional safety by
through a serviceable inline fuel filter to the electric
closing the fuel lock-off in the unlikely event of a
fuel lock off. Figure 3 shows a typical inline type LP
power failure, wiring failure or module failure.
fuel filter manufactured by Century. The primary
function of the fuel filter is to remove particles and
When the liquid service valve in the fuel container is
sediments that have found their way into the tank.
opened, liquid propane flows through the LP filter
The LP fuel filter will not remove heavy end solids
and through the service line to the fuel lock-off.
and paraffins that build up in LPG fuel systems as a
Liquid propane enters the lock-off through the 1/4
result of vaporization.
NPT liquid inlet port and stops with the lock-off in the
normally closed position. When the engine is
cranked over the main power relay applies power to
the lock-off and the SECM provides the lock-off
ground causing current to flow through the windings
of the solenoid creating a magnetic field. The
strength of this magnetic field is sufficient to lift the
lock-off valve off of its seat against spring pressure.
When the valve is open liquid propane, at tank
pressure, flows through the lock-off outlet to the
pressure regulator/converter. A stall safety shutoff
feature is built into the SECM to close the lock-off in
case of a stall condition. The SECM monitors three
engine states: Crank, when the crankshaft position
Figure 3. Inline LP Fuel Filter
sensor detects any engine revolutions; Stall, when
the key is in the ON position but the crankshaft
position sensor detects no engine revolutions; and
the Run state, when the engine reaches pre-idle rpm.

When an operator turns on the key switch the lock- the propane is reduced, the liquid propane vaporizes
off is opened, but if the operator fails to crank the and refrigeration occurs inside the regulator due to
engine the SECM will close the lock-off after 5 the vaporization of liquid propane. To replace heat
seconds. lost to vaporization, engine coolant is supplied by
the engine driven water pump and pumped through
N-2007 Pressure Regulator/Vaporizer the regulator. Heat provided by this coolant is
transferred through to the fuel vaporization chamber.
The pressure regulator/vaporizer receives liquid
LPG from the fuel storage tank, drops the pressure,
changes the LPG phase from liquid to vapor, and N-2007 Operation
provides vapor phase LPG at a regulated outlet (Refer to Figure 6.)
pressure to the mixer. To offset the refrigeration Liquid propane, at tank pressure, enters the N-2007
effect of the vaporization process, the regulator will through the fuel inlet port (1). Propane liquid then
be supplied with engine coolant flow sufficient to flows through the primary valve (2). The primary
offset the latent heat of vaporization of the LPG. A valve located at the inlet of the expansion chamber
thermostat provided in the coolant supply line to (3), is controlled by the primary diaphragm (4),
maintain regulator outlet coolant temperature at or which reacts to vapor pressure inside the expansion
below 140oF (60C) will minimize the deposit of fuel chamber. Two springs are used to apply force on
contaminants and heavy ends in the regulator and the primary diaphragm in the primary diaphragm
assure a more controlled vaporization process with chamber (5), keeping the primary valve open when
reduced pressure pulsations. no fuel pressure is present.
A higher flow pressure regulator is required on A small port connects the expansion chamber to the
larger engines. primary diaphragm chamber. At the outlet of the
expansion chamber is the secondary valve (6). The
secondary valve is held closed by the secondary
spring on the secondary valve lever (7). The
secondary diaphragm controls the secondary lever.
When the pressure in the expansion chamber
reaches 1.5 psig (10.342 kPa) it causes a
pressure/force imbalance across the primary
diaphragm (8). This force is greater than the primary
diaphragm spring pressure and will cause the
diaphragm to close the primary valve.
Since the fuel pressure has been reduced from tank

pressure to 1.5 psig (10.342 kPa) the liquid propane
Figure 5. N-2007 Regulator vaporizes. As the propane vaporizes it takes on heat
from the expansion chamber. This heat is replaced
The regulator is normally closed, requiring a vacuum by engine coolant, which is pumped through the
signal (negative pressure) to allow fuel to flow. This coolant passage of the regulator. At this point vapor
is the second of three safety locks in the MI-07 propane will not flow past the expansion chamber of
system. If the engine stops, vacuum signal stops the regulator until the secondary valve is opened. To
and fuel flow will automatically stop when both the open the secondary valve, a negative pressure
secondary (2nd stage) valve and the primary (1st signal must be received from the air/fuel mixer.
stage) valve closes. Unlike most other When the engine is cranking or running a negative
regulator/converters, the N-2007 primary valve pressure signal (vacuum) travels through the vapor
closes with fuel pressure rather than against fuel outlet connection of the regulator, which is the
pressure, extending primary seat life and adding regulator secondary chamber, and the vapor fuel
additional safety. inlet of the mixer. The negative pressure in the
secondary chamber causes a pressure/force
Liquid propane must be converted into a gaseous imbalance on the secondary diaphragm, which
form in order to be used as a fuel for the engine. overcomes the secondary spring force, opening the
When the regulator receives the desired vacuum secondary valve and allowing vapor propane to flow
signal it allows propane to flow to the mixer. As the out of the expansion chamber, through the
propane flows through the regulator the pressure is secondary chamber to the mixer.
reduced in two stages from tank pressure to slightly
less than atmospheric pressure. As the pressure of

A higher flow mixer is required on larger engines. A
lower flow mixer is required on smaller engines.
Figure 6. Parts View of N-2007 Regulator
Because vapor propane has now left the expansion

chamber, the pressure in the chamber will drop, Figure 7. CA100 Mixer
causing the primary diaphragm spring force to re-
open the primary valve allowing liquid propane to CA100 Mixer Operation
enter the regulator, and the entire process starts
Vapor propane fuel is supplied to the CA100 mixer
again. This creates a balanced condition between
by the N-2007 pressure regulator/converter. The
the primary and secondary chambers allowing for a
mixer uses a diaphragm type air valve assembly to
constant flow of fuel to the mixer as long as the
operate a gas-metering valve inside the mixer. The
demand from the engine is present. The fuel flow is
gas-metering valve is normally closed, requiring a
maintained at a constant output pressure, due to the
negative pressure (vacuum) signal from a cranking
calibrated secondary spring. The amount of fuel
or running engine to open. This is the third of the
flowing will vary depending on how far the
three safety locks in the MI-07 system. If the engine
secondary valve opens in response to the negative
stops or is turned off, the air valve assembly closes
pressure signal generated by the air/fuel mixer. The
the gas-metering valve, stopping fuel flow past the
strength of that negative pressure signal developed
mixer. The gas-metering valve controls the amount
by the mixer is directly related to the amount of air
of fuel to be mixed with the incoming air at the
flowing through the mixer into the engine. With this
proper ratio. The air/fuel mixture then travels past
process, the larger the quantity of air flowing into the
the throttle, through the intake manifold and into the
engine, the larger the amount of fuel flowing to the
engine cylinders where it is compressed, ignited and
mixer.
burned.
CA100 Mixer
The mixer is installed above the throttle body and
meters gaseous fuel into the airstream at a rate that
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel
flow is controlled by the shaping of the mixer fuel
cone and biased by the controllable fuel supply
pressure delivered by the pressure regulator. Fuel
flow must be metered accurately over the full range
of airflows. Pressure drop across the mixer air valve
must be minimized to assure maximum power
output from the engine.
Figure 8. CA100 Mixer Attached to Throttle Body
The mixer fuel inlet is fitted with a thermistor-type
temperature sensor. This permits the SECM to (Refer to Figure 98.)
correct fuel pressure to compensate for variations in The air/fuel mixer is mounted in the intake air stream
fuel temperature. Left uncorrected, fuel temperature between the air cleaner and the throttle. The design
variations can cause significant variations in air fuel of the main body incorporates a cylindrical bore or
ratio. mixer bore, fuel inlet (1) and a gas discharge jet (2).
In the center of the main body is the air valve
assembly, which is made up of the air valve (3), the
gas-metering valve (4), and air valve diaphragm (5)

and air valve spring (6). The gas-metering valve is
permanently mounted to the air valve diaphragm
assembly with a face seal mounted between the two
parts.
When the engine is not running this face seal

creates a barrier against the gas discharge jet,
preventing fuel flow with the aid (downward force) of
the air valve spring. When the engine is cranked
over it begins to draw in air, creating a negative
pressure signal. This negative pressure signal is
transmitted through four vacuum ports in the air
valve. Figure 10. Bottom View of Air Valve Assembly
Figure 9. Parts View of CA100 Mixer Figure 11. CA100 Mixer Installed with Electronic
Throttle
A pressure/force imbalance begins to build across
the air valve diaphragm between the air valve A main mixture adjustment valve on the fuel inlet of
vacuum (AVV) chamber (above the diaphragm) and the CA100 is not used in the MI-07 system, however
atmospheric pressure below the diaphragm. an idle mixture adjustment is incorporated into the
Approximately 6 inH2O (14.945 mbar) of negative mixer (Figure 12). The idle mixture adjustment is an
pressure is required to overcome the air valve spring air bypass port, adjusting the screw all the way in,
force and push the air valve assembly upward off blocks off the port and enriches the idle mixture.
the valve seat. Approximately 24 inH2O (59.781 Backing out the idle adjustment screw opens the
mbar) pulls the valve assembly to the top of its travel port and leans the idle mixture. The idle mixture
in the full open position. screw is a screw with locking threads that is factory
set with a tamper proof cap installed after
The amount of negative pressure generated is a adjustment. Accurate adjustment of the idle mixture
direct result of throttle position and the amount of air can be accomplished by adjusting for a specific fuel
flowing through the mixer to the engine. At low trim valve (FTV) duty cycle with the Service Tool
engine speeds, low AVV causes the air valve software or with a voltmeter.
diaphragm assembly to move upward a small
amount, creating a small venturi. At high engine NOTE: Adjustments should only be performed by
speeds, high AVV causes the air valve diaphragm trained service technicians.
assembly to move much farther creating a large
venturi. The variable venturi air/fuel mixer constantly
matches venturi size to engine demand.

exists across the diaphragm, reducing fuel flow and
leaning the air/fuel mixture.
Figure 12. Idle Mixture Adjustment Screw

(with tamper proof cap removed)
Fuel Trim Valve (FTV)
The Fuel Trim Valve (FTV) is a two-way electric

solenoid valve and is controlled by a pulse-width
modulated (PWM) signal provided by the SECM.
Two FTVs are used to bias the output fuel pressure
on the LPG regulator/converter (N-2007), by
metering air valve vacuum (AVV) into the
atmospheric side of the N-2007 secondary regulator
diaphragm. An orifice balance line connected to the
air inlet side of the mixer provides atmospheric
reference to the N-2007 when the FTV is closed.
The SECM uses feedback voltage from the O2
sensor to determine the amount of bias needed to
the regulator/converter.
In normal operation the N-2007 maintains fuel flow

at a constant output pressure, due to the calibrated
secondary spring. The amount of fuel flowing from
the N-2007 will vary depending on how far the
secondary diaphragm opens the secondary valve in
response to the negative pressure signal generated
by the air/fuel mixer. One side of the N-2007
secondary diaphragm is referenced to FTV control
pressure while the other side of the diaphragm
reacts to the negative pressure signal from the mixer.
If the pressure on the reference side of the N-2007
secondary diaphragm is reduced, the diaphragm will
close the secondary valve until a balance condition

Branch-Tee Fitting the balance line and referencing atmospheric
pressure. The other side of the branch-tee fitting
connects to the FTV inlet (small housing side). The
FTV outlet (large housing connector side) connects
to the AVV port. When the FTVs are open AVV is
sent to the atmospheric side of the N-2007
secondary diaphragm, which lowers the reference
pressure, closing the N-2007 secondary valve and
leaning the air/fuel mixture. The MI-07 system is
calibrated to run rich without the FTV. By modulating
(pulsing) the FTVs the SECM can control the
amount of AVV applied to the N-2007 secondary
diaphragm. Increasing the amount of time the FTVs
remain open (modulation or duty cycle) causes the
air/fuel mixture to become leaner; decreasing the
modulation (duty cycle) enriches the mixture.
A branch-tee fitting is installed in the atmospheric
vent port of the N-2007 with one side of the branch-
tee connected to the intake side of the mixer forming
Figure 13. Fuel Trim Valves Connected to MI-07 System

MPI Gasoline System Operation is solenoid valve which supplies exactly calculated
fuel as a spray to engine to best combustion under
the condition of various engine load and speed.
MPI (multi-point injection) system is used for
G420FE dual fuel engine and G420F gasoline/dual For fuel consumption reduction, engine performance
fuel engine. An electric fuel pump in gasoline fuel enhancement and emission reduction, ECM controls
tank supplies the fuel and generates the injection fuel injection to satisfy air fuel ratio required by
pressure. The gasoline fuel pressure regulator is a system by reflecting induced airflow and air fuel ratio
one-way, non-return configuration. All gasoline among emission and adjusting injector operating
specific components are automotive production time. To enhance these control characteristics, quick
parts and validated to strict automotive standards. response of injector is required, and spray feature of
Four (4) sequential injection channels are supported. injector is important for perfect combustion.
Injector as an electronic controlled fuel injection unit,
Use of unleaded gasoline of 87 octane or higher is recommended for optimal performance of the MI-07
system.
A gasoline fuel system includes the following components:

Gasoline fuel pump
Fuel filter
Pressure regulator
Fuel rail
Fuel injectors
Small engine control module (SECM) and related sensors and equipment

Electronic Throttle System MI-07 Electronic Throttle
Conventional throttle systems rely on a mechanical
linkage to control the throttle valve. To meet
The electronic throttle system controls engine output
fluctuating engine demands a conventional system
(speed and torque) through electronic control of
will typically include a throttle valve actuator
mass airflow to the engine. Any DC motor-actuated
designed to readjust the throttle opening in response
or Limited Angle Torquemotor (LAT)-actuated
to engine demand, together with an idle control
throttle with less than 5A peak and 2A steady state
actuator or idle air bypass valve.
can be controlled. The TPS must be directly coupled
to the throttle shaft for direct shaft position
In contrast, the MI-07 system uses electronic throttle
measurement.
control (ETC). The SECM controls the throttle valve
based on engine RPM, engine load, and information
A commonly used throttle is the Bosch DV-E5. This
received from the foot pedal. Two potentiometers on
throttle is available in a variety of bore sizes to meet
the foot pedal assembly monitor accelerator pedal
specific engine needs: 32mm, 40mm, and 54mm are
travel. The electronic throttle used in the MI-07
readily available throttle bore sizes; other sizes are
system is a Bosch 32mm or 40mm electronic throttle
possible. The Bosch throttle is a fully validated
body DV-E5 (Figure 14). The DV-E5 is a single unit
automotive component incorporating a brushed DC
assembly, which includes the throttle valve, throttle-
motor with gear reduction, dual throttle position
valve actuator (DC motor) and two throttle position
sensors, throttle plate, and cast aluminum housing.
sensors (TPS). The SECM calculates the correct
In the event of an electrical disconnection or other
throttle valve opening that corresponds to the
related failure, the throttle plate returns to a limp-
drivers demand, makes any adjustments needed for
home idle position at a no-load engine speed above
adaptation to the engines current operating
curb idle speed. This provides sufficient airflow for
conditions and then generates a corresponding
the engine to move the vehicle on level ground. Any
electrical (driver) signal to the throttle-valve actuator.
throttle bodies used for MI-07 meet or exceed the
specification for the Bosch throttle bodies.
In terms of response, the throttle is capable of fully

opening and closing in less than 50 msec. Position
resolution and steady state control should be 0.25%
of full travel or better.
Figure 14. Bosch Electronic Throttle Body
The MI-07 uses a dual TPS design (TPS1 and

TPS2). The SECM continuously checks and
monitors all sensors and calculations that effect
throttle valve position whenever the engine is
running. If any malfunctions are encountered, the
SECMs initial response is to revert to redundant
sensors and calculated data. If no redundant signal
is available or calculated data cannot solve the
malfunction, the SECM will drive the system into one
of its limp-home modes or shut the engine down,
storing the appropriate fault information in the SECM.

There are multiple limp-home modes available with Ignition System
electronic throttle control:
1. If the throttle itself is suspected of being
Spark-ignited engines require accurate control of
inoperable, the SECM will remove the power to
spark timing and spark energy for efficient
the throttle motor. When the power is removed,
combustion. The MI-07 ignition system provides this
the throttle blade returns to its default position,
control. The system consists of the following
approximately 7% open.
components:
2. If the SECM can still control the throttle but some
SECM
other part of the system is suspected of failure,
Ignition coil drivers *
the SECM will enter a Reduced Power mode. In
Ignition coil(s) *
this mode, the power output of the engine is
Crankshaft position sensor *
limited by reducing the maximum throttle position
Crankshaft timing wheel *
allowed.
Cam position sensor *
3. In some cases, the SECM will shut the engine
(for sequential ignition or fuel injection only)
down. This is accomplished by stopping ignition,
Cam timing wheel *
turning off the fuel, and disabling the throttle.
(for sequential ignition or fuel injection only)
Spark plugs *
The SECM, through use of embedded control

algorithms and calibration variables, determines the
proper time to start energizing the coil and fire the
spark plug. This requires accurate crank/camshaft
position information, an engine speed calculation,
coil energy information, and target spark timing. The
SECM provides a TTL compatible signal for spark
control. The coil must contain the driver circuitry
necessary to energize the primary spark coil
otherwise an intermediary coil driver device must be
provided. The SECM controls spark energy (dwell
time) and spark discharge timing.
Picture courtesy of Robert Bosch GmbH Coil-On-Plug (Coil Pack) Ignition System
Coil-on-plug (COP) is a type of distributorless
Figure 15. Throttle Body Assembly Exploded View ignition system where individual ignition coils are
mounted directly over each spark plug. No spark
plug wires are used. On most engines, the plugs
and coils are located on top of the cylinder head for
easy mounting of the coils. A topside location is best
because it keeps the coils away from the heat of the
exhaust.

COP Components Exhaust System
In a typical COP ignition system, a crankshaft
position sensor generates a basic timing signal by Heated Exhaust Gas Oxygen Sensors (HEGO)
reading notches on the crankshaft, flywheel, or
The MI-07 system utilizes two HEGO (O2) sensors.
harmonic balancer. The crank sensor signal goes to
One sensor is a pre-catalyst sensor that detects the
the small engine control module (SECM), where it is
amount of oxygen in the exhaust stream and is
used to determine firing order and turn the individual
considered the primary control point. Based upon
ignition coils on and off.
the O2 sensor feedback, the MI-07 system supplies
a stoichiometric air-fuel ratio to the catalytic
The operation of the ignition system is essentially
converter. The catalytic converter then reduces
the same as any other ignition system. Each coil has
emissions to the required levels. The second sensor
is a post-catalyst sensor that detects the amount of
up the primary system voltage from 12 volts to as
oxygen after the catalyst. This sensor is used as a
secondary control point to adjust the pre-catalyst
spark plug.
setpoint to ensure proper catalyst conversion
efficiency.
The primary difference between COP and other
ignition systems is that each COP coil is mounted
directly atop the spark plug so the voltage goes
directly to the plug electrodes without having to pass
through a distributor or wires. It is a direct
connection that delivers the hottest spark possible.
Resistor plugs are generally used to suppress
electromagnetic interference (EMI).
Misfires
COP problems can include many of the same
ailments as other ignition systems such as misfiring,
hard starting, or a no start. Spark plugs can still be
Figure 18. HEGO (O2) Sensor
fouled by oil or fuel deposits, as well as pre-ignition
and detonation.
Once a HEGO sensor reaches approximately 600F
(316C), it becomes electrically active. The
If the crankshaft position sensor fails, the loss of the
concentration of oxygen in the exhaust stream
basic timing signal will prevent the system from
determines the voltage produced. If the engine is
generating a spark and the engine will not start or
running rich, little oxygen will be present in the
run. A failed driver circuit within the SECM can kill
exhaust and voltage output will be relatively high.
an individual coil and prevent that cylinder from firing.
Conversely, in a lean situation, more oxygen will be
But with COP, an individual coil failure will only
present and a smaller electrical potential will be
cause misfiring in one cylinder.
noticed.
It is important to remember that ignition misfire can
In order for the sensor to become active and create
also be caused by other factors such as worn or
an electrical signal below 600F (316C) a heated
fouled spark plugs, loose or damaged coil connector
element is added to the sensor housing. Two wires
or terminals, dirty fuel injectors, low fuel pressure,
provide the necessary 12 Vdc and ground signal for
intake vacuum leaks, loss of compression in a
the heater element. A fourth wire provides an
cylinder, even contaminated fuel. These other
independent ground for the sensor. The pre-catalyst
possibilities should all be ruled out before a COP
sensor heater is powered by the main power relay
unit is replaced.
and is always powered. The post-catalyst sensor
heater is powered from an additional relay that is
A COP engine that cranks but fails to start, in many
controlled by the SECM. This relay is only energized
cases, will often have a problem in the crankshaft or
when the SECM calculates that water condensation
camshaft position sensor circuits. Loss of sensor
in the exhaust system and catalytic muffler prior to
signals may prevent the SECM from properly
the sensor should be evaporated. This is to avoid
synchronizing, thereby preventing the engine from
thermal shock of the sensor that could prematurely
starting and running.
fail the sensor.

The HEGO stoichiometric air-fuel ratio voltage target converter. It reduces the unburned hydrocarbons
is approximately 500 mV and changes slightly as a and carbon monoxide by burning (oxidizing) them
function of speed and load. When the pre-catalyst over a platinum and palladium catalyst. Cerium is
HEGO sensor sends a voltage signal less than 450 also used to promote oxygen storage and improve
mV the SECM interprets the air-fuel mixture as lean. oxidation efficiency.
The SECM then decreases the PWM duty cycle sent
to the fuel trim valves in order to increase the fuel
pressure to the mixer inlet; thus richening air-fuel
mixture. The opposite is true if the SECM receives a
voltage signal above 450 mV from the HEGO. The
air-fuel mixture would then be interpreted as being
too rich and the SECM would increase the duty
cycle of the trim valves.
CAUTION
The HEGO sensors are calibrated to work with

the MI-07 control system. Use of alternate As exhaust and catalyst temperatures rise the
sensors may impact performance and the ability following reaction occurs:
of the system to diagnose rich and lean
conditions. Oxides of nitrogen (NOx) are reduced into simple
nitrogen (N2) and carbon dioxide (CO2).
Hydrocarbons (HC) and carbon monoxide (CO)
are oxidized to create water (H2O) and carbon
Catalytic Muffler
dioxide (CO2).
In order to meet 2007 emission requirements a 3-
way catalyst is necessary.
All exhaust gases pass through a catalyst that is

mounted in the catalytic muffler. It filters the harmful
gases through a dense honeycomb structure coated
with precious metals such as platinum, palladium,
and rhodium. Chemical reactions occur on these
surfaces to convert the pollutants into less harmful
gases. Catalysts store oxygen on lean mixtures
(less than optimal amount of fuel) and release
oxygen on rich mixtures (more than optimal amount
of fuel). The primary pollutant produced on the lean
swing is nitrous oxide. Oxygen is removed from
nitrous oxide by the converter, resulting in nitrogen The MI-07 control system monitors the exhaust
gas, a harmless emission. On the rich cycle, the stream pre and post catalyst and uses this
primary pollutant is carbon monoxide. By adding the information to control the air-fuel mixture. By using
oxygen that was stored on the lean cycle to the the signals from the HEGOs, the SECM can
carbon monoxide, carbon dioxide is produced. increase or decrease the amount of oxygen in the
exhaust by modulating the FTVs and adjusting the
Inside the catalytic muffler is a three-way catalyst as air-fuel ratio. This control scheme allows the SECM
well as sound dampening and spark arresting to make sure that the engine is running at the
features. The three-way catalyst section consists of correct air to fuel ratio so that the catalyst can
a honeycomb coated with a mixture of platinum, perform as required to meet the emissions
palladium and rhodium. As engine exhaust gases certification.
flow through the converter passageways, they
contact the coated surface, which initiate the
catalytic process. The reduction catalyst is the first
stage of the catalytic converter. It uses platinum and
rhodium to help reduce the NOx emissions. The
oxidation catalyst is the second stage of the catalytic

SECM The SECM provides a transducer ground for all the
sensors, and a low side driver signal controlling the
General Description fuel lock-off, MIL, gasoline injectors, gasoline fuel
The Small Engine Control Module (SECM) pump, and FTVs.
controller has full authority over spark, fuel and air.
Utilizing a Freescale micro controller, the SECM has Fuel Management
48 pins of I/O and is fully waterproof and shock
During engine cranking at startup, the SECM
hardened. To optimize engine performance and
provides a low side driver signal to the fuel lock-off,
drivability, the SECM uses several sensors for
which opens the lock-off allowing liquid propane to
closed loop feedback information. These sensors
flow to the N-2007 regulator. A stall safety shutoff
are used by the SECM for closed loop control in
feature is built into the SECM to close the lock-off in
three main categories:
case of a stall condition. The SECM monitors three
Fuel Management
engine states: Crank, when the crankshaft position
Load/Speed Management
sensor detects any engine revolutions Stall, when
Ignition Management
the key is in the ON position but the crankshaft
position sensor detects no engine revolutions Run
state, when the engine reaches pre-idle RPM.
When an operator turns on the key switch the lock-

off is opened but if the operator fails to crank the
engine, the SECM will close the lock-off after 5
seconds.
To maintain proper exhaust emission levels, the

SECM uses a heated exhaust gas oxygen sensor
(HEGO) mounted before the catalyst, to measure
exhaust gas content in the LP gas system. Engine
speed is monitored by the SECM through a variable
reluctance (VR) sensor or Hall-Effect type sensor.
The SECM monitors system parameters and stores
Intake manifold air temperature and absolute
any out of range conditions or malfunctions as faults
pressure are monitored with a (TMAP) sensor.
in SECM memory. Engine run hours are also stored
The HEGO voltage is converted to an air/fuel ratio
in memory. Stored fault codes can be displayed on
value. This value is then compared to a target value
the Malfunction Indicator Light (MIL) as flash codes
in the SECM. The target value is based on
or read by the MI-07 Service Tool software through
optimizing catalyst efficiency for a given load and
a CAN (Controller Area Network) communication
speed. The SECM then calculates any corrections
link.
that need to be made to the air/fuel ratio.
The system operates in open loop fuel control until
Constant battery power (12 Vdc) is supplied through
the engine has done a certain amount of work.
the fuse block to the SECM and the main power
This ensures that the engine and HEGO are
relays. Upon detecting a key-switch ON input, the
sufficiently warmed up to stay in control. In open
SECM will fully power up and energize the main
loop control, the FTV duty cycle is based on engine
power relays.
speed and load.
The energized main power relays supply 12 Vdc
Once the HEGO reaches operating temperature the
power to the heated element of the oxygen sensors,
fuel management is in closed loop control for all
fuel lock-off, fuel trim valves (FTVs), gasoline
steady state conditions, from idle through full throttle.
injectors, gasoline fuel pump, crank sensor, cam
In closed loop mode, the FTV duty cycle is based on
sensor, and the ignition coils.
feedback from the HEGO sensor. The system may
The SECM supplies voltage to the electronic throttle
return to open-loop operation when engine load or
actuator, oil pressure switch, fuel temperature
engine speed vary beyond a chosen threshold.
sensor, and the coolant temperature sensor.
Transducer or sensor power (+ 5 Vdc) is regulated
The SECM makes any necessary corrections to the
by the SECM and supplied to the manifold
air-fuel ratio by controlling the inlet fuel pressure to
temperature/air pressure (TMAP) sensor, throttle
the air-fuel mixer Reducing the fuel pressure leans
position sensor (TPS), and the accelerator pedal
the air/fuel mixture and increasing the fuel pressure
position sensors (APP1 & APP2).
enriches the air-fuel mixture. Control is achieved by
modulating the fuel trim valves.

Speed Management NOTE : The DV-E5 throttle is not a serviceable
assembly. If a TPS sensor fails, the assembly
Drive-by-wire refers to the fact that the MI-07 control
should be replaced.
system has no throttle cable from the foot pedal to
the throttle body. Instead, the SECM is electronically
The MI-07 system also performs minimum (min) and
connected both to the foot pedal assembly and the
maximum (max) speed governing through the
throttle body.
SECM and DBW throttle. For min governing, or idle
The SECM monitors the foot pedal position and
speed control, the idle speed is fixed by the SECM.
controls the throttle plate by driving a DC motor
Unlike a mechanical system, the idle speed is not
connected to the throttle. The DC motor actuates the
adjustable by the end user. The idle speed is
throttle plate to correspond to the foot pedal position
adjusted by the SECM based on engine coolant
when the operator depresses the pedal. The SECM
temperature. At these low engine speeds, the SECM
will override the pedal command above a maximum
uses spark and throttle to maintain a constant speed
engine speed and below a minimum idle speed.
regardless of load.
The MI-07 system eliminates the need for air

velocity governors. This substantially increases the
peak torque and power available for a given system
as shown in Figure 21. When the engine speed
reaches the max governing point the speed is
controlled by closing the DBW throttle. Using the
DBW throttle as the primary engine speed control
allows for a smooth transition into and out of the
governor. If excessive over speed is detected, the
engine is shut down.
Figure 19. Foot Pedal
The use of electronic throttle control (ETC) ensures

that the engine receives only the correct amount of
throttle opening for any given situation, greatly
improving idle quality and drivability.
Two throttle position sensors (TPS1 and TPS2),

which are integral to the drive-by-wire (DBW) throttle
assembly, provide feedback for position control by
monitoring the exact position of the throttle valve.
See Figure 20.
SECM self-calibration and cross checking

compares both signals and then checks for errors.
Figure 21. Peak Torque and Power Available with

MI-07 System
Figure 20. Throttle Position Sensor (TPS) on DV-E5

Throttle

Drive-By-Wire Signal Flow Process Ignition Management
In the normal course of events, with the engine
operating at the correct temperature in defined
conditions, the SECM will use load and engine
speed to derive the correct ignition timing. In
addition to load and speed there are other
circumstances under which the SECM may need to
vary the ignition timing, including low engine coolant
temperature, air temperature, start-up, and idle
speed control.
SECM Electrical Mounting

Recommendations
In order to prevent the possibility of any SECM
malfunctions due to EMI/RFI emissions, engine
packagers and OEMs should follow industry best
practices and the SECM mounting and harness
recommendations listed below:
The SECM should be mounted in a location that

minimizes the amount of EMI the module is
exposed to by locating it as far as practical from
all high tension components, such as ignition coils,
distributors, spark plug wires, etc. It is
recommended that the SECM be mounted at least
29.5 (749 mm) away from the distributor and
ignition coil, and at least 20 (508 mm) from the
Figure 22. Drive-By-Wire Signal Flow Process nearest plug wire.
All wiring harnesses should be routed to minimize
coupling (both radiated and conducted), and be
Figure 22 describes the signal flow process of the
securely fastened to minimize movement and
MI-07 DBW section. The foot pedal assembly uses
maintain proper clearance between the SECM
two potentiometers to detect pedal position.
and all ignition system components.
These two signals, accelerator pedal position 1
The OEM must ensure that a high-quality ground
(APP1) and accelerator pedal position 2 (APP2) are
connection between the SECM and battery
sent directly to the SECM.
negative () is provided and can be maintained for
The SECM uses a series of algorithms to self
the useful life of the vehicle. This may require the
calibrate and cross check the signals from the pedal
use of star-type washers on all ground lug
assembly. A demand position for the throttle will
connections between the SECM and the battery
then be derived and sent to the throttle as a throttle
and/or special preparation of all mating surfaces
position sensor demand (TPSd). This signal will be
that complete the ground connection in order to
processed through a PID (Proportional, Integral,
ensure that the connection is sound.
Derivative) controller in the SECM to achieve the
appropriate motor-current response then passed to
Engineering judgment must be exercised on all
the throttle. The throttle moves to the commanded
applications to determine if appropriate measures
position and provides a feedback signal from the
have been implemented to minimize EMI exposure
throttle position sensors (TPS1 and TPS2) to the
to the SECM and associated cabling. The above
SECM.
recommendations do not provide any guarantee of
proper system performance.

SECM Wiring Diagrams for G420FE
CAUTIONPROPER WIRING
To prevent system faults be sure to follow good

wiring practices. Poor wiring may cause
unexpected or intermittent failures not related to
MI-07 components.
Figure 23. SECM Wiring Diagram for G420FE Engine Systems

Figure 23. SECM Wiring Diagram for G420FE Engine Systems

G420F EMS (Engine Management System) Overview
General Description
MI-07 control system provides a complete, fully Engine speed is monitored by the SECM through a
integrated engine management system for naturally Hall Effect sensor. Intake manifold air temperature
aspirated engines. and absolute pressure are monitored with a TMAP
sensor. MI-07 is a drive-by-wire (DBW) system
It provides accurate, reliable, and durable control of connecting the accelerator pedal to the electronic
spark and air over the service life of the engine in throttle through the electrical harness; mechanical
the extreme operating environment found in heavy- cables are not used. A throttle position sensor (TPS)
duty, under hood, on-engine electronic controls. monitors throttle position in relation to the
accelerator pedal position sensor (APP) command.
The SECM monitors the engine through a number of Even engine coolant temperature and adequate oil
different sensors to ensure optimal performance. pressure are monitored by the SECM
Figure 2. G420F Dual Fuel System
The LPG regulator and the mixer operate as an crank position sensor and throttle position is used by
open loop system since no mixture adjustments are the SECM to calculate load. Feedback from the
made by the SECM. The mixer does have an idle electronic throttle is provided to the SECM by the
mixture adjustment and a power valve adjustment. throttle position sensors (TPS).
Manifold pressure from the TMAP, rpm from the

Dual Fuel System of G420F
INPUT OUTPUT
Crank Sensor Throttle body
CAM sensor 4 Power TRs

4 Ignition coils
TMAP sensor
Coolant Temp
LP fuelock valve
EG oil pressure switch

4 Injectors
T/M Temp switch SECM

Fuel Pump
Accel pedal angle sensor

CAN communication
Throttle position sensor
Oxygen sensor
(Gasoline only)
T/M Inching pressure

switch
A dual fuel system operates on either LPG or

gasoline. The fuel type can be switched while the
engine is stopped or running at low speeds and low
loads. The fuel selection switch is a three-position
type where the center position is fuel off.
MPI (multi-point injection) system is used for

G420FE dual fuel engine and G420F gasoline/dual
fuel engine. On gasoline, the camshaft sensor along
with the crankshaft sensor is used to control the fuel
injectors and feedback from oxygen sensor is used
by the SECM to adjust the gasoline delivery based
on the exhaust emissions.

MI-07 System Components MI-07 System Features
The MI-07 control system provides electronic control The MI-07 system uses an advanced speed-density
to the following subsystems on mobile industrial control strategy for fuel, spark, and air throttle
engines: control. Key features include the following.
Fuel delivery system Open-loop fuel control with fuel specific controls
Spark-ignition control system for LPG
Air throttle Closed-loop fuel control with fuel specific controls
Sensors/Switches/Speed inputs for gasoline (MPI)
The chart below lists the MI-07 components required Speed-load spark control with tables for dwell,
for a G420F engine operating on LP fuel. timing, and fuel type
Speed-load throttle control with table for maximum
Key Components TPS limiting
The MI-07 system functions primarily on engine Min/max governing
components that affect engine All-speed isochronous governing
Fixed-speed isochronous governing with three
Qty DESCRIPTION switch-selectable speeds
G420FE G420F Spark timing modifiers for temperature and fuel
-LP -LP type
1 1 Engine Control Module Transient wall wetting compensation for gasoline
(SECM 48-pin) Input sensor selection and calibration
1 1 Camshaft Position Sensor Auxiliary device control for fuel pump, fuel lock-off
1 1 Crankshaft Position Sensor solenoid, tachometer, MIL, interlocks, vehicle
1 1 TMAP Sensor speed limiting, etc.
1 None Fuel Temperature Sensor CANBus data transfer for speed, torque, etc.
1 1 Transmission Oil
Temperature Switch
2 None Oxygen Sensors
1 1 Coolant Temperature
Sensor
1 1 Engine Oil Pressure Switch
2 None Fuel Trim Valve
4 4 Ignition Coils
4 4 Power TR
1 1 Fuel Lock Off Solenoid
N-2007 N-2001 LP Regulator
CA-100 CA-100 LP Mixer
(Certified)
1 1 Electronic Throttle Body
emissions and performance. These key components
include the following:
Engine/Combustion chamber design

Intake/Exhaust valve configuration, timing and lift
Intake/Exhaust manifold design
Throttle body
Air intake and air filter
LPG mixer
LPG pressure regulator
Small engine control module (SECM), firmware
and calibration
Fuel system sensors and actuators
Ignition system including spark plugs, cables, coils
and drivers
Gasoline injectors and fuel pressure regulator (dual
fuel system only)

Other system features include: LPG Fuel System Operation
Tamper-Resistance The principles outlined below describe the operation

Special tools, equipment, knowledge, and of MI-07 on an LPG fuel system.
authorization are required to effect any changes to
the MI-07 system, thereby preventing unauthorized An LPG fuel system consists of the following
personnel from making adjustments that will affect components:
performance or emissions.
Fuel filter (supplied by customer)
Diagnostics Electric fuel lock-off solenoid valve
MI-07 is capable of monitoring and diagnosing Fuel pressure regulator/vaporizer
problems and faults within the system. These Gas/Air mixer
include all sensor input hardware, control output Miscellaneous customer-supplied hoses and
hardware, and control functions such as closed-loop fittings
fuel control limits and adaptive learn limits. Upon
detecting a fault condition, the system notifies the Fuel is stored in the customer-supplied LPG tank in
operator by illuminating the MIL and activating the saturated liquid phase and enters the fuel system
appropriate fault action. The action required by each from the tank as a liquid and at tank pressure. Fuel
fault shall be programmable by the OEM customer passes through a high-pressure fuel filter and lock-
at the time the engine is calibrated. off solenoid, and is then vaporized and regulated
down to the appropriate pressure to supply the
Diagnostic information can be communicated mixer. The regulator controls the fuel pressure to the
through both the service tool interface and the MIL gas/air mixer. The mixer meters fuel delivery based
lamp. With the MIL lamp, it is possible to generate a upon airflow into the engine.
string of flashing codes that correspond to the fault
type. These diagnostics are generated only when SECM
the engine is not running and the operator initiates a
The Small Engine Control Module (SECM) controls
diagnostic request sequence such as repeated
the LPG lock-off solenoid valve. The lock-off
actuations of the pedal within a short period of time
solenoid is energized when fueling with LPG and the
following reset.
engine is turning. The lock-off is de-energized when
engine rpm is not detected.
Limp Home Mode
The system is capable of "limp-home" mode in the
event of particular faults or failures in the system. In MI-07 LP Fuel Filter
limp-home mode the engine speed is approximately The LP fuel filter of G420F engine is the same as
1000 rpm at no load. A variety of fault conditions can that of G420FE engine. See, G420FE EMS
initiate limp-home mode. These fault conditions and overview
resulting actions are determined during calibration
and are OEM customer specific. MI-07 Fuel Lock-Off (Electric)
The LP fuel lock-off of G420F engine is the same as
Service Tool
that of G420FE engine. See, G420FE EMS
A scan tool/monitoring device is available to monitor
overview
system operation and assist in diagnosis of system
faults This device monitors all sensor inputs, control
outputs, and diagnostic functions in sufficient detail N-2001 Regulator/Converter
through a single access point to the SECM to allow After passing through the electric fuel lock-off, liquid
a qualified service technician to maintain the system. propane enters the N-2001 regulator/converter
This Mototune software (licensed by Mototron (Figure 4). The N-2001 functions as a fuel vaporizer,
Communication) is secure and requires a crypt- converting liquid propane to vapor propane and as a
token USB device to allow access to information. two-stage negative pressure regulator, supplying the
correct vapor propane fuel pressure to the mixer.
The regulator is normally closed requiring a vacuum

signal (negative pressure) to allow fuel to flow. This
is the second of three safety locks in the MI-07
system. If the engine stops, vacuum signal stops
and fuel flow will automatically stop when both the

secondary (2nd stage) valve and the primary (1st N-2001 Operation
stage) valve closes. Unlike most other
regulator/converters, the N-2001 primary valve
Refer to Figure 6.
closes with fuel pressure rather than against
Liquid propane, at tank pressure, enters the N-2001
pressure, extending primary seat life and adding
through the fuel inlet port (1). Propane liquid then
additional safety.
flows through the primary valve (2). The primary
valve located at the inlet of the expansion chamber
(3), is controlled by the primary diaphragm (4),
which reacts to vapor pressure inside the expansion
chamber. Two springs are used to apply force on
the primary diaphragm in the primary diaphragm
chamber (5), keeping the primary valve open when
no fuel pressure is present.
A small port connects the expansion chamber to the

primary diaphragm chamber. At the outlet of the
expansion chamber is the secondary valve (6). The
secondary valve is held closed by the secondary
spring on the secondary valve lever (7). The
secondary diaphragm controls the secondary lever.
Figure 4. N-2001 Regulator
When the pressure in the expansion chamber
reaches 1.5 psi (10.342 kPa it causes a pressure/
force imbalance across the primary diaphragm (8).
Liquid propane must be converted into a gaseous
This force is greater than the primary diaphragm
form in order to be used as a fuel for the engine.
spring pressure and will cause the diaphragm to
When the regulator receives the desired vacuum
close the primary valve.
signal it allows propane to flow to the mixer. As the
propane flows through the regulator the pressure is
reduced in two stages from tank pressure to slightly
less than atmospheric pressure. As the pressure of
the propane is reduced the liquid propane vaporizes
and refrigeration occurs inside the regulator due to
the large temperature drop inside the regulator from
the vaporization of liquid propane. To replace heat
lost to vaporization, engine coolant is supplied by
the engine driven water pump and pumped through
the regulator. Heat provided by this coolant is
transferred through to the fuel vaporization chamber.
Figure 5 shows the heat chamber and the coolant
passage in the N-2001 regulator.
Figure 6. Parts View of N-2001 Regulator
Since the fuel pressure has been reduced from tank

pressure to 1.5 psi (10.342 kPa) the liquid propane
vaporizes. As the propane vaporizes it takes on heat
from the expansion chamber. This heat is replaced
by engine coolant, which is pumped through the
coolant passage of the regulator. At this point vapor
propane will not flow past the expansion chamber of
the regulator until the secondary valve is opened.
To open the secondary valve a negative pressure
signal must be received from the air/fuel mixer.
When the engine is cranking or running a negative
pressure signal (vacuum) travels through the vapor
fuel outlet connection of the regulator (9), which is
Figure 5. Heat Chamber and Coolant Passage the regulator secondary chamber, and the vapor fuel
inlet of the mixer. The negative pressure in the
secondary chamber causes a pressure/force

imbalance on the secondary diaphragm, which CA100 Mixer Operation
overcomes the secondary spring force, opening the
Vapor propane fuel is supplied to the CA100 mixer
secondary valve and allowing vapor propane to flow
by the N-2001 pressure regulator/converter. The
out of the expansion chamber, through the
mixer uses a diaphragm type air valve assembly to
secondary chamber to the mixer.
operate a gas-metering valve inside the mixer. The
gas-metering valve is normally closed, requiring a
Because vapor propane has now left the expansion
negative pressure (vacuum) signal from a cranking
chamber, the pressure in the chamber will drop,
or running engine to open. This is the third of the
causing the primary diaphragm spring force to re-
three safety locks in the MI-07 system. If the engine
open the primary valve allowing liquid propane to
stops or is turned off, the air valve assembly closes
enter the regulator, and the entire process starts
the gas-metering valve, stopping fuel flow past the
again. This creates a balanced condition between
mixer. The gas-metering valve controls the amount
the primary and secondary chambers allowing for a
of fuel to be mixed with the incoming air at the
constant flow of fuel to the mixer as long as the
proper ratio. The air/fuel mixture then travels past
demand from the engine is present. The fuel flow is
the throttle, through the intake manifold and into the
maintained at a constant output pressure, due to the
engine cylinders where it is compressed, ignited and
calibrated secondary spring. The amount of fuel
burned.
flowing will vary depending on how far the
secondary valve opens in response to the negative
pressure signal generated by the air/fuel mixer. The
strength of that negative pressure signal developed
by the mixer is directly related to the amount of air
flowing through the mixer into the engine. With this
process, the larger the quantity of air flowing into the
engine, the larger the amount of fuel flowing to the
mixer.
CA100 Mixer
The mixer is installed above the throttle body and
meters gaseous fuel into the airstream at a rate that
Figure 8. CA100 Mixer Attached to Throttle Body
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel
(Refer to Figure 98.)
flow is controlled by the shaping of the mixer fuel
The air/fuel mixer is mounted in the intake air stream
cone and biased by the controllable fuel supply
between the air cleaner and the throttle. The design
pressure delivered by the pressure regulator. Fuel
of the main body incorporates a cylindrical bore or
flow must be metered accurately over the full range
mixer bore, fuel inlet (1) and a gas discharge jet (2).
of airflows. Pressure drop across the mixer air valve
In the center of the main body is the air valve
must be minimized to assure maximum power
assembly, which is made up of the air valve (3), the
output from the engine.
gas-metering valve (4), and air valve diaphragm (5)
and air valve spring (6). The gas-metering valve is
A higher flow mixer is required on larger engines. A
permanently mounted to the air valve diaphragm
lower flow mixer is required on smaller engines.
assembly with a face seal mounted between the two
parts.
When the engine is not running this face seal

creates a barrier against the gas discharge jet,
preventing fuel flow with the aid (downward force) of
the air valve spring. When the engine is cranked
over it begins to draw in air, creating a negative
pressure signal. This negative pressure signal is
transmitted through four vacuum ports in the air
valve.
Figure 7. CA100 Mixer

Figure 9. Parts View of CA100 Mixer Figure 11. CA100 Mixer Installed with Electronic
Throttle
A pressure/force imbalance begins to build across
the air valve diaphragm between the air valve A main mixture adjustment valve on the fuel inlet of
vacuum (AVV) chamber (above the diaphragm) and the CA100 is not used in the MI-07 system, however
atmospheric pressure below the diaphragm. an idle mixture adjustment is incorporated into the
Approximately 6 inH2O (14.945 mbar) of negative mixer (Figure 12). The idle mixture adjustment is an
pressure is required to overcome the air valve spring air bypass port, adjusting the screw all the way in,
force and push the air valve assembly upward off blocks off the port and enriches the idle mixture.
the valve seat. Approximately 24 inH2O (59.781 Backing out the idle adjustment screw opens the
mbar) pulls the valve assembly to the top of its travel port and leans the idle mixture. The idle mixture
in the full open position. screw is a screw with locking threads that is factory
set with a tamper proof cap installed after
The amount of negative pressure generated is a adjustment. Accurate adjustment of the idle mixture
direct result of throttle position and the amount of air can be accomplished by adjusting for a specific fuel
flowing through the mixer to the engine. At low trim valve (FTV) duty cycle with the Service Tool
engine speeds, low AVV causes the air valve software or with a voltmeter.
diaphragm assembly to move upward a small
amount, creating a small venturi. At high engine NOTE: Adjustments should only be performed by
speeds, high AVV causes the air valve diaphragm trained service technicians.
assembly to move much farther creating a large
venturi. The variable venturi air/fuel mixer constantly
matches venturi size to engine demand.
Figure 12. Idle Mixture Adjustment Screw
Figure 10. Bottom View of Air Valve Assembly

MPI Gasoline System Operation SECM
The MPI Gasoline System of G420F engine is the The SECM of G420F engine is the same as that of
same as that of G420FE engine. See, MPI Gaso- G420FE engine. See, SECM of G420FE EMS over-
line System Operation of G420FE EMS overview view
Electronic Throttle System
The electronic throttle system of G420F engine is

the same as that of G420FE engine. See, Electro-
nic throttle system of G420FE EMS overview
Ignition System
The Ignition system of G420F engine is the same as

that of G420FE engine. See, Ignition system of
G420FE EMS overview
Exhaust System
Heated Exhaust Gas Oxygen Sensors (HEGO)
G420F MPI Gasoline system utilizes one HEGO

(O2) sensor. It is a pre-catalyst sensor that detects
the amount of oxygen in the exhaust stream and is
considered the primary control point. Based upon
the O2 sensor feedback, the MI-07 system supplies
a optimized air-fuel.
G420F LP system does not utilize HEGO sensor

because it is open-loop system.
Figure 18. HEGO (O2) Sensor

SECM Wiring Diagrams for G420F

EMS Inspection and Repair Fuel Temperature Sensor (FTS)
-40F to 266F (-40C to 130C) range,
48K ohm to 57 ohm sensor range
Engine Control Module (SECM)
HEGO (3) 0 to 1 V
The 48-pin Small Engine Control Module (SECM)
Auxiliary Analog Input (2) 0 to 5 V
and sensors provide the computational power,
algorithm logic, sensor inputs and control outputs to
Battery Voltage (Vbatt) (1) 8-18 V
control the system. The SECM receives signals from
the sensors, digitizes these signals, and then,
With the exception of battery voltage, all inputs are
through algorithms and calibration maps, computes
0-5 Vdc, ground referenced. Resolution should be
the desired output response to effect control of fuel,
0.1% or better. Accuracy should be 2% or better.
spark and air to the engine. The SECM also
provides a variety of other functions and features.
These include system monitoring and diagnostics to Frequency/Position Inputs
aid in maintaining efficient system operation and
auxiliary control. Crankshaft position
Variable reluctance (2-wire, 200 Vpp max) or 0-5
V Hall Effect with calibration selectable pull-up
resistor for open collector sensors Permits speed
resolution of 0.25 rpm and crankshaft position
resolution of 0.5
Camshaft position
Variable reluctance (2-wire, 200 Vpp max) or 0-5
V Hall Effect with calibration selectable pull-up
resistor for open collector sensors.
Digital Inputs
Oil pressure switch

SECM/sensor inputs and control output specifica-
Normally open, internal pull-up resistor provided
tions are specific to the application, but include a
to detect external switch to ground
selection of the following:
Transmission oil temperature switch
Analog Inputs Normally open, internal pull-up resistor provided
to detect external switch to ground
The 48-pin SECM is equipped with sufficient analog
inputs for the following sensors. Fuel select switch
Three-position switch for bi-fuel applications to
Manifold Absolute Pressure (MAP) 1bar MAP, 0 to detect gasoline mode, LPG mode, and fuel off
5V (center switch position)
Manifold Air Temperature (MAT) Ground speed select switch

-40F to 266F (-40C to 130C) range, 48 kohm Permits selecting two different maximum engine
to 85 ohm sensor range speeds
Throttle Position Sensor 1&2 (TPS1 & TPS2) 0 to Vswitched

5V Switched battery voltage
Foot Pedal Position 1&2 (FPP1 & FPP2) 0 to 5 V
Coolant Temperature Sensor (CTS)

-40F to 266F (-40C to 130C) range,
48K ohm to 85 ohm sensor range

Outputs
Saturated injector drivers (4)

10A peak, 45 V max, 1 injector per channel
capable of continuous on-time
Driver circuit designed for minimum turn-on/turn-
off delay
Minimum pulse width resolution of 1 usec
FTV drivers (2)

10A peak, 45V max. To drive an on/off fuel trim
valve with a minimum impedance of 5 ohms
Capable of continuous on-time
Drive circuit designed for minimum turn-on /turn-
off delay
FTVs will be pulse width modulated between 8
and 40 Hz with a minimum pulse width resolution
of 50 usec
Fuel lock-off solenoid valve

Low side switch, 10A peak, 4A continuous 45 V
max
Gasoline fuel pump drive

Low side switch, 10A, 4A continuous 45 V max
Electronic Spark Timing (EST) (4)

TTL compatible outputs Software configured for
coil-on-plug ignition system
Throttle control (1)

H-Bridge, 5A peak, 2.5A continuous at 2500 Hz
PWM includes current feedback for diagnostic
purposes.
MIL (malfunction indicator lamp)

Low side switch, sufficient to drive a 7W incandes-
cent lamp continuously
CANBus
CAN 2.0b serial communication for J1939 com-
munications, programming and diagnostics.
Requires proper termination resistance per CAN
2.0b.

Camshaft Position Sensor Sensor Inspection
Component Location
3 2 1
1. Turn ignition switch to OFF position and then

disconnect CMPS connector.
Description 2. Remove the CMPS from the engine.
3. Turn ignition switch to ON position.

The Camshaft Position Sensor (CMPS) is a sensor
that detects the compression TDC of the NO.1
4. Apply battery voltage to the terminal 1 and ground
cylinder.
terminal 3 of CMPS as shown in the figure.
The CMPS consists of a hall type sensor and a
target on the end of the in take camshaft.
5. Install a LED between +5V power and CMPS
When the target triggers the sensor, the sensor
terminal 2, and then set a steel wheel (or anything
voltage is 5V. If not, the sensor voltage is 0V.
made of steel; hammer, wrench, bolt and nut etc.)
These CMPS signal is sent to the ECM and the
at the CMPSs tip.
ECM uses the CMPS signal for synchronizing the
firing of sequential fuel injectors.
6. Rotate the steel wheel slowly and check if the
LED flashes light.
Schematic Diagram
If the LED blinks, the CMPS works normally.
[CIRCUIT DIAGRAM]
CMPS
ECM
3 B1 - GND
2 B10 - CMPS
SIGNAL
1 After Main
Relay
A23_DRVP
[HARNESS CONNECTORS]
3 2 1
C14
CMPS

Crank Shaft Position Sensor Schematic Diagram
Component Location
[CIRCUIT DIAGRAM]
CKPS
ECM
3 B1 - GND
2 B5 - CKPS
SIGNAL
1 After Main Relay
A23_DRVP
Description
3 2 1
The Crankshaft Position Sensor (CKPS) is a hall
effect type sensor that generates voltage using a C13
sensor and a target wheel mounted on the CKPS
crankshaft; there are 58 slots in the target wheel
where one is longer than the others.
When the slot in the wheel aligns with the sensor, Sensor Inspection
the sensor voltage out put slow.
When the metal (tooth) in the wheel aligns with the
sensor, the sensor voltage out puts high.
During one crankshaft rotation there are 58
rectangular signals and one longer signal. The ECM
calculates engine RPM by using the sensor signal
and controls the injection duration and the ignition
timing. Using the signal differences caused by the
longer slot, the ECM identifies which cylinder is at
3 2 1
top dead center.
1. Turn ignition switch to OFF position and then

disconnect CKPS connector.
2. Remove the CKPS from the engine.
3. Turn ignition switch to ON position.
4. Apply battery voltage to the terminal 1 and ground
terminal 1 and ground terminal 3 of CKPS as
shown in the figure.
5. Install a LED between +5V power and CKPS
terminal 2, and then set a steel wheel (or anything
made of steel ; hammer, wrench, bolt and nut etc.)
at the CKPS's tip.
6. Rotate the steel wheel slowly and check if the
LED flashes light.
If the LED blinks, the CKPS works normally.

MAP (Manifold Absolute Pressure) Sensor Inspection
Sensor 1. Measure the voltage between terminals 1 and 4 of

the MAP sensor connectors.
Terminal 4 : MAP sensor ground
Terminal 1 : MAP sensor output
Engine state Test specification

Ignition SW. ON 4~5V
At idle 0.5~2.0V
2. If the voltage deviates from the standard value,

replace the MAP sensor assembly.
The manifold absolute pressure (MAP) sensor is a

pressure sensitive variable resistor. It measures
changes in the intake manifold pressure which result
from engine load and speed changes, and converts
this to a voltage output. The MAP sensor is also
used to measure barometric pressure at start up,
and under certain conditions, allows the ECM to
automatically adjust for different altitudes. The ECM
supplies 5 volts to the MAP sensor and monitors the
ECM supplies 5 volts to the MAP sensor and
monitors the voltage on a signal line. The sensor
provides a path to voltage on a signal line. The
sensor provides a path to ground through its
variable resistor. The MAP sensor in put affects fuel
delivery and ignition timing controls in the ECM.
Ciruit Diagram
MAP & IAT

sensor
MAP
IAT
3 2 1 4
Sensor IAT Sensor MAP

power signal ground signal
B24 B12 B1 B18
ECM

IAT (Intake Air Temperature) Sensor Inspection
Sensor
1. Using a multimeter, measure the IAT sensor
resistance between terminals 3 and 4.
IG.SW.ON Temperature
Resistance(k)
(F)
0 (32) 4.5 ~ 7.5
20 (68) 2.0 ~ 3.0
40 (104) 0.7 ~ 1.6
80 (176) 0.2 ~ 0.4
2. If the resistance deviates from the standard value,

replace the intake air temperature sensor
The intake air temperature sensor (IAT Sensor), assembly.
built in to the MAT sensor, is a resistor-based
sensor detect the intake air temperature. According
to the intake air temperature information frim the
sensor, the ECM will control the necessary amount
of fuel injection.
Ciruit Diagram
MAP & IAT

sensor
MAP
IAT
3 2 1 4
Sensor IAT Sensor MAP

power signal ground signal
B24 B12 B1 B18
ECM

Oxygen Sensor (Pre-Catalyst) Schematic Diagram
Component Location
[CIRCUIT DIAGRAM]
HO2S (B1/S1) ECM
4
3 A23 - HO2S HEATER

(B1/S1)
1
B13 - HO2S SIGNAL
2
B1 - HO2S GND
After Main Relay

L4GC215A
Description
The heated oxygen sensor is mounted on the front

side of Catalytic Muffler, which detects the oxygen 2 1
concentration in the exhaust gas. The heated 4 3
oxygen sensor produces a voltage that varies
between 0V and 1V. When the air/fuel ratio is lean,
the oxygen concentration in the exhaust gas C16
increases and the front HO2S outputs a low voltage HO2S (B1/S1)
(approximately0~0.1V). When the air/fuel ratio is
rich, the oxygen concentration in the exhaust gas
decreases and the front HO2S outputs a high Signal Wave Form
voltage (approximately0.8~1V). The ECM constantly
monitors the HO2S and increases or decreases the
fuel injection duration by using the HO2S signal,
which is called closed-loop fuel control operation.
Specification
Temperature Front Temperature Front HO2S

HO2S Heater
() () Heater () () Resistance
Resis- ()
tance()
20 68 9.2 400 752 17.7
100 212 10.7 500 932 19.2
200 392 13.1 600 1,112 20.7 If you release the accelerator pedal suddenly after
300 572 14.6 700 1,292 22.5 engine running about 2600 rpm, fuel supply will stop
for short period and the O2 sensor service data will
display values 200mV or lower. When you suddenly
press on the accelerator pedal down, the voltage will
reach 0.6 ~ 1.0 V. When you let the engine idle
again, the voltage will fluctuate between 200 mV or
lower and 0.6 ~ 1.0 V. In this case, the O2sensor
can be determined as good.

Oxygen Sensor (Post-Catalyst) Signal Wave Form
Component Location
The amplitude of the signal output of the rear HO2S

is small compared to the front HO2S because the
rear HO2S detects emission gas purified by the
Description catalytic converter. This illustration is the normal
signal waveform of the rear HO2S at idle.
The rear heated oxygen sensor is mounted on the
rear side of the Catalytic Muffler, which detects the
catalyst efficiency. The rear heated oxygen sensor Specification
(HO2S) produces a voltage between 0V and 1V. Temperature Rear Temperature Rear
This rear heated oxygen sensor is used to estimate HO2S HO2S
the oxygen storage capability. If a catalyst has good () () Heater () () Heater
conversion properties, the oxygen fluctuations are Resis- Resistanc
smoothed by the oxygen storage capacity of the tance() e()
catalyst. If the conversion provided by the catalyst is 20 68 9.2 400 752 17.7
low due to aging, poisoning or misfiring, then the
oxygen fluctuations are similar to signals from the 10 212 10.7 500 932 19.2
front oxygen sensor.
200 392 13.1 600 1,112 20.7
Schematic Diagram 300 572 14..6 700 1,272 22.5
[CIRCUIT DIAGRAM]
HO2S (B1/S2) ECM
3
4 A23 - HO2S HEATER

(B1/S2)
2
B19 - HO2S SIGNAL
1 B1 - HO2S GND
After Main Relay
1 2
3 4
C22

ECT (Engine Coolant Temperature) Sensor Inspection
Sensor
Component Location
1. Remove the engine coolant temperature sensor

from the intake intake manifold.
2. With the temperature sensing portion of the

engine coolant temperature sensor immersed in
Description hot water, check resistance.
The Engine Coolant Temperature Sensor (ECTS) is
located in the engine coolant passage of the cylinder Temperature () ECTS Resistance(k)
head for detecting the engine coolant temperature. -20(-4) 14.13~16.83
The ECTS uses a the rmistor whose resistance 0(32) 5.79
changes with the temperature. The electrical 20(68) 2.31~2.59
resistance of the ECTS decreases as the 40(104) 1.15
temperature increases, and increases as the 60(140) 0.59
temperature decreases. The reference 5 V in the 80(176) 0.32
ECM is supplied to the ECTS via a resistor in the
ECM. That is, the resistor in the ECM and the 3. If the resistance deviates from the standard value
thermistor in the ECTS are connected in series. greatly, replace the sensor.
When the resistance value of the thermistor in the
ECTS changes according to the engine coolant
temperature, the output voltage also changes.
During cold engine operation the ECM increases the
fuel injection duration and controls the ignition timing
using the information of engine coolant temperature
to avoid engine stalling and improve drivability.

Schematic Diagram
[CIRCUIT DIAGRAM]
ECTS ECM
1
B15 - ECTS SIGNAL
2
to Cluster
3
B1 - GND
3 2 1
C11
ECTS
Installation
1. Apply sealant LOCTITE 962T or equivalent to

threaded portion.
2. Install engine coolant temperature sensor and

tighten it to specified torque.
Tightning torque
Engine coolant temperature sensor "

15~20Nm (150~200 kg.cm, 11~15 lb.ft)
3. Connect the harness connector securely.

LP Fuel Temperature Sensor [Harness Connectors]
Location
Inspection
1. Remove the LP fuel temperature sensor from the
Description adapter connected to LP mixer.
The LP Fuel Temperature Sensor (FTS) is located in
2. With the temperature sensing portion of the LP
the LP fuel passage of the LP mixer for detecting the
engine fuel temperature immersed in hot water,
LP fuel temperature. The FTS uses a thermistor
check resistance.
whose resistance changes with the temperature.
The electrical resistance of the FTS decrease as the
Temperature C (F) FTS Resistance (Ohms)
temperature increase, and increase as the
temperature decrease. The reference 5V in the ECM -20(-4) 15462
is supplied to the FTS by way of a resister in the 0(32) 5896
ECM. That is, the resistor in the ECM and the 20(68) 2498
thermistor in the FTS are connected in series. When 40(104) 1175
the resistance value of the thermistor in the FTS 60(140) 596
changes according to the LP fuel temperature, the 80(176) 323
output voltage also change.
3. If the resistance deviates from the standard value
[Circuit Diagram] greatly, replace the sensor.

Angle Sensor-Accelerator [Harness Connectors]
Location
Inspection
1. Disconnect the Accelerator Pedals connector
Description from the main engine harness.
Angle Sensor-Accelerator is located in the
2. Inspect the electrical conditions with a follow
accelerator pedal assembly. The engine speed
basic specification.
management deals with a Drive-by-wire system.
Drive-by-wire refers to the fact that the MI-07 control
Signal output is on condition that input voltage
system has no throttle cable from the foot pedal to
is 5V0.5%
the throttle body. Instead, the ECM is electronically
Rated current : 20Ma,
connected both to the foot pedal assembly and the
Power : 100mW,
throttle body. The SECM monitors the foot pedal
Wire width : 20AWG
position and controls the throttle plate by driving a
- At start point : Signal A 0.4V0.1V
DC motor connected to the throttle. The DC motor
Signal B 4.5V0.1V
actuates the throttle plate to correspond to the foot
- At end point(Push for end) :
pedal position when the operator depresses the
Signal A 3.60V0.15V
pedal. The SECM will override the pedal command
Signal B 1.39V0.15V
above a maximum engine speed and below a
minimum idle speed. The foot pedal assembly uses
two potentiometers to detect pedal position. These
3. If the result value is out of the specification,
two signals, accelerator pedal position 1 (APP1) and
replace the Accelerator Pedal.
accelerator pedal position 2 (APP2) are sent directly
to the SECM. The SECM uses a series of algorithms
to self calibrate and cross check the signals from the
pedal assembly.
[Circuit Diagram]

Transmission Oil Temperature Switch [Harness Connectors]
Location
Inspection
1. Remove the Transmission Oil Temperature
Description Switch from the transmission.
Transmission Oil Temperature Switch is located in
2. Use an ohmmeter to check the continuity between
the adapter on transmission (T/M) for operating by
the 1 terminal and the 2 terminal. If there is
the transmission (T/M) oil temperature change. This
continuity, replace the Transmission Oil
switch is normally open, and then it is closed as the
Temperature Switch.
T/M oil temperature Increases to the 1253C.
Actually if the switch is closed by high T/M oil
3. The Transmission Oil Temperature Switch is the
temperature, the ECM makes engine shutdown with
ON/OFF switch. So during the normal status the
fault set. If the T/M oil temperature decreases to the
switch circuit should be open.
118C, the switch is open again and the engine also
can run. This function can protect the engine of Tier-
3 and Non cert folk lift trucks from damage as
overheating.
[Circuit Diagram]

Ground Speed Limit Switch (optional) [Harness Connectors]
Location
Inspection
1. Remove the Ground Speed Limit Switch from the
Description transmission.
Ground Speed Limit Switch is located in the
2. Use an ohmmeter to check the continuity between
pressure port on transmission (T/M) for operating by
the 1 terminal and the 2 terminal. If there is
the transmission (T/M) oil pressure change. This
continuity, replace the Ground Speed Switch.
switch is normally opened, and then it is closed as
the T/M oil pressure increases. Actually the switch is
3. The Ground Speed Limit Switch is the ON/OFF
closed by increasing of the T/M oil pressure after
switch. So during the normal status the switch
engine cranking. And if the inching pedal is pushed
circuit should be open.
by a driver the switch is opened again by decreasing
of the T/M oil pressure. ECM can control the travel
speed of the folk lift trucks with this switch. Also the
maximum travel speed of Tier-3 and Non cert fork lift
trucks is an optional feature that can be easily
activated using the MotoView Service Tool. This
feature may be of particular interest to customers
with indoor warehouse operations.
[Circuit Diagram]

Electronic Throttle Body [Harness Connectors]
Location
Inspection
1. Check for loose, dirty or damaged connectors and
Description wires on the harness
The MI-07 system uses electronic throttle control
2. Check the throttle assembly motor housing for
(ETC). The SECM controls the throttle valve based
coking, cracks, and missing cover-retaining clips
on engine RPM, engine load, and information
received from the foot pedal. Two potentiometers on
3. Check the resistance of TPS sensor. (refer as
the foot pedal assembly monitor accelerator pedal
blow chart)
travel. The electronic throttle used in the MI-07
system is a Bosch 32mm electronic throttle body
EXPECTED
DV-E5. The DV-E5 is a single unit assembly, which SENSOR POINT TO POINT
RANGE
includes the throttle valve, throttle-valve actuator
(DC motor) and two throttle position sensors (TPS). TPS PIN 2(GND) TO 1.25K +/-
The SECM calculates the correct throttle valve TPS PIN 6(TPS1 SIGNAL) 30%
opening that corresponds to the drivers demand, (Throttle TPS PIN 3(PWR) TO 1.25K +/-
makes any adjustments needed for adaptation to the Position PIN 6(TPS1 SIGNAL) 30%
engines current operating conditions and then Sensor) TPS PIN 1(+DRIVER) ~3.0K +/-
generates a corresponding electrical (driver) signal TO PIN 4(-DRIVER) 30%
to the throttle-valve actuator.
[Circuit Diagram]

Chapter 6. LPG FUEL DELIVERY SYSTEM
G420FE LP System Inspection and

Repair
WARNING - PROPER USE
LP gas is highly flammable. To prevent

personal injury, keep fire and flammable
materials away from the lift truck when work is
done on the fuel system.
Gas vapor may reduce oxygen available for

breathing, cause headache, nausea, dizziness
and unconsciousness and lead to injury or
death. Always operate the forklift in a well
ventilated area
Liquid propane may cause freezing of tissue or

frostbite. Avoid direct contact with skin or
tissue; always wear appropriate safety
protection including gloves and safety glasses
when working with liquid propane.
CAUTION
The regulator/converter and mixer are part of a

certified system complying with EPA and CARB
2007 requirements. Only trained, certified
technicians should perform disassembly,
service or replacement of the regulator/
converter or mixer.
G420F(FE) Service Manual 204 Chapter 6. LPG FUEL DELIVERY SYSTEM

Hose Connections
Proper operation of the closed loop control greatly depends on the correct vacuum hose routing and fuel line
lengths. Refer to the connection diagrams below for proper routing and maximum hose lengths when
reinstalling system components.
Certified System Connections
Figure 26. Hose Connections for Certified Systems
Diagram Notes

Removal and Installation of N-2007 Installation Steps
N-2007 LP Regulator
Refer to Figure 28.
Follow the procedures below for removal and
reinstallation of the N-2007 regulator in certified 1. Install the nipple extension (6) with the lock-off to
systems. the regulator.
N-2007 Removal Steps 2. Install the fuel vapor outlet hose (5) to the
regulator.
Refer to Figure 28.
3. Install the two cooling lines (4) to the regulator.
1. Close the liquid outlet valve in the forklift cylinder
or fuel storage container. 4. Install the four rear-mounting bolts that hold the
regulator to the support bracket. Use a torque
2. Purge the system of fuel by starting the engine wrench and tighten each bolt to 60-70 lbf-in (6.78-
and running until all trapped fuel in the system is 7.91 N-m).
exhausted and the engine shuts down.
5. Install the fuel inlet line (1) to the lock-off, the two
3. Key switch in OFF position. vacuum lines (2) to the branch-tee fitting in the
regulator vent and re-connect the lock-off
connector (3).
4. Remove the fuel inlet line (1) from the lock-off, the
two vacuum lines (2) from the branch-tee fitting in
6. Open the liquid outlet valve in the forklift cylinder
the regulator vent and disconnect the lock-off
or fuel storage container.
connector (3).
5. Remove the four rear-mounting bolts that hold the

regulator to the support bracket. This will allow
easier access to the remaining hose clamps.
6. Remove the two cooling lines (4) from the

regulator. NOTE: Either drain the coolant system
or clamp off the coolant lines as close to the
regulator as possible to avoid a coolant spill when
these lines are disconnected.
7. Remove the fuel vapor outlet hose (5) from the

regulator.
8. Remove the nipple extension (6) with the lock-off

from the regulator.
Figure 28. N-2007 Regulator in Certified System

Removal and Installation of CA100 Mixer for 2. Purge the system of fuel by starting the engine
G420FE and running until all trapped fuel in the system is
exhausted and the engine shuts down.
reinstallation of the CA100 mixer in certified systems. 3. Key switch in OFF position.
CA100 Certified Mixer Removal Steps 4. Remove the air cleaner hose (1).
5 5. Mark the two vacuum lines to the mixer for

identification, as they must be installed correctly
for proper operation. Remove the two vacuum
lines (2).
6. Remove vapor fuel inlet line from the fuel

temperature sensor adapter (3).
10
8 7. Disconnect the fuel temperature sensor connector
(4).
11
9 3 8. Disconnect the wires leading to the electronic
4 throttle body by pinching the lock tabs on either
7 2 side of the wiring harness connector.
9. Loosen the four bolts that secure the

mixer/adapter/throttle body assembly to the intake
6 manifold.
1
10. Remove the mixer (7), the adapter, and the

throttle body (5) as an assembly by gently
pulling upwards. Take care not to drop anything
1. Gasket-ITB down the intake manifold.
2. ITB
3. O-Ring
4. O-Ring Spacer 11. Gently wiggle and pull to separate mixer and
5. Mixer
6. Bolt adapter from the throttle body. Take note of the
7. Fuel Temp Sensor adapter orientation on the mixer, as it must be
8. Adapter-Fuel Temp Sensor reinstalled correctly for proper fit on the throttle.
9. Fitting-Vacuum Small
10. Apollo Adapter-ITB, Mixer
11. Bolt 12. Remove the four mounting screws that attach
the throttle body adapter to the mixer.
13. Remove the fuel temperature sensor (not

shown) from the tee .
14. Remove the fuel temperature sensor fitting

from the mixer. Take note of the fittings
orientation on the mixer, as it must be
reinstalled correctly for proper fit.
15. Remove the short vacuum port barb from the

mixer. (See Figure 32 for location of port barb
Figure 30. CA100 Mixer in Certified System on mixer.)
1. Close the liquid outlet valve in the forklift cylinder

or fuel storage container.

CAUTION
The 1/8 NPT x 1/4 hose barb fitting that is

installed in the mixer housing uses a specific
machined orifice size through the fitting. This
orifice fitting is part of the mixer assembly and is
an integral part of the MI-07 control. If this fitting
is damaged the mixer will need to be replaced.
DO NOT replace this fitting with a standard hose
barb fitting or use a drill bit to clean out the
fitting passage way.
NOTE : A plastic O-ring spacer and an O-ring are

inside the mixer/adapter assembly. Be careful not to
lose these items when removing the assembly from
the throttle (Figure 31).
Figure 31. O-Ring and Spacer Within Mixer Adapter

Assembly

CA100 Certified Mixer Installation Steps Tests and Adjustments
Refer to Figure 30.
WARNINGPROPER USE
1. Install the vacuum port barb below the idle set
screw on the mixer (7). LP gas is highly flammable. To prevent
personal injury, keep fire and flammable
2. Install the fuel temperature sensor adapter to the materials away from the lift truck when work is
mixer. done on the fuel system.
3. Install the fuel temperature sensor to the adapter Gas vapor may reduce oxygen available for
(6). breathing, cause headache, nausea, dizziness
4. Install the four mount screws that attach the
throttle adaptor to the mixer. See Figure 32.
ventilated area
Torque bolts to 30-40 lbf-in (3.39-4.52 N-m).
5. Install the mixer/adapter assembly to the throttle Liquid propane may cause freezing of tissue or
by gently pushing downwards. frostbite. Avoid direct contact with skin or
6. Install the four bolts that mount the throttle protection including gloves and safety glasses
adapter to the electronic throttle body (5). when working with liquid propane.
7. Re-connect the fuel temperature sensor

connector (4).
CAUTION
8. Install the vapor fuel inlet line to the fuel
temperature sensor adapter (3).
9. Install the two vacuum lines to the mixer using the certified system complying with EPA and CARB
previous marks for identification. Vacuum lines 2007 requirements. Only trained, certified
must be installed correctly for proper operation. technicians should perform disassembly,
service or replacement of the
10. Install the air cleaner hose (1). regulator/converter or mixer.
Figure 32. Throttle Adapter Mount Screws

N-2007 Regulator Service Testing
For checking the N-2007 regulator/converter

operation, the following tests can be performed (See
Chapter 5 for removal/installation of the N-2007
regulator). To check the secondary regulation
(output) a simple vacuum hand pump can be used
to simulate the vacuum signal transmitted from the
air/fuel mixer when the engine is running. See listing
below for required hardware.
Break-Off Test
Figure 34. Secondary Stage Test Connection
Secondary Stage Test Hardware
Pressure Test
1. Hand vacuum pump
Primary Stage Test Hardware
2. Regulator vapor outlet test fitting 3/4 NPT x 1/4
hose barb 1. Shop air pressure regulator adjusted to 100 psi
3. Union Tee 1/4 NPT with three 1/4 NPT x 1/4 2. Shop air hose fitting (1/4 NPT to air hose)
hose barb
3. Air hose
4. Vacuum hose
4. Test gauge fitting (1/16 NPT x 1/4 hose barb)
5. 0-3 WC Magnehelic gauge (inches of water
column) 5. Vacuum hose or vinyl tubing
Secondary Stage (Break-Off) Test 6. 0-60 WC Magnehelic gauge (inches of water

column)
1. Connect the vacuum pump, the Magnehelic
gauge and the regulator vapor outlet to the Union Primary Stage Pressure Test
Tee fitting (Figure 34). Make sure there is no 1. Remove the primary test port plug from the side
leakage at any of the fittings. of the regulator and install the 1/16 NPT hose
barb fitting (Figure 35).
2. Using the vacuum pump slowly apply enough
vacuum to measure above -2 WC on the gauge. 2. Connect a compressed air line (shop air ~100psi)
This vacuum signal opens the secondary valve in to the liquid propane fuel inlet of the N-2007
the N-2007 regulator/converter. regulator (Figure 35).
3. Release the vacuum pump lever and you will see

the gauge needle start falling back toward zero.
When the pressure drops just below the specified
break-off pressure (-0.5 +/- 0.35 WC) of the
secondary spring, the needle should stop moving.
4. At this point the secondary valve should close. If

the secondary valve seat or the secondary
diaphragm is leaking the gauge needle will
continue to fall toward zero (proportional to the
leak size). An excessively rich air/fuel mixture can
be caused by a secondary valve seat leak and the
regulator should be replaced.
Figure 35. Primary Stage Test Connection

3. Apply compressed air, wait for air to exit the hose
barb in the test port, and then connect the
Magnehelic gauge (Figure 36) to the hose barb
CAUTION
using the vacuum hose or vinyl tubing. This
prevents the gauge from reading maximum LP gas is highly flammable. To prevent
pressure due to the large velocity of compressed personal injury, keep fire and flammable
air entering the primary chamber. materials away from the lift truck when work is
done on the fuel system.
4. Make sure there is no leakage at any of the
fittings. The static pressure should read between Gas vapor may reduce oxygen available for
40-60 of water column on the Magnehelic gauge breathing, cause headache, nausea, dizziness
and maintain a constant pressure for 60 seconds. and unconsciousness and lead to injury or
ventilated area

Figure 36. Magnehelic Gauge Connection to Hose

Barb
5. If the pressure reading begins to increase, a leak

is most likely present at the primary valve, either
the primary valve o-ring or the valve itself. If a leak
is present the regulator should be replaced.
6. If the pressure begins to decrease, the secondary

seat is probably not making an adequate seal and
is leaking. The regulator should be replaced.
7. If the test is successful, re-install the primary test

port plug and check the fittings for leaks. See
Chapter 5 for installation of the N-2007 regulator.
NOTE : The N-2007 primary stage pressure can

also be tested at idle on a running engine. The N-
2007 primary pressure should be between 40 inH20
(99.635 mbar) and 55 inH20 (136.999 mbar) at 750
rpm, idle.

AVV (Air Valve Vacuum) Testing Ignition Timing Adjustment
Purpose of Test With the MI-07 system, ignition-timing advance is

controlled by the SECM.
Check for excessive or inadequate pressure drop
across CA100 mixer. The initial ignition timing needs to be set by the
MOR. This setup requires a specific technique for
AVV Test Hardware each engine installation.
1. Union Tee fitting, 1/4 (6.35mm) NPT with three Connection of the MI-07 Service Tool
1/4 (6.35mm) NPT x 1/4 (6.35mm) hose barbs
To use the Service Tool, a USB (Universal Serial
2. Vacuum hose Bus) to CAN (Controller Area Network)
communication adapter by KVaser will be required
3. 0-20 H2O differential pressure Magnehelic gauge along with a Crypt Token (Figure 38). The Crypt
Token acts as a security key allowing the laptop to
retrieve the necessary data from the SECM.
AVV Test
1. Install the Crypt Token in an available USB port in
1. Install Union Tee fitting in the hose between the the computer (Figure 39).
FTVs and the AVV fitting. Connect this fitting to
the low pressure port of the Magnehelic gauge 2. With the ignition key in the OFF position, connect
(Figure 37). the KVaser communication cable from a second
USB port on the computer to the CAN
2. Leave high pressure port of the Magnehelic communications cable on the engine. (*If your
gauge exposed to ambient pressure (Figure 37). laptop computer does not have a second USB
port an appropriate USB hub will need to be used).
3. With the engine fully warmed up and running at
idle (750 rpm) place the transmission in Neutral. 3. Connect a timing light to the engine.
The AVV should be between 5 and 8 H2O of
pressure vacuum. 4. Turn the ignition key to the ON position (Do Not
Start the Engine).
4. If the measured pressure drop is excessively high,
check for sticking or binding of the diaphragm air 5. Launch the MotoView program on your computer
valve assembly inside the mixer. Replace mixer if and open the Service Tool display (Figure 40).
necessary.
5. If the measured pressure drop is low, check for

vacuum leaks in the manifold, throttle, mixer,
TMAP sensor and attached hoses.
Figure 38. KVaser

Communication Adapter
Figure 37. Magnehelic Gauge Connection

Idle Mixture Adjustment
The CA100 mixer requires adjustment of the idle

mixture screw to assure optimal emissions and
performance. This adjustment accounts for minor
part-to-part variations in the fuel system and assures
stable performance of the engine at idle. Once
adjusted, the idle mixture screw is sealed with a
tamper proof cap, after which it need not be
adjusted for the life of the vehicle.
Therefore, the only situations in which the idle

Figure 39. Crypt Token Installed on Laptop mixture screw needs to be adjusted are when the
engine is initially fitted with a fuel system at the
factory and following the field replacement of the
mixer. Under these situations, follow the procedures
below for adjustment of the idle mixture screw.
Factory Test Preparation:
1. Install the MI-07 fuel system, wiring harness and

SECM-48 control module on the engine.
2. All coolant hoses should be attached, filled with

coolant and bled to remove any air.
3. Attach LPG fuel lines.

Figure 40. Opening the Service Tool Display
4. Attach wiring harness to battery power.
5. Attach exhaust system.
6. If present, set fuel select switch to LPG fuel.
When operated at the factory, it is critical to simulate

the airflow found on a forklift at idle as nearly as
possible in order to achieve the proper air valve lift
in the mixer. It may be necessary to place a load on
the engine to achieve the required airflow without
overspeeding the engine. Means of achieving this
load include:
a) Place an electrical load on the alternator. The

alternator should be able to briefly hold loads
of approximately 1.2 kW.
b) Attach the engine to a dynamometer.
Attach the Mototune Service Tool to the wiring

harness and add parameter MAFPort to the display
screen.

Factory Adjustment Procedure: measurement at Closed Loop Idle of 25-60% is
acceptable if the optimum range of 35-55%
NOTE : Be sure engine is fully warm (ECT>167F cannot be reached through adjustment. If the FTV
[75C]) before performing the idle mixture duty cycle cannot be adjusted below 60%, the
adjustment. mixer is faulty and should be replaced.
1. Operating the engine on LPG fuel, start the NOTE : If the FTV Duty Cycle reading is NOT
engine and permit it to warm up until the coolant between 25-60%, check for possible vacuum leaks,
temperature (ECT on Mototune display) is manifold leaks, or a faulty mixer.
approximately 167F (75 oC).
2. Adjust the load until MAFPort equals 3.3 to 3.5 9. Turn the ignition key to the OFF position to shut
g/sec. down the engine.
3. Mototune display parameter LP Fuel Control must 10. Install the tamper proof cap on the idle mixture
display Closed Loop. screw adjustment port using a large pin punch,
4. Use the Mototune Service Tool to monitor Duty so that no further adjustments can be made
Cycle % on the Mototune display. (Figure 42).
5. To adjust the idle mixture screw, use a hex or
Allen-type wrench. Turning the screw in
(clockwise) should increase the duty cycle; turning
the screw out (counterclockwise) should decrease
the duty cycle.
6. Adjust the idle mixture screw on the mixer until a
reading of 35-55% is reached for the FTV Duty
Cycle in Closed Loop Idle (Figure 41). If engine
idle performance is unstable, screw the idle screw
in slightly to see if stability is obtained, but in no
case should duty cycle exceed 60%.
Figure 42. Installing Tamper Proof Cap
Figure 41. FTV Duty Cycle Percentage Displayed on

Service Tool
7. Use the accelerator pedal to increase rpm above

idle momentarily (rev the engine) then release the
pedal to return to idle rpm. The duty cycle setting
should remain within the adjustment range (35-
55%). Place your thumb over the adjustment port
for a more accurate reading by preventing air from
leaking past the mixture adjustment screw, which
may cause the duty cycle to decrease.
8. If the FTV duty cycle reading is above 55% adjust
the idle adjustment screw outward and re-check
the duty cycle reading. Continue to do this until
the FTV duty cycle reading is within the optimum
range (35-55%) and engine rpm is stable. DO
NOT adjust the screw so far outward that the
tamper proof cap cannot be installed. A duty cycle

Field Adjustment Procedure: 8. If the FTV duty cycle reading is above 55% adjust
the idle adjustment screw outward and re-check
The idle mixture adjustment should only be the duty cycle reading. Continue to do this until
necessary on a new mixer that does not have the the FTV duty cycle reading is within the optimum
tamper proof cap installed. The method for making range (35-55%). DO NOT adjust the screw so far
the idle mixture adjustment to a running engine is to outward that the tamper proof cap cannot be
use the Service Tool software by connecting a installed. A duty cycle measurement at Closed
laptop computer to the SECM. If you do not have the Loop Idle of 25-60% is acceptable if the optimum
Service Tool a multimeter capable of measuring range of 35-55% cannot be reached through
duty cycle, such as a Fluke 87 III, can be used. If adjustment. If the FTV duty cycle cannot be
using a multimeter, connect the meter positive lead adjusted below 60%, the mixer is faulty and
to between battery positive and the meter negative should be replaced.
to the FTV signal wire. For the Fluke 87, press the
RANGE button until 4 or 40 appears in the lower NOTE : If the FTV Duty Cycle reading is NOT
between 25-60%, check for possible vacuum leaks,
right-hand corner of the display. Press the Hz
manifold leaks, or a faulty mixer.
button twice so that the percent sign (%) appears on
the right-hand side of the display. The multimeter
9. Turn the ignition key to the OFF position to shut
will then read the duty cycle percentage the same as
down the engine.
the Service Tool shown in Figure 41.
10. Install the tamper proof cap on the idle mixture
1. After installing a new mixer, operate the engine
screw adjustment port using a large pin punch,
Bon LPG fuel. Start the engine and permit it to so that no further adjustments can be made
warm up until the coolant temperature (ECT on (Figure 42).
Mototune display) is approximately 167F (75 oC).
2. Place the transmission in Neutral.
3. Mototune display parameter LP Fuel Control must

display Closed Loop.
4. Use the Mototune Service Tool to monitor Duty

Cycle % on the Mototune display.
5. To adjust the idle mixture screw, use a hex or

Allen-type wrench. Turning the screw in
(clockwise) should increase the duty cycle; turning
the screw out (counterclockwise) should decrease
the duty cycle.
6. Adjust the idle mixture screw on the mixer until a

reading of 35-55% is reached for the FTV Duty
Cycle in Closed Loop Idle (Figure 41). If engine
idle performance is unstable screw the idle screw
in slightly to see if stability is obtained, but in no
case should duty cycle exceed 60%.
7. Use the accelerator pedal to increase rpm above

idle momentarily (rev the engine) then release the
pedal to return to idle rpm. The duty cycle setting
should remain within the adjustment range (35-
55%). Place your thumb over the adjustment port
for a more accurate reading by preventing air from
leaking past the mixture adjustment screw, which
may cause the duty cycle to decrease.

Parts Description
CA100 Mixer for G420FE Engine
Parts List of CA100 Mixer (Certified)
REF NO DESCRIPTION QTY

1 Torx Screws (T-25) #10-24 x 5/8 4
2 Lockwashers (T-210) #10 SST 4
3 Mixer Cover 1
4 Mixer Spring 1
5 Diaphragm 1
6 Air Valve Assembly 1
7 Gas Valve Cone (part of air valve assembly) 1
8 Mixer Body 1
9 Expansion Plug Cap 1/2 x 1/16 thick ( 12.7mm x 27mm) 1
10 Fuel Inlet 1
11 Air Horn Gasket 1
12 Air Horn Adapter 2-1/16 (52.37mm) 1
13 Fillister Head Screws SEMS Lockwasher 10-24 UNC x 5/8 4
14 Throttle Body Gasket 1
15 Fillister Head Screws SEMS Split Lockwasher #12-24 x 5/8 4

Exploded View of CA100 Mixer (Certified)
Figure 44. CA100 Certified Mixer Exploded View

N-2007 Regulator for G420FE Engine
Parts List of N-2007 Regulator (Certified)
REF NO DESCRIPTION QTY

1 N-2007 Body 1
2 Diaphragm, Primary Assembly 1
3 Springs, Primary Assembly 2
4 Cover, Primary Assembly 1
5 Spring, Secondary Seat, Red 1
6 Dowel Pin 0.094 x 1 L ( 2.39mm x 25.4mm L) Hardened Steel 1
7 Diaphragm, Secondary Assembly 1
8 Lever, Secondary 1
9 Seat, Secondary 1
10 Valve Primary 1
11 Fillister Head Screws SEMS Split Lockwasher #12-24 x 5/8 6
12 Pan Head Screw SEMS Ext. Tooth Lockwasher #12-24 x 1/4 1
13 Body Gasket 1
14 Back Plate 1
15 O-ring, Size 107 GLT Viton 1
16 Bottom Plate Gasket 1
17 Plate Cover 1
18 Fillister Head Screws SEMS Split Lockwasher #12-24 x 1-3/8 6
19 Hex Head Screws SEMS Split Lockwasher 1/4-20 x 5/8 4
20 Plug, Socket Head Pipe (T-086) 1
21 Cover, Secondary Diaphragm 1
22 Lockwasher, Int. Tooth (T-210) #8 SST 6
23 Torx Screws (T-15) #8-32 x 5/8 6

Exploded View of N-2007 Regulator (Certified)
Figure 46. N-2007 Certified Regulator Exploded View

G420F LPG System Inspection and
Repair
WARNING PROPER USE
LP gas is highly flammable. To prevent perso-

nal injury, keep fire and flammable materials
away from the lift truck when work is done on
the fuel system.

ventilated area

CAUTION

certified system complying with EPA and CARB
2007 requirements. Only trained, certified
technicians should perform disassembly,
service or replacement of the
regulator/converter or mixer.

G420F Fuel System Connections
Figure 27. Hose Connections for Non-Certified Systems
DIAGRAM NOTES
1
Only one 90 fitting permissible on vapor fuel line between mixer and regulator
3 Vapor fuel fittings (regulator and mixer) must have minimum ID of 0.46 (11.68mm)
4 Vapor hose length to be as short as possible and have no restrictions for best regulator
performance
5
Fuel outlet must be positioned vertically in the down position
NOTE: Preferred mounting of regulator is off engine

Removal and Installation of N-2001 LP N-2001 Installation Steps
Regulator/Converter
Refer to Figure 29.
reinstallation of the N-2001 regulator. 1. Install the fuel vapor outlet hose (5) from the
regulator.
N-2001 Removal Steps
2. Install the two cooling lines (4) from the regulator.
Refer to Figure 29.
3. Install the two rear-mounting bolts that hold the
1. Close the liquid outlet valve in the forklift cylinder regulator to the support bracket. Use a torque
or fuel storage container. wrench and tighten each bolt to 50-60 lbf-in (5.65-
6.78 N-m)
2. Purge the system of fuel by starting the engine
and running until all trapped fuel in the system is 4. Install the fuel inlet line (1) from the lock-off, the
exhausted and the engine shuts down. two vacuum lines (2) from the branch-tee fitting in
the regulator vent and disconnect the lock-off
3. Remove the fuel inlet line (1) from the lock-off, the connector (3).
two vacuum lines (2) from the branch-tee fitting in
the regulator vent and disconnect the lock-off 5. Open the liquid outlet valve in the forklift cylinder
connector (3). or fuel storage container.
4. Remove the two rear-mounting bolts that hold the

regulator to the support bracket. This will permit
easier access to the remaining hose clamps.
5. Remove the two cooling lines (4) from the

regulator.
NOTE: It will be necessary to either drain the

coolant system or clamp off the coolant lines as
close to the regulator as possible to avoid a coolant
spill when these lines are disconnected.
6. Remove the fuel vapor outlet hose (5) from the

regulator.
Figure 29. N-2001 Regulator in Non-Certified

System

Removal and Installation of CA100 Mixer for 1. Close the liquid outlet valve in the forklift cylinder
G420F or fuel storage container.
Follow the procedures below for removal and 2. Purge the system of fuel by starting the engine
reinstallation of the CA100 mixer in non-certified and running until all trapped fuel in the system is
systems. exhausted and the engine shuts down.
CA100 Mixer Removal Steps 3. Key switch in OFF position.
4. Remove the air cleaner hose (1).

1
5. Remove the vacuum line (2).
6. Remove the vapor fuel inlet line from the mixer (3).
7. Disconnect the wires leading to the electronic

throttle body by pinching the lock tabs on either
side of the wiring harness connector.
4
8. Loosen the four bolts that secure the
3 8 mixer /adapter/throttle body assembly to the
2
intake manifold.
7
6 9. Remove the mixer (3) and the throttle body (4) as
10 5 an assembly by gently pulling upwards. Take
care not to drop anything down the intake
manifold.
10. Gently wiggle and pull to separate mixer and

adapter from the throttle body. Take note of the
9
adapter orientation on the mixer, as it must be
reinstalled correctly for proper fit on the throttle.
1. Mixer-Non Cert 11. Remove the four mounting screws that attach
2. Fitting-To Regulator the throttle adapter to the mixer.
3. Fitting-To Regulator
4. Apollo Adapter-ITB, Mixer
5. ITB 12. Remove the vapor fuel inlet fitting from the
6. O-Ring Spacer
7. O-Ring
mixer.
8. Bolt-ITB.Conn
9. Gasket-ITB
10. Bolt
Figure 33. CA100 Mixer in Non-Certified System

CA100 Mixer Installation Steps
CAUTION
1. Install the vapor fuel inlet fitting onto the mixer.
The 1/8 NPT x 1/4 hose barb fitting that is
installed in the mixer housing uses a specific
2. Install the four mounting screws that attach the machined orifice size through the fitting. This
throttle adapter to the mixer. (See Figure 32). orifice fitting is part of the mixer assembly and is
Torque bolts to 30-40 lbf-in (3.39-4.52 N-m). an integral part of the MI-07 control. If this fitting
is damaged the mixer will need to be replaced.
DO NOT replace this fitting with a standard hose
3. Position the mixer/adapter assembly onto the
barb fitting or use a drill bit to clean out the
throttle body (4), then drop in the four mounting
fitting passage way.
bolts and gently push down on the assembly
until it rests on the throttle body. Be careful not
to pinch the O-ring.
NOTE : A plastic O-ring spacer and an O-ring are
inside the mixer/adapter assembly. Be careful not to
4. Attach the mixer/throttle body assembly to the lose these items when removing the assembly from
intake manifold, making sure gasket is in place. the throttle (Figure 31).
Tighten the four mounting bolts.
5. Connect the wiring harness to the throttle body.
6. Install the vapor fuel inlet line to the mixer.
7. Install the vacuum line (2) to the mixer.
8. Install the air cleaner hose (1).
Figure 31. O-Ring and Spacer Within Mixer Adapter

Assembly
Figure 32. Throttle Adapter Mount Screws

Tests and Adjustments Secondary Stage (Break-Off) Test
1. Connect the vacuum pump, the Magnehelic

gauge and the regulator vapor outlet to the Union
WARNING PROPER USE Tee fitting (Figure 30). Make sure there is no
leakage at any of the fittings.
LP gas is highly flammable. To prevent perso-
nal injury, keep fire and flammable materials 2. Using the vacuum pump slowly apply enough
away from the lift truck when work is done on vacuum to measure above -2 WC on the gauge.
the fuel system. This vacuum signal opens the secondary valve in
the N-2001 regulator/converter.
3. Release the vacuum pump lever and you will see
the gauge needle start falling back toward zero.
When the pressure drops just below the specified
break-off pressure (-1.2 WC) of the secondary
ventilated area spring, the needle should stop moving.
Liquid propane may cause freezing of tissue or 4. At this point the secondary valve should close. If
frostbite. Avoid direct contact with skin or the secondary valve seat or the secondary
tissue; always wear appropriate safety diaphragm is leaking the gauge needle will
protection including gloves and safety glasses continue to fall toward zero (proportional to the
when working with liquid propane. leak size). An excessively rich air/fuel mixture can
be caused by a secondary valve seat leak and the
regulator should be replaced.
N-2001 Regulator Service Testing
For checking the N-2001 regulator/converter

operation, the following tests can be performed (See
Chapter 5 for removal/installation of the N-2001). To
check the secondary regulation (output) a simple
vacuum hand pump can be used to simulate the
vacuum signal transmitted from the air/fuel mixer
when the engine is running. See listing below for
required hardware.
Break-Off Test
Secondary Stage Test Hardware
1. Hand vacuum pump
2. Regulator vapor outlet test fitting 3/4 NPT x 1/4

hose barb
Figure 30. Secondary Stage Test Connection
3. Union Tee 1/4 NPT with three 1/4 NPT x 1/4
hose barb
4. Vacuum hose

column)

Pressure Test Primary Stage Pressure Test
Primary Stage Test Hardware 1. Remove the primary test port plug from the side
of the regulator and install the 1/16 NPT hose
1. Hand vacuum pump barb fitting (Figure 31).
2. Regulator fuel inlet test fitting 1/4 NPT standard 2. Connect a compressed air line (shop air ~100 psi)
air coupling) to the liquid propane fuel inlet of the N-2001
regulator (Figure 31).
3. Test gauge fitting (1/4 NPT X 1/4 hose b)
4. Vacuum hose or vinyl tubing

column)
Figure 32. Magnehelic Gauge Connection to Hose

Barb
3. Apply compressed air, wait for air to exit the hose

barb in the test port, and then connect the
Magnehelic gauge (Figure 32) to the hose barb
Figure 31. Primary Stage Test Connection using the vacuum hose or vinyl tubing. This
prevents the gauge from reading maximum
pressure due to the large velocity of compressed
air entering the primary chamber.
4. Make sure there is no leakage at any of the

fittings. The static pressure should read between
40-60 WC on the Magnehelic gauge and
maintain a constant pressure for 60 seconds.
5. If the pressure reading begins to increase, a leak

is most likely present at the primary valve, either
the primary valve o-ring or the valve itself. If a leak
is present the regulator should be replaced.
6. If the pressure begins to decrease, the secondary

seat is probably not making an adequate seal and
is leaking. The regulator should be replaced.
7. If the test is successful, re-install the primary test

port plug and check the fittings for leaks. See
Chapter 5 for installation of the N-2001 regulator.
NOTE : The N-2001 primary stage pressure can

also be tested at idle on a running engine. The N-
2001 primary pressure should be between
40 inH20 (99.635 mbar) and 55 inH20 (136.999
mbar) at 750 rpm, idle.

AVV (Air Valve Vacuum) Testing Connection of the MI-07 Service Tool
Purpose of Test To use the Service Tool, a USB (Universal Serial

Bus) to CAN (Controller Area Network) communica-
Check for excessive or inadequate pressure drop tion adapter by KVaser will be required along with a
across CA100 mixer. Crypt Token (Figure 38). The Crypt Token acts as a
security key allowing the laptop to retrieve the
AVV Test Hardware necessary data from the SECM.
1. Union Tee fitting, 1/4 (6.35mm) NPT 1. Install the Crypt Token in an available USB port in
with three 1/4 (6.35mm) NPT x 1/4 (6.35mm) the computer (Figure 39).
hose barbs
2. Vacuum hose 2. With the ignition key in the OFF position, connect
3. 0-20 H2O differential pressure Magnehelic gauge the KVaser communication cable from a second
USB port on the computer to the CAN
AVV Test communications cable on the engine. (*If your
laptop computer does not have a second USB
1. Install Union Tee fitting in the hose between the port an appropriate USB hub will need to be used).
FTVs and the AVV fitting. Connect this fitting to
the low pressure port of the Magnehelic gauge 3. Connect a timing light to the engine.
(Figure 37).
4. Turn the ignition key to the ON position (Do Not
2. Leave high pressure port of the Magnehelic Start the Engine).
gauge exposed to ambient pressure (Figure 37).
5. Launch the MotoView program on your computer
3. With the engine fully warmed up and running at and open the Service Tool display (Figure 40).
idle (750 rpm) place the transmission in Neutral.
The AVV should be between 5 and 8 H2O of
pressure vacuum.
4. If the measured pressure drop is excessively high,

check for sticking or binding of the diaphragm air
valve assembly inside the mixer. Replace mixer if
necessary.
5. If the measured pressure drop is low, check for

vacuum leaks in the manifold, throttle, mixer,
TMAP sensor and attached hoses.
Figure 38. KVaser Communication Adapter
Figure 37. Magnehelic Gauge Connection
Ignition Timing Adjustment Figure 39. Crypt Token Installed on Laptop
With the MI-07 system, ignition-timing advance is

controlled by the SECM.

Power Valve Adjustment
1. The power valve should only be adjusted after the

idle screw has been adjusted properly. The
engine and vehicle drive train and hydraulics
should also be at normal operating temperatures.
2. Apply a load to the engine while the engine is

operating above idle speed. Torque converter stall
is the preferred operating mode for this test. If a
torque converter speed test cannot be performed,
the engine can be run at another speed (max
Figure 40. Opening the Service Tool Display governor), but a load must be applied by using
hydraulics.
Idle Mixture Adjustment NOTE : While adjusting the power valve, do not hold
engine at load point for longer than 5-10 seconds.
NOTE : Be sure engine is fully warm (ECT>167F Holding for a longer period of time will cause the fuel
[75C]) before performing the idle mixture temperature to drop, which could adversely affect
adjustment. the power valve setting.
G420F LP Fuel Systems With O2 Sensor 3. Monitor the output of the UEGO or HEGO sensor
while the engine is at the higher speed with the
Idle Adjustment load applied (phi = 1.00 to 1.05 is optimal).
1. Install mixer and a UEGO or HEGO sensor. (A 4. If the phi reading is not at the desired level, bring
UEGO sensor should be used when desired phi the engine back to idle and adjust the power valve.
settings are not at stoichiometric.)
5. Bring the engine back to the higher speed with a
2. After the mixer is installed, start and warm up the load applied and verify the power valve setting.
engine to normal operating temperature Adjust further as needed.
(ECT>167F [75C]). Also ensure that the vehicle
drive train and hydraulic systems are at normal 6. Once the power valve is set, bring the engine
operating temperatures per vehicle manufacturer back to idle and verify the idle screw setting.
recommendations.
3. Allow the engine to reach steady state at idle. G420F LP Fuel Systems Without O2 Sensor
4. While monitoring the output of the UEGO or Idle Adjustment

HEGO sensor adjust the idle screw using a
standard screwdriver until the desired phi reading 1. After the mixer is installed, start and warm up the
is achieved (phi = 1.00 to 1.01 is optimal). To engine to normal operating temperature
make the mixture richer, turn the screw clockwise; (ECT>167F [75C]). Also ensure that the vehicle
to make the mixture leaner, turn the screw drive train and hydraulic systems are at normal
counter-clockwise. operating temperatures per vehicle manufacturer
recommendations.
5. Rev the engine to take it off of idle and let it return
to idle. 2. Allow the engine to reach steady state at idle.
6. Once the engine has reached steady state at idle, 3. With the idle screw completely tightened
verify the phi reading. Adjust further as needed. clockwise, use a standard screwdriver to adjust
the idle screw counterclockwise until a minimum
average MAP value has been reached. The MAP
value is displayed on the Service Tool screen.

Power Valve Adjustment
1. The power valve should only be adjusted after the

idle screw has been adjusted properly. The
engine and vehicle drive train and hydraulics
should also be at normal operating temperatures.
2. Apply a load to the engine while the engine is

operating above idle speed. Torque converter stall
is the preferred operating mode for this test. If a
torque converter speed test cannot be performed,
the engine can be run at another speed (max
governor), but a load must be applied by using
hydraulics.
The power valve should be adjusted to obtain
maximum torque converter stall speed.
NOTE : While adjusting the power valve, do not hold

engine at load point for longer than 5-10 seconds.
Holding for a longer period of time will cause the fuel
temperature to drop, which could adversely affect
the power valve setting.
3. Once the power valve is set, bring the engine

back to idle and verify the idle screw setting.
Figure 43. Main Mixture Adjustment on Bottom of

Mixer (partial view)

Parts Description
CA100 Mixer for G420F Engine
Refer to Figure 45 exploded view on facing page.
REF NO. DESCRIPTION QTY

1 Screws 10-24 x 5/8 SEMS 4
2 Mixer Cover 1
3 Air Valve Spring 1
4 Screws 6-32 x 1/4 SEMS 5
5 Plate Backup 1
6 Diaphragm, Silicone 1
7 Air Valve Ring 1
8 Air Valve Assembly 1
9 Idle Screw 3/8-16 x 1-1/4 1
10 Idle Screw Spring 1
11 Plugs, 1/8 Pipe Hex Head 2
12 Mixer Body Assembly 1
13 Screws, 1/4-28 x 5/16 2
14 Plug, 1/4 Pipe 1
15 Screws 10-24 x 5/8 SEMS 4
16 Air Horn 1
17 Air Horn Gasket 1
18 Throttle Body to Mixer Gasket 1
Parts List for CA100 Mixer

Exploded View
CA100 Mixer
Figure 45. CA100 Non-Certified Mixer Exploded View

CA100 Disassembly and Service
5 Figure M4
4
1. With the mixer/adapter assembly removed from the
engine, and the throttle adapter removed from the
mixer, remove the four cover retaining screws from
9 the top of the mixer (Figure M4).
3 14
2
7
Figure M5
1 15
2. Gently remove the diaphragm cover from the top of
the mixer. Take care not to loose the air-valve
10
spring shown in (Figure M5).
11
(1) BODY (2) VALVE (3) SPRING (4) COVER

(5) WASHER (6) SCREW (7) GASKET (8) ADAPTER
(9) SCREW (10)GASKET (11) SCREW
Figure M6
3. Remove the air-valve assembly from the mixer as

shown in (Figure M6).

CAUTION
The 1/8 NPT X hose barb fitting that
is installed in the mixer housing uses a
specific machined orifice size through the
fitting. This orifice fitting is part of the
mixer assembly and an integral part of
the MI-04 control. DO NOT replace this
fitting with a standard hose barb fitting or
use a drill bit to clean out the fitting
passage way. If this fitting is damaged
the mixer will need to be replaced.
Figure M7
4. Clean the heavy end deposits from the mixer body CA100 Disassembled Service
with solvent. Be sure the mixer body is completely
dry before installing the new air-valve assembly. 1. Clean the air valve assembly with soap and warm
Replace the air-valve assembly as shown (Figure water to remove heavy-end deposits. Inspect the
M7). fuel metering valve and sealing ring for wear.
Replace worn components as necessary.
Replace all gaskets before assembly.
Clean the mixer body (casting) with a parts cleaning

solvent. Be sure to remove all seals and gaskets
before cleaning the casting with solvent. Make sure
all parts are completely dry before re-assembly.
NOTE
For re-assembly of the CA100
reverse the disassembly steps.
Figure M8
WARNING
DO NOT spray car carburetor cleaner or
5. Place the alignment mark on top of the air valve solvent into the mixer while installed on
assembly toward the fuel inlet of the mixer; this the engine. These chemicals may damage
places the small notches in the fuel metering valve the oxygen sensor and cause pre-mature
(fuel cone) inline with the fuel inlet and the large failure of the catalytic muffler.
notches of the fuel metering valve cone,
perpendicular to the fuel inlet of the mixer. Now
reinstall the air-valve spring and diaphragm cover
(Figure M8).
Figure M9
6. Tighten the cover fastners and reinstall the mixer

on the engine (Figure M9).

N-2001 Regulator for G420F Engine
Refer to Figure 47 exploded view on facing page.
Parts List
N-2001-RSA Regulator
REF NO. DESCRIPTION QTY

1 Cover Screws 8-32 x 5/8 SEMS 4
2 Torx Screws (T-15) 8-32 x 5/8 Tamper Resistant 2
3 Lockwasher #8 Internal Tooth 2
4 Secondary Cover 1
5 Secondary Diaphragm Assembly 1
6 Pan Head Screw 10-24 x 1/4 w/Star Washer 1
7 Secondary Lever 1
8 Secondary Valve 1
9 Secondary Lever Fulcrum Pin 1
10 Red Secondary Spring 1
11 Pilot Valve Lever 1
12 Pilot Valve Lever Fulcrum Pin 1
13 Internal Hex Head Set Screw 8-32 x 1/4 1
15 Primary Diaphragm Cover 1
16 Primary Regulator Springs 2
17 Primary Diaphragm Assembly 1
18 1/8 NPT Hex Pipe Plug Fitting 1
19 Body Assembly 1
20 Body Seal O-ring 1
21 Body Gasket 1
22 Regulator Back Plate 1
23 Primary Seal O-Ring 1
24 Primary Regulator Valve 1
26 Inlet Seal O-Ring 1
27 Inlet Plug 1
28 Hex Head Screws 1/4-20 UNC-2A x 5/8 SEMS 2

Exploded View
N-2001-RSA Regulator
Figure 47. N-2001 Regulator Exploded View

N2001 Regulator Disassembly Steps:
1 Figure R5
Figure R3
Figure R5
Remove the six primary diaphragm cover screws (4)

Figure R4 and the primary cover assembly (5).
1. Remove the six secondary cover screws (1), the

secondary cover (2) and the secondary
diaphragm (3).
2. Remove the six primary diaphragm cover screws

(4) and the primary cover assembly (5).
Figure R6
Remove the primary diaphragm by sliding the

diaphragm to one side, releasing the primary valve
pin (Figure R6).

10
3
11
Figure R7
6. Remove the body gasket (10), body o-ring seal

(11) and the fuel inlet plate, exposing the fuel inlet
expansion chamber and the coolant passage.
NOTE
For re-assembly of the N2001
regulator/converter, reverse the steps for
8 disassembly. Tighten all fasteners to
recommended torque values and test the
9 regulator before installing in the vehicle.
Torque primary cover screws to (40-50
Figure R8 inch lbs.), secondary cover screws to (15-
18 inch lbs.).
Figure R9
Turn the regulator body over with the rear fuel inlet
plate facing up. Remove the primary valve access
plug (7), the primary valve (8) and the primary valve
o-ring seal (9). The primary valve goes through the
inlet plate, then through the body assembly and is
retained by the primary diaphragm (Figure R9).

N2001 Disassembled Service
1. Clean the primary and secondary valves with
soap and warm water to remove heavy-end
deposits. Inspect the valve seats and o-rings for
wear. Replace worn components as necessary.
2. Clean the primary and secondary diaphragms

with soap and warm water. Inspect for wear, tears
or pinholes and deformations that may cause
leaks or poor performance of the .
regulator/converter.
3. Replace the body gasket of the coolant chamber

and body o-ring seal when servicing the N2001 to
avoid coolant leaks from the fuel expansion
chamber to the coolant passage.
4. Clean the regulator body (casting) with a parts

cleaning solvent. Be sure to remove all seals and
gaskets before cleaning the casting with solvent.
Figure R11
5. Make sure all parts (Figure R11) are completely

dry before re-assembly.

Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM
Specification
Items Specification
Fuel Retrun System Type Returnless

High pressure type (built in Fuel
Fuel Filter Type
Pump Assembly)
Type Built in fuel pump assembly
Fuel Pressure Regulator
Regulated Fuel Pressure 350 kpa (3.5kg/cm2, 49.8psi)
Fuel Pump Type Electrical, in-tank type
Special Tools
Tool
Illustration Application
(Numberandname)
09353-24100 Measuring the fuel line

FuelPressureGauge pressure
Connection between the

09353-38000
delivery pipe and fuel feed
Fuel Pressure Gage Adapter
line
Connection between Fuel

Pressure Gage (09353-
09353-24000
24100) and Fuel Pressure
Fuel Pressure Gage Connector
Gage Adapter (09353-
38000)
G420F(FE) Service Manual 239 Chapter 7. MPI Gasoune Fuel Delivery System
Components Location
1. Fuel Tank
2. Fuel Pump (Including full pressure regulator and fuel filter)
3. Fuel Hose Assy
4. Fuel Rail
5. Injector
Fuel Pressure Test Install The Special Service Tool (SST)
For Measuring The Fuel Pressure
Release The Internal Pressure
1. Disconnect the fuel pump connector.
2. Start the engine and wait until fuel in fuel line is

exhausted.
3. After the engine stalls, turn the ignition switch to

OFF position
and diconnect the negative (-) terminal from the
battery.
NOTE: Be sure to reduce the fuel pressure before

disconnecting the fuel feed hose, otherwise fuel will
spill out. 1. Disconnect the fuel feed hose from the delivery
pipe.
CAUTION
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by residual
pressure in the fuel line.
2. Install the Fuel Pressure Gage Adapter (09353-

38000) between the delivery pipe and the fuel
feed hose.
3. Connect the Fuel Pressure Gage Connector

(09353-24000) to the Fuel Pressure Gage
Adapter (09353-38000).
4. Connect the Fuel Pressure Gage and Hose

(09353-24100) to Fuel Pressure Gage Connector
(09353-24000).
5. Connect the fuel feed hose to the Fuel Pressure

Gage Adapter (09353-38000).
Inspect Fuel Leakage On Connection Observing the declination of the fuel pressure
when the gage reading drops and perform the
1. Connect the battery negative (-) terminal. necessary repairs using the table below.
2. Apply battery voltage to the fuel pump terminal Probable Supected

and activate the fuel pump. With fuel pressure Condition
Cause Area
applied, check that there is no fuel leakage from
the fuel pressure gauge or connection part. Fuel pressure
drops slowly
Injector leak Injector
Fuel Presure Test after engine is
stopped
1. Diconnect the negative (-) terminal from the
battery. Fuel pressure
The check
drops
valve within
2. Connect the fuel pump connector. immediately Fuel Pump
the fuel pump
after engine is
is open
3. Connect the battery negative (-) terminal. stopped
4. Start the engine and measure the fuel pressure at Release The Internal Pressure
idle.
Standard Value: 350 kpa (3.5 kg/, 49.8 psi)
If the measured fuel pressure differs from the

standard value, perform the necessary repairs
Supected
Condition Probable Cause
Area
Clogged fuel filter Fuel filter
Fuel leak on the

Fuel fuel-pressure
regulator that is 1. Disconnect the fuel pump connector.
Pressure too
low assembled on fuel Fuel Pressure
pump because of Regulator 2. Start the engine and wait until fuel in fuel line is
poor seating of the exhausted.
fuel-pressure
regulator. 3. After the engine stalls, turn the ignition switch to
OFF position and diconnect the negative (-)
Fuel terminal from the battery.
Sticking fuel Fuel Pressure
Pressure too
pressure regulator Regulator
High NOTE: Be sure to reduce the fuel pressure before
disconnecting the fuel feed hose, otherwise fuel will
5. Stop the engine and check for a change in the spill out.
fuel pressure gauge reading.
After engine stops, the gage reading should hold for

about 5 minutes
Remove The Special Service Tool (SST) Injector
And Connect the Fuel Line
Component Location
1. Disconnect the Fuel Pressure Gage and Hose
(09353-24100) from the Fuel Pressure Gage
Connector (09353-24000).
2. Disconnect the Fuel Pressure Gage Connector

(09353-24000) from the Fuel Pressure Gage
Adapter (09353-38000).
3. Disconnect the fuel feed hose from the Fuel

Pressure Gage Adapter (09353-38000).
4. Disconnect the Fuel Pressure Gage Adapter

(09353-38000) from the delivery pipe.
CAUTION
Description
prevent splashing of fuel caused by residual Based on information from various sensors, the
pressure in the fuel line. ECM measures the fuel injection amount. The fuel
injector is a solenoid-operated valve and the fuel
injection amount is controlled by length of time the
5. Conenct the fuel feed hose to the delivery pipe. fuel injector is held open. The ECM controls each
injector by grounding the control circuit. When the
Inspect Fuel Leakage On Connection ECM energizes the injector by grounding the control
circuit, the circuit voltage should be low (theoretically
1. Connect the battery negative (-) terminal. 0V) and the fuel is injected. When the ECM de-
energizes the injector by opening control circuit, the
2. Apply battery voltage to the fuel pump terminal fuel injector is closed and circuit voltage should be
and activate the fuel pump. With fuel pressure peak for a moment.
applied, check that there is no fuel leakage from
the fuel pressure gauge or connection part.
3. If the vehicle is normal, connect the fuel pump

connector.
Specification
Temperature Injector Temperature Injector

() () Resistance() () () Resistance()
-20 -4 12.2 ~ 12.3 60 140 16.6 ~ 16.8
0 32 13.3 ~ 13.5 80 176 17.7 ~ 17.9
20 68 14.4 ~ 14.6 100 212 18.8 ~ 19.0
40 104 15.5 ~ 15.7 120 248 19.9 ~ 20.1
Schematic diagram
Injector Inspection Resistance Measurement Between
Terminals
Operation check
Operation Sound Check
1. Disconnect the connector at the injector and

measure the resistance between the two
terminals.
1. Using a stethoscope, check the injectors for a
clicking sound at idle. Check that the sound is Standard value : 14.5 0.35 [at 20 (68)]
produced at shorter intervals as the engine speed
increases. 2. Re-connect the connector to the injector.
NOTE: Ensure that the sound from an adjacent Removal

injector is not being transmitted along the delivery
pipe to an inoperative injector. 1. Release residual pressure from the fuel line to
prevent fuel from spilling.
CAUTION
Cover the hose connection with rags to prevent
splashing of fuel that could be caused by
residual pressure in the fuel line.
2. If a stethoscope is not available, check the

injector operation with your finger. If no vibrations
are felt, check the wiring connector, injector, or
injection signal from ECM.
2. Remove the delivery pipe with the fuel injectors.
CAUTION
Be careful not to drop any injectors when
removing the delivery pipe.
Be aware that fuel may flow out when removing
the injector.
Inspection
1. Measure the resistance of the injectors between
the terminals using an ohmmeter.
Resistance : 14.5 0.35 [at 20 (68)]
4. Be sure the injector turns smoothly.
NOTE: If it does turn smoothly, the O-ring may be

jammed : Remove the injector and re-insert it into
the delivery pipe and recheck.
2. If the resistance is not within specifications,

replace the injector.
Installation
1. Install a new grommet and O-ring to the injector.
2. Apply a coating of solvent, spindle oil or gasoline

to the O-ring of the injector.
3. While turning the injector to the left and right, fit it

on to the delivery pipe.
Fuel Pump
Removal (Including Fuel Filter And Fuel
Pressure Regulator)
1. Release the internal pressure of the fuel lines and

hoses as following :
a. Disconnect the fuel pump assembly harness

4. Remove the fuel pump assembly.
connector (A).
b. Start the engine and wait until fuel in fuel line is

exhausted. After the engine stalls, turn the
ignition switch to OFF position.
c. Disconnect the negative (-) terminal from the

battery.
2. Disconnect the fuel feed line.
CAUTION
prevent splashing of fuel caused by residual
pressure in the fuel line.
3. Unfasten the fuel pump cap (D) counter clock

wise.
Chapter 8. BASIC TROUBLESHOOTING
Preliminary Checks Visual/Physical check
MI-07 systems are equipped with built-in fault Several of the procedures call for a Careful
diagnostics. Detected system faults can be Visual/Physical Check which should include:
displayed by the Malfunction Indicator Lamp (MIL)
and are covered in Chapter 9, Advanced SECM grounds for being clean and tight
Diagnostics. However, items such as fuel level,
plugged fuel lines, clogged fuel filters, and Vacuum hoses for splits, kinks, and proper
malfunctioning pressure regulators may not set a connection.
fault code and usually can be corrected with the
basic troubleshooting steps described on the Air leaks at throttle body mounting and intake
following pages. manifold
If engine or drivability problems are encountered Exhaust system leaks

with your MI-07 system, perform the checks in this
section before referring to Advanced Diagnostics. Ignition wires for cracking, hardness, proper
routing, and carbon tracking
NOTE: Locating a problem in a propane engine is
done exactly the same as with a gasoline engine. Wiring for pinches and cuts
Consider all parts of the ignition and mechanical
systems as well as the fuel system. Also check:
Before Starting Connections to determine that none are loose,

cracked, or missing
1. Determine that the SECM and MIL light are
Fuel level in vehicle is sufficient
operating. Verify operation by keying on engine
and checking for flash of MIL light. When the
Fuel is not leaking
ignition key is turned on, the MIL will illuminate
and remain on until the engine is started. Once
Battery voltage is greater than 11.5 volts
the engine is started, the MIL lamp will go out
unless one or more fault conditions are present. If
Steering, brakes, and hydraulics are in proper
a detected fault condition exists, the fault or faults
condition and vehicle is safe to operate
will be stored in the memory of the small engine
control module (SECM). Once an active fault
NOTE: The Visual/Physical check is very important,
occurs the MIL will illuminate and remain ON.
as it can often correct a problem without further
This signals the operator that a fault has been
troubleshooting and save valuable time.
detected by the SECM.
2. Determine that there are no diagnostic codes

stored, or there is a diagnostic code but no MIL
light.
G420F(FE) Service Manual 248 Chapter 8. Basic Troubleshooting

Basic Troubleshooting Guide
Customer Problem Analysis Sheet
1. Forklift Information
(I) VIN:
(II) ProductionDate:
(III) Hour meter Reading: (hrs)
2. Symptoms
Engine does not turn over Incomplete combustion

Unable to start
Initial combustion does not occur
Difficult to start Engine turns over slowly Other_________________

Rough idling Incorrect idling
Poor idling Unstable idling (High: ______ rpm, Low: ______ rpm)
Other__________________________________
Soon after starting After accelerator pedal depressed
After accelerator pedal released
Engine stall
Shifting from N to D-range
Other_______________________________________________
Poor driving (Surge) Knocking Poor fuel economy
Others
Back fire After fire Other____________________________
3. Environment
Constant Sometimes (_________________) Once only

Problem frequency
Other___________________________________________
Weather Fine Cloudy Rainy Snowy Other__________________
Outdoor temperature Approx._____ /
Suburbs Inner City Uphill Downhill

Place
Rough road Other___________________________________
Engine temperature Cold Warming up After warming up Any temperature

Starting Just after starting (____min) Idling Racing
Engine operation Driving Constant speed Acceleration Deceleration
Other_____________________________
4. MIL/DTC
MIL (Malfunction Indicator Lamp) Remains ON Sometimes lights up Does not light
DTC Normal DTC(_______________________________________)

Basic Inspection Procedure 4. Repair or replace the component that has a
problem.
Measuring Condition Of Electronic Parts
Resistance 5. Verify that the problem has disappeared with the
road test.
The measured resistance at high temperature after
vehicle running may be high or low. So all resistance SIMULATING VIBRATION
must be measured at ambient temperature (20, 68
), unless there is any notice. 1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays
NOTE: The measured resistance in except for with finger.
ambient temperature (20, 68) is reference value.
WARNING
Intermittent Problem Inspection Procedure
Strong vibration may break sensors, actuators
Sometimes the most difficult case in troubleshooting or relays.
is when a problem symptom occurs but does not
occur again during testing. An example would be if a 2) Connectors and Harness
problem appears only when the vehicle is cold but : Lightly shake the connector and wiring
has not appeared when warm. In this case, harness vertically and then horizontally.
technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and Simulating Heat
recreate (simulate) the environment and condition
which occurred when the vehicle was having the 1) Heat components suspected of causing the
issue. malfunction with a hair dryer or other heat
sourre.
WARNING
DO NOT heat components to the point where
they may be damaged.
DO NOT heat the ECM directly.
Simulating Water Sprinkling
1) Sprinkle water onto vehicle to simulate a rainy

day or a high humidity condition.
WARNING
DO NOT sprinkle water directly into the engine
compartment or electronic components.
Simulatingelectricalload
1. Clear Diagnostic Trouble Code (DTC).
1) Turn on all electrical systems to simulate
2. Inspect connector connection, and check terminal
excessive electrical loads (Radios, fans, lights,
for poor connections, loose wires, bent, broken or
etc.).
corroded pins, and then verify that the connectors
are always securely fastened.
3. Slightly shake the connector and wiring harness

vertically and horizontally.

Connector Inspection Procedure
Handling of Connector
4. When a tester is used to check for continuity, or to

measure voltage, always insert tester probe from
wire harness side.
1. Never pull on the wiring harness when

disconnecting connectors.
5. Check waterproof connector terminals from the

connector side. Waterproof connectors cannot be
accessed from harness side.
2. When removing the connector with a lock, press
or pull locking lever. NOTE: Use a fine wire to prevent damage to the
terminal. Do not damage the terminal when inserting
the tater lead.
3. Listen for a click when locking connectors. This

sound indicates that they are securely locked.

Checking Point for Connector Wire Harness Inspection Procedure
1. Before removing the wire harness, check the wire

harness position and crimping in order to restore
it correctly.
2. Check whether the wire harness is twisted, pulled

or loosened.
3. Check whether the temperature of the wire

harness is abnormally high.
4. Check whether the wire harness is rotating,

moving or vibrating against the sharp edge of a
part.
1. While the connector is connected:
Hold the connector, check connecting condition 5. Check the connection between the wire harness
and locking efficiency. and any installed part.
2. When the connector is disconnected: 6. If the covering of wire harness is damaged;

Check missed terminal, crimped terminal or secure, repair or replace the harness.
broken core wire by slightly pulling the wire
harness. Visually check for rust, contamination,
deformation and bend.
3. Check terminal tightening condition:

Insert a spare male terminal into a female ter-
minal and then check terminal tightening
conditions.
4. Pull lightly on individual wires to ensure that each

wire is secured in the terminal.
Repair Method of Connector Terminal
1. Clean the contact points using air gun and/or

shop rag.
NOTE: Never uses and paper when polishing the

contact points, otherwise the contact point may be
damaged.
2. In case of abnormal contact pressure, replace the

female terminal.

Electrical Circuit Inspection Procedure normal). To find exact break point, check sub line of
line 1as described in next step.
Check Open Circuit
b. Disconnect connector (B), and measure for

1. Procedures for Open Circuit resis tance between connector (C) and (B1)
and between (B2) and (A) as shown in [FIG.3].
Continuity Check In this case the measured resistance between
connector (C) and (B1) is higher than 1 and
Voltage Check the open circuit is between terminal 1 of
connector (C) and terminal 1 of connector (B1).
If an open circuit occurs (as seen in [FIG.1]), it can
be found by performing Step 2 (Continuity Check) or
Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake

the wire harness above and below or from side to
side.
Specification (Resistance)
1 or less Normal Circuit
1 or Higher Open Circuit
3. Voltage Check Method
a. With each connector still connected, measure

the voltage between the chassis ground and
terminal1 of each connectors (A), (B) and (C)
as shown in [FIG.4].
The measured voltage of each connector is 5V,

5V and 0V respectively. So the open circuit is
between connector (C) and (B).
a. Disconnect connectors (A), (C) and measure

resistance between connector (A) and (C) as
shown in [FIG.2].
In [FIG.2.] the measured resistance of line1and

2 is higher than 1 and below 1 respectively.
Specifically the open circuit is line 1(Line 2 is

Check Short Circuit
b. Disconnect connector (B), and measure the

resistance between connector (A) and chassis
1. Test Method for Short to Ground Circuit ground, and between (B1) and chassis ground
as shown in [FIG.7].
Continuity Check with Chassis Ground
The measured resistance between connector (B1)
If short to ground circuit occurs as shown in [FIG.5], and chassis groundis1 or less. The short to
the broken point can be found by performing below ground circuit is between terminal 1 of connector (C)
Step 2 (Continuity Check Method with Chassis and terminal 1 of connector (B1).
Ground) as shown below.
2. Continuity Check Method (with Chassis Ground)
NOTE: Lightly shake the wire harness above and

below, or from side to side when measuring the
resistance.
Specification (Resistance)
1 or less Short to Ground Circuit
1 or Higher Normal Circuit
a. Disconnect connectors (A), (C) and measure

for resistance between connector (A) and
Chassis Ground as shown in [FIG.6].
The measured resistance of line 1 and 2 in this

example is below 1 and higher than 1
respectively. Specifically the short to ground circuit
is line 1 (Line 2is normal). To find exact broken point,
check the sub line of line1 as described in the
following step.

Symptom Troubleshooting Guide Chart for MPI Gasoline Engine
Engine Is Not Starting
Engine Is Difficult To Start(Cranking OK)

Irregular Idling Or Engine Is Suddenly Stopped

Engine Hesitation Or Insuffient Accelelation

Troubleshooting Guide for MPI Gasoline Engine
The following number represents inspection order.

Basic Troubleshooting An intermittent Service Engine Soon light with no
stored diagnostic code may be caused by:
Intermittents Ignition coil shortage to ground and arcing at
spark plug wires or plugs
An intermittent fault is the most difficult to
troubleshoot since the MIL flashes on at random,
MIL light wire to ECM shorted to ground
causing uncertainty in the number of flashes or the
conditions present at the time of the fault. Also, the SECM grounds (refer to SECM wiring diagrams).
problem may or may not fully turn ON the MIL light
or store a code. Check for improper installation of electrical options
such as lights, 2-way radios, accessories, etc.
Therefore, the fault must be present or able to be
recreated in order to locate the problem. If a fault is EST wires should be routed away from spark plug
intermittent, use of diagnostic code charts may wires, distributor wires, distributor housing, coil and
result in the unnecessary replacement of good generator. Wires from SECM to ignition should have
components. a good connection.
Corrective Action
Most intermittent problems are caused by faulty
electrical connections or wiring. Perform careful
visual/physical check for:
Poor mating of the connector halves or terminal

not fully seated in the connector body (backed
out)
Improperly formed or damaged terminal. All

connector terminals in problem circuit should be
carefully reformed or replaced to insure proper
contact tension
Loose connections or broken wires
Poor terminal to wire connection crimp
If a visual/physical check does not find the cause of

the problem, perform the following:
(1) Drive the vehicle with a voltmeter or Service

tool connected to a suspected circuit. Check if
circuit is active and signal is reasonable.
(2) Using the Service tool, monitor the input signal

to the SECM to help detect intermittent conditions.
(3) An abnormal voltage, or Service reading, when

the problem occurs, indicates the problem may
be in that circuit.
(4) If the wiring and connectors check OK, and a

diagnostic code was stored for a circuit having a
sensor, check sensor.

Surges and/or Stumbles
Engine power varies under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no
change in the acceleration pedal.
Preliminary Checks
Perform the visual checks as described at start of Basic Troubleshooting chapter.
Be sure driver understands vehicle operation as explained in the operator manual.
PROBABLE CAUSE CORRECTIVE ACTION
The fuel management should maintain a stoichiometric air-fuel ratio under all
Oxygen sensor steady state operating conditions following engine warmup. Failure of the Pre-
malfunction catalyst O2 sensor should cause an O2 sensor fault that can be diagnosed with
the MIL lamp or Service Tool.
NOTE: To determine if the condition is caused by a rich or lean system, the

vehicle should be driven at the speed of the complaint. Monitoring pre-catalyst
O2 adapts*, dither valve duty cycle, or mechanical injector pulse width will help
Fuel system malfunction identify problem.
Check fuel supply while condition exists.
Check in-line fuel filter. Replace if dirty or plugged.
Check fuel pressure.
Check for proper ignition voltage output using spark tester.

Check spark plugs.
Remove spark plugs, check for wet plugs, cracks, wear, improper gap, burned
Ignition system electrodes, or heavy deposits.
malfunction Repair or replace as necessary.
Check condition of distributor cap, rotor and spark plug wires (where
applicable).
Check ignition timing. Refer to application manual for specs.
Check vacuum lines for kinks or leaks.

Component malfunction
Check alternator output voltage. Repair if less than 9 or more than 16 volts.
Check condition of exhaust system.
Exhaust backpressure
Check backpressure before catalyst. It should be less than 3.5 psig (24.13 kPa).
(*) Refer to Table 1 for description of gaseous and liquid O2 adapts.
Related MIL Faults:

Pre-catalyst O2 sensor errors / O2 control errors
Dither valve DC faults / EST faults / ETC faults

Engine Cranking but Will Not Start / Difficult to Start
Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.
Preliminary Checks

Be sure driver is using correct method to start engine as explained in operators manual. Use clear flood
mode during cranking by fully depressing the pedal and cranking the engine. If engine does not start, continue
troubleshooting.

Verify selected fuel with Service Tool. Make sure fuel select switch
CORRECTIVE ACTION
is in proper position.
Check for LPG vapor from LPG liquid outlet valve on tank.
Fuel container empty
Fill fuel container. Do not exceed 80% of liquid capacity.
Liquid valve closed Slowly open liquid valve.
Propane excess flow Reset excess flow valve in LPG tank.
valve closed Close liquid valve. Wait for a click sound; slowly open liquid valve.
Remove obstruction from the fuel line.

Close liquid fuel valve.
Using caution, disconnect the fuel line (some propane may
escape).
Plugged fuel line
Clear obstruction with compressed air.
Re-connect fuel line.
Slowly open liquid fuel valve.
Leak test.
Repair/replace as required.
Clogged fuel filter
See Chapter 2 Fuel Filter replacement.
Check connection
Faulty vapor connection between the
Verify no holes in hose.
pressure regulator/converter and the
Clamps must be tight.
mixer
Look for kinked, pinched and/or collapsed hose.
Repair/replace fuel lock-off.
Fuel lock-off malfunction
See Chapter 2 Fuel Lock-off.
Pressure regulator/converter Test regulator/converter operation and pressure.
malfunction See Chapter 6 Tests and Adjustments.
Incorrect air/fuel or ignition/spark
See Chapter 8 Advanced Diagnostics.
control
Verify the crankshaft position signal is present
No crankshaft position sensor signal

Engine Cranking but Will Not Start / Difficult to Start (contd.)
Check Coolant Temperature Sensor using the Service Tool; compare coolant
temperature with ambient temperature on cold engine.
If coolant temperature reading is 5 greater than or less than ambient air
temperature on a cold engine, check resistance in coolant sensor circuit or
sensor itself. Compare CTS resistance value to Diagnostic Aids chart at end
SECM / control system of this section.
malfunction Verify that there is no code for ETC spring check fault.
Check for 0% APP during cranking.
Cycle key ON and OFF and listen for throttle check (movement) on key OFF.
Check for oil pressure switch faults.
Check for sensor sticking faults.
Check TPS for stuck binding or a high TPS voltage with the throttle closed.
Check fuel lock off (propane) or fuel pump relay gasoline operation: actuator
should turn ON for 2 seconds when ignition is turned ON.
Check for contaminated fuel.
Check both gasoline injector and lock off fuses (visually inspect).
Fuel system malfunction
Check propane tank valve & pickup. A faulty
in-tank fuel pump check valve will allow the fuel in the lines to drain back to the
tank after engine is stopped. To check for this condition, perform fuel system
diagnosis.
Check FTV system for proper operation.
Check for proper ignition voltage output with spark tester.

Check spark plugs. Remove spark plugs, check for wet plugs, cracks, wear,
improper gap, burned electrodes, or heavy deposits. Repair or replace as
necessary.
Check for:
Ignition system malfunction Moisture in distributor cap*
Bare or shorted wires
Worn distributor shaft/rotor*
Loose ignition coil ground
Pickup coil resistance and connections*
(*) Where present
Related MIL Faults:

ETC spring check / ETC faults / EST faults / TPS conflict
APP faults / Encoder error / MAP faults
Injector faults / Oil pressure faults

Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During
Acceleration
Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed
down part way. Momentary lack of response as the accelerator is pushed down. Can occur at all vehicle
speeds. Usually most severe when first trying to make vehicle move, as from a stop. May cause engine to stall.
PRELIMINARY CHECKS

Drive vehicle; verify problem exists.
Remove air filter and check for dirt or other means of plugging. Replace if needed.

Check for restricted fuel filter.
Check fuel supply.
Check for clogged fuel filter and repair or replace as required. See Chapter 4
Fuel Filter replacement
Check for plugged fuel line and remove any obstruction from the fuel line:
Using caution, disconnect the fuel line (some propane may escape).
Fuel system malfunction Re-connect fuel line.
Slowly open liquid fuel valve and leak test.
Check for faulty vapor connection between pressure regulator/converter and
mixer:
Verify that there are no holes in hose.
Observe that clamps are tight.
Monitor pre-catalyst O2 with Service Tool.
Check for proper pressure regulator operation.
See Chapter 6 Test and Adjustments.
Check for proper air/fuel mixer operation.
Check spark advance for excessive retarded ignition timing. Use Service Tool.
Check secondary voltage using an oscilloscope or a spark tester to check for a
Ignition system malfunction weak coil.
Check spark plug condition.
Check poor spark plug primary and secondary wire condition.

Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During
Acceleration (contd.)
Check SECM grounds for cleanliness and secure

connection. See SECM wiring diagrams.
Check alternator output voltage. Repair if less than 9
volts or more than 16 volts.
Check for clogged air filter and clean or replace as
required.
Check exhaust system for possible restriction.
Refer to Chart T-1 on later pages.
Component malfunction Inspect exhaust system for damaged or collapsed
pipes.
Inspect muffler for heat distress or possible internal
failure.
Check for possible plugged catalytic converter by
comparing exhaust system backpressure on each
side at engine. Check backpressure by removing
Pre-catalyst O2 sensor and measuring
backpressure with a gauge.
See Chapter 3 Engine Mechanical System.
Engine mechanical Check engine valve timing and compression
Check engine for correct or worn camshaft.
Related MIL Faults:

EST faults
ETC faults
ETC spring check
TPS faults
APP faults
Encoder error
Delayed Shutdown faults

Detonation / Spark Knock
A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with throttle opening (similar to the sound of hail striking a metal roof).
PRELIMINARY CHECKS

Check for proper fuel level:
Fuel system
malfunction Check fuel pressure.
To determine if the condition is caused by a rich or lean system, the vehicle
should be driven at the speed of the complaint. Monitoring with the Service
tool will help identify problem.
Check for obvious overheating problems:

Low engine coolant
Loose water pump belt
Restricted air flow to radiator, or restricted water flow through radiator
Cooling system malfunction
Inoperative electric cooling fan
Correct coolant solution should be a mix of anti-freeze coolant (or
equivalent) and water
High coolant temperature
Ignition system Check ignition timing. See application manual.

malfunction Check spark module wiring.
Check exhaust backpressure.
Exhaust system malfunction Check for debris clogging the catalyst.
Check that pre-catalyst O2 sensor is functioning.
Check for excessive oil in the combustion chamber and/or blow by from
excessive PCV flow.
Engine mechanical Check combustion chambers for excessive carbon build up.
Check combustion chamber pressure by performing a compression test.
Check for incorrect basic engine parts such as cam, heads, pistons, etc.
Related MIL Faults:

EST faults
Encoder error
High coolant temperature faults

Backfire
Fuel ignites in intake manifold or in exhaust system, making loud popping noise.
PRELIMINARY CHECKS
Simulate condition by reviewing operation procedure practiced by vehicle operator.

Perform fuel system diagnosis check:
Fuel system Check for fuel leaks
malfunction Check for MIL faults
Check for damaged components
Check proper ignition coil output voltage with spark tester.
Check spark plugs. Remove spark plugs, check for wet plugs, cracks, wear,
improper gap, burned electrodes, or heavy deposits. Repair or replace as
Ignition system
necessary.
malfunction
Check spark plug wires for crossfire; also inspect distributor cap, spark plug
wires, and proper routing of plug wires.
Check ignition timing. Refer to application manual.
Check compression: look for sticking or leaking valves.
Check intake and exhaust manifold for casting flash and gasket
Engine mechanical
misalignment.
Refer to Chapter 3 Engine Mechanical System.
Related MIL Faults: EST faults / ETC faults / Encoder error

Pre-catalyst O2 sensor faults
Dieseling, Run-on
Engine continues to run after key is turned OFF, but runs very roughly. If engine runs smoothly, check
ignition switch and adjustment.
PRELIMINARY CHECKS

Fuel system
Check for fuel leaks or leaking injector.
malfunction
Ignition switching Make sure power to system is shut off when key is in OFF position.
Fuel lock off valve Make sure lock off valve is closing properly.
Ignition system malfunction Check spark advance at idle.
Related MIL Faults: EST faults / ETC faults / Pre-catalyst O2 sensor faults

Rough, Unstable, Incorrect Idle, or Stalling
Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.
PRELIMINARY CHECKS

Check for vacuum leaks.
Check that SECM grounds are clean and tight. See SECM wiring diagram
Monitor oxygen feedback to help identify the cause of the problem. If

the system is running lean or if the system is running rich evaluate
further i.e. dither valve duty cycle and injector pulse width.
Check for incorrect minimum idle speed that may be caused by foreign
material accumulation in the throttle bore, on the throttle valve, or on
the throttle shaft.
Fuel system Check that the injectors are clean and functioning.
malfunction Check for liquid fuel in propane pressure regulator hose. If fuel is
present, replace regulator assembly.
The pre-catalyst oxygen (O2) sensor should respond quickly to
different throttle positions. If it does not, then check the pre-catalyst O2
sensor for contamination. If the pre-catalyst O2 sensor is aged or
contaminated, the SECM will not deliver correct amount of fuel,
resulting in a drivability problem.
Fuel container empty
Ignition system
Check ignition system; wires, plugs, rotor, etc.
malfunction
Test regulator operation and pressure.
LPG pressure regulator malfunction
See Chapter 6 Tests and Adjustments
Air/fuel mixer malfunction Check mixer.
Check throttle for sticking or binding.

Check PCV valve for proper operation by placing finger over inlet hole
in valve end several times. Valve should snap back. If not, replace
valve.
Check alternator output voltage. Repair if less than 9 or more than 16
volts.
Perform a cylinder compression check.
Engine mechanical
See Chapter 3 Engine Mechanical System.

Rough, Unstable, Incorrect Idle, or Stalling (contd.)

Reset excess flow valve.
Excess flow valve closed Close liquid valve.
Wait for a click sound. Slowly open liquid valve.
Repair/replace as required
Clogged fuel filter
See Chapter 4 Fuel Filter Replacement
Remove obstruction from the fuel line.
Using caution, disconnect the fuel line (some
Plugged fuel line propane may escape).
Re-connect fuel line.
Slowly open liquid fuel valve & leak test.
Repair/replace fuel lock-off.
Fuel lock-off malfunction
See Chapter 4 Fuel Lock-Off.
Check connection.
Faulty vapor connection
Verify no holes in hose.
between the pressure regulator/converter and the
Clamps must be tight.
mixer
Check level in cooling system:

Must be full, check coolant strength
-35F (-37C) minimum
Pressure regulator freezes Check coolant hoses.
Watch for kinks and/or pinched hoses.
Verify one pressure hose and one return hose.
Test regulator. See Chapter 6

Between mixer and throttle body
Vacuum leak
Between throttle body and intake manifold
Between intake manifold and cylinder head
Related MIL Faults:

EST faults
ETC Sticking fault
Pre-catalyst adapts error

Cuts Out, Misses
Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases,
sometimes above 1500 rpm. The exhaust has a steady spitting sound at idle or low speed.
PRELIMINARY CHECKS
Check fuel system specifically for plugged fuel filter, low pressure.
Check injector drivers. Disconnect all injector harness connectors. Use
injector test light or equivalent 6-volt test light between the harness terminals
Fuel system
of each connector and observe if light blinks while cranking. If test light fails
malfunction
to blink at any connector, it is a faulty injector drive circuit harness, connec-
tor, or terminal.
Check lock off intermittent connection.
Check dither valve operation.
Check for spark on the suspected cylinder(s) using a shop oscilloscope or

spark tester or equivalent. If no spark, check for intermittent operation or
miss. If there is a spark, remove spark plug(s) in these cylinders and check
for cracks, wear, improper gap, burned electrodes, heavy deposits.
Ignition system
Check spark plug wires by connecting ohmmeter to ends of each wire in
malfunction
question. If meter reads over 30,000 ohms, replace wire(s).
Visually inspect distributor cap, rotor, and wires for moisture, dust, cracks,
burns, etc. Spray cap and plug wires with fine water mist to check for shorts.
Check engine ground wire for looseness or corrosion.
Check for electromagnetic interference (EMI). A missing condition can be

caused by EMI on the reference circuit. EMI can usually be detected by
monitoring engine rpm with Service Tool. A sudden increase in rpm with little
change in actual engine rpm indicates EMI is present. If problem exists,
check routing of secondary wires and check distributor ground circuit.
Check intake and exhaust manifolds for casting flash or gasket leaks.
Perform compression check on questionable cylinders. If compression is low,
repair as necessary.
Engine mechanical Check base engine. Remove rocker covers and check for bent pushrods,
worn rocker arms, broken valve springs, worn camshaft lobes, and valve
timing. Repair as necessary.
Related MIL Faults:

EST faults
ETC Sticking fault

Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell
Fuel economy, as measured during normal operation, is noticeably lower than expected. Also, economy is
noticeably lower than what it has been in the past. Propane fuel smell near vehicle sets off carbon monoxide
sensors.
PRELIMINARY CHECKS

Verify operator complaint: identify operating conditions.
Check operators driving habits:
Are tires at correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Check air cleaner element (filter) for being dirty or plugged.
Visually (physically) check vacuum hoses for splits, kinks, and proper connections as shown on application
manual.
Check for faulty gasoline pressure regulator.

Check for leaking injector.
Fuel system Check that dither valve duty cycle is < 15%.
malfunction Check for too high propane pressure at mixer
(> 1 positive pressure).
Monitor Pre-catalyst O2 sensor with Service Tool.
Check engine coolant level.

Cooling system
Check engine thermostat for faulty part (always open) or for
malfunction
wrong heat range.
Check ignition timing. Refer to application manual.

Check for weak ignition and/or spark control.
Ignition system
Check spark plugs. Remove spark plugs and check for wet
malfunction
plugs, cracks, wear, improper gap, burned electrodes, or heavy
deposits. Repair or replace as necessary.
Check for exhaust system restriction or leaks.

Check induction system and crankcase for air leaks.
Check for clogged air filter; clean or replace as required.
Component malfunction Check FTV for housing cracks or obstructions; repair or replace
as required.
Check for vacuum leak. Check system vacuum hoses from
regulator to FTV and mixer. Repair or replace as required.
Air/fuel mixer malfunction Check mixer.
Pressure regulator malfunction / Test regulator operation and pressure.
fuel pressure too high See Chapter 6 Tests and Adjustments.
Check compression.
Engine mechanical
Refer to Chapter 3 Engine Mechanical System.
Related MIL Faults:

Pre-catalyst O2 sensor faults / Low side driver / Dither valve duty cycle
EST faults / Fuel adapt faults / Low coolant temperature

High Idle Speed
Engine idles above the range of 700-1000 rpm.
PRELIMINARY CHECKS
Check all hoses and gaskets for cracking, kinks, or leaks.

Verify that there are no vacuum leaks.
Incorrect idle speed control
See Chapter 8 Advanced Diagnostics & Chapter 6 Tests and
Adjustments
Replace throttle.
Throttle sticking
See Fault Code 461: ETC_Sticking
Check pedal return spring travel for binding.
Check APP function with Service Tool.
Foot pedal sticking or incorrect pedal signal
Verify smooth change of APP reading with pedal movement.
Check for vacuum hose leak.
Engine mechanical Check for PCV malfunction.
Check for defective intake gasket.
Related MIL Faults:

ETC Sticking fault
Idle adapt out of range
MAP Sticking fault
MAP high value

Excessive Exhaust Emissions or Odors
Vehicle has high CO emissions.

NOTE: Excessive odors do not necessarily indicate excessive emissions.
PRELIMINARY CHECKS
Verify that no stored codes exist.
If emission test shows excessive CO and HC, check items that cause vehicle to run rich.
If emission test shows excessive NOx, check items that cause vehicle to run lean or too hot.
If the Service tool indicates a very high coolant temperature and the system
is running lean:
Cooling system Check engine coolant level.
malfunction Check engine thermostat for faulty part (always open) or for wrong heat
range.
Check fan operation
If the system is running rich, refer to Diagnostic Aids chart on the next
page.
Fuel system If the system is running lean refer to Diagnostic Aids chart on the next
malfunction page.
Check for properly installed fuel system components.
Ignition system Check ignition timing. Refer to application manual.

malfunction Check spark plugs, plug wires, and ignition components.

Check for contamination for catalytic converter (look for the removal of fuel
filler neck restrictor).
Check for carbon build-up. Remove carbon with quality engine cleaner.
Follow instructions on label.
Check for plugged PCV valve.
Check for stuck or blocked PCV hose.
Check for fuel in the crankcase.
Related MIL Faults:

Low side driver
Fuel adapt faults
EST faults

Diagnostic Aids for Rich / Lean Operation
SERVICE TOOL ITEM RICH LEAN
Pre-catalyst O2 A/ D counts Consistently > 250 Consistently < 170

Pre-catalyst O2 sensor switching
Always high ADC Always low ADC
between high and low
Trim valve duty cycle > 90% < 10%
Fuel injector pulse width at idle * < 1.0 msec > 8 msec.
Pre-catalyst O2 sensor failed
Malfunction codes Pre-catalyst O2 sensor failed rich
lean
Closed loop operation Pre-catalyst O2 sensor high Pre-catalyst O2 sensor low
(*) The duty cycle injector pulse width criteria for lean or rich operation apply only if the O2 sensor is
functioning properly. If the sensor is not operating properly the criteria may be reversed.
Rich Operation Check trim valves for proper operation, replace as

necessary
LP (Trim valve duty cycle>90%)
Check regulator out pressure, replace if out of
Inspect hoses from AVV port (port on bottom of spec
mixer) to trim valves and regulator for leaks or
blockages, replace as necessary. Gasoline (Injector Pulse Width>8 msec)
Inspect in-line orifices for blockages (in wye), Check system voltage
replace as necessary
Check fuel pressure
Check trim valves for proper operation, replace as
necessary Check injectors for sticking or obstructions
Check regulator out pressure, replace if out of

spec
Inspect fuel cone for damage, replace mixer

assembly as necessary Gasoline (Injector Pulse
Width<1.0 msec)
Check gasoline fuel pressure
Check injectors for sticking, replace as necessary
Lean Operation
LP (Trim valve duty cycle<10%)
Check for vacuum leaks, replace hoses, o-rings,

and gaskets as necessary
Check balance line for blockage, replace as

necessary
Check vapor hose for restrictions, replace as

necessary

Chart T-1 Restricted Exhaust System 4. Inspect the entire exhaust system for a collapsed
Check pipe, heat distress, or possible internal damage,
split welds, or cracked pipe.
Proper diagnosis for a restricted exhaust system is
essential before replacement of any components. 5. If there are no obvious reasons for the excessive
The following procedures may be used for diagnosis, backpressure, the catalytic converter is restricted
depending upon engine or tool used. and should be replaced using current
recommended procedures.
Check Atpre - Catalystoxygen (O2) Sensor
1. Carefully remove pre-catalyst oxygen (O2) sensor.
2. Install exhaust backpressure tester or equivalent

in place of O2 sensor using Snap-On P/N
EEVPV311A kit and YA8661 adapter or Mac tool
(see illustration).
3. After completing test described below, be sure to

coat threads of O2 sensor with anti-seize
compound prior to re-installation.
Illustration Notes
1. Backpressure gage
2. Pre-catalyst Oxygen (O2) sensor
3. Exhaust manifold
Diagnosis:
1. With the engine idling at normal operating

temperature, observe the exhaust system
backpressure reading on the gage. Reading
should not exceed 1.25 psig (8.61 kPa).
2. Increase engine speed to 2000 rpm and observe

gage. Reading should not exceed 3 psig (20.68
kPa).
3. If the backpressure at either speed exceeds

specification, a restricted exhaust system is
indicated.

Chapter 9. ADVANCED DIAGNOSTICS
MI-07 systems are equipped with built-in fault Clearing Fault (DFC) Codes
diagnostics. Detected system faults can be
displayed by the Malfunction Indicator Lamp (MIL) To clear the stored fault codes from SECM memory
as Diagnostic Fault Codes (DFC) or flash codes, you must complete the reset fault pedal maneuver.
and viewed in detail with the use of the Service Tool
software. When the ignition key is turned on, the MIL
will illuminate and remain on until the engine is
started. Once the engine is started, the MIL lamp will CAUTION
go out unless one or more fault conditions are Once the fault list is cleared it cannot be
present. If a detected fault condition exists, the fault restored.
or faults will be stored in the memory of the small
engine control module (SECM). Once an active fault
occurs the MIL will illuminate and remain ON. This First turn OFF the ignition key. Now turn ON the key
signals the operator that a fault has been detected but do not start the engine. As soon as you turn the
by the SECM. key to the ON position you must cycle the foot pedal
by depressing it to the floor and then fully releasing
the pedal (pedal maneuver). You must fully cycle the
Reading Diagnostic Fault Codes foot pedal ten (10) times within five (5) seconds to
clear the fault code list of the SECM. Simply turn the
All MI-07 fault codes are three-digit codes. When the
key OFF to exit the reset mode. The code list is now
fault codes are retrieved (displayed) the MIL will
clear and the SECM will begin storing new fault
flash for each digit with a short pause (0.5 seconds)
codes as they occur.
between digits and a long pause (1.2 seconds)
between fault codes. A code 12 is displayed at the
end of the code list.
EXAMPLE : A code 461 (ETCSticking) has been

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

from SECM Memory
To enter code display mode you must turn OFF the
ignition key. Now turn ON the key but do not start
the engine. As soon as you turn the key to the ON
position you must cycle the foot pedal by depressing
it to the floor and then fully releasing the pedal
(pedal maneuver). You must fully cycle the foot
pedal three (3) times within five (5) seconds to
enable the display codes feature of the SECM.
Simply turn the key OFF to exit display mode. The
code list will continue to repeat until the key is
turned OFF.
G420F(FE) Service Manual 277 Chapter 9. Advanced Diagnostics

Fault Action Descriptions Fault List Definitions
Each fault detected by the SECM is stored in All the analog sensors in the MI-07 system have
memory (FIFO) and has a specific action or result input sensor range faults. These are the coolant
that takes place. Listed below are the descriptions of temperature sensor, fuel temperature sensor,
each fault action. throttle position sensors, pedal position sensors,
manifold pressure sensor, HEGO sensors, and
Engine Shutdown: The most severe action is an intake air temperature sensor. Signals to these
Engine Shutdown. The MIL will light and the engine sensors are converted into digital counts by the
will immediately shutdown, stopping spark, closing SECM. A low/high range sensor fault is normally set
the fuel lock-off closing, and turning off the fuel when the converted digital counts reach the
pump and fuel injectors. minimum of 0 or the maximum of 1024 (1024 = 5.0
Vdc with ~ 204 counts per volt).
Delayed Engine Shutdown: Some faults, such as
low oil pressure, will cause the MIL to illuminate for
30 seconds and then shut down the engine.
Cut Throttle: The throttle moves to its default

position. The engine will run at idle but will not
accelerate.
Cut Fuel: Fuel flow will be turned off.
Turn on MIL: The MIL will light by an active low

signal provided by the SECM, indicating a fault
condition. May illuminate with no other action or may
be combined with other actions, depending on which
fault is active.
Additionally, the SECM includes software to learn
Soft Rev Limit / Medium Rev Limit / Hard Rev the actual range of the pedal position and throttle
Limit: System will follow various sequences to bring position sensors in order to take full advantage of
engine speed back to acceptable levels. the sensor range. Faults are set if the learned
values are outside of the normal expected range of
Level4 Power Limit / Level3 Power Limit / Level2 the sensor (e.g. APP1AdaptLoMin).
Power Limit / Level1 Power Limit: The maximum
engine power output will be limited to one of four
possible levels. The engine power is calculated from
measured engine parameters (e.g. MAP, rpm, fuel
flow, etc).
Disable Gas O2 Control: In LPG mode, closed loop

correction of air fuel ratio based on the Pre-catalyst
O2 sensor is disabled.
Disable Liquid O2 Control: In Gasoline mode,

closed loop correction of air fuel ratio based on the
Pre-catalyst O2 sensor is disabled.

Table 1. Fault List Definitions
CODE
FAULT DESCRIPTION
(MI04 CODE)
Learned full pedal end of APP1 sensor range higher than 641
APP1AdaptHiMax
expected (64)
APP1AdaptHiMin Learned full pedal end of APP1 sensor range lowe 651
APP1AdaptLoMax than expected 661
Learned idle end of APP1 sensor range higher than 631

APP1AdaptLoMin
expected (63)
Learned idle end of APP1 sensor range lower than 621

APP1RangeHigh
expected (62)
APP1 sensor voltage out of range high, normally set if the

611
APP1RangeLow APP1 signal has shorted to power or the ground for the
(61)
sensor has opened
APP1 sensor voltage out of range low, normally set if the
642
APP2AdaptHiMax APP1 signal has shorted to ground, circuit has opened or
(68)
sensor has failed

Table 1. Fault List Definitions (contd.)
CODE
FAULT DESCRIPTION
(MI04 CODE)
Learned full pedal end of APP2 sensor range lower than
APP2AdaptHiMin 652
expected
Learned idle end of APP2 sensor range higher than

APP2AdaptLoMax 662
expected
Learned idle end of APP2 sensor range lower than 632

APP2AdaptLoMin
expected (67)
APP2 sensor voltage out of range high, normally set if the

622
APP2RangeHigh APP2 signal has shorted to power or the ground for the
(66)
sensor has opened
APP2 sensor voltage out of range low, normally set if the
612
APP2RangeLow APP2 signal has shorted to ground, circuit has opened or
(65)
sensor has failed
APP position sensors do no not track well, intermittent 691

APP_Sensors_Conflict
connections to APP or defective pedal assembly (69)
No CAM signal when engine is known to be rotating, broken

CamEdgesFault 191
CAM sensor leads or defective CAM sensor
Loss of synchronization on the CAM sensor, normally due

CamSyncFault to noise on the signal or an intermittent connection on the 192
CAM sensor
No crankshaft signal when engine is known to be rotating,

CrankEdgesFault 193
broken crankshaft sensor leads or defective crank sensor
Loss of synchronization on the crankshaft sensor, normally

CrankSyncFault due to noise on the signal or an intermittent connection on 194
the crankshaft sensor
Engine Coolant Temperature is High. The sensor has
161
ECTOverTempFault measured an excessive coolant temperature typically due to
(16)
the engine overheating.
Engine Coolant Temperature Sensor Input is High. Normally
151
ECTRangeHigh set if coolant sensor wire has been disconnected or circuit
(15)
has opened to the SECM.

CODE
FAULT DESCRIPTION
(MI04 CODE)
Engine Coolant Temperature Sensor Input is Low. Normally
141
ECTRangeLow set if the coolant sensor wire has shorted to chassis ground
(14)
or the sensor has failed.
ECT_IR_Fault Engine Coolant Temperature not changing as expected 171
EST1 output open, possibly open EST1 signal or defective 421

EST1_Open
spark module (42)
EST1 output shorted high or low, EST1 signal shorted to

EST1_Short 431
ground or power or defective spark module
EST2 output open, possibly open EST2 signal or defective

EST2_Open 422
spark module

EST2_Short 432

EST3_Open 423
spark module

EST3_Short 433

EST4_Open 424
spark module

EST4_Short 434

EST5_Open 425
spark module

EST5_Short 435

EST6_Open 426
spark module

EST6_Short 436

EST7_Open 427
spark module

CODE
FAULT DESCRIPTION
(MI04 CODE)
EST7 output shorted high or low, EST7 signal shorted to ground

EST7_Short 437
or power or defective spark module
EST8 output open, possibly open EST8 signal or defective spark

EST8_Open 428
module
EST8 output shorted high or low, EST8 signal shorted to ground

EST8_Short 438
or power or defective spark module
Electronic Throttle Control Spring Return Test has Failed. The

SECM will perform a safety test of the throttle return spring
following engine shutdown. If this spring has become weak the
481
ETCSpringTest throttle will fail the test and set the fault.
(28)
NOTE: Throttle assembly is not a serviceable item and can only
be repaired by replacing the DV-EV throttle assembly.
Electronic Throttle Control Driver has failed. Normally set if either

ETC_Open_Fault of the ETC driver signals have opened or become disconnected, 471
electronic throttle or SECM is defective.
Electronic Throttle Control is Sticking. This can occur if the

throttle plate (butterfly valve) inside the throttle bore is sticking.
The plate sticking can be due to some type of obstruction; a
461
ETC_Sticking loose throttle plate or worn components shaft bearings.
(26)
NOTE: Throttle assembly is not a serviceable item and can only
be repaired by replacing the DV-EV throttle assembly.
Conflict in fuel select signals, normally set if one or both of the

FuelSelectConflict 181
fuel select signals are shorted to ground
Fuel Temperature Sensor Input is High. Normally set if the fuel

FuelTempRangeHigh temperature sensor wire has been disconnected or the circuit 932

CODE
FAULT DESCRIPTION
(MI04 CODE)
Fuel Temperature Sensor Input is Low. Normally set if the fuel
FuelTempRangeLow temperature sensor wire has shorted to chassis ground or the 931
sensor has failed.
731
GasFuelAdaptRangeHi In LPG mode, system had to adapt lean more than expected
(73)
721
GasFuelAdaptRangeLo In LPG mode, system had to adapt rich more than expected
(72)
Pre-catalyst O2 sensor indicates extended lean operation on
GasO2FailedLean 751
LPG
Pre-catalyst O2 sensor indicates extended rich operation on 771

GasO2FailedRich
LPG (77)
Pre-catalyst O2 sensor inactive on LPG, open O2 sensor 741

GasO2NotActive
signal or heater leads, defective O2 sensor, or defective FTVs (74)
Post-catalyst O2 sensor control on LPG has reached rich limit

and sensor still reads to lean. This could be caused by oxygen
leak before or just after sensor, catalyst failure, sensor failure,
GasPostO2FailedRich 772
or wiring/relay failure causing the sensor to not be properly
heated. If any Pre-O2 sensor faults are set, diagnose these
first and after correcting these faults recheck if this fault sets.
Post-catalyst O2 sensor control on LPG has reached lean limit

and sensor still reads to rich. This could be caused by catalyst
failure, sensor failure, or wiring/relay failure causing the
GasPostO2FailedLean 752
sensor to not be properly heated. If any Pre-O2 sensor faults
are set diagnose, these first and after correcting these faults
recheck if this fault sets.
Post-catalyst O2 sensor control on LPG has sensed the O2

sensor is not responding as expected. If any Pre-O2 sensor
faults are set diagnose these first and after correcting these
GasPostO2Inactive faults recheck if this fault sets. Possible causes for this fault 742
are sensor disconnected, sensor heater failed, sensor
element failed, heater relay, or SECM control of heater relay
is disconnected or failed.
Reserved for Future Use 743

CODE
FAULT DESCRIPTION
(MI04 CODE)
(Electronic Throttle Control Driver has Failed) Indeterminate
fault on Hbridge driver for Electronic Throttle Control. 491
HbridgeFault_ETC
Possibly either ETC+ or ETC- driver signals have been (29)
shorted to ground
Engine speed has exceeded the third level (3 of 3) of 571

HardOverspeed
overspeed protection (57)
Intake Air Temperature Sensor Input is High normally set if

the IAT temperature sensor wire has been disconnected, the 381
IATRangeHigh
circuit has opened to the SECM, or a short to Vbatt has (38)
occurred.
Intake Air Temperature Sensor Input is Low normally set if
371
IATRangeLow the IAT temperature sensor wire has shorted to chassis
(37)
ground or the sensor has failed.
IAT_IR_Fault Intake Air Temperature not changing as expected 391
Gasoline Injector 1 open circuit, broken injector 1 wire or

Inj1Open 131
defective injector

Inj2Open 132
defective injector

Inj3Open 133
defective injector

Inj4Open 134
defective injector

Inj5Open 135
defective injector

Inj6Open 136
defective injector

Inj7Open 137
defective injector

Inj8Open 138
defective injector
Cold Start Valve Fault, signal has opened or shorted to

LSDFault_CSValve 713
ground or power or defective cold start valve

CODE
FAULT DESCRIPTION
(MI04 CODE)
Check Engine Lamp Fault, signal has opened or shorted to
LSDFault_CheckEngine 714
ground or power or defective check engine lamp
Crank Disable Fault, signal has opened or shorted to ground or

LSDFault_CrankDisable 715
power or defective crank disable relay
Dither Valve 1 Fault, signal has opened or shorted to ground or 711

LSDFault_Dither1
power or defective dither 1 valve (71)
Dither Valve 2 Fault, signal has opened or shorted to ground or

LSDFault_Dither2 712
power or defective dither 2 valve
Fuel Pump Fault, signal has opened or shorted to ground or

LSDFault_FuelPump 716
power or defective fuel pump
Fuel lock off Valve Fault, signal has opened or shorted to ground
LSDFault_LockOff 717
or power or defective Fuel lock off valve
Malfunction Indicator Lamp Fault, signal has opened or shorted

LSDFault_MIL 718
to ground or power or defective MIL lamp
LiqFuelAdaptRangeHi In Gasoline mode, system had to adapt rich more than expected 821
LiqFuelAdaptRangeLow In Gasoline mode, system had to adapt lean more than expected 831
Pre-catalyst O2 sensor indicates extended lean operation on

LiqO2FailedLean 851
gasoline
Pre-catalyst O2 sensor indicates extended rich operation on

LiqO2FailedRich 871
gasoline
Pre-catalyst O2 sensor inactive on gasoline, open O2 sensor

LiqO2NotActive 841
signal or heater leads, defective O2 sensor
Post-catalyst O2 sensor control on gasoline has reached rich

limit and sensor still reads to lean. This could be caused by
oxygen leak before or just after sensor, catalyst failure, sensor
LiqPostO2FailedRich failure, or wiring/relay failure causing the sensor to not be 872
properly heated. If any Pre-O2 sensor faults are set, diagnose
these first and after correcting these faults recheck if this fault
sets.
Post catalyst O2 sensor control on gasoline has reached lean

limit and sensor still reads to rich. This could be caused by
catalyst failure, sensor failure, or wiring/relay failure causing the
LiqPostO2FailedLean 852
sensor to not be properly heated. If any Pre O2 sensor faults are
set, diagnose these first and after correcting these faults recheck
if this fault sets.

CODE
FAULT DESCRIPTION
(MI04 CODE)
Post-catalyst O2 sensor control on gasoline has sensed the
O2 sensor is not responding as expected. If any Pre-O2
sensor faults are set, diagnose these first and after correcting
LiqPostO2Inactive these faults recheck if this fault sets. Possible causes for this 842
fault are sensor disconnected, sensor heater failed, sensor
element failed, heater relay, or SECM control of heater relay
is disconnected or failed.
Reserved 843
521
LowOilPressureFault Low engine oil pressure
(52)
Manifold Absolute Pressure Sensor Input is High, normally set
if the TMAP pressure signal wire has become shorted to
MAPRangeHigh 342
power, shorted to the IAT signal, the TMAP has failed or the
SECM has failed.
Manifold Absolute Pressure Sensor Input is Low, normally set

MAPRangeLow if the TMAP pressure signal wire has been disconnected or 332
shorted to ground or the circuit has opened to the SECM
Manifold Absolute Pressure Sensor Input is High, normally set

if the TMAP pressure signal wire has become shorted to 341
MAPTimeRangeHigh
power, shorted to the IAT signal, the TMAP has failed or the (34)
SECM has failed
Manifold Absolute Pressure Sensor Input is Low, normally set
331
MAPTimeRangeLow if the TMAP pressure signal wire has been disconnected or
(33)
shorted to ground or the circuit has opened to the SECM
MAP_IR_HI MAP sensor indicates higher pressure than expected 351
MAP_IR_LO MAP sensor indicates lower pressure than expected 352
MAP_STICKING MAP sensor not changing as expected 353
MediumOverspeed Engine speed has exceeded the second level (2 of 3) of

572
overspeed protection
Pre -catalyst O2 sensor voltage out of range high, sensor

O2RangeHigh 921
signal shorted to power
Pre-catalyst O2 sensor voltage out of range low, sensor signal

O2RangeLow 911
shorted to ground
Post-catalyst O2 sensor voltage out of range high, sensor

O2_PostCatRangeHigh 922
signal shorted to voltage source (5V or battery)
Post -catalyst O2 sensor voltage out of range low, sensor

O2_PostCatRangeLow 912
signal shorted to ground
561
SensVoltRangeHigh Sensor reference voltage XDRP too high
(56)

CODE
FAULT DESCRIPTION
(MI04 CODE)
551
SensVoltRangeLow Sensor reference voltage XDRP too low
(55)
ServiceFault1 Service Interval 1 has been reached 991
Service Interval 4 has been reachedtime to replace HEGO

ServiceFault4 994
sensors
Service Interval 5 has been reachedtime to replace
ServiceFault5 995
engine timing belt
Engine speed has exceeded first level (1 of 3) of overspeed
SoftOverspeed 573
protection
Learned WOT end of TPS1 sensor range lower than
TPS1AdaptHiMin 271
expected
541
SysVoltRangeHigh System voltage too high
(54)
531
SysVoltRangeLow System voltage too low
(53)
Learned WOT end of TPS1 sensor range higher than 251
TPS1AdaptHiMax
expected (25)
TPS1AdaptHiMin 271
expected
Learned closed throttle end of TPS1 sensor range higher
TPS1AdaptLoMax 281
than expected
Learned closed throttle end of TPS1 sensor range lower than 241
TPS1AdaptLoMin
expected (24)
TPS1 sensor voltage out of range high, normally set if the
231
TPS1RangeHigh TPS1 signal has shorted to power or ground for the sensor
(23)
has opened
TPS1 sensor voltage out of range low, normally set if TPS1
221
TPS1RangeLow signal has shorted to ground, circuit has opened or sensor
(22)
has failed
Learned WOT end of TPS2 sensor range higher than
TPS2AdaptHiMax 252
expected
TPS2AdaptHiMin 272
expected
Learned closed throttle end of TPS2 sensor range higher
TPS2AdaptLoMax 282
than expected
Learned closed throttle end of TPS2 sensor range lower than
TPS2AdaptLoMin 242
expected
TPS2 sensor voltage out of range high, normally set if the
TPS2RangeHigh TPS2 signal has shorted to power or ground for the sensor 232
has opened

CODE
FAULT DESCRIPTION (MI04 CODE)
TPS2 sensor voltage out of range low, normally set if TPS2

TPS2RangeLow signal has shorted to ground, circuit has opened or sensor 222
has failed
TPS sensors differ by more than expected amount.

TPS_Sensors_Conflict 291
NOTE: The TPS is not a serviceable item and can only be
repaired by replacing the DV-EV throttle assembly
TransOilTemp Excessive transmission oil temperature 933

Table 2. Diagnostic Fault Codes (Flash Codes)
CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION*
FIRST CHECK
NONE
None, used as end of the fault list
12 Signifies the end of one pass NONE
identification
through the fault list
Check INJ1 wiring for an open circuit
Inj1Open
SECM (Signal) A5 to Injector 1 Pin A
Gasoline Injector 1 open
131 TurnOnMil Switched 12V to Injector 1 Pin B Check
circuit, broken injector 1 wire
Injector 1 Resistance, 12 to14 ohms
or defective injector
(cold)
Inj2Open
(cold)
Inj3Open
(cold)
Inj4Open
134 TurnOnMil SECM (Signal) A7 to Injector 4 Pin A
Switched 12V to Injector 4 Pin B
Inj5Open
135 Gasoline Injector 5 open
None N/A
Not Used circuit, broken injector 5 wire
Inj6Open
None N/A
Inj7Open
None N/A
Inj8Open
None N/A
ECTRangeLow Check ECT sensor connector and
141
Coolant Sensor failure or TurnOnMil wiring for a short to GND
(14)
shorted to GND SECM (Signal) Pin B15 To ECT Pin 3
Check if ECT sensor connector is
(1) TurnOnMil disconnected or for an open ECT
ECTRangeHigh
151 (2) Delayed Engine circuit
Coolant sensor disconnected
(15) Shutdown SECM (Signal) Pin B15 to ECT Pin 3
or open circuit
(3) CheckEngineLight SECM (Sensor GND) Pin B1 to
ECT Pin 1
(*) Fault actions shown are default values specified by the OEM.

Table 2. Diagnostic Fault Codes (Flash Codes) contd.
CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check coolant system for radiator

ECTOverTempFault
blockage, proper coolant level and for
Engine coolant temperature
(1) TurnOnMil leaks in the system. Possible ECT
is high. The sensor has
161 (2) DelayedEngine short to GND, check ECT signal wiring
measured an excessive
coolant temperature typically
(3) CheckEngineLight SECM (Sensor GND) Pin B1 to ECT
due to the engine
Pin 1 SECM (System GND) Pin A16,
overheating.
B17 Check regulator for coolant leaks
ECT_IR_Fault
Check for coolant system problems,
171 Engine coolant temperature None
e.g. defective or stuck thermostat
not changing as expected
FuelSelectConflict Check fuel select switch connection for

Conflict in fuel select signals, a short to GND
181 normally set if both of the fuel TurnOnMil SECM (SIGNAL) Pin A12
select signals are shorted to SECM (SIGNAL) Pin A15
ground SECM (Sensor GND) Pin B1
CamEdgesFault Check CAM sensor connections SECM

No CAM signal when engine (SIGNAL) Pin B10 to CAM sensor Pin
is known to be rotating, 2 SECM (Sensor GND) Pin B1 to CAM
191 None
broken crankshaft sensor sensor Pin 3 Switched 12V to CAM
leads or defective CAM sensor Pin 1 Check for defective CAM
sensor sensor
Check CAM sensor connections

CamSyncFault
SECM (SIGNAL) Pin B10 to CAM
Loss of synchronization on
sensor Pin 2
the CAM sensor, normally
192 None SECM (Sensor GND) Pin B1 to CAM
due to noise on the signal or
sensor Pin 3 Switched 12V to CAM
an intermittent connection on
sensor Pin 1 Check for defective CAM
the CAM sensor
sensor
Check Crankshaft sensor connections
CrankEdgesFault
SECM (SIGNAL) Pin B5 to Crank
No crankshaft signal when
sensor Pin 3
engine is known to be
193 None SECM (Sensor GND) PIN B1 to Crank
rotating, broken crankshaft
sensor Pin 2 Switched 12V to Crank
sensor leads or defective
sensor Pin 1 Check for defective Crank
crank sensor
sensor
CrankSyncFault Check Crankshaft sensor connections
Loss of synchronization on SECM (SIGNAL) Pin B5 to Crank
the crankshaft sensor, sensor Pin 3
194 normally due to noise on the None SECM (Sensor GND) Pin B1 to Crank
signal or an intermittent sensor Pin 2 Switched 12V to Crank
connection on the crankshaft sensor Pin 1 Check for defective Crank
sensor sensor

FAULT CORRECTIVE ACTION

DFC PROBABLE FAULT
ACTION * FIRST CHECK
Check throttle connector connection and
TPS1RangeLow
TPS1 sensor for an open circuit or short to
TPS1 sensor voltage out of range
221 GND
low, normally set if the TPS1 signal TurnOnMil
(22) SECM Pin B23 (signal) to ETC Pin 6 SECM
has shorted to ground, circuit has
Pin B1 (sensor GND) to ETC Pin 2
opened or sensor has failed
SECM (system GND) Pin A16, B17
Check throttle connector connection and
TPS2RangeLow
TPS2 sensor for an open circuit or short to
GND
222 low, normally set if the TPS2 signal TurnOnMil
SECM Pin B4 (signal) to ETC Pin 5
has shorted to ground, circuit has
SECM Pin B1 (sensor GND) to ETC Pin 2
TPS1RangeHigh
Check throttle connector and TPS1 sensor
231 wiring for a shorted circuit
high, normally set if the TPS1 TurnOnMil
(23) SECM Pin B23 (signal) to ETC Pin 6 SECM
signal has shorted to power or the
Pin B1 (sensor GND) to ETC Pin 2
ground for the sensor has opened
TPS2RangeHigh
Check throttle connector and TPS1 sensor
wiring for a shorted circuit
232 high, normally set if the TPS2 TurnOnMil
SECM Pin B4 (signal) to ETC Pin 5
SECM pin B1 (sensor GND) to ETC Pin 2
Check the throttle connector and pins for
corrosion.
TPS1AdaptLoMin To check the TPS disconnect the throttle
241 Learned closed throttle end of connector and measure the resistance from:
None
(24) TPS1 sensor range lower than TPS Pin 2 (GND) to
expected Pin 6 (TPS1 SIGNAL) (0.7 30%)
TPS Pin 3 (PWR) to
Pin 6 (TPS1 SIGNAL) (1.4 30%)
corrosion.
Learned closed throttle end of connector and measure the resistance from:
242 None
TPS2 sensor range lower than TPS Pin 2 (GND) to
expected Pin 5 (TPS2 SIGNAL) (1.3K 30%)
TPS PIN 3 (PWR) to
PIN 5 (TPS2 SIGNAL) (0.6K 30%)
TPS1AdaptHiMax
251
Learned WOT end of TPS1 sensor None N/A
(25)
range higher than expected
TPS2AdaptHiMax
252 Learned WOT end of TPS2 sensor None N/A
TPS1AdaptHiMin
271 Learned WOT end of TPS1 sensor None N/A
range lower than expected

CORRECTIVE ACTION
FIRST CHECK
TPS2AdaptHiMin
Learned WOT end of TPS2
272 None N/A
sensor range lower than
expected
TPS1AdaptLoMax
Learned closed throttle end
281 None N/A
of TPS1 sensor range higher
than expected
TPS2AdaptLoMax
282 None N/A
than expected
TPS_Sensors_Conflict
TPS sensors differ by more
than expected amount
(1) TurnOnMil
291 NOTE: The TPS is not a Perform checks for DFCs 241 & 242
(2) Engine Shutdown
serviceable item and can
only be repaired by replacing
the DV-EV throttle assembly.
Check TMAP connector and MAP
signal wiring for an open circuit TMAP
Pin 4 to SECM Pin B18 (signal)
MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1 (sensor
Manifold Absolute Pressure GND)
sensor input is low, normally TMAP Pin 3 to SECM Pin B24 (XDRP
331 set if the TMAP pressure +5 Vdc)
None
(33) signal wire has been Check the MAP sensor by
disconnected or shorted to disconnecting the TMAP connector and
ground or the circuit has measuring at the sensor:
opened to the SECM TMAP Pin 1(GND) to Pin 4 (pressure
signal KPA) (2.4k - 8.2k)
TMAP Pin 3 (power) to Pin 4 (pressure

signal wiring for an open circuit TMAP
Pin 4 to SECM Pin B18 (signal)
MAPRangeLow TMAP Pin 1 to SECM Pin B1 (sensor
Manifold Absolute Pressure GND)
sensor input is low, normally TMAP Pin 3 to SECM Pin B24
(1) TurnOnMil
set if the TMAP pressure (XDRP +5 Vdc)
332
signal wire has been Check the MAP sensor by disconnect-
(2) CutThrottle
disconnected or shorted to ing the TMAP connector and
ground or the circuit has measuring at the sensor:
opened to the SECM TMAP Pin 1(GND) to Pin 4 (pressure


DFC PROBABLE FAULT
signal wiring for a shorted circuit
MAPTimeRangeHigh TMAP Pin 4 to SECM Pin B18 (signal)
Manifold Absolute Pressure TMAP Pin 1 to SECM Pin B1 (sensor
Sensor Input is High, GND)
normally set if the TMAP TMAP Pin 3 to SECM Pin B24 (XDRP
341
pressure signal wire has None +5 Vdc) Check the MAP sensor by
(34)
become shorted to power, disconnecting the TMAP connector and
shorted to the IAT signal, the measuring at the sensor:
TMAP has failed or the TMAP Pin 1(GND) to Pin 4 (pressure
SECM has failed. signal KPA) (2.4k - 8.2k)
signal wiring for a shorted circuit
TMAP Pin 4 to SECM Pin B18 (signal)
MAPRangeHigh
TMAP Pin 1 to SECM Pin B1 (sensor
Manifold Absolute Pressure
GND)
Sensor Input is High,
TMAP Pin 3 to SECM Pin B24 (XDRP
normally set if the TMAP
(1) TurnOnMil +5 Vdc)
342 pressure signal wire has
(2) CutThrottle Check the MAP sensor by
become shorted to power,
disconnecting the TMAP connector and
shorted to the IAT signal, the
measuring at the sensor:
TMAP has failed or the
TMAP Pin 1(GND) to Pin 4 (pressure
SECM has failed
MAP_IR_HI Check for vacuum leaks. Check that
351 MAP sensor indicates higher None TMAP sensor is mounted properly.
pressure than expected Possible defective TMAP sensor.
MAP_IR_LO
352 MAP sensor indicates lower None Possible defective TMAP sensor.
pressure than expected
MAP_STICKING Check that TMAP sensor is mounted
353 MAP sensor not changing as None properly. Possible defective TMAP
expected sensor.
Check TMAP connector and IAT signal
IATRangeLow
Intake Air Temperature
Sensor Input is Low normally
371 GND)
set if the IAT temperature TurnOnMil
(37) To check the IAT sensor of the TMAP
sensor wire has shorted to
disconnect the TMAP connector and
chassis ground or the sensor
measure the IAT resistance
has failed.
Resistance is approx 2400 ohms at
room temperature.

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

for open circuit
EST3_Open EST3 system. See application note.
output open, possibly open Verify GND on ignition module Pin A
423 TurnOnMi
EST3 signal or defective (of both connectors)
engine details.


DFC PROBABLE FAULT
for open circuit
system.
EST4_Open EST4
See application manual. Verify GND on
output open, possibly open
424 TurnOnMil ignition module Pin A (of both
EST4 signal or defective
connectors)
spark module
Verify +12 Vdc on ignition module Pin
engine details.
EST5_Open EST5
425 None N/A
spark module
EST6_Open EST6
426 None N/A
spark module
EST7_Open EST7
427 None N/A
spark module
EST8_Open EST8
428 None N/A
spark module

for shorts
SECM Pin A9 (EST1) to ignition
EST1_Short EST1
module Pin D (4-pin connector)
output shorted high or low,
Verify GND on ignition module Pin A
431 EST1 signal shorted to TurnOnMil
(of both connectors) Verify +12
ground or power or defective
Vdc on ignition module Pin B (of both
spark module
connectors)
engine details.


DFC PROBABLE FAULT
for shorts
EST2_Short EST2
(of both connectors)
spark module
engine details.

for shorts
EST3_Short EST3
(of both connectors) Verify +12 Vdc on
ignition module
spark module
Pin B (of both connectors) Refer to
application manual for specific engine
details.

for shorts
EST4_Short EST4
(of both connectors)
spark module
engine details.
EST5_Short EST5
435 EST5 signal shorted to None N/A
spark module
EST6_Short EST6
436 EST6 signal shorted to None N/A
spark module

CORRECTIVE ACTION FIRST

CHECK
EST7_Short
EST7 output shorted high or low,
437 None N/A
EST7 signal shorted to ground or
power or defective spark module
EST8_Short
EST8 output shorted high or low,
438 None N/A
EST8 signal shorted to ground or
power or defective spark module
Check for debris or obstructions
ETC_Sticking
inside the throttle body
Electronic Throttle Control is
Check throttle-plate shaft for bearing
sticking. This can occur if the
wear
throttle plate (butterfly valve)
Check the ETC driver wiring for an
inside the throttle bore is sticking.
open circuit
The plate sticking can be due to (1)TurnOnMil
461 SECM Pin A17 to ETC + Pin 1
some type of obstruction, a loose (2) EngineShutdown
(26) SECM Pin A18 to ETC - Pin 4
throttle plate, or worn components (3)CutThrottle
Check the ETC internal motor drive
shaft bearings. NOTE: The throttle
by disconnecting the throttle
assembly is not a serviceable item
connector and measuring the motor
and can only be repaired by
drive resistance at the throttle
replacing the DV-EV throttle
TPS Pin 1 (+DRIVER) to
assembly
Pin 4 (-DRIVER) ~3.0-4.0
open circuit SECM Pin A17 to ETC +
ETC_Open_Fault
Pin 1
Electronic Throttle Control Driver
SECM Pin A18 to ETC - Pin 4 Check
has failed, normally set if either of
the ETC internal motor drive by
471 the ETC driver signals have None
disconnecting the throttle connector
opened or become disconnected,
and measuring the motor drive
electronic throttle or SECM is
resistance at the throttle
defective.
TPS Pin 1 (+DRIVER) to Pin 4 (-
DRIVER) ~3.0-4.0
ETCSpringTest
has failed, normally set if either of
the ETC driver signals have
opened or become disconnected,
electronic throttle or SECM is
defective.
Electronic Throttle Control Spring
Perform throttle spring test by
481 Return Test has failed. The SECM (1) TurnOnMil
cycling the ignition key and re-check
(28) will perform a safety test of the (2) EngineShutdown
for fault
throttle return spring following
engine shutdown. If this spring
has become weak the throttle will
fail the test and set the fault.
NOTE: The throttle assembly is
not a serviceable item and can
only be repaired by replacing the
DV-EV throttle assembly.

CORRECTIVE ACTION
FIRST CHECK
Check ETC driver wiring for a shorted
HbridgeFault_ETC
circuit
Electronic Throttle Control
SECM Pin A17 to ETC + Pin 1
Driver has failed.
SECM Pin A18 to ETC - Pin 4
Indeterminate fault on
491 Check the ETC internal motor drive by
Hbridge driver for electronic TurnOnMil
(29) disconnecting the throttle connector
throttle control. Possibly
and measuring the motor drive
either ETC+ or ETC- driver
resistance at the throttle
signals have been shorted to
ground
Pin 4 (-DRIVER) ~3.0-4.0
(1) TurnOnMil Check engine oil level

521 LowOilPressureFault (2) DelayedEngine Check electrical connection to the oil
(52) Low engine oil pressure Shutdown pressure switch
(3) CheckEngine Light SECM Pin B9 to Oil Pressure Switch
Check battery voltage

Perform maintenance check on
electrical connections to the battery
and chassis ground
Check battery voltage during starting
and with the engine running to verify
531 SysVoltRangeLow charging system and alternator
TurnOnMil
(53) System voltage too low function
Measure battery power at SECM with
a multimeter (with key on) SECM Pin
A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin A23 (DRVP) to
SECM Pin B17 (DRVG)
Check battery and charging system

voltage
Check battery voltage during starting
and with the engine running
Check voltage regulator, alternator,
and charging system
541 SysVoltRangeHigh Check battery and wiring for
TurnOnMil
(54) System voltage too high overheating and damage
Measure battery power at SECM with
a multimeter (with key on) SECM Pin
A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin B17 (DRVG)

CORRECTIVE ACTION
FIRST CHECK
Measure transducer power at the

TMAP connector with a multimeter
TMAP Pin 3 XDRP +5 Vdc to TMAP
Pin 1 XDRG GND
Verify transducer power at the SECM
SensVoltRangeLow
551 (1) TurnOnMil with a multimeter
Sensor reference voltage
(55) (2) EngineShutdown SECM Pin B24 +5 Vdc to SECM Pin
XDRP too low
B1 XDRG GND Verify transducer
power at ETC with a multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2
XDRG GND Verify transducer power to
the foot pedal with a multimeter.

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

CORRECTIVE ACTION
FIRST CHECK
APP2RangeLow
APP2 sensor voltage out of range
Check foot pedal connector
612 low, normally set if the APP2
TurnOnMil Check APP2 signal at SECM PIN
(65) signal has shorted to ground,
B16
circuit has opened or sensor has
failed
APP1RangeHigh
APP1 sensor voltage out of range
621 (1) TurnOnMil Check foot pedal connector
high, normally set if the APP1
(62) (2) CheckEngine Light Check APP1 signal at SECM PIN B7
APP2RangeHigh
APP2 sensor voltage out of range Check foot pedal connector
622
high, normally set if the APP2 TurnOnMil Check APP2 signal at SECM PIN
(66)
signal has shorted to power or the B16
Check APP connector and pins for
APP1AdaptLoMin
631 corrosion
Learned idle end of APP1 sensor None
(63) Cycle the pedal several times and
check APP1 signal at SECM Pin B7
APP2AdaptLoMin
632 corrosion
Learned idle end of APP2 sensor None
(67) Cycle the pedal several times and
APP1AdaptHiMax
641 Learned full pedal end of APP1
None N/A
(64) sensor range higher than
expected
APP2AdaptHiMax
642 Learned full pedal end of APP2
None N/A
expected
APP1AdaptHiMin
651 Learned full pedal end of APP1 None N/A
sensor range lower than expected
APP2AdaptHiMin
APP1AdaptLoMax
661 Learned idle end of APP1 sensor None N/A
APP2AdaptLoMax
APP_Sensors_Conflict
corrosion
APP position sensors do no not
691 (1) TurnOnMil Cycle the pedal several times and
track well, intermittent connections
(69) (2) Level1PowerLimit check APP1 signal at SECM Pin B7
to APP or defective pedal
Cycle the pedal several times and
assembly

CORRECTIVE ACTION
FIRST CHECK
Check FTV1 for an open wire or FTV
connector being disconnected FTV1
LSDFault_Dither1
Pin 1 (signal) to SECM Pin A1
Dither Valve 1 Fault, signal
711 FTV1 Pin 2 (power) to SECM (DRVP)
has opened or shorted to TurnOnMil
(71) Pin A23 Check
FTV1 for an open coil by disconnecting
dither 1 valve
the FTV connector and measuring the
resistance (~26 2 )
Check FTV1 for an open wire or FTV
connector being disconnected or signal
LSDFault_Dither2 shorted to GND
Dither Valve 2 Fault, signal FTV2 Pin 1 (signal) to SECM Pin A2
712 has opened or shorted to TurnOnMil FTV2 Pin 2 (power) to SECM (DRVP)
ground or power or defective Pin A23 Check
dither 2 valve FTV1 for an open coil by disconnecting
the FTV connector and measuring the
resistance (~26 2 )
LSDFault_CheckEngine
Check Engine Lamp Fault,
Check Check Engine Lamp for an
714 signal has opened or shorted None
open wire or shorted to GND
to ground or power or
defective check engine lamp
LSDFault_CrankDisable
Crank Disable Fault, signal
715 has opened or shorted to None N/A
crank disable relay
Check fuel lock off valve for an open

wire or connector being disconnected
LSDFault_LockOff or signal shorted to GND
Fuel lock off Valve Fault, Lockoff Pin B (signal) to SECM Pin
717 signal has opened or shorted TurnOnMil A11 Lockoff Pin A (power) to SECM
to ground or power or (DRVP) Pin A23 Check CSV for an
defective Fuel lock off valve open coil by disconnecting the CSV
connector and measuring the
resistance (~26 3 )
LSDFault_MIL
Malfunction Indicator Lamp
Check MIL lamp for an open wire or
718 Fault, signal has opened or None
short to GND.
shorted to ground or power
or defective MIL lamp
GasFuelAdaptRangeLo
Check for vacuum leaks. Check fuel
721 In LPG mode, system had to
TurnOnMil trim valves, e.g. leaking valve or hose
(72) adapt rich more than
Check for missing orifice(s).
expected

CORRECTIVE ACTION
FIRST CHECK
GasFuelAdaptRangeHi
Check fuel trim valves, e.g. plugged
731 In LPG mode, system had
TurnOnMil valve or hose. Check for plugged
(73) to adapt lean more than
orifice(s).
expected
Check that Pre-catalyst O2 sensor
connections are OK.
O2 (signal) Pin 3 to SECM Pin B13 O2
GasO2NotActive Pin 2 (HEATER GND) to SECM
Pre-catalyst O2 sensor (DRVG GNG)
741 inactive on LPG, open O2 (1) TurnOnMil Pins A16, B17 O2 Pin 1 (HEATER
(74) sensor signal or heater (2) DisableGas O2Ctrl PWR) to SECM (DRVP + 12V) Pin A23
leads, defective O2 Verify O2 sensor heater circuit is
sensor operating by measuring heater
resistance (2.1 0.4 ) O2 Pin 2
(HEATER GND) to Pin 1 (HEATER
PWR)
Check that Post-catalyst O2 sensor
connections are OK.
O2 (signal) Pin 3 to SECM Pin B19
O2 Pin 2 (HEATER GND) to SECM
(DRVG GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2
Heater Relay. Relay pin 87. This relay
only turns on after engine has been
GasPostO2NotActive running for some time and SECM has
Post-catalyst O2 sensor calculated that water condensation in
inactive on LPG, open O2 (1) TurnOnMil exhaust has been removed by exhaust
742
sensor signal or heater (2) DisableGasPost O2Ctrl heat. Post O2 Heater Relay has SECM
leads, defective O2 (DRVP + 12V) applied to the relay coil
sensor. power. The relay coil ground is
controlled by SECM Pin A20 to activate
the relay to flow current through the
post O2 heater.
Verify O2 sensor heater circuit is
operating by measuring heater
resistance (2.1 0.4 )
O2 Pin 2 (HEATER GND) to Pin 1
(HEATER PWR)
743 Reserved
GasO2FailedLean
Check for vacuum leaks. Check fuel
Pre-catalyst O2 sensor (1) TurnOnMil
751 trim valves, e.g. leaking valve or hose.
indicates extended lean (2) DisableGas O2Ctrl
Check for missing orifice(s).
operation on LPG
Correct other faults that may contribute
to 752 (e.g. faults pertaining to dither
valves, Pre-Cat O2, Post Cat O2
GasPostO2FailedLean
sensor)
752 Check for vacuum leaks Check for
indicates extended lean (2) DisableGasPost O2Ctrl
leaks in exhaust, catalytic converter,
operation on LPG
HEGO sensors; repair leaks. Check all
sensor connections (see fault 742
corrective actions).

CORRECTIVE ACTION
FIRST CHECK
GasO2FailedRich
Check fuel trim valves, e.g. plugged
771 Pre-catalyst O2 sensor (1) TurnOnMil
valve or hose.
(77) indicates extended rich (2) DisableGas O2Ctrl
Check for plugged orifice(s).
operation on LPG
Correct other faults that may

contribute to 772 (e.g. faults pertaining
to FTVs, Pre-Cat O2, Post Cat O2
GasPostO2FailedRich
sensor)
772 Look for leaks in exhaust, catalytic
indicates extended rich (2) DisableGasPostO2Ctrl
converter, HEGO sensors; repair
operation on LPG
leaks.
Check all sensor connections (see
fault 742 corrective actions).
LiqFuelAdaptRangeHi Check for vacuum leaks. Low gasoline
In Gasoline mode, system fuel pressure, perform gasoline
821 TurnOnMil
had to adapt lean more pressure test. Injector problems, e.g.
than expected plugged, defective injector.
LiqFuelAdaptRangeLow Low gasoline fuel pressure, perform

In Gasoline mode, system gasoline pressure test Injector
831 TurnOnMil
had to adapt rich more problems, e.g. leaking, defective
than expected injector.
Check that Pre-catalyst O2 sensor

connections are OK. O2 (signal) Pin 3
to SECM Pin B13 O2 Pin 2 (HEATER
LiqO2NotActive GND) to SECM (DRVG GNG)
Pre-catalyst O2 sensor Pins A16, B17 O2 Pin 1 (HEATER
inactive on gasoline, open (1) TurnOnMil PWR) to SECM (DRVP + 12V) PIN
841
O2 sensor signal or (2) DisableLiquid O2Ctrl A23
heater leads, defective Verify O2 sensor heater circuit is
O2 sensor operating by measuring heater
resistance (2.1 0.4 ) O2 Pin 2
(HEATER GND) to Pin 1 (HEATER
PWR)

CORRECTIVE ACTION
FIRST CHECK
connections are OK. O2 (return) Pin 4
to SECM Pin B1 O2 Pin 2 (HEATER
GND) to SECM (DRVG GNG)
Pins A16, B17 O2 Pin 1 (HEATER
PWR) to Post O2 Heater Relay. Relay
pin 87.
This relay only turns on after engine
LiqPostO2NotActive has been running for some time and
Post-catalyst O2 sensor SECM has calculated that water
inactive on gasoline, open (1) TurnOnMil condensation in exhaust has been
842
O2 sensor signal or (2) DisableLiqPost O2Ctrl removed by exhaust heat.
heater leads, defective Post O2 Heater Relay has SECM
O2 sensor. (DRVP + 12V) applied to the relay coil
power. The relay coil ground is
controlled by SECM Pin A20 to
activate the relay to flow current
through the post O2 heater. Verify O2
sensor heater circuit is operating by
measuring heater resistance (2.1
0.4 ) O2 Pin 2 (HEATER GND) to
Pin 1 (HEATER PWR)
843 Reserved
LiqO2FailedLean Check for vacuum leaks. Low gasoline

Pre-catalyst O2 sensor (1) TurnOnMil fuel pressure, perform gasoline
851
indicates extended lean (2) DisableLiquid O2Ctrl pressure test. Injector problems, e.g.
operation on gasoline plugged, defective injector
LiqPostO2FailedLean to Injectors, MAP, IAT, Pre-Cat O2,
Pre-catalyst O2 sensor (1) TurnOnMil Post Cat O2 sensor.
852
indicates extended lean (2) DisableLiqPost O2Ctrl Look for leaks in exhaust, catalytic
operation on gasoline converter, HEGO sensors; repair
leaks. Check all sensor connections
(see fault 842 corrective actions).
LiqO2FailedRich High gasoline fuel pressure, perform
Pre-catalyst O2 sensor (1) TurnOnMil gasoline pressure test Injector
871
indicates extended rich (2) DisableLiquid O2Ctrl problems, e.g. leaking, defective
operation on gasoline injector
LiqPostO2FailedRich to Injectors, MAP, IAT, Pre-Cat O2,
Pre-catalyst O2 sensor (1) TurnOnMil Post Cat O2 sensor.
872
indicates extended rich (2) DisableLiqPostO2Ctrl Look for leaks in exhaust, catalytic
operation on gasoline converter, HEGO sensors; repair
leaks. Check all sensor connections
(see fault 842 corrective actions).

CORRECTIVE ACTION
FIRST CHECK
Check if O2 sensor installed before the

O2RangeLow
catalyst is shorted to GND or sensor
GND.
911 voltage out of range low, (2) DisableLiquid O2Ctrl
sensor signal shorted to (3) DisableGas O2Ctrl
SECM (DRVG GND) Pins A16, B17
ground
SECM (XDRG sensor GND) Pin B1
Check if O2 installed after the catalyst

O2_PostCatRangeLow (1) TurnOnMil sensor is shorted to GND or sensor
Post-catalyst O2 sensor (2) Disable Gasoline Post GND.
912 voltage out of range low, catalyst O2Ctrl O2 (signal) Pin 3 to SECM Pin B19
sensor signal shorted to (3) Disable LPG Post Possible sources: SECM (DRVG GND)
ground catalyst O2Ctrl Pins A16, B17 and SECM (XDRG
sensor GND) Pin B1
O2RangeHigh Check if O2 sensor installed before

Pre-catalyst O2 sensor (1) TurnOnMil catalyst is shorted to +5Vdc or battery.
921 voltage out of range high, (2) DisableLiquid O2Ctrl O2 (signal) Pin 3 to SECM Pin B13
sensor signal shorted to (3) DisableGas O2Ctrl SECM (XDRP + 5V) Pin B24
power SECM (DRVP + 12V) Pin A23
Check if O2 sensor installed after

O2_PostCatRangeHigh (1) TurnOnMil
catalyst is shorted to +5Vdc or battery.
Post-catalyst O2 sensor (2) Disable Gasoline Post
922 voltage out of range low, catalyst O2Ctrl
Possible voltage sources: SECM
sensor signal shorted to (3) Disable LPG Post
(XDRP + 5V) Pin B24 and SECM
ground catalyst O2Ctrl
(DRVP + 12V) Pin A23
FuelTempRangeLow
Fuel Temperature Check fuel temp sensor connector and
Sensor Input is Low wiring for a short to GND
normally set if the fuel SECM (signal) Pin B14 to FTS Pin 1
931 TurnOnMil
temperature sensor wire SECM (sensor GND) Pin B1 to FTS
has shorted to chassis Pin 2
ground or the sensor has SECM (system GND) Pin A16, B17
failed.
FuelTempRangeHigh
Fuel Temperature
Check if fuel temp sensor connector is
Sensor Input is High
disconnected or for an open FTS circuit
normally set if the fuel
932 TurnOnMil SECM (signal) Pin B14 to FTS Pin 1
temperature sensor wire
SECM (sensor GND) Pin B1 to FTS
has been disconnected
Pin 2
or the circuit has opened
to the SECM.

CORRECTIVE ACTION
FIRST CHECK
TransOilTemp (1) TurnOnMil
Refer to drivetrain manufacturers
933 Excessive transmission oil (2) Delayed
transmission service procedures
temperature EngineShutdown
ServiceFault1 Perform service procedure related to
991 Service Interval 1 has been None Service Interval 1 (determined by
reached OEM)
reached OEM)
reached OEM)
ServiceFault4
Service Interval 4 has been Replace Pre-catalyst HEGO sensor
994 TurnOnMil
reachedreplace HEGO Replace Post-catalyst HEGO sensor
sensors
ServiceFault5
995 Service Interval 5 has been TurnOnMil Replace engine timing belt
reachedreplace timing belt

Appendix
Service Tool Software
(MotoView)
Service Tool Software Kit
Service tool software kit consists of USB-CAN
converter, Service tool software (MotoView) and
Extension cable.
A334071
Extension Cable (L=200 cm)
A334082
Extension Cable (L=20 cm)
A343079
USB (Universal Serial Bus) to CAN (Controller Area
Network) Converter Assembly
A343080
Service Tool Software (includes CD and Crypt
Token (License Dongle))
G420F(FE) Service Manual 307 Appendix

Service Tool Connection to SECM
Communications to the SECM from the Service Tool
is through a CAN port using a two wire connection.
High-speed CAN reaches 1Mbps and is used for
engine control and power-train applications.
Laptop Computer Running Service Tool

Software

Service Tool Display Parameters specific to Air/Fuel Ratio Control are
displayed in the AFR block.
Service Tool Display consists of Service Screen,
Fault Screen, Ground speed select option, Fault list
and Override screen.
Service Screen
Key parameters of a running engine are grouped

together for easy reference in the ENGINE block.
Throttle and Foot Pedal parameters are displayed

together in the CNTRL Block

Fault Screen
Active faults are displayed as they are occurring.

They ability to clear faults
A fault history list of all 10 fault records
Fault records are recorded as FIFO (First In First
Out)
Once a fault is recorded a repeat of the same fault
will not be written to the history list
Flash Codes begin at record 1 not record 10

Ground Speed Select Option
Speed Limits are set by entering RPM values in the

red boxes
Values are restricted by Upper and Lower Limits

Fault List
A FAULT LIST screen provides a complete list of

faults including Fault Codes with monitored
parameters so the technician does not have to refer
to the manual for fault descriptions or codes while
using the service tool.

Override Screen
1. Click on the Manual Value for the component.
2. Enter a new manual value that will be used when

manually overriding the component.
3. Click the Override Select box for the component
4. Select Pass-Through for normal operation or

Override to manually control the component.
WARNING
Be aware of fuel flow and ignition during manual
mode or engine damage may result.

SECM field update with Service Tool
SECM controllers can be upgraded in the field using
MotoUpdate software. Typically, MotoUpdate and
MotoViewer applications are packaged together in
the MotoService software application. Software
upgrade files may be released to the field to
enhance performance, provide additional features,
and/or correct software problems.
This document provides step-by-step instructions for

upgrading a SECM using MotoUpdate software. In
order to illustrate the process, the following example
upgrade is used throughout this document.
Current SECM software version:

VARSPEDDRAAF-01-2-5-D-000-000.siz (calibration ID)
Upgrade to software version:
VARSPEDDRAAG-01-2-5-D-000-000.siz (calibration ID)
Using field update file:
VARSPEDDRAAG -01-1-5-D-000.mfu
NEW Corresponding DLL file:
VARSPEDDRAAG.dll
STEP1 - LOAD UPDATE FILES INTO THE

APPROPRIATE DIRECTORY
Software upgrade packages include an upgrade file

(.mfu) and translation file (.dll). The (.mfu) file is
required to upgrade the module, and the (.dll) is
required by MotoViewer software to communicate
with the module after the upgrade. Therefore, both
files are provided together. Copy the field update
file (.mfu) to the C:/ECUF Files/Updates directory,
and the corresponding (.dll) file to C:/ECU
Files/TDBDLL.
Copy the .dll file to the

TDDBLL directory
Copy the .mfu update file to

the Updates directory

STEP 2 - CONNECT THE COMPUTER
Prior to launching the MotoUpdate software, a valid

Criptoken must be installed in one of the available
USB ports on the update computer. A second
available USB port will be used by the USB to CAN
converter. The USB to CAN coverter must then be
connected to the SECM. (A USB hub must be
used with computers that do not have two USB
ports).
STEP 3 - LAUNCH THE MOTOUPDATE

APPLICATION
Launch the MotoUpdate application. You will see a

Welcome scree.
Select SECM-1 in the

location field, then select
Next

The next screen will provide a list of all of the
available software upgrades available for the current
engine, based upon what update files have been
placed in the Update directory (as shown in Step-1
above). Please note that during this process, the
software must query the SECM for the current
software version, and therefore, the computer must
be connected to the SECM and the ignition key must
be in the ON position.
In general, it is usually best to see the latest revision

(e.g. 001 is later than 000) in situations where
multiple revisions are available. Additional
information is provided in the revision matrix and/or
service bulletins.
This Upgrade Options screen shows

that there are no upgrades available
for the listed Calibration ID. Note: If
no upgrades are shown, consult the
revision matrix for latest software
versions.
No Upgrader Available for this Engine
This calibration ID has one (1)

available upgrade
No Upgrader Available for this Engine
Selecting the Details button on the

pervious screen will bring up the
Upgrade Details screen

STEP 4 - PROGRAM THE MODULE
Once the desired upgrade is located and highlighted,

select Next to upgrade ithe module.
Highlight the upgrade option desired,

then select Next
Follow the on-screen instructions to complete the

update process. Once the programming process
begins, it must run to completion. If power is
interrupted or the process fails, the SECM may be
rendered unusable. Several update screens will
provide a running status of the upgrade process, as
shown below.
Note 1: After successfully upgrading the SECM,

MotoViewer software will not function without the
appropriate translation file (.dll) discussed in Step-1
above.
Once the upgrade process is complete, a complete Note 2: If the programming is unsuccessful, the
message will appear and will give the operator the programming process may be repeated. If
option of upgrading another module. If another repeatedly unsuccessful, please contact .
module is to be upgraded, select the Upgrade
again button and select next. If another upgrade is
not required, select finish.

Ground Speed Limits (Option)
The maximum allowable speed of Doosan forklifts is
an optional feature that can be easily activated using
the MotoView service tool. This feature is very
useful to customers with indoor warehouse
operations.
Heres how you can activate the speed-limiting

feature.
1) Install Speed control option onto the trucks
2) Set the new speed limit using the MotoView

Service tool, if required.
HOW TO INSTALL SPEED LIMIT OPTION
1) Switch assy-pressure
2) Jumper Harness assy
3) Elbow
4) O-ring
1. Assemble the pressure switch assy onto the main

pressure port of transmission using elbow and o-
ring like [Figure 1].
[Figure 1] Speed control option
2. Assemble the harness assy between the pressure
switch and engine wiring harness.
How To Set New Speed Limit

Default Engine Maximum Speed
Once speed control option is assembled, the default

engine maximum speed is as followed;
Engine max.
Forklift Engine
speed (rpm)
Model Model
Neutral In-Gear
G(C)15/18S-5
G420F(E) 2,450 2,000
G(C)20SC-5
G(C)20/25/30E-5 G420F(E) 2,600 2,000
G(C)20/25/30/33P-5
G424F(E) 2,600 2,000
G35C-5
G(C)35/40/45S-5
G(C)50/55C-5 G643(E) 2,500 2,000
G50/60/70S-5
Note :
Neutral: The inching pedal is pressed by a driver.
In-Gear: The inching pedal is NOT pressed by a
driver.

How to Set New Speed Limit
Maximum RPM for both the NEUTRAL state

(Normal) and IN-GEAR state (Speed Limiting) are
configurable using the MotoView Service Tool.
[Figure 2] Ground Speed Select Screen of the MotoView Service Tool
[Figure 2] shows the Speed Limit screen of the Allowable Range of RPM Limits
MotoView service tool. The green boxes are
configurable for both the NEUTRAL MAX RPM Software limits of both Neutral and In-Gear are
Setpoint and the IN-GEAR MAX RPM Setpoint. The displayed on the right side of the Speed Limit screen.
pressure switch state is displayed at the bottom of Values that are entered in the configurable green
the screen and labeled NEUTRAL SWITCH STATE. boxes cannot exceed the upper limit value or fall
below the lower limit value.
For example, as Figure 2 depicts:
With pushing of inching pedal, the maximum RPM

for normal speed governing (Neutral State) is set at
2600.
With release of inching pedal, the maximum RPM

for limited speed governing (In-Gear State) is set at
2000.

LPG And LPG Fuel Tanks The same principle is applied to LPG in a container,
commonly referred to as an LPG tank or cylinder.
Typically an LPG tank is not filled over 80% capacity
LPG Fuel Supply
allowing for a 20% vapor expansion space. Outside
air temperature effects an LPG tank and must be
Liquefied petroleum gas (LPG) consists mainly of
considered when using an LPG system. (Figure 2)
propane, propylene, butane, and butylenes in
shows the relationship between pressure and
various mixtures. LPG is produced as a by-product
temperature in a LPG tank at a steady state
of natural gas processing or it can be obtained from
condition.
crude oil as part of the oil refining process. LPG, like
gasoline, is a compound of hydrogen and carbon,
commonly called hydrocarbons. LPG Tank Pressure VS Temperature
300
In its natural state, propane is colorless and 250

odorless; an odorant (ethyl mercaptan) is added to
the fuel so its presence can be detected. There are 200
Pressure, psig
currently three grades of propane available in the 150
United States. A propane grade designation of HD5 100

(not exceeding 5% propylene), is used for internal
combustion engines while much higher levels of 50
propylene (HD10) are used as commercial grade 0
propane along with a commercial propane /butane Figure 2

-20 0 20 40 60 80
Temperature, deg F
100 120 140
mixture.
With 128 PSIG vapor pressure acting against the
liquid propane the boiling point has been raised to
APPROXIMATE COMPOSITION OF HD5
slightly more than 80 deg. F / 27 deg. C.
PROPANE BY VOLUME
Propane Propy Butane Iso- Methane
TOTAL
(C3H8) lene (C4H10) Butane (CH4)
90.0% 5%
2.0% 1.5% 1.5% 100% Compressed
min. max.
Vapor
An advantage of LPG is the ability to safely store 128 PSIG Liquid
and transport the product in the liquid state. In the Propane
liquid state propane is approximately 270 times as
dense as it is in a gaseous form. By pressurizing a
container of LPG we can effectively raise the boiling
point above 44 deg. C / -42 deg. C, keeping the LPG Tank
propane in liquid form. The point at which the liquid Figure 3
becomes a gas (boiling point) depends on the
amount of pressure applied to the container. NOTE: Vapor pressure inside an LPG tank depends
on the ambient air temperature outside the tank, not
This process operates similarly to an engine coolant the amount of liquid inside the tank. A tank that is
system where water is kept from boiling by full of liquid propane at 80 deg. F will contain the
pressurizing the system and adding a mixture of same vapor pressure as a tank that is only full of
glycol. For example water at normal atmospheric liquid propane.
pressure will boil at 212 deg. F / 100 deg. C. If an
engines operating temperature is approximately 230 LPGs relative ease of vaporization makes it an
deg. F / 110 deg. C, then the water in an open un- excellent fuel for low-rpm engines on start-and-stop
pressurized cooling system would simply boil off into operations. The more readily a fuel vaporizes the
steam, eventually leaving the cooling system empty more complete combustion will be.
and over heating the engine. If we install a 10 PSIG Because propane has a low boiling point (-44F), and
cap on the radiator, pressurizing the cooling system is a low carbon fuel, engine life can be extended due
to 10 PSIG, the boiling point of the water increases to less cylinder wall wash down and little, if any,
to 242 deg. F / 117 deg. C, which will cause the carbon build up.
water to remain in liquid state at the engines
operating temperature.

LPG Fuel Tanks Installing LPG Fuel Tanks
The two styles of LPG storage containers available When installing a tank on a lift truck, the tank must
for industrial use and lift truck applications are be within the outline of the vehicle to prevent
portable universal cylinders and permanently damage to the valves when maneuvering in tight
mounted tanks. Portable universal cylinders are spaces. Horizontal tanks must be installed on the
used primarily for off-highway vehicles and are saddle that contains an alignment pin, which
constructed in accordance with the DOT-TC (United matches the hole in the collar of the tank. When the
States Department of Transport Transport pin is in the hole, the liquid withdrawal tube is
Canada). The cylinders are referred to as universal positioned to the bottom of the tank. A common
because they can be mounted in either a vertical or problem is that often these guide-pins are broken off,
horizontal position (Figure 4). allowing the tank to be mounted in any position. This
creates two problems. 1). When the liquid
withdrawal tube is exposed to the vapor space, it
may give a false indication that the tank is empty,
when it actually is not. 2). The safety relief valve
may be immersed in liquid fuel. If for any reason the
valve has to vent, venting liquid can cause a serious
safety problem,
CAUTION
When empty, the tank is exchanged with a pre-
filled replacement tank. When exchanging a tank,
Figure 4 safety glasses and gloves should be worn.
NOTE: A 375-psig, relief valve is used on a DOT

forklift tank. The relief valve must be replaced with a
new valve after the first 12 years and every 10 years LPG Fuel Tank Components
thereafter.
The tank must be discarded if the collar is damaged

2 3 7 8
to the point that it can no longer protect the valves. It 9
must also be replaced if the foot ring is bent to the
1
point where the tank will not stand or is easily
knocked over.
4
6 12 10
11
5
Figure 5
(1) Fuel Gauge (2) 80% Stop Bleeder

(3) Pressure Relief Valve
(4) Service Valve (Tank end male coupling) (5) Filler Valve
(6) Alignment Pin
(7) Vapor Withdrawal Tube (Only used with Vapor Withdrawal)
(8) 80% Limiter Tube (9) Liquid Withdrawal Tube
(10) Foot Ring (11) Fuel Level Float (12) Collar

Fuel Gauge Service Valve
In figure 5 a visual fuel gauge is used to show the The service valve is a manually operated valve
fuel level in the tank. A mechanical float mechanism using a small hand wheel to open and close the fuel
detects the liquid propane level. A magnet on the supply to the service line (fuel supply line). The
end of the float shaft moves a magnetic pointer in service valve installs directly into the tank and has
the fuel gauge. Some units have an electronic two main categories, liquid and vapor service valves.
sending unit using a variable resistor, installed in Liquid service valves used on portable LPG tanks
place of a gauge for remote monitoring of the fuel use a 3/8 (3/8 NPT) male pipe thread on the
level. The gauge may be changed with fuel in the service valve outlet for attachment of a quick
tank. DO NOT REMOVE THE FOUR LARGE disconnect coupler.
FLANGE BOLTS THAT RETAIN THE FLOAT
ASSEMBLY, WITH FUEL IN THE TANK! An excess flow valve is built into the inlet side of the
service valve as a safety device in case of an
accidental opening of the service line or damage to
CAUTION the service valve itself. The excess flow valve shuts
It is not a legal practice to fill the tank through off the flow of liquid propane if the flow rate of the
the liquid contents gauge. liquid propane exceeds the maximum flow rate
specified by the manufacturer.
In some applications a fixed tube fuel indicator is
used in place of a float mechanism. A fixed tube
indicator does not use a gauge and only indicates
when the LPG tank is 80% full. The fixed tube
indicator is simply a normally closed valve that is
opened during refueling by the fueling attendant. Outlet
When opened during refueling and the tanks LPG
level is below 80%, a small amount of vapor will exit
the valve. When the LPG tank level reaches 80%
liquid propane will begin exiting the valve in the form Excess Flow
of a white mist (Always wear the appropriate Valve
protective apparel when refueling LPG cylinders). In Figure 6
order for this type of gauge to be accurate, the tank
must be positioned properly. When full (80% LPG)
the valve is closed by turning the knurled knob
clockwise. Typically a warning label surrounds the CAUTION
fixed tube gauge which reads STOP FILLING When the tank is in use the service valve should
WHEN LIQUID APPEARS. be completely open. If the valve is partly open,
the vehicle may not be getting enough fuel to
operate efficiently.
In addition to possibly starving the engine for

fuel, a partly open valve may restrict the flow
enough to prevent the excess flow valve from
closing in the event of a ruptured fuel line.

Most liquid service valves have an internal Filler Valve
hydrostatic relief valve and are usually labeled
LIQUID WITH INTERNAL RELIEF. The The liquid filler valve (Figure 9) has a male thread to
hydrostatic relief valve protects the fuel service line receive a fuel nozzle and typically has a plastic or
between the tank and the lock off from over brass screw on cap that is retained with a small
pressurization. The internal hydrostatic relief valve chain or plastic band to keep debris out of the filler
has a minimum opening pressure of 375 PSIG and a valve. The filler valve is a one-way flow device that
maximum pressure of 500 PSIG. These type of relief uses two check valves to allow fuel to enter the tank
valves have an advantage over external relief valves but prevent it from exiting. Both check valves are
because the propane is returned to the tank in the backpressure type check valves, designed so that
event of an over pressurization instead of venting backpressure from the tank assists the check valves
the propane to atmosphere. own spring pressure to close the valve. The first
valve uses a neoprene on metal seal and the
second valve uses a metal on metal seal.
Quick Disconnect Coupling
A weakness ring is machined into the filler valve just
The liquid withdrawal or service valve on a DOT above the check valves and will allow the filler valve
tank has male threads and accepts the female to shear off in case of an accident. The valve will
portion of a quick disconnect coupling (Figure 8). break or shear off above the check valves so that
The female portion is adapted to the liquid hose the tank will be sealed and no liquid propane can
going to the fuel system. Both halves are equipped escape.
with 100% shutoffs, which open when coupled
together to allow fuel flow. The coupler has two
seals. One is an o-ring and the other is a flat washer.
The o-ring prevents leakage from the shaft on the
other coupling and the flat washer seals when the
coupler is fully connected.
Weakness
NOTE: The flat seal and / or the o-ring will Ring
sometimes pop off when disconnecting and slide up
the shaft of the mating connector, causing the valve
not to open when fully mated. The extra washer or
o-ring must be removed from the shaft and the
coupling reconnected. Figure 9
Figure 8

Regulatory Compliance
WARNINGEXPLOSION HAZARD
EPA / CARB Emissions Certification Do not connect or disconnect while circuit is live
unless area is known to be non-hazardous.
When properly applied and calibrated, s MI-07
control system is capable of meeting EPA 2007 LSI
Substitution of components may impair suitabil-
emission standards (40 CFR Part 1048.101) when
ity for Class I, Division 2, or Zone 2 applications.
operating properly with an approved three-way
catalyst. The emission standards, including
appropriate deterioration factors over the useful life
of the system, are as follows: Electrostatic Discharge Awareness
HC+NOx: 2.0 g/hp-hr [2.7 g/kW-hr] All electronic equipment is static-sensitive, some
CO: 3.3 g/hp-hr [4.4 g/kW-hr] components more than others. To protect these
components from static damage, you must take
Evaporative emissions comply with 40 CFR Part special precautions to minimize or eliminate
1048.105. These standards apply only to volatile electrostatic discharges.
liquid fuels such as gasoline. Note that the engine
crankcase must be closed. Follow these precautions when working with or near
the control.
North American Compliance 1. Before doing maintenance on the electronic

control, discharge the static electricity on your
The N-2007 regulator is UL listed per Category ITPV body to ground by touching and holding a
LP-Gas Accessories, Automotive Type. grounded metal object (pipes, cabinets,
equipment, etc.).
The N-2007 regulator and CA100 mixer have
tamper-resistant features approved by CARB. 2. Avoid the build-up of static electricity on your
body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials
as much as possible because these do not store
Special Conditions for Safe Use static electric charges as much as synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such

Field wiring must be suitable for at least 248F
as plastic or Styrofoam cups, cup holders,
(120C).
cigarette packages, cellophane wrappers, vinyl
books or folders, plastic bottles, and plastic ash
SECM-48 inputs are classified as permanently
trays) away from the control, the modules, and the
connected IEC measurement Category I. To avoid
work area as much as possible.
the danger of electric shock, do not use inputs to
make measurements within measurement
categories II, III, or IV.
SECM-48 input power must be supplied from a

power supply/battery charger certified to IEC
standard with a SELV (Safety Extra Low Voltage)
classified output.
SECM-48 inputs and outputs may only be

connected to other circuits certified as SELV (Safety
Extra Low Voltage).

Abbreviations
ACFM Actual cubic feet per minute at the specified suction conditions
AFR Air fuel ratio
BHP Brake horsepower
Bi-Fuel Able to operate on either of two fuels
CTS Coolant temperature sensor
CNG Compressed natural gas
Dual Fuel Able to run simultaneously on two fuels, e.g. diesel and natural gas.
Often this term is incorrectly used to describe bi-fuel operation.
Spark-ignited engines are typically bi-fuel while compression ignition
engines are dual-fuel.
ECM Engine control module
FPP Foot pedal position
FPV Fuel primer valve
FTS Fuel temperature sensor
FTV Fuel trim valve
GPM Gallons per minute of flow
HEGO Heated exhaust gas oxygen (sensor)
LAT Limited-angle torque motor
LPG Liquified petroleum gas
MAP Manifold absolute pressure
MAT Manifold air temperature
MIL Malfunction indicator lamp
MOR Manufacturer of record for emissions certification on the engine
OEM Original equipment manufacturer
PHI Relative fuel-air ratio or percent of stoichiometric fuel
(actual fuel-air ratio / stoichiometric fuel-air ratio)
RPM Revolutions per minute
SECM Small engine control module
TMAP Temperature and manifold absolute pressure
TPS Throttle position sensor
VDC Voltage of direct current type
VE Volumetric efficiency
WOT Wide open throttle

SB2007E02
Service Manual
DAC CS-121
Series Alternators
hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings
in this publication and on the product labels are identified by the following symbol.
WARNING
publication.
1
Index
Specifications
Alternator ............................................................. 5
Systems Operation
Alternator ............................................................. 6
CS-121 Alternator Operation ........................... 6
Alternator Components................................ 7
Alternator Operation Schematic .................. 9
Testing And Adjusting
Troubleshooting ................................................ 10
Troubleshooting Problem List....................... 10
Troubleshooting Problems ............................ 10
Alternator ............................................................11
Alternator Output Test ....................................11
DAC Alternators 3 Index

Specifications
Alternator
DAC ALTERNATOR COVERAGE CHART

DOOSAN
Series Voltage
Part No.
D167411 CS-121 12V
CS-121 Alternator End View
ALTERNATOR SPECIFICATIONS
DOOSAN Part No. D167411
DAC Series CS-121
Voltage Rating 12V
Polarity Neg. Gnd.
Rotation CW
Test Speed 6500 rpm
Rated Output (Cold) 61A
Output Voltage 14.00.5V
CS-121 Alternator Cross-Sectional View Rotor Field Winding
-
Resistance [At 27C(80F)]
Field Current [At 14.0V or
-
27.5V and 27C(80F)]
Stator Winding Resistance -
Turn On Speed (Max.) -
Slip Rings (3) : Maximum
-
Runout (TIR)
Minimum Diameter -
Brush Length (Measured
-
On Longest Side) : New
Minimum
1007 Nm
Pulley Nut (2) Torque
(75lb Ift)
Thru Bolt (1) Torque -
3.60.8 Nm
Terminal Torques : Bat
(327 lb Iin)
Gnd -
DAC Alternators 5 Specifications

Systems Operation The alternator converts mechanical and magnetic
process is done by rotating a direct current (DC)
Alternator electromagnetic field (rotor) inside a three phase
stator. The alternating current and voltage
Introduction (generated by the stator) are changed to direct
current by a three phase, full wave rectifier system
The CS-121 DAC Alternators have three phase, full- using six silicone rectifier diodes. This alternator
wave, rectified output. does not have a diode trio. A solid state regulator is
installed in the back of the alternator. Two brushes
conduct current through two slip rings to the field coil
on the rotor.
CS-121 Alternator Operation
There is also a capacitor mounted in the back of the
alternator. The capacitor protects the rectifier from
high voltages. It also suppresses electrical noise
through a radio, if equipped.

terminal L and the ignition or key start switch for
alternator turn-on. Therefore, alternator excitation
occurs when the switch is turned on.
DAC CS-121 Alternator
The alternator is an electrical and mechanical

component driven by belt rotation from the engine. It
is used to charge the storage battery during engine
operation. This alternator is cooled by two fans that
are a part of the alternator. The external fan is
mounted behind the pulley. The fan pulls air through
holes in the back of the alternator. The air exits the
front of the alternator, cooling it in the process. The
internal fan is mounted on the rotor. This fan pulls air
through the holes in the back of the alternator to cool
the rectifier bridge and regulator. The air exits the
front of the alternator.
DAC Alternators 6 Systems Operation

Alternator Components
Alternator Components-Inside View of Rear Frame

(2) Rear frame. (7) Brush holder. (9) Regulator. (10) Rectifier.
The major components of the alternator are stator

(4), rotor (3), rectifier (10), regulator (9), brush holder
(7) and frames (2) and (5). The CS-121 alternators
feature a high ampere output per pound of weight,
with a totally new and different regulator. A diode trio
is not used. A delta wound stator, rectifier bridge,
rotor with slip rings and brushes are electrically
Alternator Components-Cross-Sectional View
similar to the SI series. alternators. The CS stands
(1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end for Charging System. The 121 denotes the outside
frame. (6) External fan. (7) Brush holder. (8) Internal fan. diameter in millimeters of the stator laminations. This
series of alternators has two fans for cooling the
alternator.
Stator
(4) Stator.
Stator (4) consists of a stator core and coils. As the

rotor turns, its varying magnetic field causes the
stator coil to produce three phase alternating current
(AC).

Rotor
(1) Slip rings. (3) Rotor. (8) Internal fan.
Rotor (3) consists of a core, coils and slip rings (1).

The rotor provides the magnetic field between the
rotor field winding and the stator. Slip rings (1)
provide the surfaces for brush contact. Internal fan
(8) pulls air through the rear frame to cool the Rectifier
rectifier bridge and regulator. (10) Rectifier.
Rectifier (10) contains three positive (+) and three

negative (-) diodes to form the full wave rectifier
bridge which is connected to the stator. Rectifier (10)
changes or rectifies three phase AC to DC.
Brush Holder
(7) Brush holder. (11) Brushes.
Brush holder (7) contains two brushes (11). They Regulator

contact the two rotating slip rings on the rotor. (9) Regulator.
Current flows to the rotor coil through the brushes
and slip rings. There is one positive (+) and one Regulator (9) controls alternator output. Most
negative (-) brush. The brush material is copper regulators limit the alternator voltage to a preset
graphite. value by controlling the field current. It operates
electronically to alternately "turn off" and "turn on"
the voltage across the field winding. This regulator
switches the field current on and off at fixed
frequency of about 400 cycles per second. By
varying the on-off time, the correct average field
current for proper system voltage control is obtained.
The regulator is mounted in the back of the
alternator.

Alternator Operation Schematic The field current is sufficient to cause the alternator
to turn on when the engine is started. At engine idle
The integral charging system schematic and speeds, voltage induced in the stator will cause the
explanation that follow indicate the terminals and stator to supply field current and also output voltage
basic circuitry for the CS-121 series alternator. and current at the Bat terminal for the vehicle
electrical system.
On some models, a resistor is used in parallel with

the indicator lamp. This feature insures alternator
turn-on in the event the lamp burns out. The zener
diodes in the rectifier bridge protect the system
against high voltages in the stator.
The regulator switches the field voltage on and off at

a fixed frequency of about 400 cycles per second.
Voltage control is obtained by varying the "on-off"
time of the field current. Thus, at low speeds, the
field may be turned on 90 percent of the time and off
10 percent of the time. This results in a relatively
high average field current, which, when combined
with the low alternator speed, produces the desired
system voltage.
As alternator speed increases, less field current is

needed to generate the desired system voltage. The
duty cycle changes to reduce the average field
current. For example, at high engine speeds, the
regulator may be on only 10 percent of the time and
off 90 percent of the time. This duty cycle will
change as operating factors change to provide just
the right amount of voltage.
Most regulators are temperature compensated to

provide the maximum voltage needed for battery
charging. As the temperature increases, the voltage
setting will decrease. Under cold weather conditions,
the regulator will operate at a higher voltage setting
to provide the higher voltage required by the battery
for charging under these conditions.
CS-121 Integral Charging System Schematic The regulator circuitry is designed to perform a
special function in the charging system called Load
Response Control. Without this function, a change in
When the switch is closed, the indicator lamp turns engine speed may occur at low engine speeds when
on and a voltage is applied to the regulator at the "L" an electrical load is added to the system. This can
terminal to cause transistor TR1 to rapidly "turn on" happen when the engine is low idle and a fan blower
and "turn off". The transistor will be turned on about is turned on.
30 percent of the time and turned off 70 percent of
the time. The battery will supply field current which Load Response Control Causes the field current and
will flow into the alternator output or Bat terminal and the alternator output current to increase gradually.
then through TR1 and the field coil to ground. Field This avoids changes in engine speed. Instead of
current does not flow through the indicator lamp. instantly supplying the added amperes needed to
operate the blower motor, the alternator provides
these added amperes over a period of a few
seconds. At first, the battery supplies the added load,
which is then gradually transferred to the alternator.

Testing And Adjusting Problem 2: Alternator Charge Rate Is Low Or Not
Regular
Troubleshooting Probable Cause:
Troubleshooting can be difficult. On the page that 1. Loose Drive Belt For Alternator:
follows is a list of possible problems. To make a Adjust the alternator drive belt.
repair to a problem, make reference to the probable
cause. 2. Loose Alternator Drive Pulley:
Check the pulley for wear. If it is worn, install a
This list of problems and probable causes will only new pulley. Tighten the pulley nut to the correct
give an indication of where a possible problem can torque shown in Specifications.
be and what repairs are needed. Sometimes more
or other repair work is needed beyond the 3. Charging Or Ground Return Circuit Or Battery
recommendations in the list. Remember that a Connections Defective:
problem is not normally caused by one part, but by Inspect all cables and connections. Clean and
the relation of one part with other parts. This list tighten all connections. Replace defective parts.
cannot give all possible problems and probable
causes. The serviceman must find the problem and 4. Regulator Is Defective:
its source, then make the necessary repairs. Replace the regulator.
5. Rectifier Is Defective:
Replace the rectifier.
Troubleshooting Problem List
6. Brushes Are Worn Or Dirty:
1. Alternator Does Not Charge. Install a new brush holder.
2. Alternator Charge Rate Is Low Or Not Regular.
Problem 3: Alternator Charges Too Much
3. Alternator Charges Too Much.
Probable Cause:
4. Alternator Is Noisy.
1. Alternator Or Regulator Has Loose Connections:
Tighten all connections to alternator or regulator.
Troubleshooting Problems 2. Regulator Is Defective:

Install a new regulator.
Problem 1: Alternator Does Not Charge
Problem 4: Alternator Is Noisy
Probable Cause:
Probable Cause:
1. Loose Drive Belt For Alternator :
Adjust the alternator drive belt. 1. Drive Belt For Alternator Is Worn Or Defective:
Install a new drive belt for the alternator.
2. Loose Alternator Drive Pulley :
2. Loose Alternator Drive Pulley:
Check the pulley for wear. If it is worn, install a Check the pulley for wear. If it is worn, install a
new pulley. Tighten the pulley nut to the correct new pulley. Tighten the pulley nut to the correct
torque shown in Specifications. torque shown in Specifications.
3. Charging Or Ground Return Circuit Or Battery 3. Drive Belt And Drive Pulley For Alternator Are Not
Connection Are Defective: In Alignment:
Inspect all cables and connections. Clean and Make an adjustment to put the drive belt and drive
tighten all connections. Replace defective parts. pulley in correct alignment.
4. Rotor Field Winding Or Regulator Is Defective: 4. Alternator Bearings Are Worn:

Install a new rotor or regulator. Install new bearings in the alternator.
DAC Alternators 10 Testing And Adjusting

Alternator
Alternator Output Test
NOTE: If the CS-121 alternator fails this test, it must

be replaced. It is only serviced as a complete unit.
Tools Needed
Digital Multimeter or Equivalent 1
AC/DC Clamp-On Ammeter 1
Machine Test
1. Put the multimeter positive (+) lead on the Bat

terminal of the alternator. Put the negative (-) lead
on the ground terminal or the frame of the
alternator. Put the clamp-on ammeter around the
positive output wire of the alternator.
2. Turn off all electrical accessories. With the fuel off,

crank the engine for 30 seconds. Wait two
minutes to let the starter cool. If the system
appears to be up to specifications, crank the
engine again for 30 seconds.
NOTE: Cranking the engine for 30 seconds partially

discharges the batteries in order to do a charging
test. If the battery is already low in charge, skip this
step. Jump-start engine or charge as required.
3. Start the engine and run at approximately 1/2

throttle.
4. Immediately check output current. This initial

charging current should be equal to or greater
than the full output current shown below:
5. Within approximately 10 minutes at 1/2 throttle

(possible longer, depending upon battery size,
condition and alternator rating), the alternator
output voltage should be as follows to indicate the
alternator is performing within spec. See the Fault
Conditions And Possible Causes Chart.
12V System ................................. 14.00.5V
6. The charging current during this period should

taper off the less than approximately 10 Amps,
depending again upon battery and alternator
capacities. See the Fault Conditions And Possible
Causes Chart.

FAULT CONDITIONS AND POSSIBLE CAUSES CHART
Current At Voltage After About Voltage After About Voltage After About
Start-Up 10 Min. Is Below Spec. 10 Min. Is In Spec. 10 Min. Is Above Spec.
Repair alternator (defective
Turn on all accessories.
regulator, open stator
If voltage drops below spec.,
Below Specification. phase, and/or rectifier). -
repair alternator (open
Check ignition or key start
rectifier and/or stator phase).
switch circuit.*
Alternator and battery in spec.
Reached Specification Repair alternator Repair alternator
Turn on all accessories to verify.
and then tapered off. (defective regulator). (shorted regulator).
Voltage must stay in spec.
Repair alternator
Exceeds Specification Alternator in spec. (shorted regulator).
Check battery.
and stays high. Check battery. Also check battery for
possible damage.
* Some models that have the CS-121 alternator do not have a resistor in the ignition of key start switch circuit, if the indicator lamp is
burned out, the alternator cannot turn on. Also, if a machine is jump started because the battery is too low, the alternator may not have
any output. This is because the battery may be too low to send current to the alternator. The alternator needs current to start the
charging process.

SB4050E00
Service Manual
CS-105D Series
Alternator
WARNING
publication.
1
Index
Specifications
Alternator........................................................ 5
Systems Operation
Alternator............................................................... 6
CS-105D Alternator Operation ........................ 6
Alternator Components ............................ 7
Alternator Operation Schematic ............... 9
Introduction..................................................... 6
Testing And Adjusting

Alternator..............................................................11
Alternator Output Test.............................11
Machine Test ..........................................11
Troubleshooting....................................................10
Troubleshooting Problem List..................10
Troubleshooting Problems ......................10
CS-105D Alternator 3 Index

Specifications
Alternator
DELCO REMY ALTERNATOR COVERAGE CHART
DOOSAN Supplier
Series Voltage
Part No. Part No.
A274017 219299 CS-105D 12V
CS-105D Alternator End View
ALTERNATOR SPECIFICATIONS
DOOSAN Part No. A274017
Series CS-105D
Voltage Rating 12V
Polarity Neg. Gnd.
Rotation CW
Test Speed 6500 rpm
Rated Output (cold) 50A
Output Voltage 14.5 0.3V
Rotor Field Winding
Resistance [At 27 2.97 ~ 3.05 OHMS
(80)0
CS-105D Alternator View
Field Current [At 14.0V
or 27.5V and -
27(80)0
Stator Winding
-
Resistance
Turn On Speed (Max.) -
Slip Rings (3) :
0.08
Maximum Runout (TIR)
Minimum Diameter -
Brush Length (Measured
17.0 0.3 mm
On Longest Side) : New
Minimum
100 10 Nm
Pulley Nut (2) Torque
(900 90 lbft)
Thru Bolt (1) Torque
10 1.0 Nm
Terminal Torques : Bat
(90 10 lbft)
Gnd -
CS-105D Alternator 5 Specifications

Systems Operation The alternator converts mechanical and magnetic
process is done by rotating a direct current (DC)
Alternator electromagnetic field (rotor) inside a three phase
stator. The alternating current and voltage
(generated by the stator) are changed to direct
Introduction current by a three phase, full wave rectifier system
using six silicone rectifier diodes. This alternator
The CS-105D Alternators have three phase, does not have a diode trio. A solid state regulator is
full-wave, rectified output. installed in the back of the alternator. Two brushes
conduct current through two slip rings to the field coil
on the rotor.
CS-105D Alternator Operation
There is also a capacitor mounted in the back of the
alternator. The capacitor protects the rectifier from
high voltages. It also suppresses electrical noise
through a radio, if equipped.

terminal L and the ignition or key start switch for
alternator turn-on. Therefore, alternator excitation
occurs when the switch is turned on.
CS-105D Alternator
The alternator is an electrical and mechanical

component driven by belt rotation from the engine. It
is used to charge the storage battery during engine
operation. This alternator is cooled by two fans that
are a part of the alternator. The external fan is
mounted behind the pulley. The fan pulls air through
holes in the back of the alternator. The air exits the
front of the alternator, cooling it in the process. The
internal fan is mounted on the rotor. This fan pulls air
through the holes in the back of the alternator to cool
the rectifier bridge and regulator. The air exits the
front of the alternator.
CS-105D Alternator 6 Systems Operation

Alternator Components
Alternator Components-Inside View of Rear Frame

(2) Rear frame. (7) Brush holder. (9) Regulator.
(10) Rectifier.
The major components of the alternator are stator

(4), rotor (3), rectifier (10), regulator (9), brush holder
(7) and frames (2) and (5). The CS-105D alternators
feature a high ampere output per pound of weight,
with a totally new and different regulator. A diode trio
is not used. A delta wound stator, rectifier bridge,
rotor with slip rings and brushes are electrically
similar to the SI series. alternators. The CS stands
Alternator Components-Cross-Sectional View for Charging System. The 105 denotes the outside
(1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator. diameter in millimeters of the stator laminations. This
(5) Drive end frame. (6) External fan. (7) Brush holder.
(8) Internal fan.
series of alternators has two fans for cooling the
alternator.
Stator
(4) Stator.
Stator (4) consists of a stator core and coils. As the

rotor turns, its varying magnetic field causes the
stator coil to produce three phase alternating current
(AC).

Rotor Rectifier
(1) Slip rings. (3) Rotor. (8) Internal fan. (10) Rectifier.
Rotor (3) consists of a core, coils and slip rings (1). Rectifier (10) contains three positive (+) and three
The rotor provides the magnetic field between the negative (-) diodes to form the full wave rectifier
rotor field winding and the stator. Slip rings (1) bridge which is connected to the stator. Rectifier (10)
provide the surfaces for brush contact. Internal fan changes or rectifies three phase AC to DC.
(8) pulls air through the rear frame to cool the
rectifier bridge and regulator.
Regulator
(9) Regulator.
Regulator (9) controls alternator output. Most

regulators limit the alternator voltage to a preset
value by controlling the field current. It operates
electronically to alternately "turn off" and "turn on"
the voltage across the field winding. This regulator
Brush Holder switches the field current on and off at fixed
(7) Brush holder. (11) Brushes.
frequency of about 400 cycles per second. By
varying the on-off time, the correct average field
Brush holder (7) contains two brushes (11). They current for proper system voltage control is obtained.
contact the two rotating slip rings on the rotor. The regulator is mounted in the back of the
Current flows to the rotor coil through the brushes alternator.
and slip rings. There is one positive (+) and one
negative (-) brush. The brush material is copper
graphite.

Alternator Operation Schematic The field current is sufficient to cause the alternator
to turn on when the engine is started. At engine idle
The integral charging system schematic and speeds, voltage induced in the stator will cause the
explanation that follow indicate the terminals and stator to supply field current and also output voltage
basic circuitry for the CS-105D series alternator. and current at the Bat terminal for the vehicle
electrical system.
On some models, a resistor is used in parallel with

the indicator lamp. This feature insures alternator
turn-on in the event the lamp burns out. The zener
diodes in the rectifier bridge protect the system
against high voltages in the stator.
The regulator switches the field voltage on and off at

a fixed frequency of about 400 cycles per second.
Voltage control is obtained by varying the "on-off"
time of the field current. Thus, at low speeds, the
field may be turned on 90 percent of the time and off
10 percent of the time. This results in a relatively
high average field current, which, when combined
with the low alternator speed, produces the desired
system voltage.
As alternator speed increases, less field current is

CS-105D Integral Charging System Schematic
needed to generate the desired system voltage. The
duty cycle changes to reduce the average field
current. For example, at high engine speeds, the
When the switch is closed, the indicator lamp turns
regulator may be on only 10 percent of the time and
on and a voltage is applied to the regulator at the "L"
off 90 percent of the time. This duty cycle will
terminal to cause transistor to rapidly "turn on" and
change as operating factors change to provide just
"turn off". The transistor will be turned on about 30
the right amount of voltage.
percent of the time and turned off 70 percent of the
time. The battery will supply field current which will
Most regulators are temperature compensated to
flow into the alternator output or Bat terminal and
provide the maximum voltage needed for battery
then through transistor and the field coil to ground.
charging. As the temperature increases, the voltage
Field current does not flow through the indicator
setting will decrease. Under cold weather conditions,
lamp.
the regulator will operate at a higher voltage setting
to provide the higher voltage required by the battery
for charging under these conditions.

Problem 2: Alternator Charge Rate Is Low Or Not
Testing And Adjusting Regular
Troubleshooting Probable Cause:
Troubleshooting can be difficult. On the page that 1. Loose Drive Belt For Alternator:
follows is a list of possible problems. To make a Adjust the alternator drive belt.
repair to a problem, make reference to the probable
cause. 2. Loose Alternator Drive Pulley:
This list of problems and probable causes will only Check the pulley for wear. If it is worn, install a
give an indication of where a possible problem can new pulley. Tighten the pulley nut to the correct
be and what repairs are needed. Sometimes more torque shown in Specifications.
or other repair work is needed beyond the
recommendations in the list. Remember that a 3. Charging Or Ground Return Circuit Or Battery
problem is not normally caused by one part, but by Connections Defective:
the relation of one part with other parts. This list Inspect all cables and connections. Clean and
cannot give all possible problems and probable tighten all connections. Replace defective parts.
causes. The serviceman must find the problem and
its source, then make the necessary repairs. 4. Regulator Is Defective:
Replace the regulator.
Troubleshooting Problem List 5. Rectifier Is Defective:

Replace the rectifier.
1. Alternator Does Not Charge.
2. Alternator Charge Rate Is Low Or Not Regular. 6. Brushes Are Worn Or Dirty:
3. Alternator Charges Too Much. Install a new brush holder.
4. Alternator Is Noisy.
Problem 3: Alternator Charges Too Much
Probable Cause:
Troubleshooting Problems
1. Alternator Or Regulator Has Loose Connections:
Problem 1: Alternator Does Not Charge Tighten all connections to alternator or regulator.
Probable Cause: 2. Regulator Is Defective:
Install a new regulator.
1. Loose Drive Belt For Alternator :
Adjust the alternator drive belt. Problem 4: Alternator Is Noisy
2. Loose Alternator Drive Pulley : Probable Cause:
new pulley. Tighten the pulley nut to the correct 1. Drive Belt For Alternator Is Worn Or Defective:
torque shown in Specifications.
Install a new drive belt for the alternator.
3. Charging Or Ground Return Circuit Or Battery
2. Loose Alternator Drive Pulley:
Connection Are Defective:
Inspect all cables and connections. Clean and
new pulley. Tighten the pulley nut to the correct
tighten all connections. Replace defective parts.
torque shown in Specifications.
4. Rotor Field Winding Or Regulator Is Defective:
3. Drive Belt And Drive Pulley For Alternator Are Not
Install a new rotor or regulator.
In Alignment:
Make an adjustment to put the drive belt and drive
pulley in correct alignment.
4. Alternator Bearings Are Worn:

Install new bearings in the alternator.
CS-105D Alternator 10 Testing and Adjusting

Alternator
Alternator Output Test
NOTE: If the CS-105D alternator fails this test, it
must be replaced. It is only serviced as a
complete unit.
Tools Needed
Digital Multimeter or Equivalent 1
AC/DC Clamp-On Ammeter 1
Machine Test
1. Put the multimeter positive (+) lead on the Bat
terminal of the alternator. Put the negative (-) lead
on the ground terminal or the frame of the
alternator. Put the clamp-on ammeter around the
positive output wire of the alternator.
2. Turn off all electrical accessories. With the fuel off,

crank the engine for 30 seconds. Wait two
minutes to let the starter cool. If the system
appears to be up to specifications, crank the
engine again for 30 seconds.
NOTE: Cranking the engine for 30 seconds partially

discharges the batteries in order to do a
charging test. If the battery is already low in
charge, skip this step. Jump-start engine or
charge as required.
3. Start the engine and run at approximately 1/2

throttle.
4. Immediately check output current. This initial

charging current should be equal to or greater
than the full output current shown below:
5. Within approximately 10 minutes at 1/2 throttle

(possible longer, depending upon battery size,
condition and alternator rating), the alternator
output voltage should be as follows to indicate the
alternator is performing within spec. See the Fault
Conditions And Possible Causes Chart.
12V System ...................................... 14.5 0.3V
6. The charging current during this period should

taper off the less than approximately 10 Amps,
depending again upon battery and alternator
capacities. See the Fault Conditions And Possible
Causes Chart.

FAULT CONDITIONS AND POSSIBLE CAUSES CHART
Voltage After About 10 Voltage After About 10 Voltage After About 10

Current At Start-Up
Min. Is Below Spec. Min. Is In Spec. Min. Is Above Spec.
Repair alternator
Turn on all accessories.
(defective regulator,
If voltage drops below
open stator phase,
Below Specification spec., repair alternator -
and/or rectifier). Check
(open rectifier and/or
ignition or key start
stator phase).
switch circuit.*
Alternator and battery in
spec. Turn on all
Reached Specification Repair alternator Repair alfernator (storted
accessories to verify.
and then tapered off (defective regulator) regulator).
Voltage must stay in
spec.
Repair alternator
Exceeds Specification Alternator in spec. (shorted regulator). Also
Check battery
and stays high. Check battery. check battery for
possible damage.
*Some models that have the CS-105D alternator do not have a resistor in the ignition of key start switch circuit,
if the indicator lamp is burned out, the alternator cannot turn on. Also, if a machine is jump started because
the battery is too low, the
alternator may not have any output. This is because the battery may be too low to send current to the
alternator. The
alternator needs current to start the charging process.

SB4243E00
Apr. 2007
Power Train
Specification
System Operation
Testing & Adjusting
D15S-5, D18S-5, D20SC-5

G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
WARNING
publication.
1
Index
Specification
Forward / Reverse Clutch Elements ................... 5
Torque Converter ................................................ 5
Valve Block Elements (On top of transmission).. 6
Valve Spring in Transmission Bearing Plate....... 7
Tightening Torques - Transmission..................... 8
Final Drives and Wheel ....................................... 9
Wheel Bearing Adjustment................................ 10
System Operation
General Information .......................................... 11
Torque Converter .............................................. 12
Transmission..................................................... 13
Transmission Power Flow - Forward................. 14
Transmission Power Flow - Reverse ................ 15
Transmission Lubrication Schematic ................ 16
Transmission Hydraulic System........................ 17
Control Valve..................................................... 26
Drive axle .......................................................... 30
Differential Pneumatic Shoe Type.................. 30
Differential Pneumatic ODB Type & Cushion Type
.......................................................................... 31
Testing and Adjusting

Troubleshooting ................................................ 32
Transmission Pressure Tests............................ 38
Converter Stall Test .......................................... 40
Maintenance
Transmission ................................................... 42
Drive axle .......................................................... 43
Electric Control System Test............................. 44
Inching Pedal Adjustment ................................. 48
Adjustments on Drive axle ................................ 51
Power Train 3 Index

Specification
Forward / Reverse Clutch
Elements
c) Bend Plate
Inside Diameter..60mm (2.36 in)
Outside Diameter..122.5mm (4.82 in)
Torque Converter
a) Outer clultch disc, b) Inner clultch disc
c) Bend plate, d) Spring
New 0.5mm (0.0197 In)

2.2 0.08
(0.0866 0.0031 In) Wom 0.35mm(0.0138 In)
minimum
New
a) Outer clutch Disc
b) Inner clutch Plate (1) Torque for six bolts that hold torque converter drive
plate to the flywheel 45 7 Nm (33 5 lbft)
Power Train 5 Specifications

Valve Block Elements (On top of transmission)
A) Spring D) Spring (outer)

Length under test force............22.5 mm (0.89 in) Length under test force ............ 22.22 mm (0.87 in)
Test force....................... ...42 3.4 N (9.4 0.8 lb) Test force .........................29 to 34 N (6.5 to 7.6 lb)
Free length after test (nominal)..34.65 mm (1.36 in) Free length after test (nominal) .. 31.7 mm (1.25 in)
Outside diameter ........................13 mm (0.51 in) Outside diameter ...................... 11.91 mm (0.47 in)
B) Spring (Inner) E) Spring (Inner)

Length under test force............... 26.6 mm (1.05 in) Length under test force .............. 20.0 mm (0.79 in)
Test force......................... 37.8 3.0 N (8.50.7 lb) Test force .................3.34 0.27 N (0.75 0.06 lb)
Free length after test (nominal)... 48.2 mm (1.90 in) Free length after test (nominal) 55.93 mm (2.20 in)
Outside diameter ........................ 10.8 mm (0.43 in) Outside diameter ...................... 7.75 mm (0.305 in)
C) Spring (outer)
Length under test force............... 26.6 mm (1.05 in)
Test force...................... 75.6 6.0N (17.0 1.3 lb)
Free length after test (nominal)... 52.6 mm (2.07 in)
Outside diameter ...................... 15.24 mm (0.60 in)

Valve Spring in Transmission Bearing Plate
A
2-Springs
Tighten to 45 Nm (33.2 Ibft)
Converter Inlet Valve
Tighten to 45 Nm (33.2 Ibft)
Converter Outlet Valve
A) Spring
Length under test force.................. 30 mm (1.18 in)
Test force..................... 18.1 1.8 N (4.07 0.4 lb)
Free length after test (nominal)..43.25 mm (1.70 in)
Outside diameter10.7 mm (0.42 in)

Housing Bolt 55 N m (4.6 Ib ft)
Bearing Shims
Bolt 20 N m (14.8 Ib ft)
Power Train
Axle Lube Pump Bolt 12 N m (8.9 Ib ft)
Bearing Plate
Pump Housing
8
Tightening Torques - Transmission
PTO Pump Bolt 30 N m (22.1 Ib ft) Flexplate Bolt 55 N m

(40.6 Ib ft)
Bearing Shims
See Instructions
U-joint Bolt 70 N m (51.7 Ib ft)
Bearing Shims
See Instructions Bolt 40 N m (29.5 Ib ft)
Housing Bolt 55 N m
Plug 50 N m (36.9 Ib ft)
(40.6 Ib ft)
Specifications
Final Drives and Wheel
Pneumatic Shoe Pneumatic ODB & Cushion
(1) Torque for bolts that hold brake assembly to drive (1) Apply LOCTITE NO.271 Thread Lock to threads of
axle arm....................176 29 Nm (130 21 lbft) spindle bolts. Torque for bolts that hold spindle to
drive axle housing is....................100.5 12.3 Nm
(2) Tighten nut slowly until torque required to turn (74.2 9.1 lbft)
bearings is ........2.45 0.49 Nm (1.80 0.35 lbft)
(2) Tighten nut slowly until torque required to turn
bearings is..............10.8 2.0 Nm (8.0 1.5 lbft)
(3) Torque for bolts that hold drive shaft to hub ...........
.....................................71 12 Nm (52.5 9 lbft)
(3) Apply Loctite No.271 Thread Lock to threads of
drive shaft bolts. Torque for bolts that hold drive
(4) Torque for drive wheel mounting nuts ....................
shaft to hub is .............. 71 12 Nm (52.5 9 lbft)
..................................176 20 Nm (130 14 lbft)
(4) Pneumatic - ODB
Apply Loctite No.271 Thread Lock to threads of
stud bolts. Torque for stud bolts is ......88 10 Nm
Pneumatic - ODB (65 7.4 lbft)
Cushion
Torque for wheel mounting bolts is ...135 15 Nm
(100 10 lbft)
(5) Apply Loctite No.271 Thread Lock to threads of

stopping bolts. Torque for bolts that hold nut and
plate is ...................... 9.8 2.0 Nm (7.2 1.5 lbft)

Wheel Bearing Adjustment
Pneumatic - Shoe Cushion
(1) Hub. (2) Bolt. (3) Nut.

(1) Hub. (2) Bolt. (3) Nut.
(1) Tighten nut (3) slowly until torque required to turn (1) Tighten nut (3) slowly until torque required to turn
bearings is 2.5 Nm (1.8 lbft), while hub (1) is bearings is 2.5 Nm (1.8 lbft), while hub (1) is
turned to put the bearings in position. turned to put the bearings in position.
(2) Tighten the bolts to hold the nut in position. (Apply (2) Tighten the bolts to hold the nut in position.
Loctite No. 272) (Apply Loctite No. 272)
Tightening Torque.......................... 7.9 to 11.7 Nm Tightening Torque ..........................7.9 to 11.7 Nm
(5.8 to 8.6 lbft) (5.8 to 8.6 lbft)
Pneumatic - ODB
(1) Hub. (2) Bolt. (3) Nut.

System Operation
General Information
Power Flow
(1) Drive axle. (2) U-joint. (3) Transmission. (4) Engine.
The basic components of the power train are engine Power from yoke of drive axle is sent through a spiral
(4), Transmission (3), U-Joint (2), Drive axle (1) and bevel gear set to the differential.
the final drives and wheels. The differential sends power out through the axles to
the final drives and wheels.
Two axle shafts connect the differential to two final
drives. The drive wheels are mounted to the final
drives.
Power from the engine goes through the flywheel into

the torque converter. Power then flows through a
transmission (3) and U-joint (2) to the yoke of drive
axle (1).
The transmission has two hydraulically operated clutch
packs that are released by spring.
Power Train 11 Systems Operation

Torque Converter The torque converter has four main parts : housing (4),
impeller(pump) (3), turbine(1) and stator(2). The
housing is connected to the engine flywheel through a
flexplate. Impeller (3) and housing (4) are welded
together and turn with the engine flywheel at engine
speed and in the direction of engine rotation. Turbine
4 (1) turns the transmission input shaft. Stator (2) is
installed stationary on stator support (5) by a
freewheel clutch that allows one way rotation of the
2 stator.
The hub, which is part of impeller (3), fits into the

transmission oil pump. The turning impeller (3) rotates
the pump to supply oil for the operation of the torque
converter and transmission
6
When the engine is turning, oil flows through the
converter to lubricate and cool it. With the
transmission in neutral, the impeller, turbine, stator
and oil are all turning together in a direct fluid coupling.
The turbine/impeller speed ratio is 1/1.
5
Once a direction is selected the direct fluid coupling no
longer exists, the turbine/impeller speed ratio changes
(the turbine will be turning slower than the impeller).
When this happens the impeller outlet pressure to
1 turbine inlet pressure changes. This causes the oil
flow in the torus (fluid path containing the impeller,
turbine and stator) to gain momentum.
As impeller (3) turns, it increases the energy state of

3 the oil and directs the oil to the outside diameter of
converter housing (4). Oil leaving impeller (3) is
directed to turbine (1) where much of the oil? energy is
absorbed by turning the turbine. The pressure and
flow change in the torus becomes torque and speed at
Torque converter the turbine and transmission input shaft.
(1) Turbine. (2) Stator. (3) Impeller. (4) Housing.
(5) Stator support. (6) Stator clutch. Oil follows the turbine blades inward toward the center
of the converter. When the turbine/impeller speed ratio
is less than .85/1, oil is directed against the concave
There is no direct mechanical connection between side of stator (2) with enough force to stop its one way
engine and the transmission. Power from the engine is rotation and lock the freewheel clutch.
transferred through the torque converter, which
hydraulically connects the engine to the transmission. Most of the energy from the oil that strikes the turbine
Transmission drive train oil is used to turn the turbine is used to turn the turbine, but some energy is left over.
and transmission input shaft. Torque multiplication comes about because the locked
stator (2) directs this left over oil back to impeller (3) in
When the lift truck works against a load, the torque the same direction as the impeller rotation. This
converter can multiply the torque from the engine and energy force of the oil increases the torque on the
send a higher torque to the transmission. turbine and transmission input shaft. During operation,
this cycle is repeated over and over.
Without the stator, oil leaving the turbine is traveling in

a direction that is against impeller rotation. Torque
multiplication is only possible because of the stator.

Transmission
5A
(1) TC Housing. (2) TM Bearing Plate. (3) TM Housing. (4) Torque Converter. (5) Input Shaft. (5A) Input Shaft Gear.
(6) Oil Pump. (7) Forward Gear. (8) Forward Clutch. (9) Reverse Shaft. (9A) Reverse Shaft Gear. (10) Reverse Clutch. (11)
Reverse gear. (12) Output gear. (13) U-joint. (14) Quill Shaft. (14A) Coupling. (15) PTO Pump.
The Transmission consists of 3 sections: The reverse shaft (9) carries the reverse shaft gear
(9A), the reverse clutch (10) and the reverse gear (11)
a) TC housing (1) which contains torque converter (4) which is in mesh and drives the output gear (12) when
and the oil pump (6) and its housing. Tangs on the the reverse clutch (10) is selected.
TC neck engage in and drive the pump. The quill shaft (14) is splined to the torque converter
and therefore rotates with engine speed and direction.
b) Bearing plate (2) which contains the rear bearings A coupling (14A) connects the PTO pump (15) to the
of input, reverse shaft and output gear and the oil quill shaft (14).
supply channels. The oil channels are sealed by
the front TC housing wall.
c) Transmission housing (3) containing input shaft (5),

forward clutch (8), forward gear (7), reverse shaft
(9), reverse clutch (10), reverse gear (11), output
gear (12) and parking brake. The input shaft
engages in and is driven by the TC turbine hub
spline and rotates in same direction as the engine.
It carries an input shaft gear (5A) which is in mesh
and drives the reverse shaft gear (9A), the forward
clutch (8) and the forward gear (7), which is in
mesh and drives the output gear, when the forward
clutch (8) is closed.

Transmission Power Flow - Forward
With the transmission control in forward, which will

pressurize the forward clutch (8), power will flow from
the engine through the torque converter to drive the oil
pump (6) and the input shaft (5), also the quill shaft
(14). Since the forward clutch (8) locks the forward
gear (7) to the input shaft, the power flows through the
forward clutch (8), the forward gear (7) to output gear
(12) which is in mesh with the forward gear. The u-
joint (13) which is splined to the output gear will
transmit power to the axle.

Transmission Power Flow - Reverse
With the transmission controls in reverse, which will

pressurize the reverse clutch (10), power will flow from
the engine through the torque converter to drive the oil
pump (6) and the input shaft (5) also the quill shaft
(14). Since the reverse clutch (10) is closed, power will
flow through input shaft gear (5A) which is in mesh
and drives reverse shaft gear (9A) and reverse shaft
(9). The reverse gear (11) which is locked to the
reverse shaft by the reverse clutch (10) is in mesh and
drives the output gear (12). The U-joint, which is
splined to the output gear will transmit power to the
axle.

Transmission Lubrication Schematic
Oil for lubrication of the clutch shaft bearings and

cooling the clutch discs and plates comes from the
outlet passage of oil cooler. Lubrication oil is also
splashed inside the transmission case. Lubrication oil
is especially important for cooling the clutches.

Relief Valve
Converter Bypass
Relief Valve
Power Train
Orifice
Oil Pump
Transmission Hydraulic System
17
Transmission Oil Sump
Systems Operation
Pump, Filter, Torque Converter And Oil Cooler
Systems
4 The oil for the operation and lubrication of the

transmission is made available by pump (2). The
pump is located in the torque converter housing and is
driven by Tangs on the torque converter neck.
6
Oil sump (1), for the transmission, is in the bottom of
the transmission case. Oil from reservoir flows through
the strainer and internal channels to the suction side of
positive displacement pump .
7
Oil from pump (2) flows to primary oil filter (3). If there
is a restriction in the oil filter or if the oil is cold and
thick, a bypass valve in the filter will open. The
8 difference in pressure at which the bypass valve will
open is 124 7 kPa (18 1 psi). From the primary oil
filter, the oil flows on to main relief valve (4). In the
10 9 spool of main relief valve there is a bypass (18). The
purpose of this bypass is to supply lubrication and
coolant oil to the torque converter at low speeds and
especially during hot oil conditions. Converter relief
valve (13) protects the torque converter from oil
pressure higher than 670 kPa (97 psi), such as during
cold oil start-ups. At this pressure, the oil is released
The basic components of the hydraulic system for back to the reservoir. Converter inlet passage has
operating the transmission are transmission oil sump converter bypass orifice (16). The purpose of this
(1), oil pump (2), primary oil filter (3), valve block, orifice is to prevent too much of a pressure load on the
containing main valve (4), orifice (5), inching valve (6), torque converter by allowing some of the oil to bypass
modulating valve (7), selection valve (8), forward and the converter. In converter outlet passage, there is
reverse solenoid valves (9,10), forward clutch (11), cooler bypass valve (15). Cooler bypass valve (15) will
reverse clutch (12), torque converter (14) with relief release oil back to the reservoir if the oil pressure
valves (13,15), bypass (16) and oil cooler (17). reaches 400 kPa (58 psi). This can happen if the oil
cooler has a restriction or if the oil is cold and thick.
The pump is located in the torque converter housing,
and valve block is located on top of transmission, the
filter is located on the right hand of the transmission
housing.
The transmission hydraulic system is explained in

three sections. The first section is the oil pump, filter,
torque converter and oil cooler systems. The second
section is the transmission lubrication system. The
third section is the transmission hydraulic control
system which controls the lift truck direction control.

Neutral Position
When the transmission is in NEUTRAL position with

the engine running, oil is pulled from reservoir and the
strainer assembly (1) to pump (2). From there, pump
oil flows through the primary filter (3) to main relief
valve (4). Oil will also flow through orifice (18) to
lubricate the torque converter during hot, low speed
conditions.
When the pump pressure reaches 895 kPa (130 psi),

relief valve spool (4A) will move to the left side and
most of the pressure oil flows to the torque converter.
Spool will move left and right to maintain 895 kPa (130
psi). Oil can also bypass the torque converter through
converter bypass orifice (16). The purpose of orifice
(16) is to prevent too much of a pressure load being
put on the torque converter.
Oil flows from the torque converter through a passage

to oil cooler (17). Oil then flows back to transmission to
cool and lubricate the clutches and shaft bearings.
In NEUTRAL position, the remaining pressure oil flows

from main relief valve (4) to inching valve (6).
Without inching (inching pedal up and valve in), oil
flows around and through the center of spool (6A) to
the bottom of the spool. The oil, at the bottom, pushes
the spool to the position shown. Oil flows around the
lands of the spool and through a passage to
modulating valve (7).
In NEUTRAL position, forward solenoid (9) and

reverse solenoid (10) are OFF. Pump oil flow is
blocked at the solenoids. Oil cannot flow through oil
passage to the forward or reverse selector spool.
Pump oil pressure is felt at slugs. This forces forward
selector spool to the right and reverse selector spool
to the left. With the spools in this position, forward
clutch (11) and reverse clutch (12) are open to drain.
Most of the oil still flows through the lube circuit.

Forward Direction
When the transmission is in FORWARD, the oil flow

from the reservoir, through the pump, primary filter,
torque converter and oil cooler circuits will be the
same as explained in NEUTRAL position.
Oil will flow from the main relief valve to inching valve
(6). Without inching (inching pedal up and valve in), oil
flows around and through the center of reducing spool
(6A) to the bottom of the spool. The oil, at the bottom,
pushes the spool up to the position shown. Oil flows
around the lands of the spool and through a passage
to modulating valve group (7).
In FORWARD, forward solenoid (9) is ON, so pump oil

is sent to the forward selector spool through oil
passage. Forward selector spool (8A) moves to the
right, causing reverse selector spool (8B) to move to
the right also.
With the reverse spool in this position, reverse clutch

(12) is open to drain, Forward selector spool (8A)
opens forward clutch (11) to pump oil. This also opens
reverse selector spool (8B) to drain through oil
passage. Forward clutch (11) will fill with pump oil.
Once filled, oil pressure begins to build up. Pump oil
goes through orifice (7B) and moves load piston (7A)
to the left as pump pressure increases. Oil pressure
increases as the load piston moves further to the left.
The pressure increases to the control pressure of 895
kPa (130 psi). Forward clutch (11) will now be fully
engaged. Modulating valve assembly (7) will now
shuttle between pump oil and drain to maintain clutch
pressure. Clutch fill time takes 0.4 seconds and
pressure increase takes 0.7 seconds. This
approximate 1.1 second clutch fill and pressure rise
time, gives a cushion engagement of forward clutch
(11).

Relief Valve
Converter Bypass
Relief Valve
Power Train
Orifice
Oil Pump
21
Systems Operation
Reverse Direction
When the transmission is in REVERSE, the oil flow

from the reservoir, through the pump, primary filter,
torque converter and oil cooler circuits will be the
same as explained in NEUTRAL position.
Oil will flow from the main relief valve to inching valve
(6). Without inching (inching pedal up and valve in), oil
flows around and through the center of reducing spool
(6A) to the bottom of the spool. The oil, at the bottom,
pushes the spool up to the position shown. Oil flows
around the lands of the spool and through a passage
to modulating valve group (7).
In REVERSE, reverse solenoid (10) is ON, so the

pump oil is sent to the reverse selector spool through
an oil passage. Reverse selector spool (8B) moves to
the left, causing forward selector spool (8A) to move to
the left also.
With the forward selector spool in this position, forward

clutch (11) is open to drain. Reverse selector spool
(8B) opens reverse clutch (12) to pump oil. This also
opens forward selector spool (8A) to drain through
passages. Reverse clutch (12) will fill with pump oil.
Once filled, oil pressure begins to build up. Pump oil
goes through orifice (7A) and moves load piston (7A)
to the left as pump pressure increases. Oil pressure
increases as the load piston moves further to the left.
The pressure increases to the control pressure of 895
kPa (130 psi). Reverse clutch (12) will now be fully
engaged. Modulating valve assembly (7) will now
shuttle between pump oil and drain to maintain clutch
pressure. Clutch fill time takes 0.4 seconds and
pressure increase takes 0.7 seconds. This
approximate 1.1 second clutch fill and pressure rise
time, gives a cushion engagement of reverse clutch
(12).

Relief Valve
Converter Bypass
Relief Valve
Power Train
Orifice
Oil Pump
23
Systems Operation
Forward Direction During Inching
When the transmission is in FORWARD (or

REVERSE) during INCHING, the oil flow from the
reservoir, through the pump, filter, torque converter
and oil cooler circuits will be the same as explained in
NEUTRAL position.
Oil will flow from the main relief valve through a

passage, to inching valve (6). Inching valve (6) lets the
operator control the oil pressure to forward clutch (11)
between 280 and 0 kPa (40 and 0 psi), which permits
a partial engagement of the clutch. Through the use of
the inching valve, the lift truck can move slowly while
the engine is at higher speeds. This lets the operator
move the lift truck slowly up to a load while the mast is
raised rapidly.
When the operator pushes the inching pedal part of

the way down, inching plunger (6B) moves out of the
inching valve. This takes away some of the spring
force between plunger (6B) and reducing spool (6A). It
also removes the balance condition between the pump
pressure, at the bottom of spool (6A), and the spring
force.
Reducing spool (6A) moves to the right, which causes
a restriction for the pump oil flow. The pressure drops
from 895 kPa (130 psi) to 280 kPa (40 psi). The
pressure can drop further depending on the position of
plunger (6A). Pressure reduces as plunger (6A) is
moved out (as the inching pedal is pushed down).
This reduced pressure flows to selector valve group

(8). The oil will flow through the valve as explained in
forward direction. The reduced (inching) pressure will
flow through a passage to partially engage forward
clutch (11). This reduced pressure permits slippage of
the forward clutch plates and discs. Therefore, the
truck will have an operator controlled movement.
The amount of oil pressure to clutch (11) depends on
the position of inching plunger (6A). As the plunger is
pulled out completely (inching pedal all the way down)
clutch pressure will drop to 0 kPa (0 psi). The forward
clutch will be disengaged at approximately 65.5 kPa
(9.5 psi).

Relief Valve
Converter Bypass
Relief Valve
Power Train
Orifice
Oil Pump
25
Systems Operation
Control Valve
Basic Control Schematic
DR DR DR
FWD REV
CLUTCH CLUTCH
SOLENOID
SOLENOID
DR DR DR
PUMP
The control schematic is shown below. The system

consists of 2 valve bores:
1. Modulating valve
2. Forward and reverse selector valves

Modulating valve function
SPRING LOAD PISTON MODULATING VALVE
ORIFICE REACTION SLUG
DR DR DR
FLOW TO SELECTOR PUMP

SPOOLS
Figure 1
The modulating valve consists of 5 basic elements: pressure to drain, and reducing Force 2.
1. Orifice If Force 1 is too large then the valve would be forced
2. Springs to the right, opening the clutch circuit to supply,
3. Load piston and increasing the value of Force 2 so it balances
4. Modulating valve Force 1. By regulating clutch pressures between
5. Reaction slug supply and drain, valve forces are balanced.
The function of the modulating valve is to control
clutch pressure during a shift. It allows the clutch
pressure to raise gently to the maximum transmission
pressure in order to provide a smooth clutch
engagement and a good shift feel for the vehicle
operator.
There are two forces acting on the modulation valve:
Force 1 = Pressure (load piston) / Area 1

Force 2 = Pressure (clutch) / Area 2
In order for the modulating valve to stay in a balance

position Force 1 must be equal to Force 2.
If for example Force 2 is too large (clutch pressure is
too large) then the valve will be forced to the left,
shutting off supply and opening the clutch and slug

Modulating valve movement during clutch fill Modulation of clutch to top pressure
Figure 3
Figure 2
MODULA TION
When a new direction is selected by the operator, the
selector spools open up a circuit to the new clutch
piston. System pressure drops as the new clutch
piston is stroking. This drop in supply pressure causes
a force imbalance on the modulating valve / reaction
slug pressure becomes smaller. Since Force 1 is still
the same, Force 1 forces the modulating valve to the
right until the end of the modulating valve opens the
load piston cavity to drain.
Figure 4
The load piston oil dumps to drain and the load piston
immediately moves to the right (shown in fig.2).
This action is called "load piston reset". It happens
very quickly in comparison to the time needed for the
clutch piston to fully stroke. Therefore the modulating As long as reaction slug pressure is greater than load
valve and load piston are ready to start controlling the piston pressure, oil will flow across the orifice from
clutch pressure in a smooth upward manner once the Area 2 to Area 1. As oil flows to the load piston the
clutch piston finishes stroking. springs will continue to compress, allowing the load
piston to move to the left. As the load piston moves to
the left the spring force increases and load piston
pressure increases.
As press (LP) increases the modulating valve will

cause a corresponding increase in clutch pressure in
order to keep the forces balanced. In simple terms as
the load piston strokes to the left the clutch pressure
rises to maximum system pressure.
This controlled rise in clutch pressure takes about 0.7

sec. and is shown in fig.4. It occurs immediately after
the clutch piston completely strokes (end of clutch fill).

Selector spools
Figure 5
The selector spool circuits are arranged in such a way

that once a gear (forward or reverse) is selected the
opposite solenoid supply is shut off and drained. This
is done to prevent any electrical or malfunction of the
other solenoid from giving a sudden and unexpected
shift.
In addition the two selector spools are arranged so
they cannot select both forward and reverse at the
same time because they mechanically interfere with
each other.
The selector spools have two areas:

1. Slug area
2. Spool area
The slug cavity is exposed to system pressure all the

time. If the solenoid allows system oil to flow to the
end of the spool and pressurize the spool area then
the spool will move toward the slug because the spool
area is larger than the slug area and the force will be
higher. When the solenoid is closed, pressure to the
spool is reduced. This allows the pressure at the slug
to move the spool away from the slug.
In fig.5 the selector spools are shown with forward

gear selected. Notice that the reverse solenoid supply
is drained through the forward spool

Drive axle
Differential Pneumatic Shoe Type
(1) Spider. (2) Pinion. (3) Gear. (4) Differential case. (5) Nut. (6) Tube. (7) Drum. (8) Hub. (9) Shaft.
The location of the differential is in the front of the lift During a turn, the force (traction) that is on the drive
truck. The differential is a part of the drive axle. It is a wheels is different. These different forces are also felt
single reduction unit with a differential drive gear (3) on opposite sides of the differential and cause pinions
fastened on the differential case (4). (2) to turn. The rotation of pinions (2) stops or slows
the inside wheel and lets the outside wheel go faster.
The differential is used to send the power from the This moves the machine through a turn under full
transmission to the wheels. When one wheel turns power.
slower than the other, the differential lets the inside
wheel stop or turn slower in relation to the outside The differential gets lubrication from oil thrown about
wheel. inside the housing.
Case (4) has four differential pinions (2). The pinions The differential turns axle shaft (9). Tube (6) which is
are engaged with two side gears. The side gears are pressed into axle housing is used as a support for hub
splined to the axle shafts (9). (8). The hub (8) and bearings are turned by axle shaft
When the lift truck moves in a forward direction and (9) through a direct connection between the hub and
there is same traction under each wheel, there is also axle shaft. The drive wheel is fastened to hub (8) and
the same torque on each axle and pinions (2) are turns with the hub.
stopped. This gives the same effect as if both wheels
were on the same axle

Differential Pneumatic ODB Type & Cushion Type
(1) Spider. (2) Pinion. (3) Gear. (4) Differential case. (5) Nut. (6) Hub. (7) Shaft. (8) Spindle.
The location of the differential is in the front of the lift During a turn, the force (traction) that is on the drive
truck. The differential is a part of the drive axle. It is a wheels is different. These different forces are also felt
single reduction unit with a differential drive gear (3) on opposite sides of the differential and cause pinions
fastened on the differential case (4). (2) to turn. The rotation of pinions (2) stops or slows
the inside wheel and lets the outside wheel go faster.
The differential is used to send the power from the This moves the machine through a turn under full
transmission to the wheels. When one wheel turns power.
slower than the other, the differential lets the inside
wheel stop or turn slower in relation to the outside The differential gets lubrication from oil thrown about
wheel. inside the housing.
Case (4) has four differential pinions (2). The pinions The differential turns axle shaft (7). Spindle (8) is used
are engaged with two side gears. The side gears are as a support for hub (6). The hub (6) and bearings are
splined to the axle shafts (9). turned by axle shaft (7) through a direct connection
When the lift truck moves in a forward direction and between the hub and axle shaft. The drive wheel is
there is same traction under each wheel, there is also fastened to hub (6) and turns with the hub.
the same torque on each axle and pinions (2) are
stopped. This gives the same effect as if both wheels
were on the same axle

3. Actuate the controls for the forward direction and
Testing and Adjusting then for the reverse direction. The actuation must
give the same positive action to the hydraulic control
circuit for clutch engagement in both directions.
Troubleshooting
4. Remove and check the filter element for loose
particles. Check the strainer behind the transmission
Troubleshooting can be difficult. A list of possible oil plug for foreign material.
problems and corrections is on the pages that follow.
a. Particles of friction material give an indication of a
This list of problems and probable causes will only clutch failure.
give an indication of where a problem can be and what b. Metallic (metal) particles in the filter give an
repairs are needed. Normally, more or other repair indication of wear or mechanical failure in the
work is needed beyond the recommendations on the transmission and/or axle.
list. Remember that a problem is not necessarily c. Rubber particles give an indication of seal or hose
caused only by one part, but by the relation of one part failure.
with other parts. This list cannot give all possible
problems and probable causes. The serviceman must If metal or rubber particles are found, all components
find the problem and its source, then make the of the transmission hydraulic system must be flushed.
necessary repairs. Make a replacement of all parts that show damage.
Always make visual checks first. Check the operation

of the machine and then check with instruments. NOTICE
Before these checks are started, fill the transmission
WARNING and axle with oil to the correct level. See the Operation
& Maintenance Manual for the procedure to check
transmission and axle oil level.
To prevent personal injury, when testing and
adjusting the power train, move the machine to an
area clear of obstructions. There must be
adequate ventilation for the exhaust. When drive Activate the controls for the FORWARD direction and
wheels are off the ground for testing, keep away then for the REVERSE direction. The modulation will
from wheels that are in rotation. be seen on pressure gauge in the clutch pressure tap
when the shift is made at low idle. The pressure will
increase to 895 kPa (130 psi) when completely filled.
Operate the machine in each direction. Make note of Operate the machine in each direction. Make note of
all noises that are not normal and find their source. If noises that are not normal and find their source. If the
the operation is not correct, make reference to the operation is not correct, make reference to the check
troubleshooting chart for "problems" and "probable List During Operation for "problems" and "probable
causes". causes".
Visual Checks
1. Check the oil level in the transmission and axle with

the engine running and with the Transmission in
NEUTRAL.
2. Check all oil lines, hoses and connections for leaks

and damage. Look for oil on the ground under the
machine.
Power Train 32 Testing And Adjusting

Check List During Operation g. Leakage inside the transmission.
Worn or broken metal seal rings on input or
Problem: Engine starts with directional control reverse shaft.
switch in FORWARD or REVERSE. Worn or broken seals around clutch piston.
Probable cause: Modulating valve assemblies stuck
Because of contaminated oil
1. Directional control switch is defective
3. External oil lines are not connected correctly.
Problem: Transmission shifts with parking brake
engaged. 4. Mechanical failure in the transmission.
Problem: Transmission operates only in

Probable cause:
FORWARD.
1. Parking brake switch is defective.
Probable cause:
Problem: Transmission will not stay in gear when
1. Forward clutch is locked up.
shifted.
2. Reverse solenoid valve does not actuate.
Probable cause:
1. Parking brake switch mounting is loose. 3. Reverse clutch components have damage.
Problem: Transmission does not operate in either a. Leakage caused by worn or broken metal sea-
direction or does not shift. ling rings.
Probable cause: b. Leakage caused by worn or broken clutch piston.
1. Problems in the electrical circuit (directional con- c. Failure of shaft seal ring.
trol)
Problem: Transmission operates only in REVERSE.
a. Open circuit between ignition switch and direc-
Probable cause:
tional control switch.
1. Reverse clutch is locked up.
b. Defective directional control switch.
c. Defective wiring harness between directional 2. Forward solenoid valve does not actuate.
control switch and transmission.
3. Forward clutch components have damage.
d. Shorted wiring harness for the solenoids.
a. Leakage caused by worn or broken metal
2. Low oil pressure or no oil pressure caused by: sealing rings
a. Iow oil, no oil or thick oil. b. Leakage caused by worn or broken seal around
clutch piston.
b. Inching control valve linkage loose, broken or
adjustment is not correct. c. Failure of shaft seal ring.
c. Inching valve reducing spool stuck open. Problem: Transmission gets hot.
d. Failure of the oil pump or a defect in the oil Probable cause:

pump.
1. Restriction in cooling circuit.
e. Main relief valve stuck open.
2. Oil level too high or too low.
f. Restriction in the oil flow circuit such as dirty oil
screen. 3. Core of the oil cooler not completely open.
4. Low pump pressure - worn or damaged pump.
5. Converter one-way clutch worn and slipping.

6. Air mixed in the oil. Air leaks on the intake side of Check List From Operation Noises
the pump.
Problem: Noise in NEUTRAL only.
7. Low oil flow through converter. Converter relief
valve stuck open (converter bypass orifice
Probable cause:
plugged)
1. Worn one-way clutch in torque converter.
8. Incorrect use of vehicle. Loads are too heavy for the
lift truck.
2. Low oil level (pump cavitation).
9. Too much inching operation (slipping the clutch
3. Worn bearing next to pump.
plates and discs).
Problem: Pump noise not normal
10. Too much stalling of torque converter.
Probable cause:
11. Cooler relief valve stuck open, full oil flow does
not go through oil cooler.
1. A loud sound at short time periods gives an
indication that foreign material is in the
Problem: Clutch engagement is slow or loss of
transmission hydraulic system.
power during engagement.
2. A constant loud noise is an indication of pump
Probable cause: failure.
1. Low oil pressure
Problem: Noise in the Transmission that is not
normal.
2. Air mixed in the oil.
Probable cause:
a. Air leaks on suction side of pump.
1. Transmission components have wear or damage.
b. Low oil level also causes aeration.
a. Damaged gears.
3. Inching valve linkage adjustment is not correct.
b. Worn teeth or clutch plates and/or clutch discs.
4. Modulating valve assembly leaks or partially stuck.
c. Slipping clutch plates and disc noise.
Problem: Clutch engagement makes a rough shift.
d. Other component parts have wear or damage.
Probable cause:
e. Failure of the thrust washers.
1. Modulating valve assembly, load piston and/or
reducing valve stuck.
2. Modulating valve assembly makes noise.
Problem: Vehicle operates in one direction and
Problem: Constant noise in the Drive axle.
creeps in that direction in NEUTRAL. Engine stalls
when shifted to the other direction.
Probable cause:
Probable cause: 1. Lubricant not to the specific level.
1. Failure of clutch in the direction the lift truck moves.
2. Wrong type of lubricant.
Clutch discs or plates are warped (damaged) or
held together because of too much heat.
3. Wheel bearings out of adjustment or have a defect.
2. Failure of the modulating valve assembly in the
4. Bevel gears not in adjustment for correct tooth
direction the lift truck moves. The valve assembly
contact.
stuck in the engaged position possibly caused by
metal burrs (particles) or oil contamination.
5. Teeth of bevel gear have damage or wear.

6. Too much or too little gear backlash. 2. Loss at bevel input pinion shaft.
7. Loose or worn pinion bearings. a. Lubricant above specification level.
8. Loose or worn shaft bearings. b. Wrong kind of lubricant.
9. Loose or worn differential bearings. c. Restriction of axle housing breather.
Problem: Noise at different intervals. d. Pinion oil seal worn or not installed correctly.
Probable cause: Problem: Drive wheels do not turn.

1. Bolts on drive gear not tightened correctly. Probable cause:
2. Drive gear has a defect (warped). 1. Broken axle shaft.
3. Loose or broken differential bearings. a. Loose wheel bearings.
4. Bevel gear bearing failure.
b. Axle shaft too short.
Problem: Noise on turns only
2. Side gear or differential pinion broken.
Probable cause:
3. Differential pinion shaft or spider broken.
1. Differential pinion gears too tight on the spider or
the pinion shaft.
2. Side gears tight in differential case. Check List From Pressure Tests
3. Differential pinion or side gears have a defect. Problem: Low pressure to FORWARD and
REVERSE clutches.
4. Thrust washers worn or have damage.
Probable cause:
5. Too much clearance (backlash) between side gears
and pinion. 1. Inching valve linkage adjustment is not correct.
6. Worn axle shaft assembly gear. 2. Inching valve reducing spool stuck open.
7. Hub gear worn. 3. Clutch piston seals cause leakages.
8. Wheel bearings worn or out of adjustment. 4. Main relief valve setting too low caused by a
defective relief valve spring.
Problem: Leakage of lubricant. 5. Low oil pressure. See Probable Cause for Low Oil
Pressure.
Probable cause:
1. Loss through hub seals.
7. Modulating valve assembly stuck.
a. Lubricant above specification level.
b. Wrong kind of lubricant.
c. Restriction of axle housing breather.
d. Hub oil seal installed wrong or has damage.

Problem: Clutch pressure and pump pressure are Problem: High lubrication pressure.
high.
Probable cause:
Probable cause:
1. Restricted external oil lines or internal passages.
1. Main relief valve is stuck.
2. A restriction in the hydraulic circuit.
3. Main relief valve not adjusted properly. Problem: High converter charge pressure.
Problem: Pressure to one clutch is low. Probable cause:
Probable cause: 1. A plugged converter bypass orifice.
1. Clutch piston seal alignment is not correct, oil leaks 2. A restriction inside the converter assembly.
through.
3. A plugged oil flow passage.
2. Seal rings on shaft or clutch piston seals are broken
or worn. Problem: Low converter charge pressure.
3. Modulating valve assembly stuck. Probable cause:
Problem: Low pump pressure. 1. Converter relief valve stuck open.
Probable cause: 2. Main relief valve movement is restricted.
1. Low oil level. Problem: Low converter outlet pressure or cooler

inlet pressure.
2. Main relief valve movement is restricted.
Probable cause:
3. Transmission oil pump is worn.
1. Low oil pressure.
4. Inner oil leakage.
2. Cooler relief valve stuck open.
5. Main relief valve not adjusted properly.
Problem: High converter outlet pressure or cooler
Problem: Low lubrication pressure or no inlet pressure.
lubrication pressure.
Probable cause:
Probable cause:
1. Restriction in oil cooler lines or a plugged oil cooler.
1. Low oil pressure or no oil pressure caused by:
a. Failure of the oil pump or a defect in the oil Problem: Low stall speed.
pump.
Probable cause:
b. Restriction in the oil flow circuit such as a dirty
oil screen. 1. Engine performance is not correct.
c. Inching valve reducing spool stuck open. 2. The one-way clutch of the torque converter does not
hold.
d. Leakage inside of transmission caused by com-
ponent defects.
2. Oil cooler has restriction to oil flow.

Problem: High stall speed in both directions. 3. Valve not correctly assembled (same as above)
Probable cause: 4. Holes not drilled into case properly
1. Low oil level. 5. Excessive leakage internally in body
2. Air in the oil. a. Porosity in body
b. Selector bore too large

3. Clutches slip (clutch plates slide in relation to one
another). c. Spool too small
4. Torque converter failure. d. Slug/spool fit not right.
Problem: High stall speed in one direction. Problem: Modulation spool problems.
Probable cause: 1. Slow or no modulation of both clutches

(If only 1 clutch does not modulate correctly then
1. There is a leak in the clutch circuit.
the problem is either with the selector spool or it is
a problem in the transmission).
2. There is a failure in that clutch assembly (clutch
slipping). Probable cause:
Problem: Selector spool problems. 1. Orifice plugged with debris
1. Transmission stays in neutral, no shift. 2. Modulation valve stuck
3. Modulation valve not correctly assembled.

Probable cause:
4. Load piston problem
1. Spools mechanically stuck
a. Stuck in bore
a. Contamination
b. Excessive valve / bore clearance
b. Case or body not flat
c. Missing springs
c. Bore / spool worn
5. Porosity in body in the area of load piston cavity
2. Solenoids not working
2. Modulation time is too quick
a. O-rings leaking (cut)
Probable cause:
b. O-rings missing
c. Ports not machined properly 1. The upstream orifice (in the oil supply) is not
installed. (The orifice is located in the valve block)
d. Contamination in solenoid
2. The load piston is only moving a small amount
e. Electrical problem before it sticks. Check the spool to see if it freely
fits in the bore. This check must be made while the
3. Orifice plugged aluminum body is still bolted down to the
transmission.
a. With debris
b. Bad part 3. The plastic orifice is not installed or the hole in the
plastic housing is too large.
4. Modulation valve stuck in "off" position
4. The modulating valve is stuck in an open position.
5. Modulation valve not correctly assembled. Check to see if the valve moves freely while the
aluminum body is still bolted down.
2. Transmission will not shift into or out of 1 gear
Probable cause: 5. The springs are not installed or the pin has jammed
the load piston.
1. Spools mechanically stuck (same as above)
2. Solenoids not working (same as above)

Transmission Pressure Tests Most problems in the hydraulic circuit can normally be
found when the pump pressure is checked. If more
information is necessary, gauges can be installed at
Tools Needed each pressure tap location. Locations of the pressure
taps and procedures for testing are given as follows. If
Pressure Gauge Group 1
any of the pressures are not correct, refer to
Troubleshooting For Problems and Probable Causes.
WARNING
1. Be sure the transmission control adjustments are
correct before tests are made.
To prevent personal injury, when the transmission See Inching Pedal Adjustment in Testing And
is tested, move the truck to a clear area, that is Adjusting.
level. Keep all other personnel away from the lift
truck. Use lifting equipment or a save method to 2. Install a tachometer to the engine to show engine
lift the front of the lift truck until the drive wheels speed during the test.
are off the floor. Put wood blocks or jack stands of
the correct capacity under it to hold it in this 3. Put a thermistor probe in place of the dipstick in the
position while pressure tests are performed. transmission oil reservoir.
4. Remove each of the following pressure tap plugs in

When the transmission tests are made, the the order shown and install the 0 to 2050 kPa (0 to
transmission oil must be at the correct level. The 300 psi) pressure gauge. After the pressure check
pressure given in the chart are taken with the is done, remove the gauge and install the plug
transmission oil temperature at 49 to 71C (120 to again.
160F). If the oil temperatue is lower than 49C
(120F) the oil pressure will be higher than that shown. 5. Check pump pressure with the transmission in
If the oil temperature is higher than 71C (160F), the neutral at pressure tap (6) on the valve body first. If
pressure will be lower than that shown. it is not correct, then check pump pressure at
pressure tap (1) on the bearing plate.
Raise the front of the lift truck off the floor. Put wood
blocks or jack stands of the correct capacity under it to a. If the pressure is low at pressure tap (6), but
hold it in this position while pressure tests are correct at pressure tap (1), there could be an oil
performed. line restriction or a defective inching valve.
WARNING NOTE: Pump pressure should be checked at

pressure tap (6) first because pressure tap (6) is
Before any pressure tap plugs or connections are easier to get to than pump pressure tap (1) on
removed, the engine must be stopped with the the bearing plate. If pump pressure is correct at
transmission controls in NEUTRAL. This will pressure tap (6), it will be correct at pressure tap
release hydraulic pressure in the transmission. (1) also.
b. If the pressure is low at both locations, see

For more identification of transmission problems, the Problem: Low pump pressure in Troubleshooting.
pressures that follow can be checked.
NOTE: Pump pressure is adjusted by adding or
a. Pump pressure in neutral. removing shims in the D700296 Plug. The plug
is located in the main relief valve on the valve
b. Forward clutch pressure in forward. body.
c. Reverse clutch pressure in reverse.
6. Check clutch pressure as follows:
d. Converter charge pressure in neutral.
a. Check forward clutch pressure at pressure tap
(4) with the transmission in forward. If the
e. Converter outlet or cooler inlet pressure in neutral.
pressure is not correct, see Problem: Low
forward clutch pressure in Troubleshooting.
f. Lubrication pressure in neutral.
b. Check reverse clutch pressure at pressure tap
(5) with the transmission in reverse. If the
pressure is not correct, see Problem: Low
reverse clutch pressure in Troubleshooting.

Pressure Tap Locations Transmission Control Group
Main Pressure Tap 6

Reverse Pressure Tap 5
Forward Pressure Tap 4
Converter Charge Pressure Tap 3

Converter Outlet Pressure Tap 2
Temperature Sensor
To Cooler
From Cooler
Lubrication Pressure Tap 7

7. Check lubrication pressure at pressure tap (7) with
the transmission in neutral.
Converter Stall Test
a. If lubrication pressure is low, see Problem: Low NOTE: Make sure that the transmission oil is at the
lubrication pressure in Troubleshooting. correct temperature for operation before tests are
made.
b. If lubrication pressure is high, see Problem:
High lubrication pressure in Troubleshooting. The converter stall test is a test to check engine power.
It can also be used to locate a problem in the
8. Check converter charge (inlet) pressure at pressure transmission or torque converter when the condition of
tap (3) with the transmission in neutral. the engine is known. An engine, which does not have
correct performance, will give an indication of a stall
a. If converter charge pressure is low, see speed that is not correct. If the engine performance is
Problem: Low converter charge pressure in correct and the stall speed is not correct, the problem
Troubleshooting. in the converter or transmission can be found with this
test.
b. If converter charge pressure is high, see
Problem: High converter charge pressure in NOTE: To check the engine performance, see the
Troubleshooting. respective engine module. This test checks the
maximum RPM that the engine, at full throttle, can turn
9. Check converter outlet or cooler inlet pressure at the converter with the turbine held stationary. To hold
pressure tap (2) with the transmission in neutral. the converter turbine, engage the brakes with the
transmission in FORWARD or REVERSE.
a. If the pressure is low, see Problem: Low
converter outlet or cooler inlet pressure in The drive wheels must not turn during the stall test.
Troubleshooting. Put a heavy load on the forks. Also put the truck in
position against a solid object that will not move (such
b. If the pressure is high, see Problem: High as a loading dock). When the tests are made, the
converter outlet or cooler inlet pressure in wheel brakes must be engaged with the left foot. The
Troubleshooting. accelerator pedal can be operated with the right foot.
NOTE: Do not activate the inching pedal when

pressure checks are made. Check for the pressures
WARNING
as shown in Transmission Pressure Chart in the order
that follows: Make tests in a clear level area only. There must
be one operator. Keep all other personnel away
Transmission Pressure Chart
from the lift truck. Check the operation of the
Low idle 2000 rpm
brakes before the tests are made.
Shift position - Neutral
830 to 1030 kPa 895 to 1100kPa
Main Line
(120 to 150psi) (130 to 160psi) Check the high idle setting before the stall test is made.
0 kPa 0 kPa Set the high idle to the specification, as given in the
Clutch
(0 psi) (0 psi) respective engine module.
14 to 70 kPa 240 to 345 kPa
Lubrication
(2 to 10 psi) (35 to 50 psi) NOTE: Make sure that the transmission oil is at the
70 to 140 kPa 590 to 795 kPa correct temperature for operation before tests are
Converter Chage
(10 to 20 psi) (85 to 115 psi) made.
Converter Outlet 25 to 55 kPa 250 to 400 kPa
or Cooler Inlet (4 to 8 psi) (36 to 58 psi) 1. Connect a tachometer to the engine. Start the
Shift position Forward or Reverse engine. Engage the wheel brakes with the left foot.
Main Line - -
725 to 860 kPa 725 to 965 kPa 2. Put the transmission control lever in FORWARD
Clutch
(105 to 125 psi) (105 to 140 psi) and push the accelerator pedal down completely
Lubrication - - with the right foot. Read the RPM on the
Converter Chage - - tachometer, then release the accelerator pedal.
Converter Outlet - -
or Cooler Inlet - -

The stall speed must be the same in FORWARD and
NOTICE REVERSE. If the stall speed is high in FORWARD and
REVERSE, check the following:
To make sure that the transmission oil does not get
hot, do not hold the transmission in a stall condition for a. Check for air in the oil.
more than ten seconds. After the transmission is
stalled, put the controls in NEUTRAL and run the b. Check the torque converter and the clutch
engine at 1200 to 1500 RPM to cool the oil. pressures according to transmission Pressure
Tests in Testing and Adjusting.
3. Repeat the procedure above for the REVERSE
direction. c. If clutch pressure is correct, make an inspection of
the clutch assembly for that direction for possible
4. The stall speeds for the different trucks are listed in damage to clutch components.
the charts that follow:
Engine
LIFT TRUCK STALL SPEED
Max.RPM
RPM100 RPM100
Engine Without Power With Power -
Brakes Applied Brakes Applied
A2300 1600 1500 260050
G420F(E)
1600 1500 245025
LP
G420F(E)
1600 1500 245025
Gasoline
Stall speeds that are low are an indication that the

engine performance is not correct or the one-way
cutch of the torque converter does not hold in reverse
direction. If the one-way clutch has a defect, the stall
speed will probably be more than 800 rpm low.

Maintenance
Transmission
Change
Filter
Grease Parking
Brake Lever
Oil Filler and Dipstick
Pin And Nut

of Parking Brake
Oil Drain Plug

and Suction Strainer
ATTENTION: When changing oil, replace filter and clean suction strainer.
Power Train 42 Maintenance

Drive axle

Electric Control System Test Directional Control Switch Check
1. Put the directional control lever in neutral. Remove
Tools Needed the cover from the front side of the steering support
Digital Multimeter 1 assembly.
NOTE : Refer to Schematic.
Checks on the transmission directional control

electrical circuit can be done with a Digital
Multimeter. All voltage checks are made at the
wiring harness connectors with the ignition switch
ON, DO NOT start the engine. All continuity checks
are done with the ignition switch OFF.
A beginning check of the direction control system

should be performed before testing the individual
components and wiring harness. When the direction
solenoids are energized they become magnetized. 2. Disconnect harness connector (2) from directional
By holding a metal screwdriver next to the control switch connector(1).
solenoids it can be determined whether they are
energized or not.
Turn the ignition switch ON, DO NOT start the

engine. Release the parking brake. Place the
direction control switch in forward and check the
forward solenoid for magnetism. Do the same for
the reverse direction.
z If the solenoids didnt energize begin testing the

control system with step 1.
z If the solenoids did energize, go to step 10.

3. Engage the parking brake and turn the ignition
switch ON, DO NOT start the engine. Put the
multimeter on the 20 volt range.
4. Put the (-) probe on a good ground. Put the (+)

probe on socket 1 of harness connector (2).
a. If the indication is battery volts, do Step 5.
b. If the indication is 0 volts, check the

Forward/Reverse fuse (No.3) located in the fuse
box and check the connecting wires for
continuity.

5. Turn the ignition switch OFF and put the multimeter Transmission Control Harness Check
on the 200 ohm range.
9. Disconnect the connector of Engine harness from
6. Check continuity between pins 4 and 7 of connector
the connector of transmission harness. Check the
(1) with the switch in neutral. forward and then
continuity engine harness from one end to the
reverse positions. There should be continuity in
other. Repair or replace the wiring harness if there
neutral and no continuity in forward and reverse.
is no continuity.
a. If the above checks are correct, do Step 7.
Transmission Solenoids Visual Check
b. If any of the above checks are not correct, 10. A visual check can be done to see if the solenoid
replace the directional control switch.
plungers are moving.
Remove the modulating valve assemblies from the
7. Check continuity between pins 1 and 2 of connector
transmission
(1) in forward and then neutral position. There
should be continuity in forward and no continuity in 11. Turn the ignition switch ON, DO NOT start the
neutral. While the continuity is checked in forward engine. Release the parking brake.
position, move the lever back and forth (but stay in
forward position) to see if the resistance goes up or 12. Put the directional control switch in neutral.
down. The resistance should be constant.
z Both solenoid plungers should be flush with the
a. If the above checks are correct, do step 8. solenoid.
b. If the above checks are not correct, replace the 13. Put the directional control switch in forward and
directional control switch. then reverse.
8. Check continuity between pins 1 and 3 of connector z The plunger of the solenoid that is activated should
(1) in reverse and then neutral positions. There move in approximately 3.18mm (.125 in).
should be continuity in reverse and no continuity in
neutral. While the continuity is checked in reverse 14. If the solenoid plungers do not move as explained
position, move the lever back and forth (but stay in in Steps 12 and 13, replace the defective solenoid.
reverse position) to see if the resistance goes up or
down. The resistance should be constant. 15. If the solenoid plungers are good, the modulating
valves could be stuck or there is mechanical failure
a. If the above checks are correct, do Step 9. in the transmission.
b. If any of the above checks are not correct,
replace the directional control switch.

Transmission Directional Control Schematic for D15/33S-5

Transmission Directional Control Schematic for G15/35S-5

Inching Pedal Adjustment WARNING
To prevent personal injury, when the inching pedal
To check the inching valve adjustment and operation, is adjusted, move the truck to a clear area that is
do the procedure that follows : level. Keep all other personnel away from the lift
truck. Use lifting equipment or a safe method to lift
the front of the lift truck until the drive wheels are
WARNING off the floor. Put wood blocks or jack stands of the
When this procedure is used, the lift truck must be correct capacity under it to hold it in this position
in an area clear of obstructions. There must be while the inching pedal is adjusted.
one operator with all other personnel away from
the lift truck. Check the operation of the brakes
before the test is made.
2. Raise the front of the lift truck off the floor. Put wood
blocks or jack stands of the correct capacity under it
while the inching pedal is adjusted.
1. With the engine at idle speed, put the transmission
in FORWARD.
14
1
Inching Pedal Adjustment
(1) Lug. (2) Bolt. (3) Nut.
Inching Operation Test
(1) Inching pedal.
3. Start the engine and put the transmission
FORWARD.
2. Slowly push down on inching pedal (1) until the
4. With the drive wheels turning, depress inching pedal
movement of the brake pedal causes the brake
until the drive wheels stop.
discs to make contact (small drag) with the brake
plates.
5. Now depress the brake pedal until brake contact is
felt.
3. Increase the engine speed to high idle. The truck
must not move.
6. Loosen nut (3) and adjust bolt (2) to contact lug (1)
that rotates the brake control cross shaft. Tighten
nut (3).
If the operation of the inching valve is not correct, do
the procedure that follows.
7. Check the inching valve operation again.
a. If something is wrong, inspect all points again

1. Adjust and bleed the wheel brakes as shown in the
Vehicle Systems module. one by one very carefully.

The adjusting procedure is as follows. Be sure that the
air bleeding of brake system should be done in
advance.
3. Adjust the height (C) of inching pedal and brake

pedal. (C) should be 101 1mm at the same level.
1. Adjust the length (A) from the spool to the

connection point of yoke. (A) should be 80 1mm
for D(G)15S-5 or 83 1mm for GC15S-5. Be sure
that 1mm of gap between the piston and the rod
should exist. In case of no gap, it would result in
brake drag or overheating of axle oil. In case of too
loose, the performance of service brake become
lowered.
2. Adjust the length (B) of rod by fixing the nuts at both

ends. (B) should be 143 1mm for D(G)15S-5 or
183 1mm for GC15S-5.
4. Adjust the gap (D) for engaging brake pedal by

inching pedal. (D) should be approx. 9.5mm.

82.5 mm
(E)
5. The distance (E) between the shaft center and its

mounting bracket should be 82.5mm.
6. The stroke of inching spool should be 8 1mm.
7. Before doing the truck test, inspect again all

relevant dimensions.
8. Inspect the service brake and then, inching

operation.

Adjustments on Drive axle
Pinion Intallation
1. Measure the depth from center of diff. carrier to the
seat of pinion bearing cup. (Dimension A)
4. Install cup of rear pinion bearing.
2. Measure the width of pinion bearing.(Dimension B)
5. Install spacer and shims on pinion (basic thickness

1.5mm (0.059in).
3. Check the etched value on the pinion face.

(Dimension c) *unit : mm
Calaulate the shimpack thickness according to the

following formula.
Shimpack thickness = A-(127+B+C)
Example) if A=160.50, B=32.00, C=+0.05 6. Install bearing cone.
Then, shimpack thickness
=160.50-(127+32.00+0.55)
= 1.45mm
* To minimize the measuring error, measure

three places at least and average them.
Power Train 51 Disassembly & Assembly

Differential Bearing and
Gear Clearance (Backlash)
Adjustments
7. Tap bearing cone to correct position (Rotate pinion

3-5 times)
Backlash Adjustment
(1) Bearing Cone. (2) Spiral Bevel Gear. (3) Bolt.
(4) Bearing Cup. (5) Bearing Cap. (6) Locknut. (7) Plate.
1. Install bearing cones (1) on the differential case.
2. Put spiral bevel gear (2) on the differential caseand

tighten eight bolts (3) to a torque of 1105 Nm
8. Assemble yoke and nut and tighten flange nut to (825 Ibft). Put bearing cups (4) on bearing cones
180 15 Nm (13311 lbft) (1).
9. Measure the rolling torque. The value of rolling 3. Put the carrier assembly in position in the housing
torque should be 1.5~2.0 Nm (1.1~1.5 lbft) assembly. Install bearing caps (5) and four bolts.
Tighten bolts to a torque 15015 Nm (11312
10. If the rolling torque exceeds 2 Nm, add one shim Ibft.)
and if it is lower than 1.5 Nm, subtract one shim
4. Install locknuts (6). Use tooling (A) to check gear
11. When the adjustment is correct, disassemble the clearance (backlash) between spiral bevel gear (2)
nut and the yoke. and pinion. Adjust locknuts (6) until the clearance
Assemble the oil seal and yoke again and then is 0.18 to 0.23 mm (.007 to .009 in.).
tighten the nut to 180 15 Nm (13311 lbft) Adjust the clearance by turning one locknut (6) in
and the other locknut out an equal amount.

5. Tighten locknuts (8) eually to preload the
differential case beaings. Proper bearing preload
of the gear is 3.1 to 4.8 Nm (27 to 42 Ibin)
6. Measure backlash again. After backlash and

preload are correct, install a plate (7) into each
locknut to hold them in position.
Short Heel Contact Setting
c. If spiral pinion shaft is too far away from spiral

bevel gear, short toe contact will be the result as
shown. The teeth of pinion will be in contact with
toe ends of convex faces (part that makes a
curve toward the outside), and top edge of heel
Correct Tooth Contact Setting. end of concave faces (pat that makes a curve
towrd the inside). To correct this, add shims
7. Check the tooth contact pattern as follow. Check under pinion bearing cone. After this is done,
the tooth contact setting between the spiral bevel check gear clearance (backlash) and tooth
gear and pinion after the gear clearance (backlash) contact again.
and bearing preload adjustments have been made
as follows. d. If spiral pinion shaft is too near to center of spiral
bevel gear, short heel contact will be the result
a. Put a small amount of Prussian blue, red lead or as shown. The teeth of pinion will be in contact
paint on the spiral bevel gear teeth. Turn the with the toe ends of concave faces (part that
pinion in both directions and check the marks makes a curve toward the inside) and the heel
made on the hypoid gearteeth. ends of convex faces (part that makes a curve
toward the/outside). To correct this, remove
shims from under pinion bearing cone. After this
is done, check gear clearnce (backlash) and
tooth contact again.
NOTE : Several adjustments of both pinion and bevel

gear can be needed before correct tooth contact and
gear clearance (backlash) is made. Always remember
that a change the tooth contact. Therefore, be sure
gear clearance (backlah) is in correct adjustment
before tooth contact is checked.
e. After gear clearnce (backlash) and tooth contact

Short Toe Contact Setting are correct, remove extra Prussian blue, red lead
or paint from spiral bevel gear and pinion.
b. With no load, corect tooth contact setting will be

as shown. The area of contact starts near the
toe of the fear and goes 50 to 70% up the length
of the tooth, with this setting, when a load is put
on the gear, the load will be over the correct
area of the teeth.

SB4248E00
Apr. 2007
Power Train
Disassembly & Assembly
D15S-5, D18S-5, D20SC-5

G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional
safety precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where
hazards exist. WARNING labels have also been put on the product to provide instructions and to identify
specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other
persons. Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
1
2
Index
Transmission.......................................... 5
Disassembly of....................................... 5
Transmission Housing................................................ 5
Disassembly of Counter Shaft.................................... 9
Assembly of Counter Shaft....................................... 11
Disassembly of Input Shaft....................................... 14
Assembly of Input Shaft ........................................... 16
Disassembly of Output Shaft.................................... 19
Assembly of Output Shaft......................................... 19
Assembly of Transmission Housing ......................... 20
Differential ................................................................ 28
Drive Axle Shoe..................................................... 31
Drive Axle ODB ..................................................... 35
WARNING
Disconnect batteries before performance of
any service work.
Power Train 3 Index

Transmission
Disassembly of
Transmission Housing
4. To remove the torque converter housing, loosen

the upper housing screws. (Hexagonal socket
17 mm)
1. Mount the transmission on a suitable jig.
5. Loosen the lower housing screws.

(Hexagonal socket 17 mm)
4
2. Loosen the screw (1) with socket head wrench
8mm.
2
6. Install 2 jackbolts (M10, 30mm (1.2in)) in
locations (4) until they stop against bearing plate,
alternately tighten bolts to separate the torque
converter housing from the transmission.
3. Remove the Gasket (2) and oil dipstick (3).

7. To remove strainer, loosen the screw with an 10. Remove the remaining screws between the
allen head wrench. T/M bearing plate and the torque converter
housing. (Hexagonal socket 17 mm).
8. Lift the torque converter housing from the T/M

bearing plate. 11. Secure the eyebolts M10 to remove the T/M
bearing plate.
9. Secure the eyebolts M10 to remove the torque

converter housing. 12. Loosen the jam nut (1) to loosen the hand
brake adjustment with the ring spanner (22
mm) and the threaded bolt (2) with the open
ended spanner (10 mm).

1
13. Turn the adjustment bolt until the strut (1) can 16. Remove the output shaft.
be removed from the brake band.
14. Remove the brake struts from the eccentric 17. Remove the input shaft with forward clutch.
shaft.
18. Use the eyebolt M18 to lift the reverse shaft.

15. Lower the loosened brake band into the
housing. Remove after dismounting the shaft

19. Remove the lube pump. (Hexagonal socket 13
mm)
20. Lift the lube pump with 2 screw drivers.

Disassembly of Counter Shaft
1
4. Remove the snap ring (1) from the support disk

with the circlip pliers.
1. Disassemble the shaft with the 2-leg puller.
5. Lift the multiple disk body.

2. Remove the safety ball from the seat with a screw
driver.
2
6. Remove the snap ring (2) while pressing the return

spring on the spring retainer with a hydraulic press.
3. Remove the double needle bearing. Slowly relieve the tension of the spring. (Tool Ref.
No 1)

1
2
3
7. Remove the parts - snap ring (1), spring 10. ATTENTION: Open the R-rings before lifting!
retainer(2) and return spring (3)
11. Remove the bearing from the shaft with a 2-leg

8. Lift the piston by using compressed air in the lower puller.
bore.
9. Remove both R-rings before lifting the bearing (4).

Assembly of Counter Shaft
4. Inner and outer piston rings must be lubricated with

transmission oil.
1. Heat bearing (1) to a temperature of 120C (248F)

and install it on the shaft.
5. Insert the piston.
ATTENTION: Canting the piston can cause damage.

2. After the bearing has cooled, the inner bearing ring
must be tapped into position.
5
2
4
6. Install return spring (3), spring retainer (4) and

snap ring (5).
3. Install both R-rings (2) in their grooves.

1
7. Install snap ring (1) by pressing the return spring. 10. Align the teeth of the clutch disks.
(Tool Ref. No 1)
11. Install the needle bearing.
8. Elements of the multiple disk body: (1) Bend plate

(2) pressure disk, (3) inner separater disk, (4) outer
clutch disks, (5) support disk
12. Put the gear wheel on the shaft.
9. Put the multiple disk body on the gear and install

the snap ring.

13. Lubricate the needle bearing before installing 16. Heat bearing (4) to a temperature of 120C
the washer. (248F) and install it on the shaft.
14. After installing the washer (1), put the ball (2) in 17. After cooling the bearing, the inner bearing ring
he hole. must be tapped to set bearing.
3
5
15. Install the steel-washer (3). 18. Install the R-ring (5).
ATTENTION: The ball must engage the notch!

Disassembly of Input Shaft
4. Remove the ball from the seat with a magnet.
1. Disassemble the shaft with a 2-leg puller.

Remove R-ring before lifting the bearing.
2
5
5. Remove the double needle bearing (4) and the

1
brass washer (5).
2. After lifting the gear wheel (1), remove bearing

6
(2) and washer (3).
6. Remove the snap ring (6) from the support disk

with the circlip pliers and remove the disks.
3. Lift the gear wheel.

1
7. Remove the snap ring (1) while pressing the 10. ATTENTION : Open the R-rings before lifting.
return spring on the spring retainer with a
hydraulic press. Slowly relieve the tension of the
spring. (Tool Ref. No 1)
11. Lift the back bearing.
8. Lift the piston by using compressed air in a

lower bore, after removing the spring retainer
and return spring.
9. Remove both R-rings before lifting the bearing.

Assembly of Input Shaft
1
4. Insert the piston.
2
ATTENTION: Canting the piston can cause

1. Ring (1) and inner needle bearing (2). damage.
2. Drive the ring and bearing with an puncher 5. Install snap ring by pressing the return spring.
(25mm, length 400 mm) ( 1.0 in X 15.75 in (Tool Ref. No 1)
length) into the shaft.
6. Put the multiple disk body on the gear.

3. Inner and outer piston rings must be lubricated
with the transmission oil.

1
7. Mount the snap ring (1) on the support disk 10. Align the teeth of the clutch disks and put gear
with the circlip pliers. wheel on the shaft.
8. Lubricate the support disk area. 11. Lubricate the washer.
9. Install the washer and needle bearings. 12. Put the ball in the hole of the shaft and the
notch in the washer.
ATTENTION: The ball must engage the notch!

1
13. Heat bearing (1) to a temperature of 120C 16. Install the heated back bearing (120C, 248C)
(248F) and install it on the shaft. on the shaft.
14. Install the bearing on the shaft. 17. After mounting and cooling, the inner bearing
ring must be tapped into position.
15. After the bearing has cooled, the inner bearing

ring must be tapped into position. Install the R- 18. Mount and hook the R-ring (2).
ring.

Disassembly of Output Shaft Assembly of Output Shaft
1. ATTENTION: Set the puller on the inner bearing 1. Heat bearing (1) to a temperature of 120C
ring! (248F) and install it on the shaft.
2. Remove the shaft with suitable puller device. 2. After cooling, the inner bearing ring must be
This can be done from either end of shaft. tapped into position.

Assembly of Transmission
Housing
4. Mount the brake band.
1. Mount the parking brake adjustment bolt.

1
5. Mount the snap ring of the park brake lever (1).
2. Eccentric shaft for parking brake.

Check the free-movement.
2
6. Oil Seal of output gear wheel (2) must be set

flush with the housing surface.
3. Check the bearing parts for damages.

Be sure all surfaces are clean.

7. Install the counter shaft. 10. Assemble the struts for the parking brake band.
Adjust after assembly.
11. Install each bearing cup on the counter shaft

assembly and the output shaft assembly.
8. Install the lnput shaft. Check for free rotation.
12. Measure the height from the surface of

transmission housing to the top of the each
bearing cup (A or A dimension)
* To minimize the measuring error measure

at least three places and average them.
13. Measure the depth from the bearing plate

surface to the shoulder of the hole for the
9. Install output shaft last. Check for free rotation. bearing of each shaft, counter and output (B or
B dimension)
* For the output shaft, measurement should

be done with the cover installed
14. Caculate the required shimpack thickness (Z)

with the following formula.
Z = B-A+(0.02 mm) or (0.001 in)

For counter shaft
= B-A-C + (0.05 mm) or (0.002 in)
(C : Cover thickness)
For output shaft

15. Insert shims according to the calculated
thickness above behind the bearing cup of each
shaft. And assemble bearing cups into the
bearing plate.
3 19. Tap the bearing plate into position over dowel

pins and tighten all bearing plate mounting bolts.
4
16. Valves in the bearing plate consist of: ball(1),

spring(2), seal ring (3) and plug (4). Tighten the
plug with allen head wrench 8 mm. (2 places)
20. Using a punch, tap bearing cone down against

input shaft. Install bearing cup against cone in
the same manner.
ATTENTION: Check for free rotation.
17. The housing areas must be cleaned and

degreased. Apply sealing compound (LOCTITE
5127) to coat on one side.
21. Measure the depth of the bearing cup below

bearing plate surface at three places. Average
this dimension and record as Dim. A
18. Lower the bearing plate.

22. Measure the height of pump pilot surface 25. Assemble the T/C pump with screws M8,
above mounting surface at three places. torque 30 2 Nm (22.1 1.5 lbft)
Average this dimention and record as Dim. B. (Hexagonal socket 13 mm).
23. Select shim thickness by subtracting B Dim. 26.Tap the outer front bearing ring back.
from A Dim. Shim thickness = A-B-0.05 mm
(0.002 in)
27. Check the shaft end play by moving the shaft

up and down. Dial indicator should not exceed
24. The sealing area of the T/C pump must be 0.05mm (0.002 in)
cleaned and degreased. Apply sealing
compound (LOCTITE 5127) to pump flange.

28. The housing areas must be cleaned and 31. Install the housing screws with a torque of 55
degreased. Apply sealing compound (LOCTITE 10 Nm (41 7 lbft).
5127) on one side of bearing plate.
29. Before joining torque converter housing to 32. Install the oil filter screen. Tighten the plug with
bearing plate, apply lubricant to T/C pump ring. an allen head wrench.
30. Install the torque converter housing. 33. Install the torque converter.

34. Mount the valve block.
ATTENTION: Tighten the screws from inner to

outer with the tightening torque of 41
Nm (30.2 lbft).

Disassembly Assembly of
Valve Body
3. Dismount / mount the inching valve.
4. Dismount / mount the selection valve.
1. Dismount/mount the solenoid valves of the forward

and reverse clutch.
5. Dismount / mount the modulation valve.
Dismount/ mount the main.
2. Dismount / mount the main valve.

6. Adjust the main pressure with the shims in the
screw of main valve

Differential
Disassembly
1. Remove the hex bolt (1) and Backing Pate(2) from

differential cap(3)
3. Loosen the bolts (5) and disassemble differential

assembly completely.
4. If needed, loosen the bolts (6) and disassemble ring

gear (7).
2. Loosen adjusting screw with special tool (Ref.No.:1)

on both side. Mark differential caps (2) and housing
for the purpose of reassembly.
Loosen the bolts (3) and remove the differential
assembly (4).

Assembly
The assembly procedure is the reverse order of
removal, but requires additional care as note below.
1. Install differential assembly into housing.
3. Install adjusting screw (2). Adjust gear clearance

(backlash) by turning one adjusting screw in and the
other screw out an equal amount.
Rotate the axle drive through 100 and check the
tooth backlash at several points of the ring ger using
a dial gauge. The tooth backlash should be 0.18 to
2. Tighten the bolts (1) to a torque of 147 to 167 Nm 0.23mm (0.007 to 0.009 in).
(108.8 to 123.6 Ibft)
4. Adjusting tooth contact
a. Coat the tooth face of the bevel pinion lightly with

red lead (minimum).
b. Rotate the bevel gear forward and backward.
c. Inspect the pattern left on the teeth. (Shown in

diagram below.)
Correct tooth contact (No load)

B. Adjust the backlash again.
b. Reduce the shim thickness at the pinion shaft to

move the pinion in direction A. The move the
bevel gear closer to the pinion gear in direction B.
Adjust the backlash again.
Tooth contact should be checked with no load on the

bevel pinion. The tooth contact pattern should cover
about 40-75% of the length of the tooth, with weak
contact at both ends.
d. If the result of the inspection shows that the

correct tooth contact is not being obtained, adjust c. Reduce the shim thickness at the pinion shaft to
again as follows. Adjust shims at pinion shaft move the pinion in direction A. The move the
Adjust backlash of bevel gear. bevel gear closer to the pinion gear in direction B.
The tooth contact should be correct on both then Adjust the backlash again.
FORWARD and REVERSE side of the teeth.
However, if it is impossible to adjust both sides
correctly, the FORWARD side must be correct.
5. Correct tooth contact
d. Increase the shim thickness at the pinion shaft to

move the pinion in direction A. Then move the
bevel gear away from the pinion gear in direction
B. Adjust the backlash again.
a. Increase the shim thickness at the pinion shaft to

move the pinion in direction A. The move the
bevel gear away from the pinion gear in direction

Drive Axle Shoe
Disassembly
1. Drain the drive axle oil.
1
6. Secure adjusting (2) screw with backing plate (1)
2. Loosen the bolts (1).
3. Remove the drive shaft (2).
4. Loosen the bolts from the lock nut (3).

drum.
5. Loosen lock nut and remove the plate (4). (Tool Ref.
No.:2) 9. Loosen the bolts (8) and remove brake assembly
(9).
10
0
6. Remove bearing cone (5) from the hub.

10. Loosen the bolts (10) and remove the drive axle
housing by using lifting device.
7. Remove the hub and drum (6) from the drive axle.
8. Remove bearing cone and cup from the hub and

Assembly
removal, but requires additional care as noted below.
4. Cork the bolts.
1. Install bearing cup and oil seal.
5. Fill 50~70% of space between bearings with Lithium

grease.
2. Install the break drum and wheel hub.
6. Install brake assembly. Tighten the bolts to a torque

of 167 to 205 Nm (124 to 151 lbft)
3. Install the wheel bolt and tighten the nuts to a

torque of 319 to 427 Nm (235 to 315 lbft)

7. Coat rib of seal with lithuim grease. Install drum 9. Lock the unt with bolts. Tightening torque is 7.9 to
completely. 11.7 Nm (5.8 to 8.6 lbft).
NOTE : Remove dirt or oil in the inside surface of the

brake drum completely.
10. Coat mating surface of hub with liquid gasket.
8. After installing plate and lock unt, check bearing

rolling torque. The torque value is 11 to 14 Nm (8.1
to 10.4 lbft)
11. Install the drive shaft and tighten the bolts to a

torque of 108 to 127 Nm (80 to 94 lbft)
12. Fill the drive axle housing with oil.
NOTE : All bolts should be coated with loctite #271

thread lock when installing.

Drive Axle ODB
Disassembly 18
1. Drain the drive axle oil.

2
5. Remove plate (18) from spindle sub assembly (2).
19
2. Loosen the bolts (1). 2
6. Remove plate sub assembly (19) from spindle sub

assembly (2).
23
20
3. Remove the spindle sub assembly (2) by using bolt

(3) (M12xP1.25, Length 40mm Min.) 21
22
7. Remove snap ring (20) from adapter (23). Remove

four discs (21) and three plates (22) from adapter
(23).
4. Remove the piston (4) by using special tool T185

(5). Remove two square seals from inside of axle
housing.
8. Remove snap ring (20) from adapter (23).

Assembly
removal, but requires additional care as noted below. 19
20
2
23
3. Install adapter sub assembly and plate (19) into

spindle (2). Please note that there are two kinds of
plates which have different thicknesses of 2.5mm
and 2.8mm. Start with plate of 2.8mm thickness.
1. Assemble snap ring (20) and adapter (23).
23
20
22
21
4. Measure the depth of the plate below spindle

surface at three places. Average these dimensions
2. Install four discs (21) and three plates (22) and record as Dim X The nominal value of X is
alternately. Start and end with disc. Align the 1.0mm.
lubrication slots among discs. Install snap ring (20).

7. Apply continuous bead of Three Bond Liquid Gasket
TB #1215 on the spindle surface.
8. Apply Loctite No.271 Thread Lock to threads of

spindle bolts (1).
Assemble bolts (1) with tightening torque of 100.5

4
12.3NM (74.2 9.1 lbft).
4 NOTE : Among spindle bolts, one shorter bolt should

be assembled near the flexible rod (9).
NOTE : After assembly of all spindle bolts, hub should

be rotated freely by hand.
5. Assembly two square seals (24)(25) into axle

housing. Apply drive axle oil of grease on the area
of square seals and on the outer surface of piston
(4).
6. Assemble piston (4) into axle housing by using

special tool T186 (26).
NOTE : Be careful not to damage square seals during

assembly.

SB4244E00
Apr. 2007
Vehicle System
Specification
System Operation
Testing & Adjusting
D15S-5, D18S-5, D20SC-5

G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
WARNING
publication.
1
Index Master Cylinder.................................................38
Shoe Type Brakes.............................................39
Parking Brake ...................................................39
Specification ............................................ 5
Control Valve ......................................................... 5 Testing and Adjusting ...........................41

Hydraulic Pump ..................................................... 6
Sideshift Cylinder................................................... 6 Troubleshooting....................................................41
Lift Cylinders.......................................................... 7 Visual Checks ...................................................41
Standard ............................................................ 7 Performance Tests............................................41
Full Free Triple and Full Free Lift Primary ........... 7 Hydraulic System and Mast ...............................42
Full Free Lift Secondary...................................... 8 Steering System................................................47
Full Free Triple Lift Secondary............................ 8 Brake System....................................................48
Tilt Cylinder............................................................ 9 Lift Cylinders Air Removal .................................50
Steering Wheel .................................................... 10 Hydraulic System..................................................51
Priority Valve ....................................................... 10 Relief Valve Pressure Check .............................51
Steering Unit........................................................ 11 Lift Relief Valve Check and Adjusment ..............52
Forward and Reverse Control Group.................... 12 Tilt and Auxiliary Relief Valve Check and
Brake SHOE ..................................................... 12 Adjusment.........................................................53
Delayed Engine Shutdown System ...................... 13 Steering System ...................................................53
Operation ......................................................... 13 Steer Wheel Bearing Adjustment -Pneumatic ....53
Diagram of Delayed Engine Shutdown System. 14 Steer Axle Stop Adjustment-Pneumatic .............54
Trouble shooting of Delayed Engine Shutdown Steer Wheel Bearing Adjustment-Cushion .........54
System............................................................. 15 Steer Axle Stop Adjustment-Cushion.................55
Diagnostic Fault Codes .................................... 15 Steering System Air Removal............................55
Delayed Engine Shutdown System Schematic.. 16 Steering System Pressure Check ......................56
OSS (Operator Sensing System).......................... 20 Brake System .......................................................58
Operation ......................................................... 20 Brake System Air Removal................................58
Symbols of OSS............................................... 20 Pedal Adjustment for Brake & Inching................58
Operator Sensing System Schematic ............... 21 Parking Brake Test............................................60
Trouble shooting of Operator Sensing System.. 22 Parking Brake Adjustment .................................60
Hydraulic System Operation................. 24
Hydraulic Schematic......................................... 24
Control Valve ....................................................... 26
External View ................................................... 26
Circuit Schematic ............................................. 26
Inlet Section ..................................................... 27
Lift Section ....................................................... 28
Tilt Section ....................................................... 30
Auxiliary Section............................................... 31
Outlet Section................................................... 32
Relief Valve...................................................... 33
Hydraulic Steering system.................................... 34
Hydraulic Schematic......................................... 34
Steering Cylinder.............................................. 35
Steering Unit .................................................... 36
Brake System ...................................................... 38
Vehicle Systems 3 Index

Specification
Control Valve
CONTROL VALVE
RELIEF PRESSURE
MODEL MAST Main Relief Pressure-lift Auxiliary Pressure-tilt,attachment
psi kPa psi kPa
D15S,G(C)15S-5 STD/FF/FFT 2,55035 17,600250
D18S,G(C)18S-5 STD/FF/FFT 2,88035 19,860250 2,04050 14,000350
D20SC,G20SC-5 STD/FF/FFT 3,12535 21,550250
(1) Torque for nuts that hold control valve sections together ................................ 24 to 28 Nm (18 to 21 lbft)
(2) Torque for nuts that hold control valve sections together ................................ 24 to 28 Nm (18 to 21 lbft)
(3) Torque for main and auxiliary relief valve ....................................................... 44 to 49 Nm (32 to 36 lbft)
(4) Torque for cap screw that hold spool cap .........................................................10 to 15 Nm (7 to 11 lbft)
Vehicle Systems 5 Specifications

Hydraulic Pump Sideshift Cylinder
Rotation is counterclockwise when seen from drive (1) Torque for head ...............................27035 Nm
end. (20025 lbft)
Type of pump : Gear
For test, use SAE 10W oil at 65C (150F) (2) Torque for piston nut ........................26025 Nm
Pump output....................19.5 cm/rev (1.19 in/rev) (19020 lbft)

Lift Cylinders Full Free Triple and Full Free Lift
Primary
Standard
(1) Put Pipe Sealant on the last three threads of

(1) Put Pipe Sealant on the last three threads of bearing.
bleed screw and tighten to a torque of ... 61Nm
(539 lbin) (2) Put Pipe Sealant of the last three threads of
bleed screw (not shown) and tighten to a torque
NOTE : All seals to be lubricated with hydraulic oil. of ....................................... 61 Nm (539 lbin)
NOTE : All seals to be lubricated with hydraulic oil.

Full Free Lift Secondary Full Free Triple Lift Secondary
(1) Put Pipe Sealant on the last three threads of (1) Put Pipe Sealant on the last three thread of
bearing. bearing.
(2) Put Pipe Sealant on the last three threads of (2) Put Pipe Sealant on the last three thread of bleed
bleed screw and tighten to a torque of ................ screw and tighten to a torque of .........................
........................................ 61 Nm (539 lbin) ........................................ 61 Nm (539 lbin)
NOTE : All seals to be lubricated with hydraulic oil. NOTE : All seals to be lubricated with hydraulic oil.

Tilt Cylinder
Forward Backward Closed Length Stroke

A252107 6 10 392.5 mm 82 mm
A252109 8 10 392.5 mm 91.5 mm
(1) Adjust pivot eye to dimension(Y) with cylinder

open (extended)
(2) Torque for bolt ............ 9515 Nm (7010 lbft)
(3) With mast at tilt back position shim as required to

permit no gap between eye (1) and spacer.
Torque for head ...... 27035 Nm (20025 lbft)
(4) Torque for jam nut ... 26025 Nm(19020 lbft)

Steering Wheel Priority Valve
(1) Torque for steering wheel nut.........75 to 88 Nm Flow ....................................................Load sensing

(55 to 65 lbin)
Relief valve (no adjustment) opens at:
............................... 8,285350 kPa (1,20050 psi)

Steering Unit
(1) Pin (1) in the body must be aligned with internal

pump gear (gerotor) (2) and drive (3) as shown.
(4) Tighten bolts in sequence shown.
Tighten to a first torque of ............14.12.8 Nm

(12525 lbin)
Tighten to a final torque of............28.22.8 Nm

(25025 lbin)
(5) Torque for plug ...................11.3 Nm (100 lbin)

Plug to be flush (even) with or below mounting
surface.

Forward and Reverse Control Brake SHOE
Group
(1) Torque for wheel cylinder bolts (1) ... 8 to 12 Nm

(6 to 9 lbin)
(1) Torque for bolts (four) ..................3.4 to 3.9 Nm

(30 to 34.5 lbin)
(2) Torque for bolts (two)...................2.8 to 3.4 Nm

(25 to 30 lbin)

Delayed Engine Shutdown System
Operation
The delayed engine shutdown system will shut the
engine down if no proper action is taken by the
operator. This system makes use of the engine
oil pressure switch, transmission oil temperature
switch and water (coolant) temperature sensor to
get
the required truck condition.
If an engine damaging condition arises, such as too

much oil pressure drop, this system will alert the
operator by warning MIL Lamp.
If the operator ignores this warning and does not

shutdown the engine within thirty seconds, this
delayed engine shutdown system will interrupt the
fuel supply to the engine, thereby saving the engine
from the critical damage.
1. Low engine oil pressure

The warning MIL lamp will turn on when the oil
pressure drops to approximately 28KPa
(4 psi) and the delayed engine shutdown
System will interrupt the fuel supply to the engine
after thirty seconds.
2. Hot engine coolant

The warning MIL lamp will turn on when the
coolant temperature reaches approximately
115(239) and the delayed engine
shutdown system will interrupt the fuel supply to the
engine after thirty seconds.
3. Hot transmission oil

The warning MIL lamp will turn on
when the transmission oil temperature
reaches approximately 125(257) and the
delayed engine shutdown system will
interrupt the fuel supply to the engine after thirty
seconds.

Diagram of Delayed Engine Shutdown System
G420F(E) / G424F(E) ENGINE LP TRUCK
G420F(E) / G424F(E) ENGINE GAS & DF TRUCK

Trouble shooting of Delayed Engine Shutdown System
When the ignition key is turned on, the MIL Lamp will illuminate and remain on until the engine is started.
Once the engine is started, the MIL Lamp will go out unless one or more fault conditions are present. If a
detected fault condition exists, the fault or faults will be stored in the memory of the small engine control
module (SECM).
Once an active fault occurs, the MIL Lamp will illuminate and remain ON. This signals the operator that a fault
has been detected by the SECM. If the MIL Lamp turns on while operating the lift truck, park the lift truck
and stop the engine, and then check the follows.
Delayed Engine shutdown : Some faults, such as low oil pressure, will cause the MIL Lamp to
illuminate for 30 seconds and then shut down the engine
CODE
FAULT DESCRIPTION
(M104 CODE)
Engine Coolant Temperature Sensor Input is High.
ECT Over Range
Normally set if coolant sensor wire has been disconnected or 151(15)
High
circuit has opened to the SECM
ECT Over Engine Coolant Temperature is High.
Temperature The sensor has measured an excessive coolant temperature 161(15)
Fault typically due to the engine overheating
Low Oil Pressure
Low engine oil pressure 521(52)
Fault
Transmission Oil
Excessive transmission oil temperature 933
Temperature
Diagnostic Fault Codes
DFC PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK

151 ECT Range High (1) Turn on MIL Check if ECT sensor connector is
(15) Coolant sensor (2) Delayed Engine disconnected or for an open ECT
disconnected Shutdown circuit SECM (Signal) Pin B15 to ECT
or open circuit (3) Check Engine Light Pin 3 SECM (Sensor GND) Pin B1 to
ECT Pin 1
161 ECT Over Temperature (1) Turn on MIL Check coolant system for radiator
(15) Fault (2) Delayed Engine blockage, proper coolant level and for
Engine coolant temperature Shutdown leaks in the system.
is high. (3) Check Engine Light Possible ECT short to GND, check ECT
The sensor has measured signal wiring SECM (Signal) Pin B15 to
an excessive coolant ECT pin 3 SECM (Sensor GND) pin B1
temperature typically due to to ECT pin 1 SECM (System GND) pin
the engine overheating. A16, B 17 Check regulator for coolant
leaks
521 Low Oil Pressure Fault (1) Turn on MIL Check engine oil level
(52) Low engine oil pressure (2) Delayed Engine Check electrical connection to the oil
Shutdown pressure switch SECM Pin B9 to Oil
(3) Check Engine Light Pressure Switch
933 Trans Oil Temperature (1) Turn on MIL Refer to drive train manufacturers
Excessive Transmission oil (2) Delayed Engine Transmission service procedures
temperature Shutdown

Delayed Engine Shutdown System Schematic
DELAYED ENGINE SHUTDOWN : G420F(E) - LP

ENG GND
NEAR COILS
E/G OIL PR
E/G CHECK
DELAYED ENGINE SHUTDOWN : G420F(E) - GAS&DF

DELAYED ENGINE SHUTDOWN : G424F(E) - LP

DELAYED ENGINE SHUTDOWN : G424F(E) - GAS&DF
DELAYED ENGINE SHUTDOWN : G424F(E) GAS&DF

OSS (Operator Sensing System)
Operation 4. Water separator (sediment) warning only diesel
Water separator lamp indicates when the engine
Operator Sensing System is operated by seat switch is running and there is much water in the fuel filter
built into the seat. If the operator leaves the seat exceeding 100cc.
without applying the parking brake within three If the lamp turns on with the engine running, park
seconds after leaving the seat, Operator Sensing the lift truck and stop the engine. Drain some fuel
System will automatically disengage the (and any water) until clean fuel flows from the
transmission and interrupt the operation of mast. filter which approximately takes 5 to 6 seconds.
In addition, the warning lamp and buzzer are
operated in order to prevent the unintentional 5. Mast interlock
movement. Alarm warning lights when operator leaves the
seat without applying parking brake and then,
Symbols of OSS operation of mast is automatically interrupted .
6. Air cleaner warning

Alarm warning lights if the dust is chock full at
the air clean.
1. Parking alarm
Alarm warning lights when the operator leaves
the seat without applying parking brake.
2. Seat belt indicator

Seat belt warning lights for 10 seconds reminds
the operator to fasten seat belt.
The truck is normally operated although warning
lamp is turned on.
3. Neutral shift feature

Transmission is automatically shifted to the
neutral when the operator leaves the seat with
the engine running and the direction lever in
forward or reverse. To restore the lift truck, return
the directional lever to the neutral position and
then, reselect a direction of travel (either forward
or reverse). The transmission will then re-engage.

Specifications
SEAT SWITCH
SEAT BELT SWITCH
AIR CLEANER SWITCH
PARKING
BRAKE SW
21
INDICATOR AS
Operator Sensing System Schematic
PILOT BUZZER RELAY FUSE FUSE

REV FWD CREEPING SPEED
SOL_VALVE_LIFT LOCK
CIRCUIT BREAKER
SOL_VALVE_UNLOAD
LP PR SW DIR SWITCH IGNITION SW
CONTROLLER - VCS
BATTERY
SEDIMENT SW
Vehicle Systems
Trouble shooting of Operator Sensing System
CONDITION PROBABLE FAULT CORRECTIVE ACTION

1. Buzzer warning 1. Seat switch open 1. Check seat switch
2. Parking brake 2. Parking brake switch open 2. Check parking brake switch
light
3. Controller defect 3. Check continuity of wire from seat switch to
controller (SW2)
4. Wiring defect
4. Measure the voltage between controller(SW2)
and GND : 12V is no problem
1. Seat belt warning 1. Seat switch open 1. Check seat switch
light
2. Controller defect 2. Check continuity of wire from seat belt switch to
controller (SW3)
3. Wiring defect
3. Measure the voltage between controller(SW3)
1. Buzzer warning 1. Seat switch open 1. Check seat switch
2. Neutral light 2. Relay (REV/FWD/Creep 2. Check relay (REV/FWD/Creep speed)

speed) defect
3. No drive 3. Check FWD/REV Solenoid
operation 3. Directional switch defect
4. Check continuity of wire from relay creeping
4. Wiring defect speed (85) to controller (C/RELAY)
5. FWD/REV Solenoid defect 5. Check continuity of wire from relay-REV(86)or Dir

SW(3) to controller (REW SW)
6. Controller defect
6. Check continuity of wire from relay-FWD(86)or
Dir SW(2) to controller (FWD SW)
1. Buzzer warning 1. Sediment switch short 1. Check sediment switch
2. Water separator 2. Wiring defect 2. Check continuity of wire from sediment switch to
warning light controller (AUX2)
3. Controller defect
3. Measure the voltage between controller(AUX2)

CONDITION PROBABLE FAULT CORRECTIVE ACTION
1. Buzzer 1. Seat switch open 1. Check seat switch
warning
2. Fift lock / Unload 2. Check Lift lock/Unload Solenoid
2. Mast interrupt solenoid defect
light 3. Check continuity of wire from solenoid-lift lock(2) or
3. Wiring defect solenoid-unload(2) to controller (ISO3691 VALVE)
3. No mast
operation 4. Controller defect 4. Check continuity of wire from solenoid-lift lock(1) or
solenoid-unload(1) to controller (IGN)
5. Measure the voltage between controller(IGN) and

controller(ISO3691 VALVE) : 12V is no problem
1. Air cleaner 1. Air cleaner switch 1. Check air cleaner switch
light short
2. Check continuity of wire from air cleaner switch to air
2. Wiring defect cleaner lamp

Hydraulic System Operation
Hydraulic Schematic
Basic Hydraulic Actuator System Schematic

(1) lift cylinder secondary, standard (2) flow protector-primary (3) lift cylinder-primary (4) flow protector-secondary, standard
(5) side shift cylinder (6) control valve (7) solenoid valve for lift lock (8) tilt cylinder (9) relief valve-auxiliary
(10) solenoid valve for unload (11) relief valve-main (12) hydraulic pump (13) hydraulic tank (14) filter-return (15) priority valve
(16) filter-suction (17) hydraulic line (18) engine-P.T.O

The hydraulic system has a hydraulic tank (13) The relief valve-main (11) releases the excessive
which holds a fluid for a hydraulic pump (12). A pressure to the hydraulic tank when the pressure in
hydraulic pump sends a pressure fluid to the the lift circuit goes higher than a setting pressure
hydraulic actuator system and hydraulic steering shown a CONTROL VALVE SECTION of
system. A pump fluid flows from hydraulic pump (12) SPECIFICATION. The relief valve-auxiliary (9)
to priority valve (15), where a fluid divides. Part of release the excessive pressure to the hydraulic tank
fluid goes to the hydraulic steering system. The when the pressure in tilt circuit and auxiliary circuit
remaining fluid goes to the control valve (6) through goes higher than a setting pressure shown a
hydraulic line (17).. CONTROL VALVE SECTION of SPECIFICATION.
The levers of control valve move spools in control The speed at which lift cylinders are lowered is
valve. The movement of spool makes a fluid for a lift controlled by the flow regulator valve integrated into
cylinder and/or tilt cylinder (8) and/or side shift lift spool.
cylinder (5).
The return hydraulic fluid from each cylinder flows Flow protector (2) & (4) integrated to lift cylinder acts
through control valve, hydraulic line (17) and a filter- as a fuse valve if the line between control valve (flow
return (14), and back to a hydraulic tank.. regulator) and flow protector is broken when the lift
cylinder is raised or lowered. This prevents the
There is a safety unload function on the first block of sudden fall of mast or carriage if a hydraulic line is
control valve that any function doesnt work even broken.
though any lever is shifted when operator leaves a
seat for more than 3 seconds. The solenoid valve The tilt backward, forward speed, side shift cylinder
(10) for unload function is electrically connected to speed are controlled by adjustable flow control kit in
the electric on-off switch beneath a seat. When the control valve.
operator leaves a seat for more than 3 seconds, the There is a counter-balance valve (or, tilt lock valve)
solenoid valve (10) is off, which let a system in tilt speed to prevent cavitation (development of air
pressure go down to less than 7 bar. Once the pocket) in tilt cylinder.
operator sits on a seat, the solenoid valve is on and For a complete hydraulic circuit, see the foldout, in
immediately all functions work normally. the back of this module.
There is a safety lift lock function on lift block that a

lowering of carriage or mast is impossible if the lift
lever is shifted for lowering when operator leaves a
seat for more than 3 seconds or a start key is off.
The solenoid valve (7) for lift lock is electrically
connected to the electric on-off switch beneath a
seat. When the operator leaves a seat for more
than 3 seconds or a start key is off, the solenoid
valve becomes off, which leads to block the lowing
flow passage. Once a start key is on and operator
sits on seat,, the solenoid valve becomes on and
immediately a lowering works normally
On the emergency that lowering doesnt work

normally, the needle valve on lift block needs to
be loosened about half counterclockwise turn ,
which makes it possible to lower the mast or
carriage when lift spool is shifted for lowering.
After lowering the mast or carriage to the ground
absolutely and a start key off, the possible
causes can be inspected. Its detailed trouble
shooting guide will be shown in TESTING and
ADJUSTING.
Vehicle Systems 25 Hydraulic System Operation

Control Valve
External View
4 Spool I.C Truck Valve
Circuit Schematic
4 Spool I.C Truck Valve
Vehicle Systems 26 Systems Operation

Inlet Section
The inlet section contains the pump inlet connection as well as a diagnostic inlet pressure gage port (new
feature to be added).
When the operator is not seated, the solenoid valve is in the normally open position, which helps divert flow
from the pump directly to the outlet of tank. In this manner, oil pressure is limited and their operation is
prevented.

Lift Section
The lift section has a single work port to direct flow to the lift cylinder is single-acting (gravity returns the
mast to the lowered position).
The lift section also contains part of the components which comprise the ISO safety features. There is a
normally closed solenoid valve that works in conjunction with a lift lock check valve. When the operator is
not seated, the solenoid valve is not energized, which ensures that pressures are equalized across the lift
lock valve closed and prevents lowering of the mast.
Lifting: When the operator shifts the lever backwards, the spool is extended out of the valve and this opens
the internal fluid passages that lift the mast. Oil flows through the high pressure parallel cavity, past the
load check valve, through the spool metering notches, past the lift lock check valve, and to the head side of
the lift cylinder.

Lowering: When the seated operator shifts the lever forward, the spool retracts into the valve, and the oil is
directed from the cylinder, past the lift lock check valve, past the pool metering notches, and to the
common tank cavity.
Secondary lowering method: A secondary lowering method is available in the event of the loss of battery
power that is needed to energize the normally closed solenoid valve.
Important Note: Before opening the secondary needle valve, make sure personnel and equipment are
safely positioned to avoid accidents. Be careful to operate this secondary valve slowly, as heavy loads may
be suspended.
A manual valve (needle valve) is located on the lift section, and it can be operated by opening the manual
valve (needle valve) counterclockwise with a wrench.
Open the manual valve (needle valve) approximately 2 turn (do not rotate more than 3 turns). Then, shift
the lift spool slowly for controlled lowering. This should be just enough for slow, controlled movement of the
mast.

Tilt Section
TILT LOCK
PLUNGER
The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery power is
off.
Tilt Forward: When the seated operator shifts the lever forward, pressure is applied to the head of the tilt
cylinder, and the forks tilt forward. Oil is directed from the high pressure parallel passage past the load
check valve, past the spool metering notches, and cylinder head.
Simultaneously, the high pressure acts on the end of the tilt lock plunger to move it towards the spring end
of the spool. This plunger movement opens additional spool metering notches which control oil flow from
the rod end of the cylinder to the tank return line.
Tilt Back: When the seated operator shifts the lever back, the high pressure oil from the parallel passage is
directed past the load check valve, past the spool metering notches, and to the rod side of the cylinder.
Exhaust oil from the head side of the cylinder is directed past the spool metering notches to tank.

Auxiliary Section
In general, one work port is pressurized by high pressure oil from the parallel passage past the load check
valve, past the metering notches, and to the cylinder. Simultaneously, oil from the other work port is
directed across the spool metering notches to tank.

Outlet Section
The outlet section contains the tank port and the secondary relief valve (with built-in anti-cavitation feature).

Relief Valve If the control lever is held in LIFT or TILT position
after the cylinder rod is fully extended or retracted,
the flow of oil from outlet port to the cylinders is
stopped. The oil under pressure must be released.
The pressure oil flows through piston (11) of the
main relief valve. The pressure oil opens pilot valve
(14).
This lets the oil flow go through spring chamber (13)
to passage (7). The oil then returns to tank. When
the pilot valve opened, it caused a decrease in the
pressure in spring chamber (13) that let piston (11)
move against the force of the spring in spring
chamber (13). This stops the flow of oil around the
pilot valve to passage (7) and moves piston (12)
down until a path is open for pump flow to go to the
tank through passage (7). This action will continue
until the control lever is moved to NEUTRAL position.
Relief Valve
(7) Passage for return oil. (11) Piston. (12) Dump valve.
(13) Spring chamber. (14) Pilot valve.

Hydraulic Steering system
Hydraulic Schematic
steering system schematic

(1) steering unit (2) hydraulic line (3) hydraulic line (4) hydraulic line (5) hydraulic line (6) power steering cylinder
(7) hydraulic line (8) pump motor (9) hydraulic line (10) hydraulic pump (11) hydraulic tank (12) priority valve
(13) suction filter (14) filter-return (15) hydraulic line (16)hydraulic line
The steering system uses the hydraulic fluid for During a right turn, pilot pressure is increased in
operation. The system has priority valve (12) which load sensing line (7) and the spool of priority valve is
sends the fluid to steering unit (1) as needed before moved to the right. The fluid flows through hydraulic
the requirements of mast operation are filled. line (9) to the steering unit. From the steering unit
The fluid is pulled from a hydraulic tank (11) to a the fluid flows through a hydraulic line (5) for right
hydraulic pump (10). Pump supplies a fluid through turn. The return fluid flows through a hydraulic line
a hydraulic hose (15) to a priority valve (12). (4) back through steering unit, a hydraulic line (2)
When the steering unit (1) is neutral position, pilot and into the hydraulic tank (11).
pressure in load sensing line (7) is reduced and the
spool of priority valve is moved to the left. The fluid
flows though hydraulic line (16) to control valve.

During a left turn, a pilot pressure is again increased Steering Cylinder
in load sensing line(7) which moves the spool of
priority valve to the right. A fluid flows through a Steering cylinder (1) gives power assistance through
hydraulic line(9) to a steering unit. From the steering the use of pressure oil at either end of the cylinder.
unit, the fluid flows through a hydraulic line(4) to a
power steering cylinder(6) to make a left turn. The The steering cylinder is double ended and the body
return fluid flows through a hydraulic line(5) back to of the cylinder is mounted stationary to the steer
steering unit, a hydraulic line(2) and into the axle. The rod assemblies at both ends of the
hydraulic tank. cylinder which allows the cylinder to move the link
assemblies.
A check valve is installed into the port of steering
unit connected to hydraulic line(9) to prevent a fluid
back to priority valve right after a turn is made,
Relief valve in priority valve will open if steering
pressure goes above 8275(+500,-0) kpa or
1200(+70,0) psi.
1
Steering Cylinder
(1) Steering Cylinder

Steering Unit
Steering Gear
(1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs.
(8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section.
Lift trucks use the load sensing, closed center (oil Oil from the priority valve goes through inlet (4) into
flow to steering unit only when needed) steering unit. the control section of the steering unit. When the
steering wheel is turned, the control section sends
All lift truck hydraulic lines serve a dual purpose in the oil to and from the metering section and also to
that they serve both the steering and cylinder and from the steering cylinder.
hydraulics through the use of a priority valve. The
priority valve sends oil to the steering unit before the The metering section is a small hydraulic pump. It
needs of the cylinder hydraulics are met. controls (meters) the oil that goes to the steering
cylinder. As the steering wheel is turned faster, there
The steering unit has two main sections: control is an increase in the flow of oil to the steering
section (A), and pump or metering section (B). cylinder. This increased flow causes the main valve
These two sections work together to send oil to the spool to move farther. As the spool moves farther,
steering cylinder. more oil can flow from the priority valve or power
steering pump to the steering cylinder, and a faster
turn is made.

Oil Flow
The oil from the priority valve flows through inlet (4).
When the steering wheel is stationary (NEUTRAL),
the oil is stopped by spool (1). The oil can not flow
through the steering unit to the steering cylinder until
the steering wheel is turned.
The steering wheel is connected to spool (1) by a

shaft assembly and splines. When the steering
wheel is turned, spool (1) turns a small amount until
springs (7) are compressed. Then, sleeve (2) starts
to turn.
As long as the steering wheel is turned, the spool
and sleeve both turn as a unit, but they turn a few
degrees apart.
When the spool and sleeve are a few degrees apart,
oil passages are opened between them. This lets
the pump oil from inlet (4) flow through passages in
body (11) to the metering section.
When the steering wheel is turned, pin (8) turns with
the sleeve and causes drive (12) to turn also. The
drive causes a rotation of gear (5) inside gear (6). Pump Gears In Metering Section
This rotation of the gear sends a controlled (5) Internal pump gear. (6) External pump gear. (8) Pin. (12) Drive.
(metered) flow of pilot oil back through body (11).
This oil flows to port (9) or (10) and then to the
steering cylinder. If the steering wheel rotation is stopped, springs (7)
Port (9) or (10), that is not used for pressure oil to will move sleeve (2) back in alignment with spool (1)
the steering cylinder, is used for return oil from the (NEUTRAL position). This will close passages
other end of the steering cylinder between the metering section and control section
and the steering unit will be in the NEUTRAL
position.
When the engine is off, the steering unit can be

manually operated. The control section will work as
a pump. The oil that is returned from the steering
cylinder is not returned to the tank. The suction of
the control section will open an internal check valve
and let return oil from the steering cylinder go to the
inlet side of the control section. During power
operation, supply pressure keeps the check valve
closed.

Brake System Brake fluid from remote reservoir (1) to replenish
master cylinder (2).
Master Cylinder
The master cylinder has a piston which pushes
brake liquid into the brake lines. The reservoir,
located on the cowl, is connected to inlet of master
cylinder. The supply lines keep master cylinder (2)
filled so no air enters the system. Reservoir (1)
supplies brake liquid to the system.
When the brake pedal is first pushed, the piston

moves into the master cylinder and push brake
liquid through outlet into the brake lines. When
floating piston seats on seal, the liquid that is
pushed by piston goes around cup seal, out through
loading piston and outlet. This action continues until
the liquid pressure in piston bore reaches the
pressure that opens relief valve. The liquid, being
pushed by piston, now returns to reservoir(1). Cup
seal, seals and the liquid inside piston is pushed
through piston and outlet.
The liquid pushed through outlet goes through the
brake lines to wheel cylinders (3).
Check valve in the master cylinder keeps a small
amount of pressure in the brake lines and wheel
cylinders (3) when the pedal is released. This small
amount of pressure helps the wheel cylinder piston
cup seal seat, which keeps air out of the brake
system.
Master Cylinder And Wheel Cylinder

(1) Master cylinder reservoir. (2) Master cylinder.
(3) Wheel cylinder.

Shoe Type Brakes Automatic Adjustment
Brakes with automatic adjustment are adjusted on

the reverse braking action. In this example the drum
rotation is counterclockwise (in reverse) which
causes a counterclockwise rotation of the brake
shoes. Secondary shoe (4) moves away from
cylinder (2) that causes link (1) to move toggle lever
(6) in a clockwise rotation. Link (8) is connected to
the lower part of toggle lever (6) and to adjustment
lever (9). By this connection, adjustment lever (9) is
moved in a counterclockwise rotation.
When the brakes are released at the end of a

reverse brake application, adjustment spring (11)
puts adjustment lever (9) into its original position. If
the brake shoe lining has worn enough to let lever
(9) engage, a tooth on adjustment screw (10), lever
(9) will rotate screw (10) to put the brakes into the
correct adjustment.
Brakes With Automatic Adjustment (Right Side Shown) Parking Brake

(1) Upper adjustment link. (2) Cylinder assembly. (3) Piston.
(4) Secondary shoe. (5) Primary shoe. (6) Toggle lever.
(7) Support plate. (8) Lower adjustment link.
(9) Adjustment lever. (10) Adjustment screw.
(11) Adjustment spring. 5
When the brake pedal is pushed down, the master 6

cylinder sends brake fluid to wheel cylinder (2).
4
Wheel cylinder pistons (3) are pushed out and move
primary shoe (5) and secondary shoe (4). The brake
1
shoes move until they make contact with the brake
drum. 2
3
When the brake action first starts, primary shoe (5)
comes in contact with the brake drum as it is in
rotation. This contact of the primary shoe puts some IDCS212S
force on secondary shoe (4) to help put it in position
against the drum.
Parking Brake Adjustment

(1) Screw. (2) Nut. (3) Stop. (4) Lever. (5) Lock. (6) Nut.

Adjustment Procedure :
1. Put the parking brake control lever in the released

position.
2. Bend lock (5) away from nut (6). Adjust nut (6) so
lever (4) is against stop (3).
3. Tighten nut (6) finger tight and bend lock (5) to

hold in place.
4. Loosen nut (2).
5. Tighten screw (1) to a torque of 5.6 to 6.8 Nm

(50 to 60 lbin)
6. Loosen screw (1) 1.2 to 1.5 turns. Hold in this

position and tighten nut (2).
See Parking Brake Adjustment in Testing &

Adjusting.

2. Remove the filter element and look for particles
Testing and Adjusting removed from the oil by the filter element. A
magnet will separate ferrous particles from non
Troubleshooting ferrous particles(piston rings, O-ring, etc).
3. Check all oil lines and connections for damage or

Troubleshooting can be difficult. A list of possible
leaks.
problems and corrections are on the pages that
follow.
4. Check all the lift chains and mast carriage welds
for wear or damage.
This list of problems and corrections will only give an
indication of where a problem can be and what
repairs are needed. Normally, some more or other Performance Tests
repair work is needed beyond the recommendations
on the list. Remember that a problem is not The performance tests can be used to find leakage
necessarily caused only by one part, but by the in the system. They can also be used to find a bad
relation of one part with the other parts. This list can valve or pump. The speed of rod movement when
not give all possible problems and corrections. The the cylinders move can be used to check the
serviceman must find out the problem and its source, condition of the cylinders and the pump.
and then makes the necessary repairs.
Lift, lower, tilt forward and tilt backward the forks
Tools Needed several times.
Fittings Group 1
1. Watch the cylinders as they are extended and
The pressure Gauge Kit or the Tetragauge Group retracted. Movement must be smooth and regular.
can be used to make the pressure tests of the
hydraulic system. Before any test is made, visually 2. Listen for noise from the pump.
inspect the complete hydraulic system for leackage
of oil and for parts that have damage. 3. Listen for the sound of the relief valve. It must not
open except when the cylinders are fully
extended or retracted, when the forks are empty.
WARNING
To prevent personal injury, when testing and Hydraulic Oil Temperature (Too Hot)
adjusting the hydraulic system, move the
machine to a smooth horizontal location and When the temperature of hydraulic oil gets over
lower the mast and carriage to the ground. If the 98.8 C (210 F), polyurethane seals in the system
mast and carriage can not be on the ground, start to fail. High oil temperature causes seal failure
make sure they are blocked correctly to keep to become more rapid. There are many reasons why
them from a fall that is not expected. Move away the temperature of the oil will get this hot.
from machines and personnel that are at work.
There must be only one operator. Keep all other 1. Hydraulic pump is badly worn.
personnel away from the machine, or where the
operator can see the other personnel. 2. Heavy hydraulic loads that cause the relief valve
to open.
Before any hydraulic plug, line or component is
removed, make sure all hydraulic pressure in the 3. The setting of the relief valve is too low.
system is released.
4. Too many restrictions in the system.
Visual Checks 5. Hydraulic oil level in the tank is too low.
A visual inspection of the hydraulic system and its 6. High pressure oil leak in one or more circuits.
components is the first step when a diagnosis of a
problem is made. Lower the carriage to the floor and 7. Very dirty oil.
follow these inspections:
8. Air in the hydraulic oil.
1. Measure the oil level. Look for air bubbles in the
oil tank.
Vehicle Systems 41 Testing and Adjusting

NOTE : If the problem is because of air in the oil,
It must be corrected before the system will 2. The relief valve opened at low oil pressure.
operate at normal temperatures. There are two
things that cause air in the oil (aeration). 3. The hydraulic pump has too much wear.
a. Return oil to the tank goes in above the level of 4. The priority valve does not work correctly.
the oil in the tank.
5. The load is not correct.
b. Air leaks in the oil suction line between the
pump and the tank. 6. Unload function doesnt work correctly.
Hydraulic System and Mast Probable Mechanical Cause:
During a diagnosis of the hydraulic system, 1. The mast is not in alignment with the other lifting
remember that correct oil flow and pressure are components and does not move freely.
necessary for correct operation. The output of the
pump (oil flow) increases with an increase in engine 2. Not enough lubricant on the parts of the mast that
speed (rpm) and decreases when engine speed move.
(rpm) is decreased. Oil pressure is caused by
resistance to the flow of oil. 3. The carriage or mast rollers and bearings areworn
and do not move (seized).
Visual checks and measurements are the first step
when troubleshooting a possible problem. Then do 4. Mast is shimmed too tight.
the operation checks and finally, do instrument test
with pressure gauges. Problem: Lift cylinder extends too slowly.
Use the Fittings Group, a stop watch, a magnet, a Probable Hydraulic Cause:
thermometer, and an inch (mm) ruler for basic tests
to measure: 1. Not enough oil supply to lift cylinder.
1. The pressure of the oil to open the relief valve. 2. Defective lift cylinder seals.
Relief valve pressures that are too low will cause
a decrease in the lift and tilt characteristics of the 3. Relief pressure set to low.
lift truck. Pressures that are too high will cause a
decrease in the life of hoses and components. 4. Unload function doesnt work correctly.
2. Drift rates in the cylinders. Cylinder drift is Probable Mechanical Cause:

caused by a leakage past cylinder pistons, O-ring
seals in the control valve, check valves that do 1. The mast is not in alignment with the other lifting
not seat correctly or poor adjustment or fit in the components and does not slide freely
control valve spools.
2. Not enough lubricant on the parts of the mast
3. Cycle times in the lift and tilt circuits: Cycle times that move.
that are too long are the result of leakage, pump
wear and/or pump speed (rpm). 3. The carriage or mast rollers and bearings are
worn and do not move (sized).
Hydraulic System and Mast
4. Masts shimmed too tight.
Problem: The hydraulic system will not lift the
load. Problem: Mast does not move smoothly.
Probable Hydraulic Cause: Probable Hydraulic Cause:
1. There is an air leak, which lets air into the 1. Air in the hydraulic system.
hydraulic system on the inlet side of the hydraulic
pump. 2. Relief valve sticks or defective.

3. Damaged cylinders. Probable Mechanical Cause:
Probable Mechanical Cause: 1. The mast is not in alignment with the other lifting
components and does not move freely.
1. Not enough lubricant on the parts of the mast that
move. 2. Carriage chains need an adjustment.
2. Load rollers defective or not adjusted correctly. 3. Not enough lubricant on the part of the mast that
moves.
3. Mast rollers not shimmed correctly.
4. The carriage or mast rollers and bearings are
4. Mast assembly is damaged or not in alignment. worn and do not move (seized) or shimmed too
tight.
Problem: The mast does not tilt correctly or
moves too slowly.
Problem: Unload function doesnt work.
Probable Hydraulic Cause:
Unload function: Once the operator leaves a seat
1. There is restriction in the hydraulic tilt lines. more than 3 seconds or a start key is off, any
function (lift, tilt, auxiliary cylinder) doesnt work even
2. There is an air leak, which lets air into the though each spool is shifted in or out. If the operator
hydraulic system on the inlet side of the hydraulic is seated on a key on, immediately each function will
pump. normally work.
3. The relief valve opens at low oil pressure. Probable Electric Cause:
4. The hydraulic pump has too much wear. 1. The electric switch (on-off) below a seat is
damaged.
5. The internal valve of the tilt spool is stuck.
2. The electric parts (relay and controller) related to
6. Control valve tilt spool has a restriction. a solenoid valve for unload function in lift section
of control valve damaged.
7. The priority valve does not work correctly.
Probable Hydraulic cause:
8. Seals in tilt cylinder are worn or damaged.
1. Hydrostator sleeve in control valve is stuck to a
9. Unload function doesnt work correctly. housing.
Probable Mechanical Cause: 2. Sleeve in a solenoid valve for unload function is

stuck to a housing.
1. Damage or failure of the tilt cylinders.
Problem: Mast will not lower completely or will
2. Mast mounting pins are seized. not lower at all
Problem: The carriage will not lower correctly.
Probable Hydraulic Cause:
1. There are restrictions in the lift line.
2. The lift spool in the control valve has a restriction

caused by foreign material and does not operate
freely.
3. The lift cylinder flow regulator valve has a

restriction.
4. Air in the hydraulic system.

Problem: Safety lift lock doesnt work
WARNING Safety lift lock function: Once the operator leaves a
seat more than 3 seconds or a start key is off, the lift
First of all, the needle valve in control valve as cylinder doesnt lower, even though lift spool is
seen in a picture below should be loosened with pulled for lowering. If the operator is seated on a key
about half counterclockwise turn, which makes on, immediately the lowering will normally work.
it possible to lower the mast or carriage safely
when lift spool is shifted for lowering. After Probable Electric Cause
absolutely lowering the mast or carriage to the
ground and a start key off, the possible causes 1. The electric switch (on-off) below a seat damaged
will be inspected. If mast or carriage wont lower
by loosening a needle valve, its cause would be 2. The electric parts (relay and controller) related to
a mechanical problem or a hydraulic problem a solenoid valve in lift section of control valve
rather than an electrical problem. After the damaged
related problems are completely fixed, the
needle valve should be re-tightened in a Probable Hydraulic Cause
clockwise turn. If not so, the safety lift lock
doesnt properly work. 1. Lift poppet (lift lock) damaged and contaminated.
2. Needle valve is loosened.
Problem: The lift or tilt cylinders do not hold

their position with the valve control levers in
neutral position.
Probable Cause:
1. The valve spools do not hold their positions

because the springs for the valve spools are
weak or broken.
2. Control valve leakage caused by worn valve

spools.
Probable Electric Cause 3. The load check valves in the control valve are bad.
1. Not to supply the electric power to solenoid valve 4. Leakage of the cylinder lines or piston seals.
in lift section of control valve.
5. There is foreign material in the control valve.
2. A broken solenoid valve in lift section of control
valve Hydraulic Gear Pump
Probable Hydraulic Cause Problem: Noise in the pump.
1. Lift poppet (lift lock) damaged and contaminated Probable Cause:
Probable Mechanical Cause 1. The oil level is low.
1. Lift cylinder damaged or bent. 2. The oil is thick (viscosity too high).
2. Load roller defective (bearing) or not adjusted 3. The pump inlet line has a restriction in it.
4. Worn parts in the pump.

5. Oil is dirty.
6. Air leaks into the inlet line.

Problem: The oil temperature is too high. 5. The pump has too much wear.
Probable Cause: 6. Failure of the pump shaft or coupling.
1. The oil level is low. 7. The bolts of the pump do not have the correct
torque.
2. There is a restriction in an oil passage.
8. Filter by-pass not working or installed backward.
3. The relief valve setting is too low.
Hydraulic Control Valve
4. The oil is too thin.
Problem: The control spools do not move freely.
5. There is air leakage in the system.
Probable Cause:
6. The pump has too much wear.
1. The temperature of the oil too high.
7. The system operates at too high a pressure.
2. There is foreign material in the fluid.
a. Relief valve setting too high.
3. The fitting connections in the valve body are too
b. Attachment components cause a restriction tight.
during movement.
4. The fastening bolts of the valve assembly do not
c. Restrictions in flow regulator valve, load check have the correct torque and have twisted the
body.
8. Severe hydraulic usage.
5. Linkage of the lift and tilt levers does not operate
Problem: Leakage on the shaft seal. smoothly.
Probable Cause: 6. Bent lift or tilt spools.
1. The shaft seal is worn. 7. Damage to the return springs of the spools.
2. There is a broken gasket behind the seal. 8. The valve is not at normal temperature for
operation.
3. The inner parts of the pump body are worn.
4. Operation with too low oil level in tank causes Problem: Control valve spools have leakage
suction on the seal. around the seals.
5. Seal cut on shoulder of pump or keyway during Probable Cause:

installation.
1. There is foreign material under the seal.
6. Seal lips are dry and hardened from heat.
2. The valve spools are worn.
Problem: There is failure of the pump to deliver 3. The seal plates are loose.
the fluid.
4. The seals have damage or are badly worn.
Probable Cause:
1. Low Level of the oil in the tank.
2. There is a restriction in the pump inlet line.
3. There is air leakage in the pump inlet line.
4. The viscosity of the oil is wrong.

Problem: The load lowers when the lift spool is Lift and Tilt Cylinders
moved from the NEUTRAL position to the RAISE
position. Problem: Leakage around the piston rod.
Probable Cause: Probable Cause:
1. There is foreign material in the load check valve 1. Cylinder head (bearing) seals are worn.
area.
2. Piston rod is worn, scratched or bent.
2. The load check valve and seat show wear.
Problem: There is leakage of oil inside the
3. Sudden loss of pump oil pressure. cylinder or loss of lift or tilt power.
4. Damage to the relief valve which causes low oil Probable Cause:
pressure.
1. The piston seals are worn and let oil go through.
Problem: Spool do not return to neutral.
2. Cylinder has damage.
Probable Cause:
Problem: The piston rods show wear.
1. The springs are broken.
Probable Cause:
2. The spool is bent.
1. The cylinders are not in correct alignment.
3. The system valve has foreign particles in it.
2. Oil is dirty.
4. The control linkage is not in alignment.
Problem: Foreign material behind the wiper
5. The fastening bolts of the valve have too much rings causing scratches on the cylinder rod.
torque.
Probable Cause:
Problem: No motion or slow, then a too sudden
action of the hydraulic system. 1. The wiper rings show wear and do not remove
dirt and foreign material.
Probable Cause:
1. The relief valve is not correctly set, or will not

move in base and/or is worn.
2. There is air in the system.
3. Dirt or foreign particles between relief valve

control poppet and its seat.
4. Valve body has a crack inside.
5. Spool not moved to a full stroke.

Steering System Problem: Low oil pressure.
Problem: Too much force needed to turn Probable Cause:

steering wheel.
1. Low oil level.
Probable Cause:
2. Priority valve relief valve spring weak.
1. Priority valve releases pressure oil at a low setting.
3. Relief valve (priority valve) will not move from the
2. Pump oil pressure is low, worn pump. open position.
3. Steering gear covers are too tight. 4. Oil leakage inside or outside of the system.
4. Steering column not aligned with steering gear. 5. Defective pump.
5. Priority valve spool is held in one position. Problem: Pump makes noise and the steering
cylinder rod does not move smoothly.
6. Steering gear without lubrication.
Probable Cause:
7. Low fluid level in the hydraulic supply tank.
1. Air in the steering hydraulic circuit.
8. Steer axle damaged.
2. The pump has too much wear.
9. Worn steer cylinder piston seal.
3. Loose connection of the oil line on the inlet side
Problem: Steering wheel does not return to of the pump.
center position correctly.
4. The viscosity of the oil is wrong.
Probable Cause:
5. The oil level in the hydraulic tank is low.
1. Steering gear covers are too tight.
6. Worn steer cylinder piton seal.
2. Steering column is not in correct alignment.
Problem: Lift truck does not turn when steering
3. Valve spool in the steering gear has a restriction. wheel is slowly turned.
4. Priority valve check valve permits lift and tilt Probable Cause:
hydraulic oil to affect steering hydraulic circuit.
1. The oil level of the tank is low.
Problem: Oil leakage at the pump. 2. There is air in the steering system.
Probable Cause: 3. The pump operation is no correct.
1. Loose hose connections. 4. Dirt in the steering system.
2. Defective shaft seal. 5. Steering gear operation is not correct.
6. Steering cylinder has worn parts.
7. Restriction in the steer axle linkage.

Problem: The temperature of the oil is too hot. Problem: Pedal resistance is not solid (spongy).
Probable Cause: Probable Cause:
1. The viscosity of the oil is wrong. 1. Leakage or low fluid level.
2. Air mixed with the oil. 2. Air in the brake hydraulic system.
3. The relief valve is set too high (priority valve). 3. Loose master cylinder mounting.
4. There is a restriction in line circuit. Problem: Hard pedal.
5. Unit being held in relief mode for long periods of Probable Cause:
time.
1. Mechanical resistance on the pedal or shoe.
Brake System 2. Brake shoe adjustment not correct.
Problem: Brakes make noise or pull (grab). 3. Restriction in the brake line.
Probable Cause: 4. Bad master cylinder.
1. Brake shoe adjustment not correct. 5. Lining surface looks like glass (glazed), or is worn.
2. Lining surface looks like glass (glazed) or is worn. Problem: Pedal gradually goes to the floor.
3. Oil or brake fluid is on the lining. Probable Cause:
4. Dirt on the brake drum lining surface. 1. Leakage or low fluid level.
5. Brake drum is badly worn or has grooves (scored). 2. Bad master cylinder.
6. Restriction in the brake line. Problem: Extra (excessive) pedal travel.
7. Brake drum is out of round. Probable Cause:
Problem: Both brake shoes will not release all 1. Leakage or low fluid level.
the way (drag).
2. Air in the brake hydraulic system.
Probable Cause:
3. Bad master cylinder.
1. Brake shoe adjustment not correct.
4. Lining surface looks like glass (glazed), or worn.
2. Brake pedal adjustment not correct.
5. Operation of brake adjuster is not correct.
3. Mechanical resistance at the pedal or shoe.
4. Restriction in brake line.
5. Bad wheel cylinder.

Problem: Brake will not make application.
Probable Cause:
1. Leakage or low fluid level.
3. Oil or brake fluid is on the lining.
4. Air in the brake hydraulic system.
5. Bad master cylinder.
6. Linkage is not in correct adjustment, or is bent.
Problem: Not braking evenly, or rough feeling of

braking (chatter).
Probable Cause:
2. Oil or brake fluid is on the lining.
3. Bad contact between the lining and drum.
4. Loose lining.
5. Brake drum out of round.
6. Loose wheel bearing.
7. Bad wheel cylinder.

Lift Cylinders Air Removal
After the lift cylinder has been disassembled and
then assembled again, it may be necessary to
remove the air (bleed) from the cylinder.
1. With no load, lift and lower the mast and carriage

through one complete cycle.
2. With the forks on the floor, check the oil level in

the hydraulic tank. Add oil (if necessary) to bring
the oil level to the full mark.
Lift Cylinder Air Removal (FFTL - Secondary Cylinders)
(24) Bleed Screw.
3. With no load, left and lower the mast and
carriage again through four complete cycles.
5. Open bleed screws (23 and 24) no more than
WARNING one turn. The weight of the carriage will force air
and hydraulic oil out of the cylinders through the
The oil will have high pressure present. To bleed screws. Close the bleed screws before all
prevent personal injury, do not remove the bleed the pressure is out of the cylinders. This will
screws completely . Keep hands and feet away prevent air from entering back through the bleed
from any parts of the truck that move, because screws.
the forks will lower when the bleed screw is
loose. 6. Repeat Steps 4 and 5 until there is no air bubbles
at the bleed screws.
4. Lift the forks high enough to put a load on all
stages of the lift cylinders. (The illustrations 7. After all the air is removed, tighten the bleed
shown are of a full free triple lift mast.). screws.
8. Fill the hydraulic tank to the full mark.
9. Lift and lower the mast and carriage again

hrough one complete cycle. If the mast does not
operate smoothly, repeat Step 3 through 9.
Lift Cylinder Air Removal (FFTL - Primary Cylinder)

(23) Bleed Screw.

Hydraulic System
Relief Valve Pressure Check
Use the pressure Gauge kit to check the relief valve
pressure.
WARNING
Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump
have been stopped. Personal injury can be
caused if this pressure is not released before
any work is done on the hydraulic system. To
prevent possible injury, lower the carriage to the
ground, turn the key switch off and move the
control levers to make sure all hydraulic
pressure is released before any fitting, plug,
hose or component is loosened, tightened,
removed or adjusted. Always move the lift truck
to a clean and level location away from the travel
of other machines. Be sure that other personnel
are not near the machine when the engine is
running and tests or adjustments are made.
Relief pressure gage point (1)
RELIFE PRESSURE
Auxiliary Relief
Model Mast Main relief pressure-lift Valve
Pressure
Psi Kpa psi Kpa
D15S, G(C)15S-5 STD/FF/FFT 2,55035 17,600250
2,040 14,000
D18S, G(C)18S-5 STD/FF/FFT 2,88035 19,860250
50 350
D20S, G20SC-5 STD/FF/FFT 3,12535 21,550250
Remove the plug from elbow (1). Install pressure-checking adapter (4) and, connect pressure-tube (5) and
pressure gage (6). Pressure gage (6) has a range of 2,8000kpa (4,000psi)

Lift Relief Valve Check and Adjusment
1. Turn the key switch on and activate the

hydraulics until the hydraulic oil is at the normal
operating temperature.
2. With the engine at fast rpm under unload

condition, hold the lift control lever in the lift up
position and watch the gauge. The gauge
indication is the pressure that opens the relief
valve at the end of lift cylinder stroke.
3. The correct pressure setting is shown in the chart.
4. If an adjustment to the relief valve setting is

necessary, loosen locknut (3).
(4) Pressure-checking adapter (5) Pressure- tube

(6) Pressure-gauge
Relief valve Adjustment (3) Locknut (4) Stud
5. Turn stud (4) clockwise to increase or

counterclockwise to decrease the pressure
setting of the relief valve. (wrench size 4mm)
6. Tighten the locknut and check the pressure

setting again for correct adjustment.

Tilt and Auxiliary Relief Valve Check and Steering System
Adjusment
Steer Wheel Bearing Adjustment -
1. Turn the key switch on and activate the Pneumatic
hydraulics until the hydraulic oil is at the normal
operating temperature. Put the carriage in the full
sideshift position.
2. With the engine at fast rpm, hold the sideshift

position and watch the gauge. The gauge
indication is the pressure that opens the relief
valve.
3. The correct pressure setting is shown in the chart.
4. If an adjustment to the relief valve setting is

necessary, loosen locknut (7)
(1) Tighten nut (1) slowly to 133 Nm (98 lbft) while

turning the wheel.
(2) Loosen nut (1) completely, retighten nut (1) to a

torque of 505 Nm (374 lbft). Bend lock (2)
to hold nut (1) in position.
Relief valve Adjustment (7) Locknut (8) Stud
5. Turn stud (8) clockwise to increase or

counterclockwise to decrease the pressure
setting of the relief valve.
6. Tighten the locknut and check the pressure

setting again for correct adjustment. (wrench size
4mm)

Steer Axle Stop Adjustment-Pneumatic Steer Wheel Bearing Adjustment-
Cushion
Steer Axle End.

(1) Bolt (2) Nut (A) 80angle
Use the procedure that follows to make an

Bearing Adjustment
adjustment to the steer axle turning angle.
(1) Nut. (2) Lock.
1. Adjust the cylinder rod extension so it is equal on

1. Tighten nut (1) slowly to 70 Nm (50 lbft), while
both sides of the axle.
the wheel is turned, to put the bearing into
position.
2. Loosen nuts (2).
2. Loosen nut (1) completely and the tighten the nut
3. Turn the steer wheel one direction until the
to 505 Nm (374 lbft). Bend lock (2) to hold
steering cylinder internal stop is reached.
the nut in position.
4. Adjust stop bolt (1).
5. Tighten nut (2). Turn the steer wheel the opposite

direction and do the same procedure for the
opposite stop bolts. This will give a maximum
cramp angle of 80.

Steer Axle Stop Adjustment-Cushion 2. Loosen nut (5) and (4) on steer axle ends. Turn
setscrew (8) and (3) all the way in. Put right steer
knuckle in forward cramp until steering cylinder
internal stop is reached. Adjust setscrew (6) of
right end of steer axle and setscrew (3) of left
end of steer to contact steer knuckle. Tighten
nuts (5) and (4) to hold the adjustment.
Steering System Air Removal
1. Fill the hydraulic Tank or reservoir nearly full. Be

ready to add oil when the engine is started. Do
not let oil level go below the outlet to the pump.
2. Start the engine and keep at low idle. Add oil

immediately to the tank or reservoir as needed.
NOTE : This oil will now flow from the pump, the
Steer Axle Left End. priority valve and the steering gear, then back to the
(1) Setscrew (2) Nut (3) Setscrew (not shown) priority valve, hydraulic control valve, hydraulic tank
(4) Nut (not shown) and finally to the pump again. When no more oil can
be added and oil is clear, do the procedure that
follows :
3. Lift a capacity load to take the weight off of the

steer axle. Turn the steering wheel as rapidly as
possible to remove the air in the steering cylinder
and lines.
4. Add oil immediately when the valve spool is

activated to replace oil that flows through the
circuit.
NOTICE
Be sure to keep the oil level in the hydraulic tank
above the outlet to the pump. Do not hold steer
wheels against stops for an extended period of
time. This will cause the oil to get hot and
damage the components.
Steer Axle Right End
(5) Nut (6) Setscrew (7) Nut (8) Setscrew
(A) 80 +0-2 Cramp angle (reference)
5. Turn the steer wheels until they have reached the
stop in one direction, then quickly turn the
Use the procedure that follows to adjust the steer steering wheel in the opposite direction to the
axle turning angle. opposite stop.
1. Loosen nut (2) and (7) on steer axle ends. Turn 6. This procedure must go on approximately 15 to
setscrew (1) and (8) all the way in. Put left steer 20 times, to remove the air from the system. Add
knuckle in forward cramp until steering cylinder oil as required.
internal stop is reached. Adjust setscrew (1) of
left end of steer axle and setscrew (8) of right
end of steer to contact steer knuckle. Tighten
nuts (2) and (7) to hold the adjustment.

NOTE: The oil in the lines to the steering cylinder Check steering system relief pressure as
stops at the piston. The oil in the cylinder does not follows:
flow in a circuit. As the piston moves backward and
forward, the oil moves backward and forward in the 1. Turn the engine off.
lines. Air in these lines, and in the cylinder, may
move slowly into the steering control valve and then 2. Remove plug from elbow (1) Install pressure-
to the tank. checking adapter (4) and connect pressure-tube
(5) and pressure gage (6). Pressure gage (6) has
a range of 28,000 kpa (4,000psi).
WARNING
Personal injury can result if loss of steering 3. Move the seat to the normal position for
occurs. Do not operate the vehicle until the air is operation, turn the key switch to the ON position
removed. and activate the hydraulic controls until the oil is
at a temperature for normal operation.
7. When the oil in the tank is clear (not cloudy), the
4. Turn the steer wheels to the left or right against
system is free of air.
the stops and make a note of the indication on
the pressure gauge.
8. Fill the tank to the recommended level.
5. The indication on the pressure gauge must be
the priority valve relief setting of 8275(500,0)
Steering System Pressure Check kPa or 1,200 (70,0) psi. If the indication is
correct and a problem exists, then there is
If the steering system does not work correctly, check possibly a mechanical failure in the steering
the hydraulic tank for the correct oil level and the system.
hoses and connections for leakage. If all these items
are correct, use the Pressure Gauge Kit to check the 6. If the indication is not correct, then there is
steering hydraulic system and its relief pressure steering hydraulic failure in the components.
setting.
Hydraulic Steering Gear

(1) Pressure gauge plug (M10 x P1)
WARNING
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all
hydraulic pressure is released in the steering
system. Move the steer wheels to the left and (4) Pressure-checking adapter. (5) Pressure-tube.
right and then to the straight forward direction. (6) Pressure gauge.

NOTICE
Do not let valve be closed for more than 3 or 4
seconds or damage can be caused to the
steering system components.
a. With the engine running, turn the steer wheels

in any directions and read the indication on
pressure gauge (6).
b. If the indication is approximately the pressure

shown in Step 5, then the steering gear has a
hydraulic failure.
c. If the indication is too low or too high, then the

priority valve or its components must be
replaced.
7. If the steering unit and the priority valve are

working properly, the steering cylinder is
defective and must be repaired.
8. Correct the problem and check steering relief

valve pressure again.

Brake System Pedal Adjustment for Brake & Inching
Brake System Air Removal

The adjusting procedure is as follows. Be sure that the
Systems With Remote Reservoir air bleeding of brake system should be done in
advance.
Remote Reservoir Location

(1) Remote reservoir. 1. Adjust the length (A) from the spool to the
connection point of yoke. (A) should be 80 1mm
When the brake pedal resistance is spongy (not for D(G)15S-5 or 83 1mm for GC15S-5. Be sure
solid) it is usually an indication that there is air in the that 1mm of gap between the piston and the rod
brake hydraulic system. The cause may be low fluid should exist. In case of no gap, it would result in
or oil level, leakage in the system, a broken brake brake drag or overheating of axle oil. In case of too
line or a brake line that is not connected. loose, the performance of service brake become
lowered.
To remove air from the brake system, do the
procedure that follows : 2. Adjust the length (B) of rod by fixing the nuts at both
ends. (B) should be 143 1mm for D(G)15S-5 or
1. Fill remote reservoir (1) with the correct brake 183 1mm for GC15S-5.
fluid to 12.7 mm (.50 in) from the filler cap. See
the Operation and Maintenance Manual for the
correct brake fluid.
2. Put pressure on the brake pedal and open bleed

screw to let air out of the system. Close bleed
screw while pressure is still on the brake pedal ;
then let the pedal return to the original position.
3. Do Step 2 again as many times as necessary

until the brake fluid is free of air.
4. Use the procedure in Steps 2 and 3 again,

except this time use the right bleed screw.
5. Fill remote reservoir (1) again, with the correct

fluid, to the level explained in Step 1.

82.5 mm
(E)
C
5. The distance (E) between the shaft center and its

mounting bracket should be 82.5mm.
3. Adjust the height (C) of inching pedal and brake
pedal. (C) should be 101 1mm at the same level. 6. The stroke of inching spool should be 8 1mm.
7. Before doing the truck test, inspect again all relevant

dimensions.
8. Inspect the service brake and then, inching

operation.
4. Adjust the gap (D) for engaging brake pedal by

inching pedal. (D) should be approx. 9.5mm.

Parking Brake Test Parking Brake Adjustment
WARNING
5
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 6
starts to move.
4
1. Drive the fully loaded lift truck up a 15% incline. 1

2
2. Half way up the incline, stop the lift truck with the
service brakes. Apply the parking brake. 3
3. If the parking brake has the correct adjustment,

the lift truck will be held in this position. IDCS212S
4. If the parking brake does not hold, do the steps in

parking Brake Adjustment.

(1) Screw. (2) Nut. (3) Stop. (4) Lever. (5) Lock. (6) Nut
NOTICE
Turn the adjustment screw clockwise to tighten.
Turning the screw too far counterclockwise
could allow parts to fall into the bottom of the
transmission. The transmission would then
require disassembly to remove the parts.
1. Put the parking brake control in the released

position.
2. Make sure lever (4) is against stop (3). If against

stop, go to Step 5. If not against stop, go to Step
3.
3. Bend lock (5) away from nut (6). Loosen nut (6)
until lever (4) is against stop (3).
4. Tighten nut (6) finger tight and bend lock (5) to

hold in place. Be sure to do this correctly.

5. Loosen nut (2).
6. Tighten screw (1) to a torque of 5.6 to 6.8 Nm (50

to 60 lbin).
7. Loosen screw (1) 1.2 to 1.5 turns, hold in this

position and tighten nut (2).
7
8

(7) Switch Assembly. (8) Screws.
8. Loosen screws (8).
9. Adjust switch assembly (7) until switch actuation

occurs between the 2nd. Or 3rd click as the
parking brake is engaged. Tighten screws (8).

SB4245E00
Apr. 2007
Vehicle System
D15S-5, D18S-5, D20SC-5

G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
WARNING
publication.
Vehicle System 1 Index

Install Knuckle, Kingpin and Bearing..................... 38
Index Steer Axle-Pneumatic............................................ 38
Remove & Install Steer Axle.................................. 38
Steer Cylinder - Pneumatic.................................... 40
Disassembly & Assembly Disassemble Steer Cylinder .................................. 40
Assemble Steering Cylinder .................................. 41
Disassembly & Assembly ........................................ 5 Link, Knuckle, Kingpin and Bearing....................... 42
Hood (with seat) Assembly ...................................... 5 Remove & Install Link, Knuckle, Kingpin and
Overhead Guard ...................................................... 5 Bearing .................................................................. 42
Secondary Lift Cylinder............................................ 6 Counterweight ....................................................... 43
Disassemble Secondary Lift Cylinder...................... 6 Remove Counterweight ......................................... 43
Assemble Secondary Lift Cylinder........................... 7 Radiator ................................................................. 44
Primary Lift Cylinder ................................................ 8 Remove & Install Radiator..................................... 44
Disassemble Primary Lift Cylinder........................... 8 Fan Belt & Alternator Belt LP truck..................... 45
Assemble Primary Lift Cylinder ............................... 9 Alternator Diesel truck ........................................ 46
Hydraulic Control Valve ......................................... 10 Electric Starting Motor ........................................... 46
Remove Hydraulic Control Valve........................... 10 Remove & Install Electric Starting Motor............... 46
Install Hydraulic Control Valve............................... 10 Fuel Filter Diesel................................................. 47
Hydraulic Control Valve ......................................... 11 Remove & Install Fuel Filter .................................. 47
Assembly Instruction.............................................. 12 Oil Filter ................................................................. 47
Hydraulic Pump ..................................................... 15 Remove & Install Oil Filter ..................................... 47
Remove & Install Hydraulic Pump ......................... 15 Air Cleaner Housing Assembly.............................. 48
Disassemble Hydraulic Pump................................ 15 Remove & Install Air Cleaner Housing Assembly . 48
Assemble Hydraulic Pump .................................... 16 Engine and Transmission ...................................... 49
Tilt Cylinder............................................................ 18 Remove & Install Engine and Transmission.......... 49
Remove & Install Tilt Cylinders.............................. 18
Disassemble & Assemble Tilt Cylinder.................. 18
Brake Master Cylinder ........................................... 21
Remove & Install Brake Master Cylinder............... 21
Disassemble & Assemble Brake Master Cylinder . 23
Steering Wheel ...................................................... 23
Remove & Install Steering Wheel.......................... 23
Steering Unit .......................................................... 24
Remove & Install Steering Unit.............................. 24
Disassemble Steering Unit .................................... 25
Steer Axle .............................................................. 32
Steer Wheel & Hub-Pneumatic.............................. 32
Steer Wheel Bearing-Cushion ............................... 34
Remove Steer Wheel & Bearing............................ 34
Tie Rods ................................................................ 35
Remove Tie Rods .................................................. 35
Install Tie Rods ...................................................... 35
Steer Axle-Cushion................................................ 36
Remove & Install Steering Axle ............................. 36 WARNING
Steer Cylinder-Cushion.......................................... 36 Disconnect batteries before pertormance of any
Remove & Install Steering Cylinder....................... 36
disassembly & assembly.
Disassemble & Assemble Steering Cylinder ......... 36
Knuckle, Kingpin and Bearing ............................... 37
Remove Knuckle, Kingpins and Bearing ............... 37
Vehicle System 3 Index

Hood (with seat) Assembly

Remove & Install Hood (with seat)
Assembly
5. Use the hoist to remove hood and seat assembly

(3)
6. Install the hood and seat assembly in the reverse

order of removal.
Overhead Guard
WARNING
The hood and seat assembly can fall when nut
(1) is removed from the support cylinder rod. To
avoid personal injury, support the seat and hood
assembly before removing nut (1).
1. Raise the hood. Support the seat with a hoist.
2. Remove nut (1) from the support cylinder.

Remove the cylinder rod from the bracket.
3. Remove the four bolts (2).
4. Lower the hood.
1. Support overhead guard (1) with lifting straps and

a hoist.
Vehicle System 5 Disassembly & Assembly

Secondary Lift Cylinder
Disassemble Secondary Lift
Cylinder
Start By :
a. Remove secondary lift cylinders.
2. Remove the bolts (3), washers and nuts.
1. Put secondary lift cylinder (1) in position as shown.
3. Remove the plugs, washers, nuts (4) and bolts.
4. Remove front overhead guard (1).
2. Remove rod-cover assembly (2) with wrench.
5. Remove the washers, nuts, and four bolts (5).
6. Remove rear leg (6).
7. Install overhead guard (1) and rear leg (6) in the

reverse order of removal.
3. Remove rod (3) from the cylinder body.

4. Remove ring (4) from the cylinder rod. 7. Remove wiper seal (9), U-packing (10), backup
ring (11) and two slide rings (12) from the rod
cover.
Assemble Secondary Lift Cylinder
5. Remove screw bleeders (5) and steel ball (6) from

the rod cover.
1. Install two slide rings (12), backup ring (11) U-

packing (10) and wiper seal (9) on the inside of
the rod cover.
6. Remove O-ring seal (7) and backup ring (8) from

the rod cover.
2. Install backup ring (8) and O-ring seal (7) onto the
rod cover.

Primary Lift Cylinder
Disassemble Primary Lift Cylinder
Start By :
a. Remove primary lift cylinder.
3. Install the steel ball (6) and screw-bleeder (5)

onto the rod cover.
1. Remove head assembly (1).
2. Remove rod (2) from the cylinder body.
4. Install rod (3) with a ring into the cylinder body.
3. Remove ring (3) from the cylinder rod.
5. Install rod cover assembly (2) on the cylinder and

tighten using wrench.
End By :
a. Install secondary lift cylinder.
4. Remove O-ring seal (4) and backup ring (5) from

the head assembly.

5. Remove wiper seal (6), backup ring (7), U- 5. Install ring (3) on the cylinder rod.
packing (8) and two slide rings (9) from the head
assembly.
Assemble Primary Lift Cylinder
6. Install cylinder rod (2) in the cylinder body.
7. Install head assembly (1) on the cylinder body.

1. Install backup ring (7) and U-packing (8) in the Tighten the head assembly.
head assembly.
End By :
2. Install wiper seal (6). Install the seal with the lip
toward the outside. a. Install primary lift cylinder.
3. Install two slide rings (9) in the head assembly.
NOTE: Install the back-up ring with the curved side

contacting the O-ring seal.
4. Install the backup ring (5) and O-ring seal (4) on

the head assembly.

Hydraulic Control Valve Install Hydraulic Control Valve
Remove Hydraulic Control Valve
WARNING
Before any hydraulic plug, line or component is
removed, make sure all hydraulic pressure in the
system is released.
1. Put hydraulic control valve assembly (3) in

position and install the mounting nuts and bolts (4)
that hold it. Assemble the levers and cover to the
control valve cover.
1. Put identification marks on all hydraulic lines and

hoses.
2. Disconnect all hydraulic lines and hoses (1) from

the hydraulic control valves. Put plugs or caps on
the lines and hoses, also on the openings on the
control valves to keep out dirt and foreign material.
2. Remove the caps or plugs from the lines and

hoses, also from the openings on the control
valves.
3. Connect hydraulic lines and hoses (1) to the

control valves. Be sure the lines are installed at
the correct locations.
3. Remove the valve cover (2). Disconnect the

levers from the hydraulic control valve. Remove
hydraulic control valve assembly (3) by loosening
three bolts (4).

Hydraulic Control Valve
Disassembly Instruction 1. Loosen the tie rod nuts and remove the tie rods
from the valve sections.
General :
2. Remove o-rings between valve sections and set
Subassemblies (such as relief valves, check aside to avoid damage.
valves, and spools) may be removed without
having to loosen the tie rods and disassembling 3. Spools, relief valves, load check valves, lift lock
the entire valve. poppets, solenoid valves, and plugs can be
removed from the valve sections. Refer to the
Disassemble the valve sections on a flat working associated assembly procedures for specific
surface. torque and handling details. Inspect and repair or
replace the assemblies as complete units, as
Ensure that the disassembly area will be clean may be necessary.
and free of contamination.
4. Valve components are precision items, and care
Keep the disassembly area neat to avoid loss or must be taken when handing them to avoid
damage of parts. damage or the introduction of contamination that
could adversely affect performance.

Assembly Instruction Block Subassembly :
1. Attach all the O-rings to the appropriate

General :
grooves between the spool sections.
Ensure that the assembly area will be clean and 2. Stack the valve sections such that all the work
free of contamination. ports are facing up, the spool ends are all in
Use a flat (within 0.2 mm) work surface when the same direction, and they are resting on a
bolting the valve sections together. flat (within 0.2 mm), uniform surface.
Use calibrated torque wrenches and
instrumentation. 3. Insert all the tie rods through the drilled holes
The formal Bills of Material, descriptions, and in each of the housings.
views are found in the attached documentation.
Additional auxiliary valve sections may be added 4. Press the sections together, being careful not
to the main control valve in a similar manner as to damage sealing surfaces or seals.
indicated below, as approved by the O.E.M.
5. Install nuts to both ends of all tie rods and
progressively torque in a circular pattern until
reaching a torque of 2.4 ~2.9 kgfm on all tie
rods. Periodically, make sure that the valve
remains flat while applying torque.

Inlet Section : Tilt Section :
1. Install the main relief valve assembly into the 1. The spool assembly should already consist of the
lower side cavity of the section, as illustrated. tilt spool (with tilt plunger and spring inserted into
Torque to 4.5 - 5.0 kgfm. the bore on the spring end), the return spring, one
spring seat on either end of the spring, the seal
2. Install the normally open solenoid valve assembly plate, a spool seal, and a dust wiper. All of these
in the side cavity of the inlet directly above the are assembled on the end of the spool the clevis.
main relief valve. Torque 3.5 - 4.0 kgfm.
2. Insert the clevis end of the spool into the right -
hand side of the spool bore (the tallest end of the
Lift Section : housing). Place the spool cap over the spool and
spring assembly and connect the cap to the
1. The spool assembly should already consist of the housing using two bolts. Torque both bolts
lift spool, the return spring, one spring seat on alternatively until a torque of 1.0 - 1.5 kgfm is
either end of the spring, the seal plate, a spool reached on both bolts.
seal, and a dust wiper. All of these are assembled
on the end of the spool opposite the clevis. 3. Install the second spool seal and dust wiper over
the clevis end of the spool and retain with a seal
2. Insert the clevis end of the spool into the right- plate and two bolts. Torque both bolts alternatively
hand side of the spool bore (the tallest end of the until a torque of 1.0 - 1.5 kgfm is reached on both
housing). Place the spool cap over the spool and bolts.
housing using two bolts. Torque both bolts 4. The load check assembly is inserted into the top
alternatively until a torque of 1.0 - 1.5 kgfm is center cavity. Torque 3.5 - 4.0 kgfm.
reached on both bolts.
3. Install the second spool seal and dust wiper over

the clevis end of the spool and retain with a seal
plate and two bolts. Torque both bolts alternatively
until a torque of 1.0 - 1.5 kgfm is reached on both
bolts.
4. The load check assembly is inserted into the top

center cavity. Torque to 3.5 - 4.0 kgfm.
5. The normally closed solenoid is installed in the

rightmost cavity on the top of the section. Torque
to 3.5 - 4.0 kgfm.
6. Install the lift lock check valve assembly in the

remaining open cavity in the top of the housing.
Torque 4.5 - 5.0 kgfm.
7. Install the needle valve subassimbly in the cavity

on the inlet-facing surface of the housing. Torque
to 1.0 - 1.5 kgfm.

Auxiliary Sections : 3. Install the second spool seal and dust wiper over
(Same procedure for all aux sections, but spool the clevis end of the spool and retain with a seal
assembly components may vary) plate and two bolts. tighten both bolts alternatively
until a torque of 1.0 - 1.5 kgfm is reached on both
1. The spool assembly should already consist of the bolts.
proper aux spool, the return spring, one spring
seat on either end of the spring, the seal plate, a 4. The load check assembly is inserted into the top
spool seal, and a dust wiper. All of these are center cavity. Torque to 3.5 - 4.0 kgfm.
assembly on the end of the spool opposite the
clevis. Outlet Section :
2. Insert the clevis end of the spool into the right- 1. Install the secondary relief valve into the cavity on
hand side of the spool bore (the tallest end of the the clevis end of the housing. Torque to 4.5 - 5.0
housing). Place the spool cap over the spool and kgfm.
housing with two bolts. tighten both bolts
alternatively until a torque of 1.0 - 1.5 kgfm is
reached on both bolts.

Hydraulic Pump Disassemble Hydraulic Pump
Start By:
Remove & Install Hydraulic Pump
a. Remove hydraulic pump.
WARNING
To prevent personal injury, release any pressure
in hydraulic system. Slowly loosen the cap of
the hydraulic tank to release any pressure in the
tank. Be cautious of hot hydraulic oil when any
lines are disconnected in the hydraulic system.
NOTE: Identify and mark all sections of the

hydraulic pump for purposes of reassembly.
1. Remove four bolts (1) and washer (2) to remove

pump rear cover (3).
2. Remove seal (4) from the pump body.
1. Disconnect the lines (1) front and rear from

hydraulic pump (2).
2. Remove two bolts (3) that hold hydraulic pump (2)

to the transmission. Remove the pump.
3. Make a replacement of the pump gasket if

necessary.
4. Put hydraulic pump (2) in position on the

transmission, and install the bolts that hold it.
5. Tighten the bolts (3) to a torque of 45 7 Nm

(33 3 lbft). 3. Remove seal (5), back up-ring (6) and bush (7)
from the pump gears.
6. Connect the lines (1) to hydraulic pump (2).

Assemble Hydraulic Pump
4. Remove gears (8) from the pump body. Separate

the pump sections.
NOTE: When installing seal (14), make sure the lip

of the seal is positioned toward the inside of the
pump housing. The outer surface of seal (14) should
be 6 0.4 mm (0.24 0.2 in) below the outer
surface of the pump end cover.
1. Use tool group (A) to install seal (14) in the pump

body.
5. Remove O-ring (9), seal (10), back up-ring (11)

and bush (12) from the pump body.
Replace seals, back up-ring, O-ring with new if
needed.
2. Install bush (12), back-up ring (11), seal (10) and

O-ring (9) in the pump body.
6. Remove snap ring (13) and seal (14) from the

flange (15).
3. Install gears (8) in the pump body.

4. Install bush (7) back-up ring (6) and seal (5) in the
pump body.
5. Install seal (4) on the pump body.
6. Install the bolts (1), washers (2) and pump rear

cover (3) onto the pump body. Tighten the bolts
for rear cover (3) to a torque of 45 Nm (33 lbft).
End By:
a. Install the hydraulic pump.

Tilt Cylinder
Remove & Install Tilt Cylinders
NOTE: The procedure for removing and installing
the tile cylinders is the same for both cylinders.
WARNING
If both tilt cylinders are to be removed at the
same time, make sure that the mast is held
either by a hoist or is securely held in place by
blocks. 3. Remove bolts (4), the washer. Remove rear tilt
cylinder pin (5).
4. Remove tilt cylinder (6) from the lift truck.
5. Install the tilt cylinder in the reverse order of

removal.
NOTE: When installing bolts (4), apply Loctite

NO.242.
Disassemble & Assemble Tilt

Cylinder
1. Put identification marks on the hydraulic lines. Start By :
Disconnect hydraulic lines (1) from the tilt cylinder.
Put caps or plugs on the lines and the openings a. Remove tilt cylinder.
on the tilt cylinder to keep out dirt or foreign
material.
1. Use wrench to remove rod cover (1) from the

cylinder body.
2. Remove bolts (2), washes from the cylinder eye.
Remove pin (3).
NOTICE
Use extra care not to damage the highly finished
surface of the cylinder rod and the bore of the
cylinder body during disassembly and assembly of
the tilt cylinder.
2. Remove rod assembly (2) from the cylinder body.

NOTICE
Check the condition of all seals. If any parts are
worn or damaged use new parts for replacement.
3. Remove nut (3) from the cylinder rod.
4. Remove piston and seal assembly (4) from the

cylinder rod.
5. Remove rod cover assembly (5).
9. Remove O-ring seal (10) and backup ring (11)

from the rod cover.
6. Remove spacer with a O-ring seal and shims from

the cylinder rod (2) if they are installed.
7. Loosen the nut and bolt (6) on the rod eye. 10. Remove wiper seal (12) and U-packing (14) from
Remove cylinder rod. the rod cover.
8. Remove slipper seal (7) and O-ring seal (8) from 11. Remove the DU-bush (15) from the rod cover. If
the piston (9). the DU-bush has a large amount of wear,
replace the DU-bush.
NOTE: Use the following steps to assemble the tilt

cylinder.

12. Install wiper seal (12) in the rod cover. Position 16. Position the cylinder rod eye in a vise as shown.
the lip of the seal toward the outside of the rod
cover as shown. 17. Install cylinder rod (2) and shims. Tighten the nut
and bolt (6) on the rod eye to a torque of 95 15
13. Install U-packing (14) in the rod cover. Nm (70 10 lbft).
18. Install the spacer with O-ring seal onto the

cylinder rod if needed.
14. Install O-ring seal (10) and backup ring (11) on

the rod cover.
19. Install rod cover assembly (5) on the cylinder rod.
20. Install piston assembly (4) onto the cylinder rod.

The torque for the nut (3) is 260 25 Nm (190
20 lbft).
15. Install slipper seal (7) and O-ring seal (8) on the
piston (9).

Brake Master Cylinder
Remove & Install Brake Master
Cylinder
21. Install the rod assembly (2) in the cylinder body.
22. Use wrench to tighten rod cover (1). The torque

for rod cover (1) is 270 35 Nm (200 25
lbft).
End By :
a. Install tilt cylinder.
1. Remove the cotter pin from pin (1). Remove pin

(1).
NOTE: Plug and cap all openings to avoid

contamination and debris from entering the system
after removing any tubes or lines.
2. Prepare the bottle to get the drained oil

Disconnect the hose (2) from master cylinder.
Since the oil will be drained, raise the hose
upward and then, drain the oil to the bottle.
3. Disconnect tube (3) from master cylinder.
4. Support the brake master cylinder. Remove two

bolts (4).
5. Remove the brake master cylinder (5).
6. Install the brake master cylinder in the reverse

order of removal. Refer to the dimension for the
linkage shown at the next page.

7. Bleed the brake system. Refer to the Testing and
Adjusting Manual for further information.

Disassemble & Assemble Brake Steering Wheel
Master Cylinder
Remove & Install Steering Wheel
Start By :
a. Remove master cylinder.
1. Remove cap (1) from the steering wheel.
1. Remove head (1) and boot (2).
2. Remove snap ring (3) from master cylinder.
3. Remove bolt (4) from master cylinder.
2. Remove nut (2) and up (3) from the steering

wheel shaft. Put location marks on the steering
wheel and the steering wheel shaft for installation
purposes.
3. Use plastic hammer to remove the steering wheel

4. Remove union (5) and washers (6). from the shaft.
5. Remove plate (7) and piston (8). NOTE: Use the following steps to install the steering
wheel.
6. Remove secondary cup (9) from piston.
4. Put the steering wheel on the steering wheel shaft
7. Remove spacer (10) and primary cup (11). in its original position.
8. Remove spring (12) and check valve (13). 5. Install cup (3) and nut (2). Tighten nut (2) to a
torque of 80 7 Nm (60 5 lbft).
9. Assemble the master cylinder in the reverse order
of disassembly. 6. Install cap (1).
End By :
a. Install master cylinder.

Steering Unit
WARNING
Remove & Install Steering Unit To prevent personal injury, be sure pressure in
the hydraulic system has been released before
Start By: disconnecting any hydraulic lines. Slowly loosen
the cap of the hydraulic tank to release any
a. Remove steering wheel. pressure in the tank. Be cautious of hot
hydraulic oil when any lines are disconnected in
the hydraulic system.
NOTE: Identify and mark all hydraulic hoses for

purposes of reassembly.
4. Disconnect five hoses from steering unit (5).
NOTICE
Steering unit (5) and column (2) can separate after
bolts (4) have all been removed, causing unit (5) to
fall. To avoid damaging components, support the
1. Open the access cover for the fuse panel.
steering pump while removing bolts (4).
2. Loosen four bolts (1). Slide directional control
switch (3) off of steering column (2). Set switch 5. Support steering unit (5) while removing the
(3) aside, clear of the steering column. remaining two bolts (4). Remove steering unit (5)
and steering column (2).
6. Install the steering unit in the reverse order of

removal.
End By :
a. Install steering wheel.
3. Remove two bolts (4).

Disassemble Steering Unit
Cleanliness is extremely important when repairing a
steering unit. Work in a clean area. Before
disconnecting lines, clean port area of unit
thoroughly.
Use a wire brush to remove foreign material and
debris from around exterior joints of the unit.
Although not all drawings show the unit in a vise, we

recommend that you keep the unit in the vise during
disassembly. Follow the clamping procedures
explained throughout the manual.
2. Remove 5/16 inch cap screws and washers if

applicable (7 each).
3. Remove end cap.
4. Remove seal from end cap.
1. Clamp unit in vise, meter end up. Clamp lightly on

edges of mounting area. Use protective material
on vise jaws. Housing distortion could result if
jaws are overtightened.
5. Remove meter. Be careful not to drop star.
6. Remove seal from meter.
7. Remove drive spacer(s).

12. Rotate spool and sleeve until pin is horizontal.
8. Remove drive. Push spool and sleeve assembly forward with
your thumbs just far enough to free gland
9. Remove spacer plate. bushing from housing. Remove bushing.
10. Remove seal from housing.
13. Remove quad ring seal from seal gland bushing.
14. Use a thin bladed screwdriver to pry dust seal

from seal gland bushing. Do not damage
bushing.
11. Remove housing from vise. Place housing on a

clean soft cloth to protect surface finish. Use a
thin bladed screwdriver to pry retaining ring from
housing.

15. Remove two bearing races and the needle thrust 18. Push spool partially from control end of sleeve,
bearing from spool and sleeve assembly. then remove 4 centering springs from spool
carefully by hand.
19. Push spool back through and out of sleeve.

Rotate spool slowly when removing from sleeve.
20. Remove seal from housing.
16. Remove spool and sleeve assembly from 14

hole end of housing.
Attention: Do not bind spool and sleeve in housing.

Rotate spool and sleeve assembly slowly when 21. Remove check ball seat.
removing from housing.
22. Tip housing to remove check ball.
17. Push pin from spool and sleeve assembly.

Assemble Steering Unit
Check all mating surfaces. Replace any parts that
have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry with
air. Do not wipe dry with cloth or paper towel
because lint or other matter can get into the
hydraulic system and cause damage. Do not use a
coarse grit or try to file or grind these parts.
Note: Lubricate all seals with clean petroleum jelly

such as Vaseline.
Do not use excessive lubricant on seals for meter

section.
Refer to parts listings covering your steering unit 6. Assemble spool and sleeve carefully so that the
when ordering replacement parts. A good service spring slots line up at the same end. Rotate spool
policy is to replace all old seals with new seals. while sliding parts together. Some spool and
sleeve sets have identification marks, align these
marks. Test for free rotation. Spool should rotate
smoothly in sleeve with finger tip force applied at
splined end.
1. Use a needle nose pliers to lower check ball 7. Bring spring slots of both parts in line and stand
retainer into check valve hole of housing. Make parts on end of bench. Insert spring installation
sure retainer is straight (not tilted on edge) in tool through spring slots of both parts. Position 2
housing. pairs of centering springs on bench so that
extended edge is down and arched center section
2. Install check ball in housing is together. In this position, insert one end of
entire spring set into spring installation tool, with
3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm [.30 spring notches facing sleeve.
in.] ID seal. Install seals on check ball seat as
shown. 8. Compress extended end of centering spring set
and push into spool sleeve assembly withdrawing
4. Lubricate check ball seat and seals thoroughly installation tool at the same time.
before installing seat in housing. When installing
seat do not twist or damage seals. Install check 9. Center the spring set in the parts so that they
ball seat in housing, insert open end of seat first. push down evenly and flush with the upper
Push check ball seat to shoulder of hole. surface of the spool and sleeve.
5. Install set screw. Use a 1/4 inch hex key to torque 10. Install pin through spool and sleeve assembly
set screw to 11 Nm [100 lbin]. To prevent until pin is flush at both sides of sleeve.
interference make sure top of set screw in slightly
below housing mounting surface.

11. Position the spool and sleeve assembly so that
the splined end of the spool enters the 14 hole
end of housing first.
16. Install seal gland bushing over the spool end
Attention: Be extremely careful that the parts do not with a twisting motion. Tap the bushing in place
tilt out of position while inserting. Push parts gently with a rubber hammer. Make sure the bushing
into place with slight rotating action, keep pin nearly is flush against the bearing race.
horizontal. Bring the spool assembly entirely within
the housing bore until the parts are flush at the
meter end or 14 hole end of housing.
Do not pull the spool assembly beyond this point to
prevent the cross pin from dropping into the
discharge groove of the housing. With the spool
assembly in this flush position, check for free
rotation within the housing by turning with light finger
tip force at the splined end.
12. Place housing on clean lint free cloth. Install

47,5 mm [1.86 in.] ID seal in housing.
13. Install 2 bearing races and the needle thrust 17. Install retaining ring in housing. After installing
bearing in the order shown. ring, tap on ring end or pry with screwdriver
around entire circumference of ring to properly
14. Install 25 mm [1 in.] ID dust seal in seal gland seat ring in groove.
bushing, flat or smooth side must face down
towards bushing.
15. Install the quad ring seal in seal gland bushing.

Smooth seal in place with your finger. Do not
use any seal that falls freely into pocket of
bushing.

18. Clamp housing in vise. Clamp lightly on edges of 21. Rotate spool and sleeve assembly until pin is
mounting area. Do not over tighten jaws. parallel with port face. Install drive, make sure
you engage drive with pin. To assure proper
Note: Check to insure that the spool and sleeve are alignment, mark drive as shown. Note
flush or slightly below the 14 hole surface of the relationship between slotted end of drive to
housing. splined end of drive when marking.
Attention: Clean the upper surface of the housing
by wiping with the palm of clean hand. Clean each
of the flat surfaces of the meter section parts in a
similar way when ready for reassembly. Do not use
cloth of paper to clean surfaces.
22. Install 73.5 mm [2.89 in.] ID seal in spacer plate

or gerotor (meter).
19. Install 73.5 mm [2.89 in.] ID seal in housing.
20. Install spacer plate. Align bolt holes in spacer

plate with tapped holes in housing.

Actual Displacement Spacer
cm3/r(in3/r) Length mm[in.]
45 [ 2.8 ] None
60 [ 3.6 ] None
75 [ 4.5 ] None
95 [ 5.9 ] 3.56 [ .140 ]
120 [ 7.3 ] 6.10 [ .240 ]
145 [ 8.9 ] 10.29 [ .405 ]
160 [ 9.7 ] 12.19 [ .480 ]
185 [ 11.3 ] 15.62 [ .615 ]
230 [ 14.1 ] 21.97 [ .865 ]
295 [ 17.9 ] 28.45 [ 1.120 ]
370 [ 22.6 ] 41.15 [ 1.620 ]
460 [ 28.2 ] 53.67 [ 2.113 ]
590 [ 35.9 ] 66.37 [ 2.613 ]
740 [ 45.1 ] 91.77 [3.613 ]
24. Install drive spacer (s) when used, in meter.
25. Install 73.5 mm [2.89 in.] ID seal in gerotor

(meter) or end cap, see notes.
26. Install end cap on gerotor, align holes.
23. With seal side of meter toward spacer plate,

align star valleys on drive. Note the parallel
relationship of reference lines A, B, C, and D.
Align bolt holes without disengaging meter from
drive.
27. Install 7 dry cap screws in end cap. Pretighten

screws to 11-17 Nm [100-150 lbin] then torque
screws to specifications.

Steer Axle
Steer Wheel & Hub-Pneumatic
Remove Steer Wheels & Hub
6. Bend the tap in locking washer (4) clear slot in nut.
7. Remove nut (5). Remove locking washer (4).
1. Raise the rear of the machine and support with

wooden block.
2. Remove six nuts (1).
8. Remove washer and bearing cone (6) from the

hub (7).
3. Remove steer wheel (2).
9. Remove hub (7) from steering knuckle (8).
4. Remove wheel cap (3).
5. Eliminate grease in the hub.

13. Pack bearing cones (6) and (12), and lubricate
the contact surfaces of the bearing cups with
Multipurpose Grease.
14. Reverse the procedures and steps 1 through 12

to install the steer wheels and bearings.
15. Adjust the steer wheel bearings as follows:
a. Tighten nut (5) to a torque of 135 14 Nm

(100 10 lbft) while slowly rotating steer
wheel (2).
10. Remove seal (9) and bearing cup (10) from hub b. Loosen nut (5) completely.
(7).
c. Tighten nut (5) again to a torque of 50 5
Nm (37 4 lbft).
d. Grease the inside of hub fully.
e. Fit the locking washer (4) and bend a tab of

locking washer into a slot of nut (5). Be careful
not to miss this job.
16. Install wheel cap (3).
17. Install steer wheel (2).
18. Rasise the rear of the machine and remove the

11. Remove bearing cup (11) from the hub. wooden block.
12. Remove bearing cone (12) from knuckle.
NOTE: Check the condition of all seals, bearings

and components. If any parts are worn or damaged,
use new part for replacement.

Steer Wheel Bearing-Cushion
Remove Steer Wheel & Bearing
NOTE: The procedure to remove the steer wheels is
the same for the right and left steer wheel.
5. Remove bearing cone (4) from steer wheel (5).
6. Remove steer wheel (5). Steer wheel (5) weighs

34 kg (75 lb).
1. Support the steer axle with a floor jack.
2. Remove wheel cap (1).
7. Remove seal (6) from the back of steer wheel (5).
8. Remove bearing cone (7) and the bearing cup

from the back of steer wheel (5).
3. Bend the tab in locking washer (2) clear of the slot

in nut (3).
4. Remove nut (3). Remove locking washer (2).
9. Remove bearing cup (8) from the front of steer

wheel (5).
NOTE: Check the condition of all seals, bearings

and components. If any parts are worn or damaged
use new parts for replacement. For purposes of
assembly, lower the temperature of the bearing cups
and before installing into steer wheel (5). Use tooling
(B) to install bearing cups and seals.

10. Pack bearing cones (4) and (7) and lubricate the
contact surfaces of the bearing cups with
Multipurpose Grease.
11. Reverse the procedures and steps 4 through 9

to install the steer wheels and bearings.
12. Adjust the steer wheel bearings as follows :
a. Tighten nut (3) to a torque of 70 Nm (52 lbft)

while slowly rotating steer wheels (5).
b. Loosen nut (3) completely.

3. Remove bearing (4) from the tie rod.
c. Tighten nut (3) again to a torque of 505 Nm
(374 lbft).
Install Tie Rods
d. Fit the locking washer (2) and bend a tab of
locking washer (2) into a slot of nut (3). Be
careful not to miss this job.
13. Install wheel cap (1).
14. Remove floor jack and lower the lift truck.
Tie Rods
Remove Tie Rods
1. Install the bearing in the tie rod.
1. Remove the cotter pin (1), pins (2) and seals from
the tie rod.
2. Put seals (1) in position as shown. Install tie rod
2. Remove tie rod (3). (2) with the others seals.
3. Install the pins and retaining rings that hold the tie
rod in position.

Steer Axle-Cushion
Remove & Install Steering Axle
WARNING
Be sure the pressure in the hydraulic system is

released before any lines or hoses have been
disconnected
1. Remove four bolts (1). For installation purposes,

the torque for bolts (1) is 10020 Nm (7414
lbft).
2. Remove steer cylinder (2).
NOTE: There are dowels in the cylinder mounting

holes.
3. Install steer cylinder (2) in the reverse order of

removal.
End By :
1. Put identification marks on steering lines (1).
Disconnect steering lines (1) from the steering a. Install tie rods.
cylinder.
b. Install steer axle.
2. Put a floor jack in position under the steer axle.
Remove bolts (2).
Disassemble & Assemble Steering
3. Lower steer axle with the floor jack to remove it
from under the machine. The weight of the steer
Cylinder
axle is about 150 kg (330 lb).
4. Install the steer axle in the reverse order of

removal.
NOTE: When installing bolts (2), torque to the bolts

(2) to 27040 Nm (19929 lbft)
Steer Cylinder-Cushion
Remove & Install Steering Cylinder
1. Put location marks on end caps (1) as to their
Start By : position on the steer cylinder tube (2).
a. Remove steer axle. 2. Remove end caps (1) from the steer cylinder.
b. Remove tie rods. 3. Remove rod assembly (3) from the tube.

Knuckle, Kingpin and Bearing
Remove Knuckle, Kingpins and

Bearing
Start By :
a. Remove steer wheels and bearings.
b. Remove tie rods.
4. Remove seal (4) from the rod assembly (3).
1. Remove bolt and nut (1) that hold the kingpin in

position.
5. Remove O-ring (5) from each end cap assembly
(1).
2. Remove cotter pin (2), nut (3) and washer.
6. Remove wiper seal (6), U-cup seal (7) and wear

ring (8) from each end cap assembly.
7. Assemble the steering cylinder in the reverse

order of disassembly.
3. Push kingpin (4) and the bearing out of the

steering axle with a brass drift and hammer.

4. Remove steering knuckle (5) from the steering 4. Tighten kingpin nut (1) to a torque of 21 Nm
axle. Remove the bearings (6) and seals (7). (15.5 lbft). while rotating knuckle in both
directions to seat bearings. Then loosen kingpin
nut completely. Retorque nut to 6 to 7 Nm (4.5
Install Knuckle, Kingpin and to 5.1 lbft).
Bearing 5. Install cotter pin to lock nut at this torque.
End By :
a. Install tie rods.
b. Install steer wheels and bearings.
Steer Axle-Pneumatic
Remove & Install Steer Axle
WARNING
1. Install the seal and bearing in the knuckle. Install
the seal with the sealing lip away from the bearing. Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
NOTE: Prepack bearings with multipurpose EP disconnected.
NLGI NO.2 LITHIUM GREASE prior to assembly.
2. Put the knuckle in position on the steer axle.
3. Lubricate pins with EP NLGI NO.2 LITHIUM

GREASE.
1. Raise the rear of the lift truck and support with

wooden block.
2. Disconnect two hoses (1). Plug and cap all

openings to prevent contamination and debris
from entering the system.

3. Support the steer axle with a floor jack. NOTE: Use bolts (2) and cap to align steer axle (4)
with the mounting bosses while raising steer axle (3)
4. Loosen rear mounting bolt (2) until approximately into position with the floor jack.
two bolt threads are left in the mounting boxes.
9. Seat steer axle (3) as follows:
5. Lower the steer axle onto the bolt heads with the
floor jack. a. Install bolts (2) through cap (5) and into the
mounting bosses approximately two bolt
6. Remove front mounting bolts and mounting caps threads.
from the steer axle.
b. Use the floor jack to raise steer axle (3) into the
mounting boss.
c. Tighten bolts (2) to a torque of 270 40 Nm

(200 30 lbft).
Typical Example
7. Remove steer axle (3).
NOTE: Use the following steps to install the steer

axle.
10. Connect two hoses (1).
Typical Example
8. Use a floor jack to position steer axle (3).

Steer Cylinder - Pneumatic
Disassemble Steer Cylinder
Start By:
a. Remove steer cylinder.
5. Remove piston (4) from the cylinder rod.
1. Put location marks on rod-cover (1) as to their

position on the steering cylinder tube.
2. Remove rod covers (1) from the steer cylinder.
6. Remove and inspect O-ring seal (5).
3. Remove cylinder tube (2) from the rod assembly.
4. Remove retaining rings (3) from the cylinder rod.

1. Assemble each rod cover as follows:
a. Install DU-bush (9).
b. Install U-packing (8).
c. Install wiper seal (7).
d. Install O-ring seal (6).
7. Disassemble each rod cover as follows:
a. Remove O-ring seal (6).
b. Remove wiper seal (7).
c. Remove U-packing (8).
d. Remove DU-bush (9).
2. Install O-ring seal (5) on the cylinder rod

Assemble Steering Cylinder
3. Install piston (4) on the cylinder rod.

Link, Knuckle, Kingpin and
Bearing
Remove & Install Link, Knuckle,
Kingpin and Bearing
Start By :
a. Remove steer wheels and bearings.
4. Install rings (3) on each side of piston.
1. Remove the split pins, nuts (1) and washers from

the links (2).
5. Install cylinder tube (2) on the rod assembly. 2. Remove the links (2).
3. Remove the bolts (3) and covers (4) from the

knuckle (5).
4. Remove the knuckle from the steer axle.
6. Install rod cover (1) on cylinder tube (2).
End By:
a. Install the steering cylinder.

5. Remove the bearings (6), king pin (7) and seals
(8).
6. Install the links, kunckles, kingpins, and bearings

in the reverse order of removal.
End by :
a. Install steer wheels and bearings.

Counterweight
Remove Counterweight
4. Remove bolts (5) from the rear of the

counterweight.
5. Remove counterweight (6) from the frame of the

1. Disconnect fuel line (1).-for G(C)15/18/20S(C)-5 lift truck.
Install Counterweight
2. Remove bolts (3) to remove LP container

mounting brackets (2) and LP tank. - for
G(C)15/18/20S(C)-5
1. Put two suitable eyebolts (4) in the counterweight,
and fasten a hoist to it.
2. Put counterweight (6) in position on the lift truck

frame.
3. Install two suitable eyebolts (4) in the

counterweight and fasten a hoist.

Radiator
Remove & Install Radiator
Start By :
a. Remove counterweight
1. Drain the coolant from radiator.
3. Install bolts (5) at the rear of the counterweight.

Tighten bolt to a torque of 400 50Nm (300 37
lbft).
4. Remove the eyebolts and the hoist. Install LP

container mounting brackets (2) and bolts (3) that
hold it. - for G(C)15/18/20S(C)-5
2. Disassemble the muffler(1).
5. Connect fuel line (1) to the counterweight. - for

G(C)15/18/20S(C)-5

Fan Belt & Alternator Belt LP
truck
For G(C)15/18/20S(C)-5
3. Support the radiator and remove three mounting

bolts and washers (2).
1. Loosen the bolt (1) and (2) and, shift the clamp
(3) inward. And, shift the alternator toward the
engine.
4. Loosen clamp (3).

Remove hoses (4) - inlet and outlet - from the
radiator.
5. Remove the radiator.
6. Install the radiator in the reverse order of removal.
7. Install the muffler.
End by :
a. Install counterweight.
2. Replace the fan belt (4)

2. Loosen top bolt (2) and then remove belt (3) from
the pulley.
3. Support the alternator. Remove bolt (3) and

washer. Remove the alternator.
4. Install the alternator in the reverse order of

removal.
5. Adjust the belt tension properly.
3. Install the fan belt and adjust the belt tension Electric Starting Motor
properly by tightening the bolt (2) and (1).
Remove & Install Electric Starting
4. In case of replacing the alternator belt, it needs to
remove the fan belt at first. Motor
5. To replace the alternator belt (5), loosen the bolt

(2) and the bolt (1).
6. Shift the alternator (6) toward the engine.
7. lnstall the alternator belt in the reverse order of

removal.
Alternator Diesel truck
1. Disconnect the battery positive cable. Be careful

not to miss this job.
2. Disconnect starter wires (1) and (2).
3. Remove two bolts (3) and then remove starter (4)

from the engine rear plate.
4. Install the starter in the reverse order of removal.
1. Disconnect wiring harness (1) from the alternator.

Fuel Filter Diesel Oil Filter
Remove & Install Fuel Filter Remove & Install Oil Filter
<D15/18/20S(C)-5> <D15/18/20S(C)-5>
1. Loosen hose clamp (1) and disconnect the

connector.
2. Remove fuel filter element (2).
3. Check the condition of seal. Replace seal with

new if worn or damaged.
4. Put the new fuel element (2) in position.
5. Assemble the connector and then, tighten clamp

(1).
<G15/18/20S(C)-5>
1. Remove the oil filter housing (1) from the base.
2. Install a new oil filter housing (1) on the oil filter

base.

Air Cleaner Housing
Assembly
Remove & Install Air Cleaner
Housing Assembly
3. Remove nut (3). Remove the secondary filter

element (4) from the housing.
1. Remove the cover (1).
4. Loosen hose clamps (5) and pull hose off of air

cleaner housing.
2. Remove the primary element (2).
5. Remove two bolts (6) that hold air cleaner

housing.
6. Remove air cleaner housing from the frame.
7. Install air cleaner in the reverse order of removal.

Engine and Transmission
Remove & Install Engine and
Transmission
Start By:
Park the lift truck on the plain ground and lift it off
the ground. Put the wooden block under the lift truck,
if drive axle needs to be removed.
a. Remove mast and overhead guard.

b. Remove floor plate. 2. Disconnect the inching cable (2).
c. Remove the accel pedal.
d. Drain the transmission oil, axle oil if required.
e. Disconnect the battery cable. NOTICE
Plug and cap all openings to avoid contamination
and debris from entering the system after removing
NOTICE any tubes or lines.
Put identification marks on all wiring, hoses and
lines to assure the proper installation before
disassembly.
3. Disconnect the hoses (3) from the left hand tilt

cylinder.
1. Disconnect the parking cable (1).
4. Remove bolt (4) and pump (5).

5. Disconnect two connectors (6) for solenoid valves. 9. Disassemble the u-joint (9). The torque for
reassembly is 70 10 Nm (53 8 lbft). Apply
LOCTITE#262.
6. Disconnect (2) cooling hoses, hyd. hoses and

harnesses.
10. Support the drive axle by crane and disassemble
four bolts (10) each side. For the reassembly
purpose, the torque for bolt is 380 25 Nm (285
20 lbft).
7. Disconnect the tube (8) for brake pressure lines.
8. Disconnect the connector to SECM in case of

G(C) 18S-5 truck.
NOTE: At this point, make a final check to be sure
all removals and disconnections have been made
from the transaxle and engine.

17. Loosen the mounting bolts for transmission. Be
sure again if the transmission oil is drained. The
torque for reassembly is 55 10 Nm (42 7
lbft).
11. Remove the drive axle from the frame. Put the
drive axle on the wooden block.
12. Disconnect wire harness for fuel sender.
18. Remove nut and washers from the engine mount,

13. Disconnect the fuel line and air cleaner hose. located on each side of the engine. For the
reassembly purpose, the torque for nut (29) is 55
14. Discennect the exhaust tube. 10 Nm (47 7 lbft).
19. Disassemble the six bolts for mounting the plate

to Hywheel. For the reassembly purpose, the
torque is 25 7 Nm (19 5 lbft).
20. Support the engine with a hoist. Remove seven

bolts and washers from the converter housing.
For the reassembly purpose, the torque for the
bolt is 55 10 Nm (42 7 lbft).
15. Disconnect the battery cables and all other

harnesses connected to the fixed items.
NOTE: At this point, make a check to be sure all

removals and disconnections have been made from
the drive axle, transmission and engine.
16. Support the engine and transmission with a hoist

21. Remove the engine from the transmission.
22. Install the engine in the reverse order of removal.
End By:
a. Install floor plate.
b. Install seat and hood.
c. Install overhead guard.
d. Install mast.

SB2143E04
Apr. 2007
Mast System
Testing & Adjusting
G15S-5, G18S-5, G20SC-5

GC15S-5, GC18S-5, GC20SC-5
D15S-5, D18S-5, D20SC-5
B16X-5, B18X-5, B20X-5
B13T-5, B15T-5, B18T-5
B15S-5, B18S-5
BC15S-5, BC18S-5, BC20SC-5
WARNING
publication.
1
Index

Forks......................................................................5
Backrest .................................................................5
Carriage .................................................................6
Mast .......................................................................9
Testing & Adjusting
Chain Adjustments ...............................................22

Chain Wear Test ..................................................22
Carriage and Mast Height Adjustment...................23
Forks Parallel Check ............................................23
Tilt Cylinder Alignment..........................................24
Drift Test ..............................................................24
Tilt Cylinder Adjustment........................................25
Lift & Tilt Mounting Group Adjustment...................26
Mast mounting Group Adjustment.........................27
Lift Trucks Mast System 3 Index

Lift Trucks Mast System 4 Index
Forks Backrest
Remove & Install Forks Remove & Install Backrest
1. Fasten a hoist to the backrest. Remove bolts(2)

that fasten the backrest to the carriage.
2. Remove backrest (1).

Backrest weighs 32 kg (71 lb).
3. Install backrest (1) in the reverse order of

removal.
1. Remove stopper bolt and washer (3).
2. Lift fork pin (1).
3. Use a suitable C-clamp, strap and hoist to support

the fork as shown.
4. Slide the fork to slot (2) in the middle of the

carriage.
5. Remove the fork. The weight of the fork is 35 kg

(77 lb).
6. Repeat steps 1 through 4 for the remaining fork.
7. Install the forks in the reverse order of removal.
8. Put the forks in position. Lower both fork pins (1)

to lock the forks in position.
9. Install stopper bolt and washer (3).
Lift Trucks Mast System 5 Disassemble & Assembly

Carriage
Remove & Install Carriage
Start By:
a. Remove forks.
b. Remove backrest.
4. Remove two nuts (6).

Remove carriage stop bolt (7).
1. Remove two bolts (1) from the cross head (2).
2. Remove cross head (2) from the cylinder rod (3).
5. Raise the inner mast to pull out carriage as

shown.
3. Remove hoses (5).
6. Remove carriage from bottom of inner mast (9).
Carriage weighs 64kg (141 lb).
NOTE : Use the following steps to install the

carriage.
7. Raise the inner mast (9) to put in the carriage (8)

onto the mast, and lower the inner mast to cover
carriage bearing fully.

End By:
a. Install backrest.
b. Install forks.
Disassemble Carriage
Start By:
a. Remove carriage.
8. Install stop bolt (7).

Shim stop bolt as required to obtain a 4 to 6 mm
(.157 to .242 in) lap with top carriage stop on the
inner upright.
9. Put the chains in position over cross head. Install

nuts(6) onto the chain anchors to a torque of 300
30 Nm (22022 lbft).
1. Remove the roll pins and pins (2) to disconnect

chains (1).
10. Install hoses (5).
2. Remove lower roller bearings (3) and the shims

from the carriage.
11. Install cross head (2) to cylinder rod (3).
12. Install hose guard (2) and bolts (1) to a torque of

82 Nm (61.5 lbft).

1. Select bearings from the chart to obtain minimum
clearance (C) between bearings and channel leg
for full channel length. Use same bearing at all
four locations.
CARRIAGE BEARING CHART

Part No. Bearing Size Bearing O.D.*
D580006 Undersize 98.5 mm (3.878 in)
D580007 Standard 99.0 mm (3.898 in
D580008 Oversize 99.5 mm (3.917 in)
3. Remove screw (5) and washer (4). * Permissible tolerance of 0.08 mm (.003in)
Remove two top roller bearings (6) and the shims.
Refer to carriage Adjustment in Testing & Adjusting.
4. Remove bolt (7), washer, pin-adjust (8) and
side-roller bearing (9) from the carriage.
Assemble Carriage
NOTE : The standard, Full Free Lift and Full Free

Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is
shown in the following illustrations.
To make the carriage clearance adjustments,

carriage must be removed from the mast.
Use the procedure that follows to adjust carriage

load bearings. 2. Find narrowest point by ruler on the inner mast in
the area where the bearings make contact.
3. Install enough shims (1) that have been divided

into two equal groups behind bearings (2). At
installation, there is to be contact [zero clearance
Carriage Adjustment
(A)] between the bearings and the narrowest
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
point of inner mast.
(7) Side-roller bearings. (8) Lower bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero clearance.
4. Do step 2 through 3 for other sets of bearings.
(B) 4.0 to 6.0 mm. (.157 to .242 in) clearance.
(C) Minimum clearance. (D) 4.5 0.5 mm

Mast
Remove & Install Mast
Start By:
a. Remove forks.
Move the truck to the place where pit is set up.
5. Tighten screw (3) that holds the top and middle

bearings (4) to the carriage to a torque of 347
Nm (255 lbft).
1. Support mast assembly (2) with a hoist and strap

(1) as shown.
6. Position chains (6) on the carriage. Install pins (5)

and the roll pins.
End By:
a. Install carriage, raise the inner mast and insert the

carriage from the bottom of inner mast.
NOTICE
Place identification marks on all hydraulic
connectors and hoses to assure proper installation.
Plug and cap all hydraulic connectors and hoses to
avoid debris and contamination from entering the
system.
2. Disconnect hose(3).
NOTE : For B15/18/20T-5(36V), see article 6 prior to

disconnecting hose (3).

8
WARNING
Tilt cylinders (4) can drop when pin(6) is
removed. 6. B16/18/20X-5, B15/18/20T-5
To avoid component damage or personal injury, Tilt forward mast assembly with the hoist.
support tilt cylinder (4) while removing pin(6). Remove bolts (8) from each side.
3. Remove bolt (5) from each side of mast assembly WARNING

(2). Loosen the tension of straps to be connected
with hoist when mast assembly is tilted forward.
4. Remove pin (6) from the tilt cylinders on each If straps are too tight, mast assembly could slide
side of the mast assembly. off when bolts (7), (8) are removed.
7. Use the hoist to remove mast assembly from the

truck.
8. Install the mast in the reverse order of removal.
End By:
a. Install forks.
5. D,G15/18/20S(C)-5, GC15/18/20S(C)-5,
B15/18S-5, BC15/18/20S(C)-5
Tilt forward mast assembly about 8 with the
hoist.
Remove four bolts (7) from pit each side of the
base of mast assembly.

Disassemble Mast
Start By:
a. Remove lift chain to be connected primary lift

cylinder.
b. Remove primary lift cylinder.
NOTE: The following disassembly and assembly

procedure is for a full free triple lift mast.
4. Disconnect and remove chains (5) from the

bottom of the mast.
1. Remove hoses (1) along with the hose support

clamps (2).
5. Remove tube assy (9) and bolt (10) from

stationary mast and disconnect regulator (8) from
secondary cylinder.
2. Remove hose sheave (3).
3. Remove chain nut (4) from the top of the mast

(each side).

6. Remove top cylinder retainer bolts (11) from each
side of the mast. D,G15/18/20S(C)-5, GC15/18/20S(C)-5, B15/18S-5,
BC15/18/20S(C)-5
7. Remove cylinder retainer brackets (12) from each

cylinder.
B16/18/20X-5, B15/18/20T-5
10. Remove bearing mounting pins (15) and screw

(16) from the mast lower hinge mounting part.
8. Remove secondary cylinders (13). Each cylinder
weighs 38 kg (84 lb). 11. Check the condition of the bearings (17) located
in each of the mast mounting bracket.
Replace the bearings (17) with new if worn or
damaged.
9. Check the condition of bearings (14) located in

each of the tilt cylinder pin bores. Replace
bearings (14) with new if worn or damaged.

12. Move inner mast channel (21) downward. 17. Move intermediate mast channel (24) downward.
13. Remove bearings (18) and shims from the 18. Remove bearings (22) and the shims from the
intermediate mast channel (24). stationary mast channel.
14. Remove nylon pads (19) and shims. 19. Remove nylon pads (23) and the shims.
15. Remove bearings (20) and shims from the inner 20. Remove bearings (25) and the shims from the
mast channel (21). intermediate mast channel (24).
16. Fasten nylon straps and hoist to inner channel 21. Fasten nylon straps and a hoist to the
(21). Remove inner channel. The weight of the intermediate mast channel (24). Remove
inner channel is 110 kg (243 lb). intermediate mast channel. The intermediate
mast channel weighs 112kg (247 lb).

Assemble Mast
NOTE: The standard, Full Free Lift and Full Free

Triple Lift mast load bearings are all adjusted the
same way. The mast shown in the following
illustrations is the Full Free Triple Lift mast.
1. Make sure all parts are clean and free of dirt and
foreign material.
2. Check all parts for damage, use new parts for

replacement.
A. Lower Bearing Adjustment of Intermediate 4. Find narrowest point by ruler on the stationary
Mast mast in the area where the bearings make
contact at 420 mm (16.5 in) channel lap.
NOTICE
When the correct amount of shim has been installed
behind bearings (1) there will be contact (zero
clearance) between the bearings and the inner mast
at most narrow point of mast.
Mast Adjustment Lower Bearings

(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. 5. Lifting by crane, insert intermediate mast into
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims. stationary mast from the upper side.
3. Select lower bearings (3) and (4) from the chart to

obtain minimum clearance (B) between bearing
and channel leg for full channel length. Use same
be aring on left and right side.
MAST And Carriage Bearings

Part No. Bearingsize Bearing O.D.*
D580006 Undersize 98.5 mm (3.878 in)
D580007 Standard 99.0 mm (3.898 in)
D580008 Oversize 99.5 mm (3.917 in)
* Permissible tolerance 0.08 mm (.003 in)

6. Install 1mm shim and bearing (1) of stationary 9. Install 1mm shim and bearing (4) of intermediate
upper basically. lower basically.
NOTE: When installing shims (2) behind bearings

(1), make sure the amount of shim is
divided equally when positioned behind
each bearing.
7. Install the correct amount of shim (2) behind

rollers until contact (zero clearance) is made
between the bearings.
8. Install pads (3) to each side. Mast Adjustment Lower Bearings

Refer to Upper Pad Adjustment of Disassebly & (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
Assembly. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
NOTE: When installing shims (5) behind bearings

(4), make sure the amount of shim is divided equally
when positioned behind each bearing (4).

10. Make sure intermediate mast lower bearings are 13. Install 1 mm shim to each bearing of stationary
properly shimmed in the stationary mast by mast upper basically. Bearing should be
rolling up and down and moving intermediate selected D580006 undersize bearing.
mast to right and left. If clearance between both
masts can be detected, pull out the intermediate
mast from the stationary mast with crane and
add shim 0.5 mm or 1 mm to both intermediate
lower bearings.
11. In case of standard and full free mast, inner

lower bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If intermediate mast is stuck
and cannot move by rolling up and down, there
might be excessive shim. Pull out the
intermediate mast from the stationary mast and
remove shim 0.5 mm to both intermediate lower
bearings. Repeat same procedure of above until 14. Install 1mm shim and bearing (4) of intermediate
properly shimmed. There is to be contact zero lower basically.
clearance (C) between intermediate lower
bearings and stationary channel at
approximately 420 mm (16.5 in) channel lap.
B. Upper Bearing Adjustment of Stationary Mast
12. Lift by crane, insert intermediate mast into

stationary mast from the upper side.

bearings. Repeat same procedure of above until
properly shimmed. There is to be contact zero
clearance (F) between stationary upper bearings
and the widest point of intermediate mast to be
checked before.
C. Upper Pad Adjustment
Mast Adjustment Upper Bearings

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
Mast Adjustment Upper Bearings

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
17. Install shims (8) behind each pad (7) until there
is 0.80 mm (.031 in) maximum clearance (E)
between the pads and the inner and
15. Make sure stationary mast upper bearings are intermediate masts with the masts at full
properly shimmed by rolling up and down and extension. Lift by crane, and pull out
moving intermediate mast to right and left. If intermediate mast from stationary mast and
clearance between both masts can be detected, insert the shims behind each pad. In case of
pull out the intermediate mast from the standard and full free mast, the pads of
stationary mast with crane and add shim 0.5 mm stationary upper can be easily extruded by
or 1 mm to both stationary upper bearings. pulling down the inner mast from the bottom of
stationary mast.
16. In case of standard and full free mast, stationary
upper bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If intermediate mast is stuck
and cannot move by rolling up and down, there
might be excessive shim. Pull out the
intermediate mast from the stationary mast and
remove shim 0.5 mm to both stationary upper

D. Lower Bearing Adjustment of Inner Mast
19. Find narrowest point by ruler on the intermediate

mast in the area where the inner lower bearings
make contact full length of intermediate mast
excluding minimum channel lap 420 mm (16.5
in).

(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
18. Select lower bearings (3) and (4) from the chart
to obtain minimum clearance (B) between
bearing and channel leg for full channel length. 20. Lifting by crane, insert inner mast (11) into
Use same bearing on left and right side. intermediate mast (12) from the upper side.
MAST And Carriage Bearings

Part No. Bearing size Bearing O.D.*
D580006 Undersize 98.5 mm (3.878 in)
D580007 Standard 99.0 mm (3.898 in)
D580008 Oversize 99.5 mm (3.917 in)
* Permissible tolerance L0.08mm (.003in)
21. Install 1 mm shim and bearing (13) of

intermediate upper basically.

E. Upper Bearing Adjustment of intermediate
Mast
Follow same procedure with above B.
F. Upper Pad Adjustment of Intermediate Mast
Follow same procedure with above C.
24. If the bearings were removed from the mast

mounting brackets, install new ones.
25. Put a small amount of clean grease on mounting

22. Install 1mm shim and bearing (14) of inner lower bearing. Install mounting pins and screw into
basically. mast mounting brackets.
Refer to Mast Mounting Group Adjustment of
Testing & Adjusting.
26. If the bearings were removed from the tilt

cylinder pin bores (15), install new ones.

(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
23. Make sure inner mast lower bearings are

properly shimmed in the intermediate mast by
rolling up and down and moving inner mast to
right and left. If clearance between both masts
can be detected, pull down the inner mast from
the bottom of intermediate mast. Inner lower
bearings can be easily extruded. Add shim 0.5
mm or 1 mm to both inner lower bearings. If 27. Install secondary cylinders (16) into the
inner mast is stuck and cannot move by rolling stationary mast.
up and down, there might be excessive shim.
Pull out the inner mast from the intermediate
mast and remove shim 0.5 mm to both inner
lower bearings. Repeat same procedure of
above until properly shimmed. There is to be
contact zero clearance (C) between inner lower
bearings and intermediate channel at narrowest
point.

28. Install secondary cylinder mounting brackets 31. Connect chains (25) at the bottom of the mast.
(17) over the secondary cylinders.
32. Connect chains (26) at the chain bracket of

29. Install top cylinder retainer bolts (18) for the stationary mast upper.
secondary cylinders.
33. Install sheave (27) of lift hose.
33. Install sheave (27) of lift hose.
34. Install hoses (28) along with the hose support

clamps.
End by:
30. Install regulator (22) to secondary cylinder and
tube assy (23) and bolts (24) to stationary mast. a. Install primary lift cylinder.
b. Install lift chain to be connected primary lift

cylinder.

2. Select upper bearing from the chart to obtain
Testing & Adjusting minimum clearance (C) between bearings and
channel leg for full channel length. Use same
bearing at all two locations. (For G20SC-5,
Carriage Adjustment GC20SC-5, B20T, D20SC-5, and B20X, bearings
are same with upper, middle 4 locations.)
NOTE: The standard, Full Free Lift and Full Free
Triple Lift carriage load bearings are all adjusted the
* Permissible tolerance of 0.08mm (.003in)
same way. The Full Free Triple Lift carriage is
shown in the following illustrations. MAST And Carriage Bearings
To make the carriage clearance adjustments, Part No. Bearingsize Bearing O.D.*
carriage must be removed from the mast. D580006 Undersize 98.5 mm (3.878 in)
D580007 Standard 99.0 mm (3.898 in)
Use the procedure that follows to adjust carriage
load bearings. D580008 Oversize 99.5 mm (3.917 in)
3. Equally shim both sides until contact (A) is made

(zero clearance) between bearings and inner
mast at narrowest point
4. Shim bolt as needed to obtain a 4.0 to 6.0 mm

(.157 to .242 in) overlap (B) between bolt (3) and
the carriage stop on the inner upright.
(See Carriage Adjustment in Testing &
Adjusting).
5. Torque for screw........... 34 7 Nm (25 5 lbft).
6. Refer to Carriage Assembly* of Disassembly &

Assembly.
Carriage Adjustment
(3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Side-roller Bearings. (8) Lower Bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero Clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) Clearance.
(C) Minimum Clearance. (D) 4.5 0.5 mm
1. Select lower bearings from the chart to obtain

minimum clearance (C) between bearings and
channel leg for full channel length. Use same
bearing in all two locations.
Lift Trucks Mast System 21 Testing & Adjusting

Chain Adjustments
3. Put LOCTITE NO.242 Thread Lock on the
Chain Adjustment Check threads of the locknuts after the adjustment is
completed.
Lift the carriage and mast high enough to put their Outer Lift Chains
full weight on the carriage and mast chains. Check (2) Chain Anchor Bolts.
the chains, and make sure the tension is the same.
Chain Adjustment Chain Wear Test

If the tension is not the same on both chains, do the Chain wear test is a measurement of wear of the
procedure that follows: chain links and pins. Do the steps that follow to
check chain wear.
WARNING 1. Lift the mast and carriage enough to put tension
Personal injury can be caused by sudden on the lift chains.
movement of the mast and carriage. Blocks
must be used to prevent the mast and carriage 2. Measure precisely ten links of chain distance at
from any movement while the adjustments are the center of pins in millimeter.
made. Keep hands and feet clear of any parts A chain wear gauge can also be used.
that can move.
3. Calculate chain wear rate.
New one pitch = 15.88 mm
Chain wear rate (%)
= Actual measurement - 158.8 X 100

158.8
WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2%
or more could cause damage or injury to
persons.
Inner Lift Chains

(1) Chain Anchor Nuts. 4. If the chain wear indication is 2% or more,
replace the lift chain.
1. Lift the mast and carriage and put blocks under
the mast and carriage to release the tension from
the lift chains.
2. Make adjustments to chain anchor nuts (1) or
bolts (2) for equal tension of the mast and
carriage chains.

Carriage and Mast Height Adjustment NOTE: If the above measurements are not correct,
make adjustments to the chains to get the correct
1. Move the mast either forward or backward so it is measurement. See Chain Adjustments in TESTING
in the vertical position. AND ADJUSTING.
2. Lower the carriage completely. Forks Parallel Check
1. Lift the mast and operate the tilt control lever,

until the top surface of the forks is parallel with
the floor. Place two straight bars, that are the
same width as the carriage, across the forks as
shown. Measure the distance from the bottom of
each end of the two bars to the floor. The forks
must be parallel within 3 mm (.12 in) for Full
Tapered and Polished (FTP) forks, all other forks
6.4 mm (.25 in), for their complete length.
2. If not parallel, determine which one is defective

and replace it.
3. On Full Free Lift and Full Free Triple Lift models,

the bottom of the inner mast must be even with
the bottom of the stationary mast.
Forks Parallel Check
4. Measure the distance from the bottom of the
(Typical Example)
inner upright to the bottom of carriage bearing
end.
5. The measurement (A) must be as follows:
<STD>
D,G15/18/20S(C)-5 ................... 22 mm(0.866 in)
B15/18S-5.................................. 7 mm (0.276 in)
B16/18/20X-5, GC15/18/20S(C)-5,
B15/18/20T-5, BC15/18/20S(C) -5
................................................ -6 mm (-0.236 in)
<FFL & FFTL>

D,G15/18/20S(C)-5 ................... 36 mm (1.417in)
B15/18S-5................................ 21 mm (0.827 in)
GC15/18/20S(C)-5, BC15/18/20S(C)-5
................................................ 11 mm (0.433 in)
B15/18/20T-5, B16/18/20X-5...... 8 mm (0.315 in)

Tilt Cylinder Alignment Tilt Cylinder Length Check
If the tilt cylinders are out of alignment, extra

stresses in the mast assembly and the mast hinge
area will result. To prevent damage, the tilt cylinders
must stop evenly at the end of the tilt back and tilt
forward strokes.
Tilt Angle Check
1. Tilt the mast to full forward position. Measure the

extended length of the cylinder rods from the
cylinder housing to the mast. The difference of
length between the two cylinder rods must be
within 3.18 mm (.125 in) of each other.
Tilt Angle Check (Typical Example) Drift Test
Drift is movement of the mast or carriage that is the

The tilt angle of the mast must be checked in the full result of hydraulic leakage in the cylinders or control
tilt back and full tilt forward positions. A tilt indicator valve. Before testing the drift:
or a protractor can be used to measure the angle.
Both sides of the mast must be checked to make
WARNING
sure that the mast is not twisted.
Personal injury can be caused by sudden
The tilt angle is determined by the tilt cylinders used. movement of the mast or carriage. Use wood
See tilt cylinders in specifications to determine the blocks and clamps to hold the mast in this
tilt angle from the cylinder being used. position. Keep hands and feet clear of any parts
that can move.
1. Check the chain adjustment and tilt cylinder

alignment and make necessary adjustments.
2. Lift the mast approximately 762 mm (30 in). Use

wood blocks and clamps to hold the mast in this
position.
3. Check the mast hinge bolts to make sure they are

tight.
4. Remove the blocks and clamps and lower the

mast.

Drift Test For Lift System
1. Secure a rated capacity load on the forks of the

lift truck. Operate the lift truck through a complete
lift and tilt cycle until the oil is at normal
temperature of operation, 45 to 55 C (113 to
131 F).
2. Put the mast in a vertical position.

Raise a rated capacity load to a sufficient height
to test the lift cylinders.
3. Measure any drift of the carriage for a ten minute Tilt Cylinder Adjustment
period. Drift for all models shall not exceed 100.0 (1) Pivot eye. (2) Bolt. (3) Rod.
mm (4.00 in).
1. Loosen bolt (2) at pivot eye (1).

Tilt Cylinder Adjustment
2. Turn rod (3) into or out of pivot eye (1) to obtain
the correct length. The miNmum length from the
WARNING end of rod to the rear face of eye is 16 mm.
Tilt cylinder pivot eyes can loosen if the torque
on the pivot eye clamping bolt is not tight
enough. This will let the tilt cylinder rod turn in
the tilt cylinder eye. The cylinder rod may twist
out of the pivot eye and the tilt cylinder will be
out of alignment or may let the mast fall and
cause personal injury or damage. When the rod
lengths are made even, the tilt angle differences
or the mast alignment will no longer be a
problem.
To correct the tilt angle or tilt cylinder length, an

adjustment must be made to the tilt cylinder as
follows :
3. Tighten bolt (2) and the nut to a torque of 95 5

Nm (7010 lbft).

Lift & Tilt Mounting Group (1) With chains adjusted for equal tension, run mast
to full lift. If mast does not kick (move) to one
Adjustment side, no shims are needed. If mast does kick
(move) to one side, disconnect cylinder from the
bar on that side. Add shim, connect cylinder,
adjust chains and run mast to full lift to check for
kick. Repeat process if necessary. The total
shim pack must not be more than three shims
maximum.
(2) Install bearing outer race to a depth of (F)

....................................4.50.8 mm (.177.031 in).
(3) Tilt cylinder installation shown.
(4) (Full Free Lift Mast Only):

Tighten nuts until U-bolt is firm against cylinder,
do not apply standard torque.

Mast mounting Group Adjustment
26
For B16/18/20X-5, B15/18/20T-5
For B15/18S-5, BC15/18/20S(C)-5,
D,G15/18/20S(C)-5, GC15/18/20S(C)-5 1. Tighten screw (1) that holds bearing (3) to hinge
bracket of stationary mast to a torque of 347
Nm (255 lbft)
2. Install roll pin (2) to a depth 2 ~ 3 mm (0.079 ~

0.118 in) from surface of bearing.
3. Apply the crean grease to a surface of bearing.
4. Apply Loctite No242 to bolts and tighten with a

torque 18020 Nm (130 15 lbft).

SB4246E00
A p r. 2 0 0 7
Hydraulic Schematic
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
T MAIN CONTROL VALVE HYDRAULIC SCHEMATIC
141kgf/cm 2 2 SECTION A385000 MODEL : D15S-5, D18S-5, D20SC-5
3 SECTION A385001 G15S-5, G18S-5, G20SC-5
4 SECTION A385002
GC15S-5, GC18S-5, GC20SC-5
P/S CYLINDER B4
AUX2
D(G)15S A271264 TILT CYLINDER
A4
GC15S A251573 (A252110)
LIFT CYLINDER
AUX1 B3
STANDARD D501914
A3 PRIMARY D501986
FFT
SECONDARY D511486
PRIMARY D501865
FF
SECONDARY D511624
B2
TILT
A2
PRIMARY
SECONDARY
or STANDARD
LIFT
STEERING UNIT A1
D(G)15S A385006
GC15S A385007
PROTECTOR
220kgf/cm2 (D502539)
PROTECTOR
(D501495)
FLOW REGULATOR
P (D501493)
84kgf/cm2
PRIORITY VALVE
RELIEF PRESSURE
(A251581)
MODEL MAST Main Relief Pressure-lift Auxiliary Pressure-tilt, Attachment
psi Kpa psi Kpa

RETURN FILTER
(D516976) D15S, G(C)15S-5 STD/FF/FFT 2,55035 17,600250
MAIN PUMP D18S, G(C)18S-5 STD/FF/FFT 2,88035 19,860250 2,04050 14,000350
M
D15S D514201 D20SC, G20SC-5 STD/FF/FFT 3,12535 21,550250
SUCTION FILTER
(A155222) G(C)15S D514174
D502605
SB4247E00
Apr. 2007
Electric Schematic
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
Doosan Infracore Co., L

HEAD OFFICE : 7-11, Hwasu-dong, Dong-gu, Incheon, K
Tel : 82-32-211-1114
http://iv.doosaninfracore.co.kr
ELECTRIC SCHEMATIC
MODEL : D15S-5, D18S-5, D20SC-5
A384001-00
ELECTRIC SCHEMATIC
MODEL : G15S/18S/20SC-5 Non-Certi GAS & DF
G20/25/30E-5 Tier-3 DF & Non-Certi GAS, DF
A404010-01
ELECTRIC SCHEMATIC
MODEL : G15S/18S/20SC-5 Non-Certi & Tier-3 LP
GC15S/18S/20SC-5 Tier-3 LP
G20/25/30/32E-5 Non Certi & Tier-3 LP
GC20/25/30/32E-5 Non Certi & Tier-3 LP
A404014-01
SB2353E00
Operation &
Maintenance Manual
LIFT TRUCKS
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
0703
Table of Contents
Table of Contents
Information Section Maintenance Section

Foreword .....................................................................2 Inspection, Maintenance and Repair of Lift Truck
Forks ....................................................................... 107
Tire Inflation Information ........................................ 111
Safety Section Torque Specifications ............................................ 112
Cooling System Specifications.............................. 114
Important Safety Information .....................................4 Fuel Specifications................................................. 116
Safety ..........................................................................5 Lubricant Specifications......................................... 118
Warning Signs and Labels .................................5 Lubricant Viscosities and Refill Capacities........... 121
General Hazard Information.............................10 Maintenance Intervals............................................ 122
Operation Information.......................................11 When Required....................................................... 126
Maintenance Information ..................................14 Every 10 Service Hours or Daily ........................... 133
Pressure Air.......................................................14 First 50-100 Service Hours or a Week ................. 137
Fluid Penetration ...............................................14 First 250 Service Hours or a Month ...................... 143
Crushing or Cutting Prevention........................14 Every 250 Service Hours or Monthly .................... 144
Operator Restraint System (If Equipped) ........17 Every 500 Service Hours or 3 Months.................. 152
Avoiding Lift Truck Tipover...............................21 Every 1000 Service Hours or 6 Months................ 156
Safety Rules ......................................................24 Every 1500 Service Hours or 9 Months................ 161
How to Survive in a Tipover .............................29 Every 2000 Service Hours or Yearly..................... 163
Every 2500 Service Hours or 15 Months.............. 169
General Scetion
Specifications............................................................30 Index Section
Noise and Vibration ..................................................36
Capacity Chart - Without Sideshift ..........................37 Index........................................................................ 174
Capacity Chart - With Sideshift................................38
Serial Number ...........................................................39
Operator's Warning and Identification Plate ...........40
Operation Scetion
Operator's Station and Monitoring Systems ...........42
Seat Switch System(If Equipped)............................47
Lift Truck Controls ....................................................48
Direction Control Lever ............................................48
Refueling ...................................................................51
Before Starting the Engine.......................................54
Starting the Engine ...................................................56
G420F Dual Fuel System (If Equipped)..................59
After Starting the Engine..........................................61
Lift Truck Operation..................................................95
Operating Techniques..............................................98
Parking the Lift Truck .............................................102
Lift Fork Adjustment................................................103
Storage Information................................................104
Transportation Hints ...............................................105
Towing Information .................................................106
1
Information Section
Foreword
Photographs or illustrations guide the operator
Literature Information through correct procedures of checking, operation
and maintenance of the DOOSAN operator restraint
This manual should be stored in the operator's
system.
compartment in the literature holder or seat back
SAFE and EFFICIENT OPERATION of a lift truck
literature storage area.
depends to a great extent on the skill and alertness
This manual contains safety, operation,
on the part of the operator. To develop this skill the
transportation, lubrication and maintenance
operator should read and understand the Safe
information.
Driving Practices contained in this manual.
Some photographs or illustrations in this publication
Forklift trucks seldom tipover, but in the rare event
show details or attachments that can be different
they do, the operator may be pinned to the ground
from your lift truck. Guards and covers might have
by the lift truck or the overhead guard. This could
been removed for illustrative purposes.
result in serious injury or death.
Continuing improvement and advancement of
Operator training and safety awareness is an
product design might have caused changes to your
effective way to prevent accidents, but accidents
lift trucks which are not included in this publication.
can still happen. The DOOSAN operator restraint
Read, study and keep this manual with the lift truck.
system can minimize injuries. The DOOSAN
Whenever a question arises regarding your lift truck,
operator restraint system keeps the operator
or this publication, please consult your DOOSAN
substantially within the confines of the operators
dealer for the latest available information.
compartment and the overhead guard.
Safety This manual contains information necessary for Safe
Operation. Before operating a lift truck make sure
The Safety Section lists basic safety precautions. In that the necessary instructions are available and
addition, this section identifies the text and locations understood.
of warning signs and labels used on the lift truck.
Read and understand the basic precautions listed in Operation
the Safety Section before operating or performing
The Operation Section is a reference for the new
lubrication, maintenance and repair on this lift truck.
operator and a refresher for the experienced one.
This section includes a discussion of gauges,
Operator Restraint System (If Equipped) switches, lift truck controls, attachment controls,
transportation and towing information.
This manual contains safety, operation and
maintenance information for the DOOSAN operator Photographs and illustrations guide the operator
through correct procedures of checking, starting,
restraint system. Read, study and keep it handy.
operating and stopping the lift truck.
Operating techniques outlined in this publication are
WARNING basic. Skill and techniques develop as the operator
gains knowledge of the lift truck and its capabilities.
Your DOOSAN truck comes equipped with an
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DOOSAN
operator restraint system.
2
Information Section
Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without specific
intervals are listed under When Required topics.
Items in the Maintenance Intervals chart are
referenced to detailed instructions that follow.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the Maintenance Intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at Every 500 Service
Hours or 3 Months, also service those items listed
under Every 250 Service Hours or Monthly and
Every 10 Service Hours or Daily.
Environment Management
Note that DOOSAN INFRACORE is ISO 14001
certified which is harmonized with ISO 9001.
Periodic ENVIRONMENTAL AUDITS &
ENVIRONMENTAL PERFORMANCE
EVALUATIONS have been made by internal and
external inspection entities. LIFE-CYCLE ANALYSIS
has also been made through out the total product
life. ENVIRONMENT MANAGEMENT SYSTEM
includes DESIGN FOR ENVIRONMENT from the
initial stage of the design. ENVIRONMENT
MANAGEMENT SYSTEM considers environmental
laws & regulations, reduction or elimination of
resource consumption as well as environmental
emission or pollution from industrial activities,
energy saving, environment-friendly product design
(lower noise, vibration, emission, smoke, heavy
metal free, ozone depleting substance free, etc.),
recycling, material cost reduction, and even
environmentally oriented education for the
employee.
3
Safety Section

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 precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as WARNING
as shown below.
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is
used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
4
Safety Section
Safety
The safety rules and regulations in this section are
representative of some, but not all rules and Warning Signs and Labels
regulations noted under the Occupational Safety
There are several specific safety signs on your lift
and Health Act (OSHA) and are paraphrased
truck. Their exact location and description of the
without representation that the OSHA rules and
hazard are reviewed in this section. Please take the
regulations have been reproduced verbatim.
time to familiarize yourself with these safety signs.
Please refer to 1910. 178 in Federal Register Vol.
Make sure that you can read all safety signs. Clean
37, No. 202, the National Fire Protection Association
or replace these if you cannot read the words or see
No. 505 (NFPA), American National Standard, ANSI
the pictures. When cleaning the labels use a cloth,
B56. 1 Safety Standard for Low lift and High Lift
water and soap. Do not use solvent, gasoline, etc.
Trucks and subsequent revisions for a complete list
You must replace a label if it is damaged, missing or
of OSHA rules and regulations as to the safe
cannot be read. If a label is on a part that is replaced,
operation of powered industrial lift trucks. Since
make sure a new label is installed on the replaced
regulations vary from country to country outside in
part. See your dealer for new labels.
U.S.A., operate this lift truck in accordance with local
regulations.
DOOSAN lift trucks are manufactured according to Training Required To Operate or Service
the regulations and standards laid down in EU Warning
Machinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives 89/655/EC
and 89/391/EC and its amendments for the safe use
of DOOSAN lift trucks.
The most effective method of preventing serious
injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.
Do not operate a lift truck if in need of repair,
defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so. Located on the right of the steering wheel.
WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DOOSAN LIFT TRUCK dealers.
This also provides allowable lift truck capacity

information.
5
Safety Section
General Warnings to Operator 8. Do not permit riders on forks or machine at any

time.
9. Do not allow anyone to stand or pass under the
elevated portion of any machine.
10.Be sure operating surface can safely support
machine.
11.Operate machine and attachments only from
operator's position.
12.Do not handle unstable or loosely stacked loads.
13.Use minimum tilt when picking up or depositing a
load.
Located on the right side of the operator's seat. 14.Use extreme care when handling long, high, or
wide loads.
WARNING 15.Forks should be completely under load and
spread apart as far as load permits.
Only trained and authorized personnel may
operate this machine. For safe operation, read 16.Machine should be equipped with overhead
and follow the operation and maintenance guard or equivalent protection. Where load
Manual furnished with this lift truck and observe requires it, use load backrest extension. Use
the following warnings: extreme caution if operating without these
1. Before starting machine. Check all controls and devices.
warning devices for proper operation. 17.Parking - Lower lifting mechanism to floor. Put
2. Refer to machine identification plate for allowable directional control or shift lever in neutral. Set
machine capacity. Do not overload. Operate parking/secondary brake. Turn ON - OFF
machines equipped with attachments as partially switch off. Chock wheels if machine is on incline.
loaded machines when not handling a load. Disconnect battery when storing electric
machines.
3. Put directional control or shift lever in neutral
before ON - OFF switch is turned on. 18.Observe safety rules when handling fuel for
engine powered machine and when changing
4. Start, turn and brake smoothly. Slow down for batteries for electric machines.
turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid running
over loose objects or holes in the roadway
surfaces. Use extreme caution when turning on
inclines.
5. Travel with load as low as possible and tilted
back. If load interferes with visibility, travel with
load trailing.
6. On grade operations travel with load up grade.
7. Watch out for pedestrians and obstructions.
Check overhead clearances.
6
Safety Section
Pressure Warning No Standing On Forks Warning, No

Standing Under Forks Warning
WARNING
Contents under pressure may be hot. Allow to WARNING
cool before opening. Do not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do not
stand or walk under the forks.
Located on the radiator top tank by the radiator cap.
Hand Placement Warning Located on the lift cylinder.
WARNING Load Backrest Must Be In Place Warning
WARNING
Operation without this device in place may be
No hands. Do not place hands in this area. Do hazardous.
not touch, lean on, or reach through the mast or
permit others to do so.
Located on the load backrest.
Located on the mast.
7
Safety Section
Overhead Guard Must Be In Place Moving Fan Warning

Warning
WARNING
WARNING To avoid personal injury, stay clear of moving
Operation without this device in place may be fan.
hazardous. This guard conforms to A.N.S.I.
B56.1 and F.E.M. Section 4.
This design has been tested with an impact of
appropriate value.
Located inside the engine compartment cover.
Packing brake
Located on the Overhead Guard.
No Riders Warning
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
Pull the lever BACK to engage the

parking brake.
Push the lever FORWARD to release

the parking brake.
Located beside the operator's station.
8
Safety Section
Applying the parking brake puts the transmission in

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

brake is not automatically applied. Alarm will sound
if parking brake is not applied.
WARNING
Correct adjustment is necessary to provide
adequate braking. See the MAINTENANCE section
for adjustment procedures. The lift truck may creep
at engine idle and can cause damage, injury or
death. Always apply the parking brake when leaving
the lift truck. The parking brake is NOT automatically
applied.
9
Safety Section
Always use the overhead guard. The overhead

General Hazard Information guard is intended to protect the lift truck operator
from overhead obstructions and from falling objects.
A truck that is used for handing small objects or
uneven loads must be fitted with a load backrest.
If the lift truck must be operated without the
overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is no
possibility of falling objects from any adjacent
storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
backrest extension (if equipped).
Do not raise loads any higher than necessary and
never raise a load higher than 1830 mm (72 in) with
the overhead guard removed.
Always use load backrest extension when the
Attach a Do Not Operate or similar warning tag to carriage or attachment does not fully support the
start switch or controls before servicing or repairing load. The load backrest extension is intended to
the lift truck. prevent the load or any part of the load from falling
Do not start or service the lift truck when a DO NOT backwards into the operator's station.
OPERATE or similar warning tag is attached to the When operation the lift truck, do not depend only on
start switch or controls. flashing lights or back-up alarm (if equipped) to warn
Wear a hard hat, protective glasses and other pedestrians.
protective equipment as required by job conditions. Always be aware of pedestrians and do not proceed
Know the width of your attachments so proper until the pedestrians are aware of your presence
clearance can be maintained when operating near and intended actions and have moved clear of the
fences, boundary obstacles, etc. lift truck and/or load.
Do not wear loose clothing or jewelry that can catch Do not drive lift truck up to anyone standing in front
on controls or other parts of the lift truck. of an object.
Keep the lift truck, especially the deck and steps, Obey all traffic rules and warning signs.
free of foreign material such as debris, oil tools and Keep hands, feet and head inside the operator
other items which are not part of the lift truck. station. Do not hold onto the overhead guard while
Secure all loose items such as lunch boxes, tools operating the lift truck. Do not climb on any part of
and other items which are not part of the lift truck. the mast or overhead guard or permit others to do
Know the appropriate work-site hand signals and so.
who gives them. Accept signals from one person Do not allow unauthorized personnel to ride on the
only. forks or any other part of the lift truck, at any time.
When working in a building or dock, observe floor
load limits and overhead clearances.
Inhaling freon gas through a lit cigarette or other

smoking method or inhaling fumes released from a
flame contacting freon can cause bodily harm or
death. Do not smoke when servicing air conditioners
or wherever freon gas may be present.
Never put maintenance fluids into glass containers.
Use all cleaning solutions with care.
Do not use steam, solvent, or high pressure to clean
electrical components.
Report all needed repairs.
10
Safety Section
Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before
mounting.
Face the lift truck when mounting and dismounting.
Use both hands face the lift truck when mounting
and dismounting.
Use the handgrips for mounting and dismounting.
Do not try to climb on or off the lift truck when
Inspect the part of the chain that is normally carrying tools or supplies.
operated over the crosshead roller. When the chain Never get on or off a moving lift truck.
bends over the roller, the movement of the parts Do not use any controls as handholds when entering
against each other causes wear. or leaving the operator's station.
Inspect to be sure that chain link pins do not extend Never get on or off a moving lift truck. Never jump
outside of the bore hole. off the lift truck.
If any single link pin is extended beyond its Keep hands and steering wheel free of slippery
connecting corresponding link, it should be material.
suspected of being broken inside of its bore hole.
Inspect the chain anchor and the anchor links for
wear. Before Starting the Lift Truck
Do not change any factory set adjustment
values(including engine rpm setting) unless you Perform a walk-around inspection daily and at the
have both authorization and training. Especially start of each shift. Refer to the topic Walk-around
Safety equipment and switches may not be removed Inspection in Every 10 Service Hours or Daily
or adjusted incorrectly. Repairs, adjustments and section of this manual.
maintenances that are not correct can make a Adjust the seat so that full brake pedal travel can be
dangerous operating condition. obtained with the operator's back against the seat
For any checkup, repair, adjustments, maintenance back.
and all other work concerning your forklift truck, Make sure the lift truck is equipped with a lighting
please contact your DOOSAN dealer. We would like system as required by conditions.
to draw your attention to the fact that any secondary Make sure all hydraulic controls are in the HOLD
damages due to improper handling, insufficient position.
maintenance, wrong repairs or the use of other than Make sure the direction control lever is in the
original DOOSAN spare parts waive any liability by NEUTRAL position.
DOOSAN. Make sure the parking brake is engaged.
Make sure no one is standing and/or working on,
underneath or close to the lift truck before operating
the lift truck.
11
Safety Section
Operate the lift truck and controls only from the Operating the Lift Truck
operator's station.
Make sure the lift truck horn, lights, backup alarm (if Always keep the lift truck under control.
equipped) and all other devices are working Obey all traffic rules and warning signs.
properly. Never leave the lift truck with the engine operating,
Check for proper operation of mast and attachments. or with the parking brake disengaged.
Pay particular attention to unusual noises or erratic Operate the engine only in a well ventilated area.
movement which might indicate a problem. Lower mast, with or without load, before turning or
Make sure service and parking brakes, steering, and traveling. Tip over could result. Watch out for
directional controls are operational. overhead obstructions.
Make sure all personnel are clear of lift truck and Always observe floor load limits and overhead
travel path. clearance.
Refer to the topic Lift Truck Operation in the Start, turn, and brake smoothly, slow down for turns,
Operation Section of this manual for specific grades, slippery or uneven surfaces.
starting instructions.
Starting the Lift truck
Use special care when operation on grades. Do not

angle across or turn on grades. Do not use lift truck
on slippery grades. Travel with forks downgrade
when unloaded. Travel with load upgrade.
Do not start the engine or move any of the controls if Do not overload, or handle offset, unstable, or
there is a DO NOTOPERATE or similar warning loosely stacked loads. Refer to load capacity plate
tag attached to the start switch or controls. on the lift truck. Use extreme caution when handing
suspended, long, high or wide load.
Before Operating the Lift Truck

Test brakes, steering controls, horn and other
devices for proper operation. Report faulty
performance. Do not operate lift truck until repaired.
Learn how your lift truck operates. Know its safety
devices. Know how the attachments work.
Before moving the lift truck, look around. Start, turn
and brake smoothly.
An operator must constantly observe his lift truck for

proper operation.
12
Safety Section
Loading or Unloading Trucks/Trailers

Do not operate lift trucks on trucks or trailers which
are not designed or intended for that purpose.
Be certain truck or trailer brakes are applied and
wheel chocks in place (or be certain unit is locked to
the loading dock) before entering onto trucks or
trailers.
If trailer is not coupled to tractor, make sure the
trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
prevent upending or corner dipping.
Tilt elevated load forward only when directly over Be certain dock plates are in good condition and
unloading area and with load as low as possible. properly placed and secured. Do not exceed the
Do not stunt ride or indulge in horseplay. rated capacity of dock boards or bridge plates.
Always look and keep a clear view of the path of
travel. Lift Truck Parking
Travel in reverse if load or attachment obstructs
visibility. Use extreme caution if visibility is When leaving the operator station, park the lift truck
obstructed. in authorized areas only. Do not block traffic.
Stay in designated travel path, clear of dock edges,
ditches, other dropoffs and surfaces which cannot
safely support the lift truck.
Slow down and use extra care through doorways,
intersections and other location where visibility is
reduced.
Slow down for and avoid pedestrians, other vehicles,
obstruction, pot holes and other hazards or objects
in the path of travel.
Always use overhead guards except where
operation conditions do not permit. Do not operate
lift truck in high stacking areas without overhead
guards.
When stacking, watch for falling objects. Use load
backrest extension and overhead guard. z Park the lift truck level, with the forks lowered and
Refer to the topic Operation Techniques in the the mast tilted forward until the fork tips touch the
Operation Section of this manual. floor.
z Move the direction control lever to NEUTRAL.
z Engage the parking brake.
z Turn the key switch off and remove the key.
z Turn the disconnect switch to OFF and remove
the key (if equipped).
z Block the drive wheels when parking on an
incline.
13
Safety Section
They will throw or cut any object or tool that falls or

Maintenance Information is pushed into them.
Do not use a kinked or frayed wire rope cable. Wear
Perform all maintenance unless otherwise specified
gloves when handling the wire rope cable.
as follows:
Retainer pins, when struck with force, can fly out
z Park the lift truck in authorized areas only.
and injure nearby persons. Make sure the area is
z Park the lift truck level, with the forks lowered and
clear of people when driving retainer pins.
the mast tilted forward until the fork tips touch the
Wear protective glasses when striking a retainer pin
floor.
to avoid injury to your eyes.
z Place the transmission controls in neutral.
Chips or other debris can fly off objects when struck.
Make sure no one can be injured by flying debris
z Stop the engine.
before striking any object.
z Remove the start switch key and turn the
disconnect switch OFF (if equipped).
z Block the drive wheels when parking on an Falling Objects Protective Structure(FOPS)
incline.
This is an attached guard located above the
operator's compartment and secured to the lift truck.
Pressure Air To avoid possible weakening of the Falling Objects
Protective Structure (FOPS), consult a DOOSAN
Pressure air can cause personal injury. When using
dealer before altering, by adding weight to, welding
pressure air for cleaning, wear a protective face
on, or cutting or drilling holes into the structure.
shield, protective clothing and protective shoes.
The overhead guard is not intended to protect
The maximum air pressure must be below 205 kPa
against every possible impact. The overhead guard
(30 psi) for cleaning purposes.
may not protect against some objects penetrating
into the operator's station from the sides or ends of
the lift truck.
Fluid Penetration The lift truck is equipped with an overhead guard
Always use a board or cardboard when checking for and FOPS as standard. If there is a possibility of
a leak. Escaping fluid under pressure, even a pin- overhead objects falling through the guard, the
hole size leak, can penetrate body tissue, causing guard must be equipped with smaller holes or a
serious injury, and possible death. If fluid is injected plexiglass cover.
into your skin, it must be treated by a doctor familiar Any altering done that is not specifically authorized
with this type of injury immediately. by DOOSAN invalidates DOOSAN's FOPS
certification. The protection offered by this FOPS will
be impaired if it has been subjected to structural
Crushing or Cutting Prevention damage. Structural damage can be caused by an
overturn accident, by falling objects, etc.
Support equipment and attachments properly when Do not mount any item such as fire extinguishers,
working beneath them. Do not depend on hydraulic first aid kits and lights by welding brackets to or
cylinders to hold it up. Any attachment can fall if a drilling holes in any FOPS structure. See your
control is moved, or if a hydraulic line breaks. DOOSAN dealer for mounting guidelines.
Never attempt adjustments while the lift truck is
moving or the engine is running unless otherwise
specified.
Where there are attachment linkages, the clearance
in the linkage area will increase or decrease with
movement of the attachment.
Stay clear of all rotating and moving parts.
Keep objects away from moving fan blades.
14
Safety Section
Burn Prevention Fire or Explosion Prevention

All fuels, most lubricants and some coolant mixtures
Coolant
are flammable.
At operating temperature, the engine coolant is hot Fuel leaked or spilled onto hot surfaces or electrical
and under pressure. The radiator and all lines to components can cause a fire.
heaters or the engine contain hot water or steam. Do not smoke while refueling or in a refueling area.
Any contact can cause severe burns. Do not smoke in areas where batteries are charged,
Steam can cause personal injury. or where flammable materials are stored.
Check the coolant level only after engine has been Batteries in series can be located in separate
stopped and the fill cap is cool enough to remove compartments. When using jumper cables always
with your bare hand. connect positive(+) cable to positive(+) terminal of
Remove the cooling system fill cap slowly to relieve battery connected to starter solenoid and negative(-)
pressure. cable from external source to starter negative(-)
Cooling system additive contains alkali that can terminal.
cause personal injury. Avoid contact with the skin (If not equipped with starter negative(-) terminal,
and eyes and do not drink. connect to engine block.)
Allow cooling system components to cool before See the Operation Section of this manual for specific
draining. starting instructions.
Clean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have all
Oils
loose or frayed electrical wires tightened, repaired or
Hot oil and components can cause personal injury. replaced before operation the lift truck.
Do not allow hot oil or components to contact the Keep all fuels and lubricants stored in properly
skin. marked containers and away from all unauthorized
At operation temperature, the hydraulic tank is hot persons.
and can be under pressure. Store all oily rags or other flammable material in a
Remove the hydraulic tank fill cap only after the protective container, in a safe place.
engine has been stopped and the fill cap is cool Do not weld or flame cut on pipes or tubes that
enough to remove with your bare hand. contain flammable fluids. Clean them thoroughly
Remove the hydraulic tank fill cap slowly to relieve with nonflammable solvent before welding or flame
pressure. cutting on them.
Relieve all pressure in air, oil fuel or cooling systems Remove all flammable materials such as fuel, oil
before any lines, fittings or related items are and other debris before they accumulate on the lift
disconnected or removed. truck.
Do not expose the lift truck to flames, burning brush,
etc., if at all possible.
Batteries Shields, which protect hot exhaust components from
Batteries give off flammable fumes which can oil or fuel spray in the event of a line, tube or seal
explode. failure, must be installed correctly.
Do not smoke when observing the battery electrolyte Do not operate in areas where explosive gases exist
levels. or are suspected.
Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes.
Always wear protective glasses when working with
batteries.
15
Safety Section
z End fittings damaged or leaking.

Fire Extinguisher
z Outer covering chafed or cut and wire reinforcing
Have a fire extinguisher-type BC and 1.5KG exposed.
minimum capacity-on rear overhead guard leg with z Outer covering ballooning locally.
latch and know how to use it. Inspect and have it z Evidence of kinking or crushing of the flexible part
serviced as recommended on its instruction plate. of hose.
z Armouring embedded in the outer cover.
z End fittings displaced.
Ether
Make sure that all clamps, guards and heat shields
Ether is poisonous and flammable. are installed correctly to prevent vibration, rubbing
Breathing ether vapors or repeated contact of ether against other parts, and excessive heat during
with skin can cause personal injury. operation.
Use ether only in well-ventilated areas.
Do not smoke while changing ether cylinders.
Tire Information
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living Explosions of air-inflated tires have resulted from
areas or in the operator's compartment. heat-induced gas combustion inside the tires. The
Do not store ether cylinders in direct sunlight or at heat, generated by welding or heating rim
temperatures above 39C (102F). components, external fire, or excessive use of
Discard cylinders in a safe place. Do not puncture or brakes can cause gaseous combustion.
burn cylinders. A tire explosion is much more violent than a blowout.
Keep ether cylinders out of the reach of The explosion can propel the tire, rim and axle
unauthorized personnel. components as far as 500 m (1500 ft) or more from
the lift truck. Both the force of the explosion and the
flying debris can cause personal injury or death, and
Lines, Tubes and Hoses
property damage.
Do not bend or strike high pressure lines. Do not
install bent or damaged lines, tubes or hoses.
Repair any loose or damaged fuel and oil lines,
tubes and hoses. Leaks can cause fires. Contact
your DOOSAN dealer for repair or replacement.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. See Fluid Penetration
in the Safety Section for more details. Tighten all
connections to the recommended torque. Replace if
any of the following conditions are found.
Do not approach a warm tire closer than the outside

of the area represented by the shaded area in the
above drawing.
16
Safety Section
Dry nitrogen(N2) gas is recommended for inflation of

tires. If the tires were originally inflated with air, Operator Restraint System (If
nitrogen is still preferred for adjusting the pressure. Equipped)
Nitrogen mixes properly with air.
Nitrogen inflated tires reduce the potential of a tire Warning Signs and Labels
explosion, because nitrogen does not support
combustion. Also, nitrogen helps prevent oxidation Your DOOSAN lift truck has the following tipover
and the resulting deterioration of rubber and warning decals.
corrosion of rim components. Make sure that you can read all safety signs. Clean
Proper nitrogen inflation equipment and training in or replace these if you cannot read the words or see
its use are necessary to avoid overinflation. A tire the pictures. When cleaning the labels use a cloth,
blowout or rim failure can result from improper or water and soap. Do not use solvent, gasoline, etc.
misused equipment. You must replace a label if it is damaged, missing or
Stand behind the tread and use a self-attaching cannot be read. If a label is on a part that is replaced,
chuck when inflation a tire. make sure a new label is installed on the replaced
Servicing, changing tires and rims can be dangerous part. See you DOOSAN Lift Truck dealer for new
and should be done only by trained personnel using labels.
proper tools and procedures. If correct procedures The most effective method of preventing serious
are not followed while servicing tires and rims, the injury or death to yourself or others is to familiarize
assemblies could burst with explosive force and yourself with the proper operation of the lift truck, to
cause serious personal injury or death. Follow be alert, and to avoid actions or conditions which
carefully the specific information provided by your can result in an accident.
tire or rim servicing personnel or dealer.
WARNING
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.
17
Safety Section
If Optional Suspension Seat (Weight

Adjusting Type) Equipped
Forward and Backward Adjustment
The seat can be adjusted by pushing the lever on

the right side of seat.
The Survive in tipover warning is located on the

overhead guard. It shows the proper use of the Forward and Backward
operator restraint system. Adjustment
Seat Adjustment
Adjust the seat before operating the lift truck. After

adjusting, set the seat to make sure it is properly
locked. Do not adjust the seat while the truck is in
motion .
Move the lever, slide the seat to the desired position,

and release the lever.
motion.
WARNING
Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and
down.
18
Safety Section
Weight adjustment Seat Belt

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

interrupted during extension of the belt, or if the
belt cannot be inserted into the buckle properly,
replace the seat belt assembly.
Backrest Inclination
The backrest angle can be adjusted by using the
lever on the left side of seat.
2. Belt Maintenance Every 500 service hours.

Check that the belt fastening works properly and
that winding device is free from run lock when
jerked. Check that the belt is suitably fastened to
the seat. Check that the seat is correctly secured
to the hood and the chassis. On visual inspection,
fastenings must be intact, otherwise, contact the
safety manager.
WARNING
Your DOOSAN truck comes equipped with a
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DOOSAN operator restraint system.
19
Safety Section
WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen in an accident.
3. In the event of a tipover, the seat and restraint

system should be inspected for damage and
replaced, if necessary.
NOTE: Operator restraints shall be examined at the
regular truck service intervals. It is
recommended that they be replaced if any
of the following conditions are found:
z Cut or frayed strap
z Worn or damaged hardware including anchor
points
z Buckle or retractor malfunction
z Loose stitching
WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.
3. Be sure to fasten the belt across your hips, not
Fasten the Seat Belt across your abdomen.
NOTE: The belt is designed to automatically adjust

to your size and movement. A quick pull on
the belt will confirm that the automatic
adjuster will hold the belt position in the
event of an accident.
1. Grip the plate (connector) of the belt and pull the

belt from the retractor. Then insert the plate into
the slot of the buckle until a snap is heard. Pull
on the belt to confirm it is latched.
2. Make sure the belt is not twisted.
20
Safety Section
Release the Seat Belt Avoiding Lift Truck Tipover

Lift Truck Stability
Push the button of the buckle to release the belt.

The belt will automatically retract when released.
Hold the plate of the belt and allow the belt to slowly
retract. Counterbalanced lift truck design is based on the
balance of two weights on opposite sides of a
fulcrum (the front axle). The load on the forks must
be balanced by the weight of the lift truck. The
location of the center of gravity of both the truck and
the load is also a factor. This basic principle is used
for picking up a load. The ability of the lift truck to
handle a load is discussed in terms of center of
gravity and both forward and sideways stability.
Center of Gravity (CG)
The point within an object, at which the whole weight

of the object may be regarded as being
concentrated, is called the center of gravity or CG. If
the object is uniform, its geometric center will
coincide with its CG. If it is not uniform, the CG
could be at a point outside of the object. When the
lift truck picks up a load, the truck and load have a
new combined CG.
21
Safety Section
Stability and Center of Gravity Lift Truck Stability Base
The stability of the lift truck is determined by the For the lift truck to be stable (not tip over forward or
location of its CG; or, if the truck is loaded, the to the side), the CG must stay within the area of the
combined CG of the truck and load. The lift truck lift truck stability base a triangular area between
has moving parts and, therefore, has a CG that the front wheels and the pivot of the steer wheels. If
moves. The CG moves forward or backward as the the CG moves forward of the front axle, the lift truck
mast is tilted forward or backward. The CG moves will tip forward. If the CG moves outside of the line
up or down as the mast moves up or down. The CG on either side of the stability base, the lift truck will
and, therefore, the stability of the loaded lift truck, tip to the side.
are affected by a number of factors such as:
z the size, weight, shape and position of the load
z the height to which the load is lifted
WARNING
z the amount of forward or backward tilt Dynamic forces (braking, acceleration, turning)
z tire pressure also affect stability and can produce tipover
z dynamic forces created when the lift truck is even when the CG is within the stability triangle.
accelerated, braked or turned
z condition and grade of surfaces on which the lift
truck is operated
Capacity Load (Weight and Load Center)
These same factors are also important for unloaded

lift trucks. They tip over sideways easier than a
The capacity load of the lift truck is shown on the
loaded lift truck carrying its load in the lowered capacity/nameplate riveted to the truck. It is
position. determined by the weight and load center. The load
center is determined by the location of the CG of the
load.
22
Safety Section
The load center shown on the nameplate is the

horizontal distance from the front face of the forks,
or the load face of an attachment, to the CG of the
load. The location of the CG in the vertical direction
is the same as the horizontal dimension.
Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
mast, and having no special-purpose attachment. In
addition, the capacity load assumes that the load
center is no further from the top of the forks than it is
from the face of the backrest. If these conditions do
not exist, the operator may have to reduce the safe
operating load because the truck stability may be
reduced. The lift truck should not be operated if its
capacity/nameplate does not indicate capacity load.
NOTE: If the load is not uniform, the heaviest

portion should be placed closer to the
backrest and centered on the forks.
NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DOOSAN shall not be removed,
altered or replaced without DOOSANs approval.
2. DOOSAN assumes no responsibility for lift trucks
placed in service without a valid DOOSAN
Nameplate.
3. If necessary to change your specification,
contact your DOOSAN lift truck dealer.
23
Safety Section
Safety Rules
Do not operate a lift truck unless you are in the

operators seat. Keep hands and feet inside the
operators compartment. Do not put any part of the
body outside of the operators compartment. Never
Only properly trained and authorized personnel put any part of body into the mast structure or
should operate forklift trucks. Wear a hard hat and
between the mast and the truck
safety shoes when operating a lift truck. Do not wear
loose clothing.
Do not start, stop, turn or change direction suddenly

Inspect and check the condition of your forklift truck or at high speed. Sudden movement can cause the
using the operator's check list before starting work. lift truck to tip over. Slow the speed of your truck and
Immediately report to your supervisor any obvious use the horn near corners, exits, entrances, and
defects or required repairs. near people.
Do not operate your truck in unauthorized areas. Never operate a lift truck with wet hands or shoes.
Know your forklift truck and think safety. Never hold any controls with grease on your hands.
Do not compromise safety. Your hands or feet will slide off of the controls and
Follow all safety rules and read all warning signs. cause an accident.
24
Safety Section
Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the
Do not let other people ride on the truck. rated capacity shown on the capacity plate.
Lift trucks are designed to carry loads, not people.
Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.
Do not operate your truck without the load backrest

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

pick up an off center load. Such a load increases the
possibility of a tipover to the side. Make sure loads
are correctly stacked and positioned across both
forks. Always use the proper size pallet. Position the
forks as wide as possible under the load. Position
loads evenly on the forks for proper balance. Do not Do not drive on slippery surfaces.
lift a load with one fork. Sand, gravel, ice or mud can cause a tipover.
If unavoidable, slow down.
25
Safety Section
Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward.
load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards.
cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
Do not jump off if your truck starts to tip over.

Look out for overhead obstructions when raising or
Stay in your seat to survive.
stacking loads. Do not travel with a raised load. Do
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.
Go up ramps in forward direction and down ramps in

reverse direction when moving loads.
Never elevate a load with the forklift truck on an
Do not move loose loads that are higher than the incline.
load backrest. Go straight off and straight down. Use an assistant
Be alert for falling loads when stacking. when going up or down a ramp with a bulky load.
Travel with the load tilted back and the forks as low
as possible.
This will increase stability to the truck and load and
permit better visibility for you.
26
Safety Section
Do not stack or turn on ramps.

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

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

Avoid running over loose objects. support the weight of the truck and load.
Look in the direction of travel. Look out for other Make sure that they are correctly positioned.
persons or obstructions in your path of travel. Put blocks on the vehicle you enter to keep it from
An operator must be in full control of his lift truck at moving.
all times.
27
Safety Section
Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully
Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in
make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and
Never overtake other vehicles. turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work..
Do not use your lift truck to push or tow another

truck.
Do not let another push or tow your truck.
If a truck will not move, call a service technician.
Exhaust from all internal combustion engines

contains carbon monoxide, a colorless, odorless,
tasteless, poisonous gas. Exposure to carbon
monoxide can cause serious injury or health
problems, including death. and avoid unnecessary
idling of the engine. If nausea, dizziness or
headaches are experienced stop the truck and seek
fresh air.
Forklift trucks may only be refueled at specially

reserved locations. Switch off the engine when
refueling.
Smoking and handling of naked flames during
refueling are strictly prohibited. This prohibition also
applies during the changing of the LPG (liquefied
propane gas) tank.
Mop up spilt fuel and do not forget to close the fuel
tank before restarting the engine.
28
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 operators

compartment.
G
Always use operator restraint system.
Lean away from the direction of fall.
Dont jump.
Lean forward.
Hold on tight.
G 29
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type electric, diesel, gasoline, LPG
6 Operator type Stand-on, rider seated
7 Tires c = cushion, p = pneumatic
8 Wheels (x = driven) number, front/rear
DIMENSIONS
9 maximum fork height with rated load mm
Lift with STD
10 two - stage mast
free lift mm
11 special free lift mm
12 Fork carriage ISO class
thickness X width X length mm
13 Forks
fork spacing (minimum X maximum) mm
14 Tilt of mast forward/backward deg
15 length without forks mm
16 width mm
17 mast lowered height mm
Overall dimensions
18 mast extended height mm
19 overhead guard height mm
20 seat height mm
21 Outside turning radius mm
22 Load moment constant (from center of front wheel to fork face) mm
23 90 stacking aisle (add load length and clearance) mm
23a 90 intersecting aisle mm
PERFORMANCE
24 travel, loaded/unloaded km/h
25 Speeds lift, loaded/unloaded mm/s
26 lowering, loaded/unloaded mm/s
28 Drawbar pull at 1.6 km/h, loaded/unloaded kg
30 Gradeability at 1.6 km/h, loaded/unloaded %
31 Acceleration time traveling loaded/unloaded s
WEIGHT
32 Total weight kg
33 with load front/rear kg
Axle load
34 without load front/rear kg
CHASSIS
35 number of front/rear
36 Tires front size
size
37 rear size
38 Wheelbase mm
39 Tread front/rear mm
40 at the lowest point mm
Ground clearance loaded
41 at the center of wheelbase mm
42 Service brake
43 Parking brake
DRIVE
45 Battery voltage/capacity V/AH
49 manufacturer/model
50 rated output (at rpm) gas/LPG KW(hp)
51 Engine max. torque (at rpm) gas/LPG N-m(Ib-ft)
52 cycle/cylinders/displacement cc
53 fuel consumption l/hr
55 Type
Transmission
56 number of speeds forward/reverse
30
General Section
DOOSAN DOOSAN DOOSAN 1

G15S-5 G18S-5 G20SC-5 2
1500 1750 2000 3
500 500 500 4
gas/LPG gas/LPG gas/LPG 5
rider - seated rider-seated rider-seated 6
p p p 7
X2/2 X2/2 X2/2 8
3300 3300 3300 9

135 135 135 10
11
ll ll ll 12
35 X 100 X 900 35 X 100 X 900 40 X 100 X 900
13
216 X 905
286 X 1044 286X1044 286X1044
6/8 6/8 6/8 14
2170 2215 2250 15
1070 1070 1070 16
2185 2185 2185 17
4355 4355 4360 18
2170 2170 2170 19
1005 1005 1005 20
1977 2022 2050 21
394 394 399 22
2360 2398 2422 23
1720 1750 1780 23a
18.4/18.7 18.4/18.7 18.4/18.7 24

600/650 600/650 600/650 25
450 450 450 26
1340 1340 1340 28
28 26 24 30
31
2800 3010 3170 32

3775/525 4140/620 4520/650 33
1320/1485 1270/1740 1235/1935 34
2/2 2/2 2/2 35

6.50 X 10 - 12 6.50 X 10 - 12 6.50 X 10 - 12 36
5.00 X 8 - 10 5.00 X 8 - 10 5.00 X 8 - 10 37
1400 1400 1400 38
890/910 890/910 890/910 39
120 120 120 40
150 150 150 41
foot/hydraulic foot/hydraulic foot/hydraulic 42
hand/mechanical hand/mechanical hand/mechanical 43
12/45 12/45 12/45 45

G420F G420F G420F 49
33.9(45.5)/2300 33.9(45.5)/2300 33.9(45.5)/2300 50
152(112)/1600 152(112)/1600 152(112)/1600 51
4/4/1975 4/4/1975 4/4/1975 52
53
Powershift powershift powershift 55
1/1 1/1 1/1 56
31
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
6 Operator type Stand-on, rider seated
7 Tires c = cushion, p = pneumatic
DIMENSIONS
9 maximum fork height with rated load mm
Lift with STD
10 free lift mm
two - stage mast
thickness X width X length mm
13 Forks
15 length without forks mm
16 width mm
17 mast lowered height mm
Overall dimensions
18 mast extended height mm
19 overhead guard height mm
20 seat height mm
21 Outside turning radius mm
22 Load moment constant (from center of front wheel to fork face) mm
23 90 stacking aisle (add load length and clearance) mm
23a 90 intersecting aisle mm
PERFORMANCE
24 travel, loaded/unloaded km/h
25 Speeds lift, loaded/unloaded mm/s
26 lowering, loaded/unloaded mm/s
28 Drawbar pull at 1.6 km/h, loaded/unloaded kg
WEIGHT
32 Total weight kg
33 with load front/rear kg
Axle load
34 without load front/rear kg
CHASSIS
36 Tires front size
size
37 rear size
38 Wheelbase mm
39 Tread front/rear mm
40 at the lowest point mm
Ground clearance loaded
41 at the center of wheelbase mm
42 Service brake
43 Parking brake
DRIVE
49 manufacturer/model
50 rated output (at rpm) kW(hp)
51 Engine max. torque (at rpm) N-m(Ib-ft)
55 Type
Transmission
56 number of speeds forward/reverse
32
General Section

D15S-5 D18S-5 D20SC-5 2
1500 1750 2000 3
500 500 500 4
diesel diesel diesel 5
p p p 7
X2/2 X2/2 X2/2 8
3300 3300 3300 9

135 135 135 10
11
ll ll ll 12
35 X 100 X 900 35 X 100 X 900 40 X 100 X 900
13
216 X 905
286 X 1044 286X1044 286X1044
6/8 6/8 6/8 14
2170 2215 2250 15
1070 1070 1070 16
2185 2185 2185 17
4355 4355 4360 18
2170 2170 2170 19
1005 1005 1005 20
1977 2022 2050 21
394 394 399 22
2360 2398 2422 23
1720 1750 1780 23a
19.1/19.7 19.1/19.7 19.1/19.7 24

600/650 600/650 600/650 25
500/450 500/450 500/450 26
1392 1392 1392 28
33 30 28 30
31
2880 3090 3250 32

3800/580 4165/677 4545/705 33
1340/1560 1290/1840 1260/1990 34
2/2 2/2 2/2 35

6.50 X 10 - 12 6.50 X 10 - 12 6.50 X 10 - 12 36
5.00 X 8 - 10 5.00 X 8 - 10 5.00 X 8 - 10 37
1400 1400 1400 38
890/910 890/910 890/910 39
120 120 120 40
150 150 150 41
hand/mechanical hand/mechanical hand/mechanical 43
12/60 12/60 12/60 45

CUMMINS/A2300 CUMMINS/A2300 CUMMINS/A2300 49
32.8(44)/2400 32.8(44)/2400 32.8(44)/2400 50
150(110)/1600 150(110)/1600 150(110)/1600 51
4/4/2290 4/4/2290 4/4/2290 52
53
Powershift powershift powershift 55
1/1 1/1 1/1 56
33
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center Ib/kg
4 Load center distance inch/mm
6 Operator type Stand-on, rider-seated
7 Tire type c = cushion, p = pneumatic
DIMENSIONS
9 Lift with STD maximum fork height with rated load inch/mm
10 two - stage mast free lift inch/mm
13 Forks thickness X width X length inch
15 length without forks inch/mm
16 width inch/mm
17 Overall dimensions mast lowered height inch/mm
18 mast extended height inch/mm
19 overhead guard height inch/mm
20 seat height inch/mm
21 Outside turning radius inch/mm
22 Load moment constant inch/mm
(from center of front wheel to fork face)
23 90 stacking aisle (add load length and clearance) inch/mm
23a 90 intersecting aisle inch/mm
PERFORMANCE
24 travel, loaded/unloaded mph
kph
25 Speeds lift, loaded/unloaded fpm
mm/s
26 lowering, loaded/unloaded fpm
mm/s
28 Drawbar pull at 1.0 km/h, loaded/unloaded Ib/kg
WEIGHT
32 Total weight unloaded Ib/kg
33 Axle load without load, front/rear Ib
kg
34 without load, front/rear Ib
kg
CHASSIS
36 Tires front size
size
37 rear size
38 Wheelbase inch/mm
39 Tread front/rear inch
mm
40 Ground clearance loaded at the lowest point inch/mm
41 at the center of wheelbase inch/mm
42 Brakes service brakes
43 parking brakes
DRIVE
49 model
50 rated output (at rpm) kW
hp
51 Engine max. torque N-m
Ib-ft
55 Type
Gear shaft
56 no. of speeds forward/reverse
57 Operating pressure system/attachment bar
34
General Section

G15S-5(TIER-3) G18S-5(TIER-3) G20SC-5(TIER-3) 2
3000/1500 3500/1750 4000/2000 3
24/500 24/500 24/500 4
LPG LPG LPG 5
p p p 7
X 2/2 X 2/2 X 2/2 8
130/3300 130/3300 130/3300 9

5.3/135 5.3/135 5.3/135 10
11
ll ll ll 12
1.4 X 4 X 35 1.4 X 4 X 35 1.6 X 4 X 35 13
35 X 100 X 900 35 X 100 X 900 40 X 100 X 900
6/8 6/8 6/8 14
85.5/2170 87.5/2215 88.5/2250 15
42/1070 42/1070 42/1070 16
86/2185 86/2185 86/2185 17
171.5/4355 171.5/4355 171.7/4360 18
85.5/2170 85.5/2170 85.5/2170 19
39.5/1005 39.5/1005 39.5/1005 20
1977 2022 2050 21
15.5/394 15.5/394 15.7/399 22
2360 2398 2422 23

69.7/1720 68.9/1750 70.1/1780 23a
11.4/11.6 11.4/11.6 11.4/11.6 24

19/20.5 19/20.5 19/20.5
118.1/128 118.1/128 118.1/128 25
600/650 600/650 600/650
98.4/88.6 98.4/88.6 98.4/88.6 26
500/450 500/450 500/450
2954/1340 2954/1340 2954/1340 28
28 26 24 30
31
6172/2800 6636/3010 6988/3170 32

8322/1157 9127/1367 9965/1433 33
3775/525 4140/620 4520/650
2910/3274 2800/3836 2723/4266 34
1320/1485 1270/1740 1235/1935
2/2 2/2 2/2 35

6.50x10-12 6.50x10-12 6.50x10-12 36
5.00x8-10 5.00x8-10 5.00x8-10 37
55.1/1400 55.1/1400 55.1/1400 38
35/35 35/35 35/35 39
890/910 890/910 890/910
4.7/120 4.7/120 4.7/120 40
6/150 6/150 6/150 41
hand/mech hand/mech hand/mech 43
12/45 12/45 12/45 45

G420FE G420FE G420FE 49
33.9@2300 33.9@2300 33.9@2300 50
45.5@2300 45.5@2300 45.5@2300
152@1600 152@1600 152@1600 51
112@1600 112@1600 112@1600
1975 1975 1975 52
53
Powershift Powershift Powershift 55
1/1 1/1 1/1 56
57
35
General Section
Noise and Vibration
Sound Pressure Level at Whole-body Vibration

Power level(LWA )
Operators ear (Leq.) Level
By Noise Directive
according to EN12053 according to EN13059
Model 2000/14/EC 2
Guaranteed Sound (m/s )
dB(A) dB(A) Mean Uncertainty
D15/18S-5, D20SC-5
81 107
(W/O Cabin)
0.8 0.2
G15/18S-5, G20SC-5
80 103
(W/O Cabin)
36
General Section
Capacity Chart - Without Sideshift

SINGLE TYRE
MODEL STD, FFL FFT
G15S-5
D15S-5
G18S-5
D18S-5
G20SC-5
D20SC-5
37
General Section
Capacity Chart - With Sideshift

SINGLE TYRE
MODEL STD, FFL FFT
G15S-5
D15S-5
G18S-5
D18S-5
G20SC-5
D20SC-5
38
General Section
Serial Number
Serial Number Locations
For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.
Power Shift Transaxle Serial Number

______________________________
Lift Truck Serial Number

______________________________
Side Shift Serial Number (If Equipped)

______________________________
2.0 liter Spark Ignition Engine Serial Number

(G420F(E))
______________________________
2.3 liter Diesel Engine Serial Number

______________________________
39
General Section
Operator's Warning and Identification Plate

Familiarize yourself with the OPERATOR'S WARNING Plate and IDENTIFICATION, LIFT CAPACITY and
ATTACHMENTPLATES. DO NOT exceed Capacity as equipped load ratings
Operator's Warning Plate Lift Truck Capacity Rating

Do not exceed allowable lift truck working capacity
load ratings.
The capacity of the lift truck is given by weight and
distance to the load center. For example: a capacity
of 1500kg(3300 lb) at 500mm(24in) means that the
lift truck can lift 1500kg(3300lb) if the load center is
500 mm (24in) from both the vertical and horizontal
faces of the forks.
Before attempting to lift any load, ensure that the
weight and load center combination is within the
capacity of the lift truck as shown on the capacity
rating plate. To determine the load center measure
the distance from the face of the carriage to the
Located by the right side of the operator's seat on gravitational center of the load.
the engine compartment cover. The rated capacity on the plate refers to the capacity
of the lift truck as it left the factory. Subsequent
changes of any form to the equipment or battery can
Identification, Lift Capacity and alter the lift trucks rating.
The rated capacity of the lift truck applies to
Attachment Plate operating conditions where the lift truck is on level
ground. The capacity of the lift truck is reduced on
inclines.
Below are abbreviations that may appear on the
IDENTIFICATION, LIFT CAPACITY and
ATTACHMENTPLATES and their meanings.
Located on the cowl to the right side of the steering

column.
40
General Section
Mast Abbreviations Attachment Abbreviations

STD - Standard Mast (single inner member, (includes Special Forks)
low free lift) Special Carriage-increased width,
SC-
FF - Full Free Lift Mast (single inner height or outreach
member with high free lift duplex SSS - Shaft-type Sideshift Carriage
cylinder)
HSS - Hook-type Sideshift Carriage (ITA)
FFT - Triple Lift Mast (two inner members)
with either low or full free lift
CW - Counterweight
characteristics.
QUAD - Quadruple (Quad) Mast(with three SF - Special Forks

inner members)
SWS - Swing Shift, Sideshift
NOTE : When only a mast-type is listed on the
identification plate, a standard carriage and RAM - Ram or Boom
forks are used.
DBCBH - Double Cube Block Handler
HFP - Hydraulic Fork Positioner
CR - Crane Arm or Crane Boom
TH - Tire Handler
CTH - Container Handler
LPP - Load Push-Pull Device
CC - Carton Clamp
RC - Roll Clamp
LS - Load Stabilizer
PWH - Pulp Wood Handler
SS-ST - Sideshift-Side Tilt Carriage
41
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.
Diesel (12V)
LPG/GAS (12V)
42
Operation Section
1. Engine Oil Pressure Indicator Light - Check the cooling system for a malfunction. Both
Indicates insufficient engine oil pressure. tenth & ninth will flash out of phase when the coolant
The light will come on when the ignition temperature reaches approximately 106C (223F)
switch is turned to the ON position. The on all engines.
light should go off after the engine is started. If the
light turns on while operating the lift truck, 7. Transmission Oil Temperature
insufficient engine oil pressure is indicated. Park the Gauge - Indicates transmission oil
lift truck and stop the engine. temperature. If both tenth & ninth flash
Check the system for a malfunction. The light will out of phase while operating the lift truck,
turn on when the oil pressure drops to approximately excessive transmission oil temperature is indicated.
70kPa (10psi). Park the lift truck and stop the engine.
Check the system for a malfunction. Both tenth &
2. Alternator Indicator Light - Indicates if ninth will flash out of phase when the transmission
the battery charging system is operational. oil temperature reaches approximately 80 to 100 C
The light will come on when the ignition (175 to 220 F).
switch is turned to the ON position.
The light should go off after the engine is started, 8. G420F(E) LP Engine Malfunction
indicating the alternator is producing sufficient Indicator Lamp (MIL) G420F(E) engine
voltage to charge the battery. If the light turns on control system is equipped with built-in
with the engine running, check the alternator fault diagnostics. Detected system faults
charging system for a malfunction. can be displayed by the Malfunction Indicator Lamp
(MIL) as Diagnostic Fault Codes(DFC) or flash
3. Diesel Engine Start Preheat Indicator codes, and viewed in detail with the use of service
Light (Diesel Engine Only) - The light will tool software. When the ignition key is turned ON
come ON when the key is turned to the the MIL will perform a self-test, illuminate once and
ON position from the OFF position. This then go OFF. If a detected fault condition exists, the
indicates that the glow plugs are preheating the fault or faults will be stored in the memory of the
pre-combustion chambers for easier starting. engine control module(ECM). Once a fault occurs
The amount of time needed to preheat the the MIL will illuminate and remain ON. This signals
pre-combustion chambers is approximately seven the operator that a fault has been detected by the
seconds, depending on the surrounding air SECM.
temperature. When the light goes OFF the
maximum pre-combustion chamber temperature has 9. Seat Belt Warning Light Indicates
been reached and the key can be turned to the when the seat belt does not fastened by
START position to start the engine. operator. The light will come on when the
ignition switch is turned to the on position
4. Diesel Engine Water in Fuel Filter the light should go off often engine is started.
Indicator Light - Indicates when the
engine is running, there is water in the 10. Service Hour Meter - Indicates the
fuel filter exceeds 100cc. total number of hours the engine and the
The light will come ON when the ignition switch is lift truck have operated. The hour meter
turned to the ON position. The light should go off will operate when the ignition switch is in
after the engine is started. If the light turns on with the ON position, whether the engine is running or
the engine running, park the lift truck and stop the not. The hour meter is used to determine lubrication
engine. and maintenance intervals.
Drain some fuel (and any water) until clean fuel
flows from the filter which approximately takes 5 to 6 11. Parking indicator light- The light will
seconds. come ON when the parking lever is
applied.
5. Fuel Level Gauge - Indicates fuel level
(Gas, Diesel, or Dual Fuel Trucks Only) 12. Front Floodlights- Push down on the
switch(17), to the first step, to turn the
6. Engine Coolant Temperature Gauge front floodlights on.
- Indicates coolant temperature. If both Front and Rear Floodlights Push down on the
tenth & ninth flash out of phase while switch(17), to the second step, to turn both the front
operating the lift truck, overheating is and rear floodlights on. The floodlights are optional.
indicated. Park the lift truck and stop the engine.
43
Operation Section
13. Transmission Neutral Position Light

- Indicates the neutral position of Electrical Disconnect Switch (If
transmission. Equipped)
14. Brake Fluid Oil Light (If Equipped)
The light is ON when the brake fluid oil of
brake reservoir comes down to low level
position. Refill the proper brake fluid oil if
its light is ON.
15. Low Level Light of LP GAS

Indicates the low Level of LP GAS (LP or
DUAL only)
16. Directional Turning Indicator Light
17. Front and Rear Floodlishts Switch

The front floodright is ON when push down
switch to the first step. 1. ON - Connects the battery for electrical
The front and rear floodlights are ON when push power to all electrical circuits.
down switch to the second step.
2. OFF - Disconnects the battery from all
electrical circuits.
18. Horn Switch - Push on the horn button

to sound the horn.
44
Operation Section
Fuel Selector Switch (If Dual Fuel

Engine Compartment
Equipped)
1. The engine compartment is accessible by pulling

the latch and raising the hood and seat assembly.
(Note : Unlock latch before pulling - if key
equipped) NOTE : The switch is located in the engine
compartment or on the cowl.
1. LPG - This position supplies electrical power to

the LP fuelock solenoid, when the
ignition switch is in the ON or the
START position. With the LP- Gas fuel
tank valve open and when engine oil
pressure is present, LP-Gas can then
flow the tank through the converter to
the carburetor.
2. OFF - This position shuts off all fuel supply to
the carburetor and is used when
changing from Gasoline to LP-Gas or
2. The hood and seat assembly is held up by a air LP-Gas to Gasoline fuel.
lift cylinder. Make certain the air lift cylinder is Electrical power shuts off the gasoline
operating properly and securely holds the hood fuelock valve and the LP fuelock
up before doing anything in the engine solenoid. Before switching to the LPG
compartment.
position, allow the engine to run until all
of the gasoline in the carburetor is
Circuit Breaker consumed and the engine stops.
3. GAS - This position supplies electrical power to
the gasoline fuelock solenoid. This will
allow gasoline fuel to flow from the tank
through the fuel filter and fuel pump to
the carburetor.
Circuit Breaker - Protects the main

electrical circuits. To reset the circuit
breaker, push the button in. It is located in
the engine compartment.
45
Operation Section
Seat
NOTE : Seat arrangements may vary. Basic
operation will be similar.
Seat adjustment should be checked at the beginning
of each shift and when operators change.
Lock the seat into position before operating, to
prevent an unexpected seat change.
Adjust seat to allow full brake pedal travel with

operator's back against seat back.
NOTE : The seat can only be correctly adjusted

with the operator fully seated.
Tilting Steering Column
To adjust the steering column, push down the

knob(1) and move the steering column to the
desired position, then release the knob(1)
46
Operation Section
Seat Switch System(If Equipped)
NOTICE
Prior to operating the lift truck, be sure to

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

dealer if this applies to your truck) with an
alarm that will sound if the parking brake is
not applied when leaving the machine.
47
Operation Section
Lift Truck Controls

Direction Control Lever Transmission Inching Control
Pedal
1. Forward - Push the lever forward for Inching Control Pedal - Pushing down on
FORWARD direction travel. the inching pedal, modulates the hydraulic
pressure to the clutch packs, permitting
2. Neutral - Move the lever to center disc slippage.
position for NEUTRAL. Further pushing on the pedal completely relieves
clutch pack pressure and applies the service brakes
3. Reverse - Pull the lever back for to stop and hold the lift truck.
REVERSE direction travel.
NOTE : The purpose of the inching control pedal is
to provide precise inching control at slow
travel speed, with high engine rpm. This is
used for fast hydraulic lift during load
approach, pickup or positioning.
48
Operation Section
Service Brake Pedal Parking Brake Lever
Push DOWN on the brake pedal to slow or Pull the lever BACK to engage the parking
stop the lift truck. brake.
RELEASE the brake pedal to allow the lift Push the lever FORWARD to release the
truck to move. parking brake.
Accelerator Pedal Lift Control
NOTE : To prevent a sudden change of position of

Push DOWN on the pedal to increase the load, operate all lift, tilt and attachment controls
engine rpm (speed). smoothly.
RELEASE the pedal to decrease engine 1. Lower Position - Push the lever
rpm (speed). FORWARD smoothly to lower the load.
2. Hold Position - When the lever is

released it will return to the HOLD or
center position Lifting or lowering action
will stop.
3. Lift Position - Pull the lever BACK

smoothly to lift the load.
49
Operation Section
Tilt Control
1. Mast Tilt Forward - Push the lever

FORWARD smoothly to tilt the mast
forward.
2. Mast Hold - When the lever is released

it will return to the HOLD or center
position. Tilting action will stop.
3. Mast Tilt Back - Pull the lever BACK

smoothly to tilt the mast backward.
Sideshift Attachment Control (If

Equipped)
1. Sideshift Left - Push the lever

FORWARD to shift the carriage to the left.
2. Sideshift Hold - When the lever is

released it will return to the HOLD or center
position. Sideshifting action will stop.
3. Sideshift Right - Pull the lever BACK to

shift the carriage to the right.
50
Operation Section
Refueling
Gasoline or Diesel Engine
Equipped
WARNING
Explosive fumes may be present during
refueling. Do not smoke in refueling areas.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to those indoors.
Stop the engine and get off the lift truck during 1. Park the lift truck only at a designated safe
refueling. location. Place the transmission in NEUTRAL.
Lower the forks to the ground. Engage the
parking brake. Stop the engine.
NOTICE
Do not allow the lift truck to become low on fuel

or completely run out of fuel. Sediment or other
impurities in the fuel tank could be drawn into
the fuel system. This could result in difficult
starting or damage to components.
Fill the fuel tank at the end of each day of operation

to drive out moisture laden air and to prevent
condensation. In the cold weather, the moisture
condensation can cause rust in the fuel system and
hard starting due to its freezing. Do not fill the tank
to the top. Fuel expands when it gets warm and may 2. Remove the filler cap.
overflow. 3. Fill the fuel tank slowly. Install the filler cap. If
spillage occurs, wipe off excess fuel and wash
down area with water.
NOTE : Drain water and sediment from fuel tank as
required by prevailing conditions. Also,
drain water and sediment from the main
fuel storage tank weekly and before the
tank is refilled. This will help prevent water
or sediment being pumped from the
storage tank into the lift truck fuel tank.
51
Operation Section
Changing LP-Gas Tanks
WARNING
Only trained, authorized personnel should fill or
exchange LP-Gas tanks.
Personnel engaged in filling of LP-Gas
containers should wear protective clothing such
as face shield, long sleeves and gauntlet gloves.
Do not refuel or store LP-Gas powered lift trucks
near any underground entrance, elevator shafts 2. Close the fuel shut off valve at the LP - Gas tank.
or any other place where LP-Gas could collect in Run the engine until it stops, then turn off the
a pocket causing a potentially dangerous
ignition switch and electrical disconnect the
condition. switch (if equipped).
Examine all LP-Gas containers before filling and 3. Disconnect the fuel supply line.
again before reuse, for damage to various valves,
liquid gauge, fittings and hand valve wheels.
All defective or damaged LP-Gas containers
must be removed from service.
Explosive fumes may be present during
refueling.
Do not smoke in refueling areas.
safe locations. Safe outdoor locations are
preferable to indoor locations.
Stop the engine and get off the lift truck during
refueling. 4. Loosen the retaining clamps and remove the
The careless handling of LP-Gas containers can tank.
result in a serious accident. 5. Check the mounting to be sure the locating pin
Use extreme care when transporting containers (dowel) is not missing or broken.
to prevent damage to them.
NOTICE
1. Park the lift truck on level ground, with the
parking brake applied, the transmission in If the location pin (dowel) is missing or broken,
NEUTRAL, the forks lowered and the engine be sure the pin is replaced.
running at low idle.
52
Operation Section
WARNING
The LP-Gas tank must not extend past the
counterweight.
12.Clamp the tank securely.

13.Connect the fuel supply line.
14.Open the fuel valve by slowly turning the valve
counterclockwise. If the fuel valve is opened too
quickly, a back pressure check valve will shut off
the fuel supply. If this happens, close the fuel
6. Check to be sure that the LP-Gas warning plate valve completely. Wait five seconds and then
is in position on the lift truck, and is legible. open the fuel valve very slowly.
7. Check to be sure the replacement tank is of the 15.Inspect the LP-Gas fuel lines and fittings with a
correct type. soap solution after filling the tank or when
looking for leaks.
8. Inspect the replacement tank for damage such
as dents, scrapes or gouges and for indication of
leakage at valves or threaded connections.
9. Check for debris in the relief valve, for damage to

various valves and liquid level gauge.
10.Inspect the quick-disconnect couplings for
deterioration, damage or missing flexible seals.
11.Position the replacement tank so that the

locating pin (dowel) is in place.
53
Operation Section
Before Starting the Engine

5. Inspect the carriage, forks or attachments for
Walk-Around Inspection wear, damage and loose or missing bolts.
Make a thorough walk-around inspection before 6. Inspect the tires and wheels for cuts, gouges,
mounting the lift truck or starting the engine. Look foreign objects, inflation pressure and loose or
for such items as loose bolts, debris buildup, oil or missing bolts.
coolant leaks and cut or gouged tires. Check
condition of tires, mast, carriage, forks or
attachments. Have repairs made as needed and all
debris removed.
Before starting the gas engine, push the accelerator
pedal all the way down once and then slowly it to set
the automatic choke.
7. Inspect the overhead guard for damage and

loose or missing mounting bolts.
8. Inspect the hydraulic system for leaks, worn
hoses or damaged lines.
9. Look for transmission and drive axle leaks on the
lift truck and on the ground.
1. Inspect the operator's compartment for loose
items and cleanliness.
2. Inspect the instrument panel for broken or
damaged indicator lights or gauges.
3. Test the horn and other safety devices for proper
operation.
Typical Example
10.Inspect the engine compartment for oil, coolant

and fuel leaks.
4. Inspect the mast and lift chains for wear, broken

links, pins and loose rollers.
54
Operation Section
Typical Example
13.Observe the fuel level gauge after starting the
11.Measure the engine crankcase oil level with the truck. Add fuel if necessary.
dip stick. Maintain the oil level between the MAX.
and MIN., (or FULL and ADD) notches on the dip WARNING
stick.
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
Typical Example
12.Observe the engine coolant level in the coolant

recovery bottle. With the engine cold, maintain
the level to the COLD mark. If the recovery bottle
is empty, also fill the radiator at the top tank.
14.To position the seat, PUSH the lever away from

the seat track and move the seat forward or
backward to a comfortable position.
55
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. Dont press accelerator pedal, and turn the

ignition switch to the START position.
2. Once the engine starts, release the ignition

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

1. Engage the parking brake, if not already 4. If engine coolant is cold, engine speed could be
engaged. Place the transmission directional higher than low idle speed. Dont drive forklift until
control lever in the NEUTRAL position. engine speed becomes normal low idle speed.
NOTICE
If the inside of engine cylinder is wet by gasoline,
the engine could not start. In this case, press
accelerator pedal fully and turn the ignition switch to
ON position for 10 seconds. The inside of cylinder
would be dry because ECM does not allow gasoline
fuel injection. Repeat it three times. Dont press
accelerator pedal and turn the ignition switch to the
START position to start engine.
2. Lift trucks equipped with electrical disconnect

switches ; the engine will not start unless the
disconnect switch is in the ON (closed) position.
Before starting, turn the disconnect switch to the
OFF (open) position.
56
Operation Section
LP-Gas Engine Diesel Engine

Starting a Cold Diesel Engine
WARNING 1. Turn the key to the ON position. The start
preheat light will come ON. The preheat light will
LP - Gas fuel is flammable and can cause stay ON approximately seven seconds,
personal injury. depending on the surrounding air temperature.
Inspect LP - Gas fuel lines and fitting for leaks.
Inspect tank for secure mounting.
NOTICE
Do not engage the starter for more than 10 seconds.
2. When the preheat light goes OFF, turn the key to

the START position, with the accelerator pedal
fully depressed.
3. Release the key when the engine starts and
release the accelerator pedal to a low idle
position.
4. If the engine stalls or does not start, turn the key
to the OFF position, then repeat steps 1 thru 3.
1. Turn the tank fuel valve ON by slowly turning the

valve counterclockwise. Observe the LP Gas Starting a Warm Diesel Engine
gauge (if equipped).
1. Turn the key to the ON position and then to
2. Dont press accelerator pedal, and turn the START position, without waiting for the preheat
ignition switch to the START position. light to go OFF. At the same time fully depress
the accelerator.
switch. 2. Release the key when the engine starts and
4. If the engine does not start, repeat step 2. position.
5. If engine coolant is cold, engine speed could be

higher than normal low idle speed. Dont drive
forklift until engine speed becomes normal low
idle speed.
57
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.
Typical Example
NOTICE
Do not reverse battery cables. It can cause

damage to the alternator.
cables in parallel with the lift truck battery
cables : POSITIVE(+) to POSITIVE(+) and
NEGATIVE(-) to NEGATIVE(-).
Attach ground cable last, remove first. All lift
trucks equipped with DOOSAN built internal
combustion engines are NEGATIVE(-) ground.
58
Operation Section
G420F Dual Fuel System (If Equipped)

3. Move lever (1) to the LPG (3) position.
Changing From Gasoline to LP -
Gas
4. Open the fuel valve, on the LP - Gas tank, by

slowly turning the valve counterclockwise.
NOTE : The Underwriters Laboratory (U.L.) 5. Turn the ignition switch key to the OFF position
requires that the gasoline tank must be at and then to the START position to start the
least one - quarter full when operating on engine. Release it when the engine starts.
LP - Gas. This will allow the lift truck to be
restarted on gasoline and moved to an
approved refueling area, when operating in Changing From LP - Gas to
a hazardous area.
Gasoline
1. Park the lift truck level in an authorized refueling
1. Park the lift truck level in an authorized refueling area with the forks lowered, the parking brake
area with the forks lowered, the parking brake applied, the transmission in NEUTRAL and the
applied, the transmission in NEUTRAL and the engine running.
engine running.
2
3 4
Typical Example 2. Close the fuel valve on the LP - Gas tank.
2. Move lever (1), on the fuel selector switch to the

OFF(2) position. Leave lever (1) in this position
until the engine stops.
59
Operation Section
2
3 4
Typical Example
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) 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.
60
Operation Section
After Starting the Engine

Observe all indicator lights and gauges frequently 4. The diesel engine water in fuel filter indicator
during operation, to make sure all systems are light(4), will not come ON with the engine running,
working properly. All of the indicator lights will come unless water in fuel filter exceeds 100cc. Stop
ON with the ignition switch in the ON position before the engine immediately and drain the water if the
the engine is started. light comes ON.
5. Observe the fuel level gauge (5) for fuel level in
Diesel (12V)
the tank.
6. The engine coolant temperature gauge pointer
(6), will be in the green band with the engine
running, unless the coolant temperature is
excessive.
7. The transmission oil temperature gauge pointer
running, unless the oil temperature is excessive.
LPG/GAS (12V)
3
8. Observe the hour meter(8) make sure it is
operating properly.
1. The engine oil pressure indicator light (1), will not

come ON with the engine running, unless there
is low or no oil pressure. Stop the engine
immediately, if the light comes ON.
2. The alternator indicator light (2), should not come
ON during normal operation. The alternator is not
producing the sufficient voltage to charge the
battery if the light comes ON with the engine
running.
3. The Spark-ignition G420F(E) engine MIL
(Malfunction Indicator Light) (3) will not come ON
with the engine running, unless the fault or faults
are stored in the memory of the engine control
module (ECM). Stop the engine and check the
electric engine control system if the light comes
ON. Refer G420E Engine of this section.
61
Operation Section
Electronic Controlled Spark-Ignition Engines

G420FE Engine
EMS (Engine management system) of G420F(E) (SECM) uses two heated exhaust gas oxygen
engine is a closed loop system utilizing a 3-way sensors (HEGO) in the exhaust system to monitor
catalytic muffler to reduce the emission level in the exhaust gas content. One HEGO is installed in front
exhaust gas. In order to obtain maximum effect of the catalytic muffler and one is installed after the
from the catalyst, an accurate control of the air fuel catalytic muffler.
ratio is required. A small engine control module
EMS schematic of G420FE Dual fuel engine
The SECM makes any necessary corrections to the Even engine coolant temperature and adequate oil
air fuel ratio by controlling the inlet fuel pressure to pressure are monitored by the SECM. The SECM
the air/fuel mixer by modulating the dual fuel trim controller has full adaptive learning capabilities,
valves (FTV) connected to the regulator. Reducing allowing it to adapt control function as operating
the fuel pressure leans the air/fuel mixture and conditions change. Factors such as ambient
increasing the fuel pressure enriches the air/fuel temperature, fuel variations, ignition component
mixture. To calculate any necessary corrections to wear, clogged air filter, and other operating
the air fuel ratio, the SECM uses a number of variables are compensated.
different sensors to gain information about the
engines performance. Engine speed is monitored MPI (multi-point injection) is used for this system.
by the SECM through a variable reluctance (VR) or Fuel injection pressure and flow rate depend on
Hall Effect sensor. Intake manifold air temperature engine-specific fuel injection requirements. A
and absolute pressure are monitored with a TMAP variety of regulators and injectors can be used to fit
sensor. MI-07 is a drive-by-wire (DBW) system individual needs. The gasoline fuel pressure
connecting the accelerator pedal to the electronic regulator is a one-way, non-return configuration. All
throttle through the electrical harness; mechanical gasoline specific components are automotive
cables are not used. A throttle position sensor production parts and validated to strict automotive
(TPS) monitors throttle position in relation to the standards. Four (4) sequential injection channels
accelerator pedal position sensor (APP) command. are supported.
62
Operation Section
G420F Engine
EMS (Engine management system) of G420F engine is an open loop LP system and/or closed loop gasoline
system. 3-way catalytic muffler is not used for this system.
LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM.
Manifold pressure from the TMAP, rpm from the crank position sensor and throttle position is used by the
SECM to calculate load. Feedback from the electronic throttle is still provided to the SECM by the throttle
position sensors (TPS).
EMS schematic of G420F Dual Fuel engine
63
Operation Section
Basic Troubleshooting(LP)
The MI-07 systems are equipped with built-in fault basic checks that should be made before referring
diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or
displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
and are covered in the Advanced Diagnostics
section. Items such as fuel level, plugged fuel Locating a problem in a propane engine is done
lines, clogged fuel filters and malfunctioning exactly the same way as with a gasoline engine.
pressure regulators may not set a fault code by the Consider all parts of the ignition and mechanical
Small Engine Control Module (SECM). Below are systems as well as the fuel system.
Problem Probable Cause Corrective Action

Fuel container empty Fill fuel container
Engine Cranking z Do not exceed 80% of liquid
but Will Not Start capacity
Liquid valve closed Slowly open liquid valve
Excess flow valve closed Reset excess flow valve
z Close liquid valve
z Wait for a click sound
z Slowly open liquid valve
Plugged fuel line Remove obstruction from the fuel line
z Close liquid fuel valve
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Re-connect fuel line
z Slowly open liquid fuel valve
z Leak test
Broken Fuse - SECM Replace Fuse for SECM
z See Maintenance Section, Fuses
replacement
Clogged fuel filter Repair/replace as required
z See Maintenance Section, LP Fuel
Filter replacement
Faulty vapor connection between Check connection
the pressure regulator/converter z Verify no holes in hose
and the mixer z Clamps must be tight
z Look for kinked, pinched and/or
collapsed hose
Fuel Lock-off malfunction Repair/replace Fuel Lock-off
z See Engine Service Manual
Pressure regulator/converter Test pressure regulator/converter operation
malfunction z See Engine Service Manual
Incorrect air/fuel or ignition/spark See Advanced Diagnostics
control
No VR Sensor Signal Verify the VR signal is present
z See Advanced Diagnostics
64
Operation Section

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

Slowly open liquid valve
Filter replacement
z Using caution, disconnect the fuel line
(some propane may escape)
z Clear obstruction with compressed air
z Leak test
collapsed hose
z Fill fuel container
Air filter clogged Check air filter
z Clean/replace as required
Incorrect air/fuel or ignition control See Advanced Diagnostics
Engine Mechanical See Engine Service Manual
65
Operation Section

Will Not Run z Fill fuel container
Continuously z Do not exceed 80% of liquid capacity
Filter replacement

z Slowly open liquid fuel valve & Leak
test
Pressure regulator freezes Check level in cooling system
z Must be full, check coolant strength
z -35F minimum
Check coolant hoses
z Watch for kinks and/or pinched hoses
z Verify one pressure hose and one
return hose
Incorrect idle speed or ignition See Advanced Diagnostics
problem
Will Not z Fill fuel container
Accelerate/Hesita z Do not exceed 80% of liquid capacity
tion During Excess flow valve closed Reset excess flow valve
Acceleration z Close liquid valve
66
Operation Section

Will Not z See Maintenance
Accelerate/Hesita Section, LP Fuel Filter replacement
tion During Faulty vapor connection between Check connection
Acceleration the pressure regulator/converter z Verify no holes in hose
collapsed hose
Throttle butterfly valve not opening See Advanced Diagnostics
or sticking
Foot Pedal signal incorrect or
intermittent
Incorrect air/fuel or ignition control
Engine Stalls z Fill fuel container
Filter replacement
test
67
Operation Section

Engine Stalls z See Engine Service Manual
collapsed hose
z -35F minimum
z Check coolant hoses
return hose
Pressure regulator malfunction Test pressure regulator operation
Vacuum leak Check for vacuum leaks
z Between mixer and throttle body
z Between throttle body and intake
manifold
z Between intake manifold and cylinder
head
Air/Fuel Mixer malfunction Check mixer
Engine Mechanical See Engine Manufacturers Service Manual

Rough Idle the pressure regulator/converter z Verify no holes in hose
collapsed hose

manifold
head
68
Operation Section

Incorrect Idle speed control See Advanced Diagnostics & See Engine
Rough Idle Incorrect timing or spark control Service Manual
High Idle Speed Throttle sticking Service Manual
Foot pedal sticking or incorrect Check pedal return spring travel for binding
pedal signal z See Advanced Diagnostics
Poor High Speed z See Maintenance section, Fuel Filter
Performance replacement

test
collapsed hose
Restricted exhaust system Check exhaust system
z Measure exhaust back pressure
Incorrect ignition control
See Advanced Diagnostics & See Engine
Incorrect air/fuel control
Service Manual
Incorrect throttle position
69
Operation Section

Excessive Fuel z See Engine Service Manual
Consumption/LP Air filter clogged Check air filter
G Exhaust Smell z Clean/replace as required
Vacuum leak Check system vacuum hoses from
regulator to FTV and mixer
z Repair/replace as necessary
Pressure regulator malfunction/fuel Test pressure regulator operation
pressure too high z See Engine Service Manual
Faulty FTV Check FTV for housing cracks or
obstructions
z See Advanced Diagnostics FTV
operation
z Repair and/or replace as necessary
Weak ignition and/or spark control See Advanced Diagnostics
Incorrect air/fuel control See Advanced Diagnostics
Exhaust system leaks Repair exhaust system
Oxygen sensor failure Replace as necessary
70
Operation Section
Basic Troubleshooting (Gasoline)

Fuel tank empty Fill fuel container
Engine Cranking z The tank should be at least full to
but Will Not Start properly prime the fuel pump.
(Gas) z Fuel select switch is not on GAS
z See Maintenance section Primary
and Secondary Fuel Filter replacement
the pressure regulator/ converter z Verify no holes in hose
and the mixer (LP) z Clamps must be tight
collapsed hose
Electric Fuel Pump malfunction Check electrical connection
(GAS) z Check Relay and fuse
Turn key ON and verify pump is operating
Fuel Pressure regulator malfunction Test pressure regulator operation
Fuel Injector malfunction Test Injector operation
Incorrect air/fuel or ignition/ spark See Advanced Diagnostics
control
71
Operation Section

Fuel tank almost empty Fuel Pump Cavitations
Difficult to Start z The tank should be at least full to
(Gas) properly prime the fuel pump
z Fuel select switch is not on GAS
z See Maintenance section, Primary and
Secondary Fuel Filter replacement
(GAS) z Check Relay and fuse Turn key ON
and verify pump is operating
Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Will Not Run running the lift truck on LP If the problem does not exist in LPG mode
Continuously proceed with the corrective action steps
(Gas) below.
If the problem also exists in LPG mode then

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

z The tank should be at least full to
properly prime the fuel pump
72
Operation Section

Will Not Run (GAS) z Check Relay and fuse Turn key ON
Continuously and verify pump is operating
(Gas) z See Engine Service Manual



problem
Will Not running the lift truck on LPG If the problem does not exist in LPG mode
Accelerate/Hesita proceed with the corrective action steps
tion During below.
Acceleration or
Engine Stalls the root cause is most likely to be
(Gas) something other than the fuel system

z The tank should be at least full to
properly prime the fuel pump


73
Operation Section

Will Not or sticking
Accelerate/Hesita Foot Pedal signal incorrect or
tion During intermittent
Acceleration or Incorrect air/fuel or ignition control
Engine Stalls
(Gas) Engine Mechanical See Engine Service Manual
Rough Idle (Gas) running the lift truck on LPG If the problem does not exist in LPG mode
proceed with the corrective action steps
below.

z See Advanced Diagnostics & Service

Manual
manifold
head
74
Operation Section

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

High Idle Speed Service Manual
(Gas) Throttle sticking
pedal signal
See Advanced Diagnostics
75
Operation Section

Poor High Speed running the lift truck on LPG If the problem does not exist in LPG mode
Performance proceed with the corrective action steps
(Gas) below.

See Advanced Diagnostics & Dual Fuel

Engine Service Manual
z See Maintenance section, Fuel Filter
replacement
test
collapsed hose
z See Dual Fuel Engine Service Manual

Poor High Speed z See Engine Service Manual
Performance Restricted exhaust system Check exhaust system
(Gas) z Measure exhaust back pressure
Incorrect ignition control See Advanced Diagnostics & Engine
Incorrect air/fuel control Service Manual
76
Operation Section
Displaying Fault Codes (DFC) from

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

EXAMPLE: A code 461 (ETCSticking) has been

(1) Malfunction Indicator Lamp(MIL) for Engine control system.
77
Operation Section
Table 2. MI-07 Diagnostic Fault Codes (Flash Codes)
DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK

NONE
identification
Inj1Open
131 TurnOnMil Switched 12V to Injector 1 Pin B
Check Injector 1 Resistance, 12 to14
ohms (cold)
Inj2Open
ohms (cold)
Inj3Open
ohms (cold)
Inj4Open
Check Injector 4 Resistance, 12 to 14
ohms (cold)
Check ECT sensor connector and wiring
ECTRangeLow for a short to GND
141
Coolant Sensor failure or TurnOnMil SECM (Signal) Pin B15 To ECT Pin 3
(14)
shorted to GND SECM (Sensor GND) Pin B1 to ECT Pin 1
SECM (System GND) Pin A16, B17
(1) TurnOnMil Check if ECT sensor connector is
ECTRangeHigh
151 (2) DelayedEngine disconnected or for an open ECT circuit
or open circuit
(3) CheckEngineLight SECM (Sensor GND) Pin B1 to ECT Pin 1
78
Operation Section
Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) contd.

ECTOverTempFault
leaks in the system.
Engine coolant temperature is (1) TurnOnMil
Possible ECT short to GND, check ECT
161 high. The sensor has (2) DelayedEngine
signal wiring
(16) measured an excessive Shutdown
SECM (Signal) Pin B15 to ECT Pin 3
coolant temperature typically (3) CheckEngineLight
SECM (Sensor GND) Pin B1 to ECT Pin 1
due to the engine overheating.
Check regulator for coolant leaks
ECT_IR_Fault
Check for coolant system problems, e.g.
defective or stuck thermostat
FuelSelectConflict Check fuel select switch connection for a
Conflict in fuel select signals, short to GND
CamEdgesFault SECM (SIGNAL) Pin B10 to CAM sensor
No CAM signal when engine is Pin 2
191 known to be rotating, broken None SECM (Sensor GND) Pin B1 to CAM
crankshaft sensor leads or sensor Pin 3
defective CAM sensor Switched 12V to CAM sensor Pin 1
Check for defective CAM sensor
CamSyncFault
SECM (SIGNAL) Pin B10 to CAM sensor
Loss of synchronization on the
Pin 2
CAM sensor, normally due to
noise on the signal or an
sensor Pin 3
intermittent connection on the
Switched 12V to CAM sensor Pin 1
CAM sensor
CrankEdgesFault
SECM (SIGNAL) Pin B5 to Crank sensor
Pin 3
engine is known to be rotating,
broken crankshaft sensor
sensor Pin 2
leads or defective crank
Switched 12V to Crank sensor Pin 1
sensor
Check for defective Crank sensor
CrankSyncFault
Pin 3
crankshaft sensor, normally
194 None SECM (Sensor GND) Pin B1 to Crank
sensor Pin 2
79
Operation Section

TPS1RangeLow Check throttle connector connection and
TPS1 sensor voltage out of TPS1 sensor for an open circuit or short to
221 range low, normally set if the GND
TurnOnMil
(22) TPS1 signal has shorted to SECM Pin B23 (signal) to ETC Pin 6
ground, circuit has opened or SECM Pin B1 (sensor GND) to ETC Pin 2
sensor has failed SECM (system GND) Pin A16, B17
range low, normally set if the GND
222 TurnOnMil
TPS2 signal has shorted to SECM Pin B4 (signal) to ETC Pin 5
TPS1RangeHigh
TPS1 sensor voltage out of Check throttle connector and TPS1 sensor
231 range high, normally set if the wiring for a shorted circuit
TurnOnMil
power or the ground for the SECM Pin B1 (sensor GND) to ETC Pin 2
sensor has opened
TPS2RangeHigh
range high, normally set if the wiring for a shorted circuit
232 TurnOnMil
power or the ground for the SECM pin B1 (sensor GND) to ETC Pin 2
sensor has opened
corrosion.
None
TPS Pin 3 (PWR) to
corrosion.
242 None
TPS PIN 3 (PWR) to
TPS1AdaptHiMax
251 Learned WOT end of TPS1
None N/A
expected
TPS2AdaptHiMax
252 None N/A
sensor range higher than
expected
TPS1AdaptHiMin
271 None N/A
expected
80
Operation Section

TPS2AdaptHiMin
272 None N/A
expected
TPS1AdaptLoMax
281 None N/A
than expected
TPS2AdaptLoMax
Learned closed throttle end of
282 None N/A
TPS2 sensor range higher
than expected
NOTE: The TPS is not a (1) TurnOnMil
291 Perform checks for DFCs 241 & 242
serviceable item and can (2) Engine Shutdown
only be repaired by
assembly.
Check TMAP connector and MAP signal
wiring for an open circuit
MAPTimeRangeLow
TMAP Pin 1 to SECM Pin B1 (sensor GND)
TMAP Pin 3 to SECM Pin B24 (XDRP +5
sensor input is low, normally
Vdc)
331 set if the TMAP pressure
None Check the MAP sensor by disconnecting
(33) signal wire has been
the TMAP connector and measuring at the
disconnected or shorted to sensor:
ground or the circuit has TMAP Pin 1(GND) to
opened to the SECM
Pin 4 (pressure signal KPA) (2.4k - 8.2k)
TMAP Pin 3 (power) to
MAPRangeLow
sensor input is low, normally Vdc)
set if the TMAP pressure (1) TurnOnMil Check the MAP sensor by disconnect-ing
332
signal wire has been (2) CutThrottle
disconnected or shorted to
sensor:
ground or the circuit has
TMAP Pin 1(GND) to
opened to the SECM
81
Operation Section

MAPTimeRangeHigh Check TMAP connector and MAP signal wiring
Manifold Absolute Pressure for a shorted circuit
Sensor Input is High, normally TMAP Pin 4 to SECM Pin B18 (signal)
set if the TMAP pressure TMAP Pin 1 to SECM Pin B1 (sensor GND)
signal wire has become TMAP Pin 3 to SECM Pin B24 (XDRP +5 Vdc)
341
shorted to power, shorted to None Check the MAP sensor by disconnect-ing the
(34) the IAT signal, the TMAP has TMAP connector and measuring at the sensor:
failed or the SECM has failed. TMAP Pin 1(GND) to
MAPRangeHigh Check TMAP connector and MAP signal wiring
(1) TurnOnMil
342 shorted to power, shorted to Check the MAP sensor by disconnecting the
(2) CutThrottle
the IAT signal, the TMAP has TMAP connector and measuring at the sensor:
failed or the SECM has failed TMAP Pin 1(GND) to
MAP_IR_HI Check for vacuum leaks. Check that TMAP
351 MAP sensor indicates higher None sensor is mounted properly. Possible defective
pressure than expected TMAP sensor.
MAP_IR_LO
MAP_STICKING
Check that TMAP sensor is mounted properly.
353 MAP sensor not changing as None
Possible defective TMAP sensor.
expected
Check TMAP connector and IAT signal wiring
IATRangeLow for a shorted circuit
Intake Air Temperature TMAP Pin 2 to SECM Pin B12 (signal)
Sensor Input is Low normally TMAP Pin 1 to SECM Pin B1 (sensor GND)
371
set if the IAT temperature TurnOnMil To check the IAT sensor of the TMAP
(37)
sensor wire has shorted to disconnect the TMAP connector and measure
chassis ground or the sensor the IAT resistance
has failed. Resistance is approx 2400 ohms at room
temperature.
82
Operation Section

IATRangeHigh for a shorted circuit
Sensor Input is High normally TMAP Pin 1 to SECM Pin B1 (sensor GND)
381
(38)
sensor wire has been disconnect the TMAP connector and measure
disconnected or the circuit has the IAT resistance
opened to the SECM. Resistance is approx 2400 ohms at room
temperature.
IAT_IR_Fault Check connections to TMAP sensor. Check
391 Intake Air Temperature not None that TMAP sensor is properly mounted to
changing as expected manifold.
Check coil driver wiring and connector for open
circuit
SECM Pin A9 (EST1) to OEM ignition system.
EST1_Open See application note.
EST1 output open, possibly Verify GND on ignition module
421 TurnOnMil
open EST1 signal or defective Pin A (of both connectors)
spark module Verify +12 Vdc on ignition module
Pin B (of both connectors)
Refer to application manual for specific engine
details.
circuit
EST2_Open system. See application note.
422 TurnOnMil
details.
circuit
423 TurnOnMil
details.
83
Operation Section

Check coil driver wiring and connector for
open circuit
EST4_Open system. See application manual.
424 TurnOnMil
engine details.
EST5_Open
425 EST5 output open, possibly
None N/A
open EST5 signal or defective
spark module
EST6_Open
None N/A
spark module
EST7_Open
EST7 output open, possibly
427 None N/A
spark module
EST8_Open
428 None N/A
spark module
shorts
SECM Pin A9 (EST1) to ignition module
EST1_Short
Pin D (4-pin connector)
EST1 output shorted high or
Verify GND on ignition module
431 low, EST1 signal shorted to TurnOnMil
Pin A (of both connectors)
Verify +12 Vdc on ignition module
spark module
engine details.
84
Operation Section

shorts
EST2_Short
spark module
engine details.
shorts
EST3_Short
spark module
engine details.
shorts
EST4_Short
spark module
engine details.
EST5_Short
435 low, EST5 signal shorted to None N/A
spark module
EST6_Short
spark module
85
Operation Section

EST7_Short
spark module
EST8_Short
spark module
Check for debris or obstructions inside
ETC_Sticking the throttle body
Electronic Throttle Control is Perform the throttle test using the
sticking. This can occur if the Service Tool and re-check for fault
inside the throttle bore is
wear
sticking. The plate sticking can
be due to some type of Check the ETC driver wiring for an
(1) TurnOnMil
461 obstruction, a loose throttle (2) EngineShutdown open circuit
(26) SECM Pin A17 to ETC + Pin 1
plate, or worn components shaft (3) CutThrottle
bearings. SECM Pin A18 to ETC - Pin 4
NOTE: The throttle assembly Check the ETC internal motor drive by
is not a serviceable item and disconnecting the throttle connector and
measuring the motor drive resistance at
can only be repaired by
the throttle
assembly.
Pin 4 (-DRIVER) ~3.0-4.0
Check the ETC driver wiring for an open
circuit
ETC_Open_Fault
has failed, normally set if either
Check the ETC internal motor drive by
471 of the ETC driver signals have None
disconnecting the throttle connector and
opened or become
disconnected, electronic throttle
the throttle
or SECM is defective.
Pin 4 (-DRIVER) ~3.0-4.0
ETCSpringTest
Spring Return Test has failed.
The SECM will perform a safety
test of the throttle return spring
following engine shutdown. If
(1) TurnOnMil
481 this spring has become weak Perform throttle spring test by cycling
(2) EngineShutdown
(28) the throttle will fail the test and the ignition key and re-check for fault
set the fault.
NOTE: The throttle assembly
is not a serviceable item and
assembly.
86
Operation Section

Check ETC driver wiring for a shorted circuit
HbridgeFault_ETC SECM Pin A17 to ETC + Pin 1
Electronic Throttle Control SECM Pin A18 to ETC - Pin 4
Driver has failed. Perform the throttle test using the Service
Indeterminate fault on Tool and re-check for fault
491
Hbridge driver for TurnOnMil Check the ETC internal motor drive by
(29)
electronic throttle control. disconnecting the throttle connector and
Possibly either ETC+ or measuring the motor drive resistance at the
ETC- driver signals have throttle
been shorted to ground TPS Pin 1 (+DRIVER) to
Pin 4 (-DRIVER) ~3.0-4.0
Perform maintenance check on electrical
connections to the battery and chassis
ground
Check battery voltage during starting and
531 SysVoltRangeLow with the engine running to verify charging
TurnOnMil system and alternator function
(53) System voltage too low
Measure battery power at SECM with a
multimeter (with key on)
SECM Pin A16 (DRVG)
SECM Pin B17 (DRVG)
Check battery and charging system voltage
with the engine running
Check voltage regulator, alternator, and
charging system
541 SysVoltRangeHigh Check battery and wiring for overheating
TurnOnMil and damage
(54) System voltage too high
SECM Pin A16 (DRVG)
SECM Pin B17 (DRVG)
87
Operation Section

TMAP Pin 3 XDRP +5 Vdc to
TMAP Pin 1 XDRG GND
Verify transducer power at the
SECM with a multimeter
SensVoltRangeLow (1) TurnOnMil
551 SECM Pin B24 +5 Vdc to SECM
Sensor reference voltage (2) EngineShutdown
(55) Pin B1 XDRG GND
XDRP too low
Verify transducer power at
ETC with a multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2 XDRG
GND
Verify transducer power to the foot pedal with a
multimeter.
TMAP Pin 1 XDRG GND
SensVoltRangeHigh (1) TurnOnMil
561 SECM Pin B24 +5 Vdc to
(56) SECM Pin B1 XDRG GND
XDRP too high
Verify transducer power at ETC with a
multimeter
GND
multimeter.
HardOverspeed Usually associated with additional ETC faults
Engine speed has Check for ETC Sticking or other ETC faults
571 (1) TurnOnMil
exceeded the third level (3 Verify if the lift truck was motored down a steep
(57) (2) HardRevLimit
of 3) of overspeed grade
protection
MediumOverspeed Usually associated with additional ETC faults
(1) TurnOnMil
572 exceeded the second level Verify if the lift truck was motored down a steep
(2) MediumRevLimit
(2 of 3) of overspeed grade
protection
SoftOverspeed Usually associated with additional ETC faults
(1) TurnOnMil
573 exceeded the first level (1 Verify if the lift truck was motored down a steep
(2) SoftRevLimit
protection
APP1RangeLow
APP1 sensor voltage out
of range low, normally set (1) TurnOnMil
611 Check foot pedal connector
if the APP1 signal has (2)
(61) Check APP1 signal at SECM PIN B7
shorted to ground, circuit CheckEngineLight
has opened or sensor has
failed
88
Operation Section

CHECK
APP2RangeLow
612
low, normally set if the APP2 signal TurnOnMil Check APP2 signal at SECM PIN
(65)
has shorted to ground, circuit has B16
APP1RangeHigh
APP1 sensor voltage out of range (1) TurnOnMil Check foot pedal connector
621
high, normally set if the APP1 signal (2) CheckEngine Check APP1 signal at SECM PIN
(62)
has shorted to power or the ground Light B7
for the sensor has opened
APP2RangeHigh
622
high, normally set if the APP2 signal TurnOnMil Check APP2 signal at SECM PIN
(66)
has shorted to power or the ground B16
APP1AdaptLoMin corrosion
631
Learned idle end of APP1 sensor None Cycle the pedal several times and
(63)
range lower than expected check APP1 signal at SECM Pin
B7
632
(67)
B16
APP1AdaptHiMax
641
Learned full pedal end of APP1 None N/A
(64)
sensor range higher than expected
APP2AdaptHiMax
642
(68)
APP1AdaptHiMin
APP2AdaptHiMin
APP1AdaptLoMax
APP2AdaptLoMax
corrosion
APP_Sensors_Conflict Cycle the pedal several times and
691 APP position sensors do no not track (1) TurnOnMil check APP1 signal at SECM Pin
(69) well, intermittent connections to APP (2) Level1PowerLimit B7
or defective pedal assembly Cycle the pedal several times and
check APP2 signal at SECM Pin
B16
89
Operation Section

Check FTV1 for an open wire or FTV connector
LSDFault_Dither1 being disconnected
711
has opened or shorted to TurnOnMil FTV1 Pin 2 (power) to SECM (DRVP) Pin A23
(71)
ground or power or defective Check FTV1 for an open coil by disconnecting
dither 1 valve the FTV connector and measuring the
resistance (~26 2 )
LSDFault_Dither2 being disconnected or signal shorted to GND
712 has opened or shorted to TurnOnMil FTV2 Pin 2 (power) to SECM (DRVP) Pin A23
resistance (~26 2 )
Check Check Engine Lamp for an open wire or
shorted to GND
crank disable relay
Check fuel lock off valve for an open wire or
connector being disconnected or signal shorted
LSDFault_LockOff
to GND
Fuel lock off Valve Fault,
Lockoff Pin B (signal) to SECM Pin A11 Lockoff
717 signal has opened or shorted TurnOnMil
Pin A (power) to SECM (DRVP) Pin A23
Check CSV for an open coil by disconnecting
defective Fuel lock off valve
the CSV connector and measuring the
resistance (~26 3)
LSDFault_MIL
Check MIL lamp for an open wire or short to
GND.
GasFuelAdaptRangeLo Check for vacuum leaks.
721 In LPG mode, system had to Check dual dither valves, e.g. leaking valve or
TurnOnMil
(72) adapt rich more than hose
expected Check for missing orifice(s).
90
Operation Section
GasFuelAdaptRangeHi Check dual dither valves, e.g. plugged valve or

731 In LPG mode, system had hose.
TurnOnMil
(73) to adapt lean more than Check for plugged orifice(s).
expected
Check that Pre-catalyst O2 sensor connections
are OK.
GasO2NotActive
O2 Pin 2 (HEATER GND) to SECM (DRVG
Pre-catalyst O2 sensor
(1) TurnOnMil GNG) Pins A16, B17
741 inactive on LPG, open O2
(2) DisableGas O2 Pin 1 (HEATER PWR) to SECM (DRVP +
(74) sensor signal or heater
O2Ctrl 12V) Pin A23
leads, defective O2
Verify O2 sensor heater circuit is operating by
sensor
measuring heater resistance (2.1 0.4)
O2 Pin 2 (HEATER GND) to Pin 1 (HEATER
PWR)
connections are OK.
GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2 Heater
Relay. Relay pin 87. This relay only turns on
GasPostO2NotActive
after engine has been running for some time
Post-catalyst O2 sensor
(1) TurnOnMil and SECM has calculated that water
inactive on LPG, open O2
742 (2) DisableGasPost condensation in exhaust has been removed by
sensor signal or heater
O2Ctrl exhaust heat. Post O2 Heater Relay has
leads, defective O2
SECM (DRVP + 12V) applied to the relay coil
sensor.
power. The relay coil ground is controlled by
SECM Pin A20 to activate the relay to flow
current through the post O2 heater.
PWR)
GasO2FailedLean Check for vacuum leaks.
(1) TurnOnMil
Pre-catalyst O2 sensor Check dual dither valves, e.g. leaking valve or
751 (2) DisableGas
indicates extended lean hose.
O2Ctrl
operation on LPG Check for missing orifice(s).
Correct other faults that may contribute to 752
(e.g. faults pertaining to dither valves, Pre-Cat
GasPostO2FailedLean O2, Post Cat O2 sensor)
(1) TurnOnMil
Pre-catalyst O2 sensor Check for vacuum leaks
752 (2) DisableGasPost
indicates extended lean Check for leaks in exhaust, catalytic converter,
O2Ctrl
operation on LPG HEGO sensors; repair leaks.
Check all sensor connections (see fault 742
GasO2FailedRich Check dual dither valves, e.g. plugged valve or
(1) TurnOnMil
771 Pre-catalyst O2 sensor hose.
(2) DisableGas
(77) indicates extended rich Check for plugged orifice(s).
O2Ctrl
operation on LPG
91
Operation Section

(e.g. faults pertaining to FTVs, Pre-Cat O2, Post
GasPostO2FailedRich
(1) TurnOnMil Cat O2 sensor)
772 (2) DisableGasPost Look for leaks in exhaust, catalytic converter,
indicates extended rich
O2Ctrl HEGO sensors; repair leaks.
operation on LPG
LiqFuelAdaptRangeHi
Low gasoline fuel pressure, perform gasoline
In Gasoline mode,
821 TurnOnMil pressure test.
system had to adapt lean
Injector problems, e.g. plugged, defective
more than expected
injector.
LiqFuelAdaptRangeLo Low gasoline fuel pressure, perform gasoline
w pressure test
831 In Gasoline mode, TurnOnMil Injector problems, e.g. leaking, defective
system had to adapt rich injector.
more than expected
are OK.
LiqO2NotActive
inactive on gasoline,
841 (2) DisableLiquid O2 Pin 1 (HEATER PWR) to SECM (DRVP +
open O2 sensor signal or
O2Ctrl 12V) PIN A23
heater leads, defective
O2 sensor
PWR)
Check that Post-catalyst O2 sensor connections
are OK.
GNG) Pins A16, B17
LiqPostO2NotActive
after engine has been running for some time and
(1) TurnOnMil SECM has calculated that water condensation in
842 (2) DisableLiqPost exhaust has been removed by exhaust heat.
O2Ctrl Post O2 Heater Relay has SECM (DRVP + 12V)
applied to the relay coil power. The relay coil
O2 sensor.
ground is controlled by SECM Pin A20 to
activate the relay to flow current through the
post O2 heater.
PWR)
LiqO2FailedLean
(1) TurnOnMil Low gasoline fuel pressure, perform gasoline
851 (2) DisableLiquid pressure test.
indicates extended lean
O2Ctrl Injector problems, e.g. plugged, defective
operation on gasoline
injector
92
Operation Section

(e.g. faults pertaining to Injectors, MAP, IAT,
LiqPostO2FailedLean
(1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor)
852 (2) DisableLiqPost Look for leaks in exhaust, catalytic converter,
LiqO2FailedRich
(1) TurnOnMil High gasoline fuel pressure, perform gasoline
871 (2) DisableLiquid pressure test
O2Ctrl Injector problems, e.g. leaking, defective injector
(e.g. faults pertaining to Injectors, MAP, IAT,
LiqPostO2FailedRich
(1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor)
872 (2) DisableLiq Look for leaks in exhaust, catalytic converter,
PostO2Ctrl HEGO sensors; repair leaks.
O2RangeLow (1) TurnOnMil Check if O2 sensor installed before the catalyst
Pre-catalyst O2 sensor (2) DisableLiquid is shorted to GND or sensor GND.
911 voltage out of range low, O2Ctrl O2 (signal) Pin 3 to SECM Pin B13
sensor signal shorted to (3) DisableGas SECM (DRVG GND) Pins A16, B17
ground O2Ctrl SECM (XDRG sensor GND) Pin B1
(1) TurnOnMil Check if O2 installed after the catalyst sensor is
O2_PostCatRangeLow
(2) Disable asoline shorted to GND or sensor GND.
Post-catalyst O2 (signal) Pin 3 to SECM Pin B19
912 voltage out of range low,
O2Ctrl Possible sources: SECM (DRVG GND) Pins
sensor signal shorted to
(3) Disable LPG A16, B17 and SECM (XDRG sensor GND) Pin
ground
Post-catalyst O2Ctrl B1
O2RangeHigh Check if O2 sensor installed before catalyst is

(1) TurnOnMil
Pre-catalyst O2 sensor shorted to +5Vdc or battery.
(2) DisableLiquid O2Ctrl
921 voltage out of range high, O2 (signal) Pin 3 to SECM Pin B13
(3) DisableGas
sensor signal shorted to SECM (XDRP + 5V) Pin B24
O2Ctrl
power SECM (DRVP + 12V) Pin A23
(1) TurnOnMil
O2_PostCatRangeHigh (2) Disable asoline Check if O2 sensor installed after catalyst is
Post-catalyst O2 sensor Post-catalyst shorted to +5Vdc or battery.
922 voltage out of range low, O2Ctrl O2 (signal) Pin 3 to SECM Pin B19
sensor signal shorted to (3) Disable LPG Possible voltage sources: SECM (XDRP + 5V)
ground Post-catalyst Pin B24 and SECM (DRVP + 12V) Pin A23
O2Ctrl
FuelTempRangeLow
Fuel Temperature Sensor Check fuel temp sensor connector and wiring for
Input is Low normally set if a short to GND
931 the fuel temperature TurnOnMil SECM (signal) Pin B14 to FTS Pin 1
sensor wire has shorted to SECM (sensor GND) Pin B1 to FTS Pin 2
chassis ground or the SECM (system GND) Pin A16, B17
sensor has failed.
FuelTempRangeHigh
Fuel Temperature Sensor Check if fuel temp sensor connector is
Input is High normally set if disconnected or for an open FTS circuit
932 the fuel temperature TurnOnMil SECM (signal) Pin B14 to FTS Pin 1
sensor wire has been SECM (sensor GND) Pin B1 to
disconnected or the circuit FTS Pin 2
93
Operation Section

933 Excessive transmission oil (2) DelayedEngine
transmission service procedures.
ServiceFault4
994 TurnOnMil
reached-replace HEGO Replace Post-catalyst HEGO sensor
sensors
ServiceFault5
reached-replace timing belt
94
Operation Section
Lift Truck Operation

Power Shift Transaxle
WARNING
1. Start the engine. See topic "Starting the Engine."
A lift truck with the engine running but without
an operator can move slowly (creep) if the
transmission is engaged.
This could result in personal injury.
Always place the transmission control lever in
the NEUTRAL (center) position and apply the
parking brake before dismounting the lift truck.
5. Release the service brake.

6. Push down on the accelerator pedal to obtain the
desired travel speed. Release the pedal to
2. Push down on the service brake pedal to hold decrease travel speed.
the lift truck until ready to move it.
3. Release the parking brake.
NOTE : The parking brake must be released before
the directional control can be used.
WARNING
Sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift truck
to tip over.
4. Select the direction of travel by pushing the
directional lever FORWARD for forward direction Stop the loaded lift truck completely, before
or by pulling the lever BACK for reverse shifting to reverse.
direction. Failure to comply could result in personal injury.
NOTE : Where conditions permit, directional

changes can be made under full power at
speeds up to 8 km/h (5 mph). A speed of 8
km/h (5 mph) is a fast walk. Directional
shift changes at speeds above 8 km/h (5
mph) are considered abusive. Bring the lift
truck to a complete stop where load
stability or other factors prevent safe
operation under full power shifts safe
operation under full power shifts.
95
Operation Section
Inching
NOTE : The purpose of the inching pedal is to
provide precise lift truck inching control at
very slow travel speed and high engine
rpm. This is used for fast hydraulic lift,
during load approach, pick up or load
positioning.
7. To change the lift truck direction of travel,

release the accelerator pedal.
8. Push down on the service brake pedal to reduce
the lift truck speed as necessary.
1. To inch (creep) in either direction, slowly push

down on the inching pedal. This will start to apply
the service brakes and allow the transmission
clutch discs to slip.
2. Vary the position of the inching pedal and the
accelerator pedal to control the inching speed
and distance.
3. Pushing down further on the inching pedal will
9. Move the directional lever to the desired direction disengage the transmission completely and
of travel. Slowly push down on the accelerator apply the service brakes fully to stop and hold
pedal as the lift truck changes direction. the lift truck. This will provide full engine power
for fast hydraulic lift.
10.When the direction change is completed,
continue to push down on the accelerator pedal
to obtain the desired travel speed.
11.To stop the lift truck when traveling in either

direction, release the accelerator pedal.
12.Push down on the service brake pedal and bring
the lift truck to a smooth stop.
96
Operation Section
Steering Knob (If Equipped)

There is a steering knob available for inclusion with
new truck deliveries. This option is solely intended
for slow travel situations when two handed steering
is not possible due to hydraulic operations.
WARNING
Loss of stability can occur when a lift truck
steering wheel is rotated quickly while the truck
is in motion. A steering knob will assist with
easy rotation of the steering wheel, but if a
steering knob is improperly used (e.g., rotating
the steering wheel quickly while the truck is in
motion), this can contribute to truck instability
and a tip over. A steering knob is intended for
slow travel maneuverability ONLY.
97
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 Typical Example

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

2. Move the lift truck FORWARD until the load
clear of the other material.
touches the carriage.
4. Lower the cradled load to the travel position.
NOTE : Lift and tilt speeds are controlled by engine
rpm.
98
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
Typical Example
Do not tilt the mast forward with the load unless
directly over the unloading area, even if the
power is off.
2. For better vision, travel in reverse with bulky
loads.
99
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
counterweight swing.
100
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 the

overheating. Clean them out regularly with a
blast of compressed air. Also, check the leakage
of water.
2. Check the fan belt tension and adjust to proper
tension
3. Even if the engine overheats and the coolant
boils over, let the engine idle for a while with
opening engine hood until temperature falls
1. Block drums or round objects. Tilt the mast before shut off the engine.
FORWARD and side the fork tips along the floor
to get under the load.
2. Before lifting, tilt the mast BACK slightly until the

load is cradled on the forks.
101
Operation Section
Parking the Lift Truck

Park the lift truck level, with the forks lowered and
floor. Block the drive wheels when parking on an
incline.
5. Turn the key in the ignition switch to the OFF

position and remove the key.
1. Park in an authorized area only. Do not block

traffic. If LP - Gas equipped, do not park near
elevator shafts or any other area where LP-Gas
could collect in a pocket (low area), causing a
potentially dangerous condition.
NOTE : If an LP- Gas equipped lift truck is stopped

or parked for an indefinite or prolonged
period of time, shut off the LP-Gas fuel
tank valve.
6. Actuate each loading lever several times to

remove the residual pressure in the respective
cylinders and hoses.
2. Place the transmission controls in NEUTRAL.
7. Block the drive wheels if parking on an incline.
3. Engage the parking brake.
4. Lower the forks to the ground.
WARNING
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.
102
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. After adjustment, set the fork locks to keep the
forks in place.
WARNING
Make sure the forks are locked before carrying a
load.
103
Operation Section
Storage Information
z Cover components such as the breather and air
Before Storage cleaner which may be caught with humidity.
z The machine should be operated at least once a
Before storing your lift truck, clean and inspect as
week. Fill the cooling system, if cooling water is
the following procedures.
discharged, and mount the battery. Start the
z Wipe away grease, oil, etc. adhering to the body
engine and warm up thoroughly. Move the
of the truck with waste cloth, and use water, if
machine a little forwards and backwards. Operate
needed.
the hydraulic controls several times.
z While cleaning the truck, check general condition
of the truck. Especially check the truck body for
recess or damage and tires for wear or nails or To Operate the Lift Truck After a
stones in the tread.
z Fill the fuel tank with fuel specified.
Long Time Storage
z Check for leakage of hydraulic oil, engine oil, fuel,
z Remove covers and antirust from each of the
or coolant, etc. components and exposed parts.
z Apply grease, where needed.
z Drain the engine crankcase, transmission (clutch
z Check for looseness of nuts and bolts, especially
type machine), differential and final reduction
hub nuts. gear, clean the inside of them and add new oil.
z Check mast rollers to see that they rotate
z Drain off foreign matter and water from the
smoothly. hydraulic oil tank and fuel tank.
z Prime the oil into the lift cylinders by actuating the
z Remove the head cover from the engine cylinder.
lift lever all the way several times. Oil valves and rocker shaft and check each valve
z Drain off coolant completely in water of cold
for proper operation.
weather, if antifreeze is not used. z Add cooling water to the specified level.
z Charge the battery and mount it on the machine.
Connect the cables.
Long Time Storage z Perform pre-operational checks carefully. (refer to
Perform the following service and checks in addition Before Starting the Engine)
to the Parking the lift truck services. z Warm up the machine.
z Taking the rainy season into consideration, park
the machine at a higher and hard ground.
z Avoid parking on soft grounds such as an asphalt
ground in summer.
z Dismount the battery from the machine.Even
though the machine is parked indoors, if the place
is hot or humid, the battery should be kept in a
dry, cool place. Charge the battery once a month.
z Apply antirust to the exposed parts which tend to
rust.
104
Operation Section
Transportation Hints
Lift Truck Shipping Machine Lifting and Tiedown

Check travel route for overpass clearances. Make Information
sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
overhead guard or cab. NOTICE
To prevent the lift truck from slipping while loading,
or shifting in transit, remove ice, snow or other Improper lifting or tiedowns can allow load to
slippery material from the loading dock and the truck shift and cause injury and/or damage.
bed before loading.
1. Weight and instructions given herein apply to lift

NOTICE trucks as manufactured by DOOSAN.
Obey all state and local laws governing the 2. Use proper rated cables and slings for lifting.
weight, width and length of a load. Position the crane for level lift truck lift.
Observe all regulations governing wide loads. 3. Spreader bar widths should be sufficient to
prevent contact with the lift truck
4. Use the tiedown locations provided for lift truck
NOTICE
tiedown.
Remove ice, snow or other slippery material Check the state and local laws governing weight,
from the shipping vehicle and the loading dock. width and length of a load.
Contact your DOOSAN Lift Truck dealer for shipping
instructions for your lift truck.
Always block the trailer or the rail car wheels before

loading the lift truck.
Position the lift truck on the truck bed or the rail car.
Apply the parking brake and place the transmission
control in NEUTRAL.
Turn ignition switch to the OFF position and remove
the key. If LP-Gas equipped, shut off the LP-Gas
fuel tank.
Block the wheels and secure lift truck with tiedowns.
105
Operation Section
Towing Information
To provide sufficient control and braking when
WARNING moving a disabled lift truck downhill, a larger towing
Personal injury or death could result when lift truck or additional lift trucks connected to the rear
towing a disabled lift truck incorrectly. could be required. This will prevent uncontrolled
rolling. The different situation requirements cannot
Block the lift truck wheels to prevent movement be given, as minimal towing lift truck capacity is
before releasing the brakes. The lift truck can required on smooth level surfaces to maximum on
roll free if it is not blocked. inclines or poor surface conditions.
Follow the recommendations below, to properly Consult your DOOSAN Lift Tuck dealer for towing a
perform the towing procedure. disabled lift truck.
These towing instructions are for moving a disabled

lift truck a short distance, at low speed, no faster
than 2 km/h (1.2 mph), to a convenient location for
repair. These instructions are for emergencies only.
Always haul the lift truck if long distance moving is
required.
Shield must be provided on the towing lift truck to
protect the operator if the tow line or bar should
break.
Do not allow riders on the lift truck being towed
unless the operator can control the steering and/or
braking. 1. Release the parking brake.
Before towing, make sure the tow line or bar is in
good condition and has enough strength for the
towing situation involved. Use a towing line or bar NOTICE
with a strength of at least 1.5 times the gross weight
of the towing lift truck for a disabled lift truck stuck in Release the parking brake to prevent excessive
the mud or when towing on a grade. wear and damage to the parking brake system.
Keep the tow line angle to a minimum. Do not
exceed a 30 angle from the straight ahead position.
Connect the tow line as low as possible on the lift 2. Check that the service brake pedal is released.
truck that is being towed.
Quick lift truck movement could overload the tow 3. Key switch is in the OFF position.
line or bar and cause it to break. Gradual and 4. Direction control lever is in neutral.
smooth lift truck movement will better.
Normally, the towing lift truck should be as large as 5. Fasten the tow bar to the lift truck.
the disabled lift truck. Satisfy yourself that the towing
6. Remove the wheel blocks. Tow the lift truck
lift truck has enough brake capacity, weight and
slowly. Do not tow any faster than 2 km/h (1.2
power, to control both lift trucks for the grade and
mph).
the distance involved.
WARNING
Be sure all necessary repairs and adjustments
have been made before a lift truck that has been
towed to a service area is put back into
operation.
106
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck Forks

The following section gives practical guidelines for Users may also refer to the International
inspection, maintenance and repair of lift truck forks. Organization For Standardization-ISO Technical
It also provides general information on the design Report 5057-Inspection and Repair of Fork Arms
and application of forks and the common cause of and ISO Standard 2330-Fork Arms-Technical
fork failures. Characteristics and Testing.
Lift truck forks can be dangerously weakened by While there are no specific standards or regula-
improper repair or modification. They can also be tions in the United States, users should be familiar
damaged by the cumulative effects of age, abra- with the requirements for inspection and mainte-
sion, corrosion, overloading and misuse. nance of lift trucks as provided by the 29 Code
A fork failure during use can cause damage to the Federal Register 196610.178 Powered Industrial
equipment and the load. A fork failure can also Truck, and ANSI/ASME Safety Standard(s) B56.1,
cause serious injury. B56.5 or B56.6 66as applicable to the type of
A good fork inspection and maintenance program machine(s) in use.
along with the proper application can be very effec-
tive in preventing sudden failures on the job.
Repairs and modifications should be done only by
the fork manufacturer or a qualified technician who Environment Protection
knows the material used and the required welding When servicing this lift truck, use an authorized ser-
and heat treatment process.
vicing area and an approved container to collect
Users should evaluate the economics of returning
coolant, oil, fuel, grease, electrolyte and any other
the forks to the manufacturer for repairs or pur- potential environmental pollutant before any lines,
chasing new forks. This will vary depending on
fittings or related items are disconnected or removed.
many factors including the size and type of fork.
After servicing, dispose of those materials in an
Forks should be properly sized to the weight and authorized place and container. When cleaning the
length of the loads, and to the size of the machine
lift truck, be sure to use an authorized area.
on which they are used. The general practice is to
use a fork size such that the combined rated capac-
ity of the number of forks used is equal to or greater
than the Standard(or rated) Capacity of the lift
truck.
The individual load rating, in most cases, will be
stamped on the fork in a readily visible area. This is
generally on the top or side of the fork shank.
z Afork rated at 1500 pounds at 24 inch load center
will be stamped 1500B24.
z Afork rated at 2000 kg at 600 mm load center will
be stamped 2000B600.
The manufacturer identification and year and date of
manufacture is also usually shown.
Some countries have standards or regulations which
apply specifically to the inspection and repair of
forks.
107
Maintenance Section
z Repetitive Overloading
Causes of Fork Failure Repetitive cycling of loads which exceeds the
Improper Modification or Repair fatigue strength of the material can lead to fatigue
failure. The overload could be caused by loads in
Fork failure can occur as a result of a field modifi- excess of the rated fork capacity and by use of
cation involving welding, flame cutting or other sim- the forks tips as pry bars. Also, by handling loads
ilar processes which affect the heat treatment and in a manner which causes the fork tips to spread
reduces the strength of the fork. and the forks to twist laterally about their
In most cases, specific processes and techniques mountings.
are also required to achieve proper welding of the
particular alloy steels involved. Critical areas most z Wear
likely to be affected by improper processing are the Forks are constantly subjected to abrasion as
heel section, the mounting components and the fork they slide on floors and loads. The thickness of
tip. the fork blade is gradually reduced to the point
where it may not be capable of handling the load
Bent or Twisted Forks for which it was designed.
Forks can be bent out of shape by extreme over- z Stress Risers

loading, glancing blows against walls or other solid Scratches, nicks and corrosion are points of high
objects or using the fork tip as a pry bar. stress concentration where cracks can develop.
Bent or twisted forks are much more likely to break These cracks can progress under repetitive load-
and cause damage or injury. They should be ing in a typical mode of fatigue failure.
removed from service immediately.
Fatigue Overloading
Parts which are subjected to repeated or fluctuating Extreme overloading can cause permanent bend-
loads can fail after a large number of loading cycles ing or immediate failure of the forks. Using forks of
even though the maximum stress was below the less capacity than the load or lift truck when lifting
static strength of the part. loads and using forks in a manner for which they
The first sign of a fatigue failure is usually a crack were not designed are some common causes of
which starts in an area of high stress concentration overloading.
This is usually in the heel section or on the fork
mounting.
As the crack progresses under repetitive load
cycling, the load bearing cross section of the
remaining metal is decreased in size until it
becomes insufficient to support the load and com-
plete failure occurs.
Fatigue failure is the most common mode of fork
failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.
108
Maintenance Section
Fork Inspection First Installation

1. Inspect forks to ensure they are the correct size
for the truck on which they will be used. Make
sure they are the correct length and type for the
loads to be handled.
If the forks have been previously used, perform
the 12 Month Inspection.
If the forks are rusted, see Maintenance and

Repair.
2. Make sure fork blades are level to each other

within acceptable tolerances. See Forks, Step
4, in the 2000 Service Hours or Yearly in
Establish a daily and 12 month inspection routine by
keeping a record for the forks on each lift truck.
Initial information should include the machine serial 3. Make sure positioning lock is in place and work-
number on each the forks are used, the fork manu- ing Lock forks in position before using truck. See
facturer, type, original section size, original length Forks, Step 7, in the 2000 Service Hours or
and capacity. Also list any special characteristics Yearly in Maintenance Intervals.
specified in the fork design.
Record the date and results of each inspection,
making sure the following information is included.
Daily Inspection
1. Visually inspect forks for cracks, especially in the
z Actual wear conditions, such as percent of heel section, around the mounting brackets, and
original blade thickness remaining. all weld areas. Inspect for broken or jagged fork
z Any damage, failure or deformation which might tips, bent or twisted blades and shanks.
impair the use of the truck.
z Note any repairs or maintenance. 2. Make sure positioning lock is in place and work-
ing. Lock the forks in position before using the
An ongoing record of this information will help in truck. See 2000 Service Hours or Yearly in
identifying proper inspection intervals or each Maintenance Intervals.
operation, in identifying and solving problem areas 3. Remove all defective forks from service.
and in anticipating time for replacement of the forks.
109
Maintenance Section
twice, gradually and without shock. Maintain the

12 Months Inspection test for 30 seconds each time.
Forks should be inspected, at a minimum, every 12 Check the fork arm before and after the second
months. If the truck is being used in a multi-shift or application of the test load. It shall not show any
heavy duty operation, they should be checked every permanent deformation.
six months. See Forks in the 2000 Service Hours Consult the fork manufacturer for further informa-
or Yearly in Maintenance Intervals. tion as may be applicable to the specific fork
involved.
Testing is not required for repairs to the positioning
Maintenance and Repair lock or the markings.
1. Repair forks only in accordance with the manu-
facturers recommendations.
Most repairs or modifications should be done only
by the original manufacturer of the forks or an
expert knowledgeable of the materials, design,
welding and heat treatment process.
2. The following repairs or modifications SHOULD

NOT be attempted.
Flame cutting holes or cutouts in fork blades.
Welding on brackets or new mounting hangers.
Repairing cracks or other damage by welding.
Bending or resetting.
3. The following repairs MAY be performed.
Forks may be sanded or lightly ground, to
remove rust, corrosion or minor defects from
the surfaces.
Heel sections may be ground with a carbon

stone to remove minor surface cracks or
defects. Polish the inside radius of the heel
section to increase the fatigue life of the fork.
Always grind or polish in the direction of the
blade and shank length.
Repair or replace the positioning locks on hook

type forks.
Repair or replace most fork retention devices

used with other fork types.
4. A fork should be load tested before being

returned to service on completion of repairs
authorized and done in accordance with the
manufacturers recommendations.
Most manufacturers and standards require the
repaired fork to be tested with a load 2.5 times
the specified capacity and at the load center
marked on the fork arm.
With the fork restrained in the same manner as

its mounting on the lift truck, apply the test load
110
Maintenance Section
Tire Inflation Information

The tire inflation pressures shown in the following 1
chart are cold inflation shipping pressures. Tire Inflation Press9ures

Ply Rating Shipping Adjustment
Size or Pressure A tire inflation in a warm shop area, 18 to 21C (65
Strength Index kPa psi to 70F), will be underinflated if the machine works
6.5X10 12 900 130 in freezing temperatures. Low pressure shortens the
5.0X8 8 800 115 life of a tire.
1
Standard tire, ply rating and inflation pressures.
Tire Inflation
The operating inflation pressure is based on the
weight of a ready - to - work machine without
attachments, at rated payload, and in average oper-
ating conditions. Pressures for each application may
vary and should always be obtained from your tire
supplier.
NOTE : Fill tires to the recommended pressures

listed L 35 kPa (5 psi). Tires can be filled
with nitrogen.
WARNING
Deflate tire before removing wheel nuts at tire Typical Example
change.
WARNING
Personal injury or death could result when tires
are inflated incorrectly.
Use a self - attaching inflation chuck and stand
behind the tread when inflating a tire.
Proper inflation equipment, and training in using
the equipment, are necessary to avoid
overinflation. A tire blowout or rim failure can
result from improper or misused equipment.
NOTICE
Set the tire inflation equipment regulator atno more
than 140 kPa (20 psi) over the recommended tire
pressure.
111
Maintenance Section
Torque Specifications
Metric Hardware Torque for Standard Bolts, Nuts,
Most of the nuts, bolts, studs, and threaded holes in and Taperlock Studs
your lift truck are metric. In this manual we provide
specifications in both metric and U.S. customary
measurement. Always replace metric hardware with NOTICE
metric hardware. See the parts books for proper
replacement. The two charts below give general torques for
bolts, nuts, and taperlock studs of SAE Grade 5
NOTE : For proper fit, use only metric tools on met- or better quality.
ric hardware. Non-metric tools might slip
and cause injury.
Torques for Bolts and Nuts With
Torque for Standard Hose Clamps Standard Threads
- Worm Drive
Standard Nut and Bolt Torque
Thread Size
Inch
NOTICE Nm
1
lbft
The chart below gives the torques for initial 1/4 12 + 4 9+3
installation of hose clamps on new hose and for
reassembly or retightening of hose clamps on 5/16 25 + 7 18 + 5
existing hose.
3/8 45 + 7 33 + 5
7/16 70 + 15 50 + 11
Initial Installation Torque On
Clamp Width New Hose 1/2 100 + 15 75 + 11
1
Nm lbin 9/16 150 + 20 110 + 15
16 mm (.625 in) 7.5 + 0.5 65 + 5 5/8 200 + 25 150 + 18
13.5 mm (.531 in) 4.5 + 0.5 40 + 5 3/4 360 + 50 270 + 37
8 mm (.312 in) 0.9 + 0.2 8+2 7/8 570 + 80 420 + 60
Reassembly Or
1 875 + 100 640 + 75
Clamp Width Retightening Torque
1 1/8 1100 + 150 820 + 110
1
Nm lbin
1 1/4 1350 + 175 1000 + 130
16 mm (.625 in) 4.5 + 0.5 40 + 5
1 3/8 1600 + 200 1180 + 150
13.5 mm (.531 in) 3.0 + 0.5 25 + 5
1 1/2 2000 + 275 1480 + 200
8 mm (.312 in) 0.7 + 0.2 6+2 1
1 Newton meter (Nm) is approximately the same as 0.1
1
1 Newton meter (Nm) is approximately the same as 0.1 kg .m.
kg.m.
112
Maintenance Section
Torques for Taperlock Studs Torque for Metric Fasteners
Standard Taperlock Stud

Thread Size Torque NOTICE
Inch
Be very careful never to mix metric with U.S.
1
Nm lbft customary (standard) fasteners. Mismatched or
incorrect fasteners will cause lift truck damage
1/4 8+3 6+2 or malfunction and may even result in personal
injury.
5/16 17 + 5 13 + 4
3/8 35 + 5 26 + 4
Original fasteners removed from the lift truck should
7/16 45 + 10 33 + 7 be saved for reassembly whenever possible. If new
fasteners are needed, they must be of the same size
1/2 65 + 10 48 + 7 and grade as the ones that are being replaced.
The material strength identification is usually shown
5/8 110 + 20 80 + 15 on the bolt head by numbers (8.8, 10.9, etc.). This
chart gives standard torques for bolts and nuts with
3/4 170 + 30 125 + 22 Grade 8.8.
7/8 260 + 40 190 + 30 NOTE : Metric hardware must be replaced with
metric hardware. Check parts book.
1 400 + 60 300 + 45
1 1/8 500 + 700 370 + 50

Standard Torque
Thread Size
1 1/4 650 + 80 480 + 60
Metric
1 3/8 750 + 90 550 + 65 Nm
1
lbft
1 1/2 870 + 100 640 + 75 M6 12 + 4 9+3

1
M8 25 + 7 18 + 5
kg.m.
M10 55 + 10 41 + 7
M12 95 + 15 70 + 11
M14 150 + 20 110 + 15
M16 220 + 30 160 + 22
M20 450 + 70 330 + 50
M24 775 + 100 570 + 75
M30 1600 + 200 1180 + 150
M36 2700 + 400 2000 + 300

1
kg .m.
2
ISO - International Standards Organization.
113
Maintenance Section
Cooling System Specifications

and the coolant level stabilizes. Add coolant as nec-
Coolant Information essary to fill the system to the proper level.
Never operate without a thermostat in the cooling
system. Cooling system problems can arise without
NOTE : The following information is generic and
a thermostat.
valid for lift trucks.
Engine operating temperatures have increased to
improve engine efficiency. This means proper cool-
ing system maintenance is especially important.
Overheating, overcooling, pitting, cavitation erosion,
cracked heads, piston seizures, and plugged
radiators are classic cooling system failures. In fact,
coolant is as important as the quality of fuel and
lubricating oil.
NOTICE
DOOSAN recommends that the coolant mixture
contain 50% commercially available automotive
antifreeze, and 50% water.
The coolant mix with concentration of antifreeze
smaller than 30% does not provide sufficient corro-
sion protection. Concentrations over 60% adverse-
ly affect freeze protection and heat transfer rates.
Never add coolant to an overheated engine, engine
damage can result. Allow the engine to cool first.
If the machine is to be stored in, or shipped to, an
area with freezing temperatures, the cooling sys-
tem must be protected to the lowest expected out-
side (ambient) temperature.
The engine cooling system is normally protected to
-28(-20) with antifreeze, when shipped from the
factory unless special requirements are defined.
Check the specific gravity of the coolant solution
frequently in cold weather to ensure adequate pro-
tection.
Check the specific gravity of the coolant solution

frequently in cold weather to ensure adequate
protection.
Clean the cooling system if it is contaminated, the
engine overheats or foaming is observed in the
radiator.
Old coolant should be drained, the system cleaned
and new coolant added every 2000 service hours or
yearly.
Refer to topic, Cooling System - Clean, Change in
Every 2000 Service Hours or Yearly section.
Filling at over 20 liters (5 U.S. gallons) per minute
can cause air pockets in the cooling system.
After draining and refilling the cooling system, oper-
ate the engine with the radiator cap removed until
the coolant reaches normal operating temperature
114
Maintenance Section
Coolant Water Antifreeze

insoluble chemical compounds by combining with NOTICE
phosphates. DOOSAN recommends using automotive antifreeze
The tendency of silicates and phosphates to pre- suitable for gasoline engines having aluminum
cipitate out-of-solution increases with increasing alloy parts. Antifreeze of poor quality will cause
water hardness. Hard water, or water with high lev- corrosion of the cooling system, and thus always
els of calcium and magnesium ions encourages the use automotive antifreeze prepared by a reliable
formation of insoluble chemicals, especially after a maker, and never use it mixed with antifreeze of
number of heating and cooling cycles. different brand.
DOOSAN prefers the use of distilled water or DOOSAN recommends that the coolant mix con-
deionized water to reduce the potential and severi- tain 50% commercially available automotive
ty of chemical insolubility. antifreeze, or equivalent and acceptable water to
maintain and adequate water pump cavitation tem-
perature for efficient water pump performance.
Acceptable Water
Premix coolant solution to provide protection to the
Water Content Limits (PPM) lowest expected outside (ambient) temperature.
Pure undiluted antifreeze will freeze at -23C(-10F).
Chlorides (Cl) 50 maximum Use a greater concentration (above 50%) of com-
mercially available automotive antifreeze only as
Sulfates (SO 4) 50 maximum needed for anticipated outside (ambient) tempera-
tures. Do not exceed the recommendations, provid-
Total hardness 80mg/l ed with the commercially available automotive
antifreezes, regarding the coolant mixture of
Total solids 250 maximum antifreeze to water.
PH 6.0 to 8.0
ppm = parts per million Make proper antifreeze additions.
Using water that meets the minimum acceptable Adding pure antifreeze as a makeup solution for
water requirement may not prevent drop-out of cooling system top-up is an unacceptable practice. It
these chemical compounds totally, but should mini- increases the concentration of antifreeze in the
mize the rate to acceptable levels. cooling system which increase the concentration of
dissolved solids and undissolved chemical inhibitors
in the cooling system. Add antifreeze mixed with
water to the same freeze protection as your cooling
system.
Use the chart below to assist in determining the
concentration of antifreeze to use.
Antifreeze Concentrations
Protection Temperature Concentration
Protection to -15C (5F) 30% antifreeze and 70% water
Protection to -23C (-10F) 40% antifreeze and 60% water
115
Maintenance Section
Fuel Specifications
Crude oil is used to describe oils/fuels that are not
General Fuel Information refined and are in the original state as when pumped
from the ground. Certain types of crude oils can be
Use only fuel as recommended in this section.
burned in DOOSAN Engines.
PREFERRED DISTILLATE FUEL

NOTICE
FOR DISEL ENGINES
Fill the fuel tank at the end of each day of oper- Specifications Requirements*
ation to drive out moisture laden air and to pre- Aromatics (AST D1319) 35% Max.
vent condensation. Maintain a constant level Ash (ASTM D482) 0.02% Weight Max.
near the top of the day tank to avoid drawing Cetane Number 35 Min. for 45 Max.
moisture into the tank as the level decreases. (ASTM D613) 40 Min. for DI Engines
Do not fill the tank to the top. Fuel expands as it
Not Above Lowest Expected
gets warm and can overflow.o not fill the fuel Cloud Point (ASTM D97)
Ambient Temperature
filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to Gravity API (ASTM D287) 30 Min. and 45 Max.
the fuel system parts. 6C (10F) Below
Pour Point (ASTM D97)
Ambient Min.
Sulfur (ASTM D2788, 0.5% Max.
Drain the water and sediment from main fuel stor- D3605 orD1552) (See Sulfur Topic)
age tank before it is refilled. This will help prevent Viscosity, Kinematic @ 20.0 cSt Max.
water and/or sediment from being pumped from the 38C (100F) (ASTM D445) 1.4 cSt Min.
fuel storage tank into the engine fuel tank. Water & Sediment
0.01% Max.
(ASTM D1796)
*As delivered to fuel system
Diesel Specifications
Fuel Types Fuel Sulfur Content
DOOSAN Diesel Engines have the ability to burn a The percentage of sulfur in the fuel will affect the
wide variety of fuels. These fuels are divided into engine oil recommendations. Fuel sulfur is chemi-
two general groups, preferred and permissible. cally changed during combustion to form both sul-
The Preferred Fuels provide maximum engine ser- furous and sulfuric acid. These acids chemically
vice life and performance. They are distillate fuels. attack metal surfaces and cause corrosive wear.
They are commonly called diesel fuel, MDO diesel,
furnace oil, gas oil or kerosene (for cold weather Certain additives used in lubricating oils contain
operation). alkaline compounds that are formulated to neutral-
Experience has proven that distillate fuels meeting ize these acids. The measure of this reserve alka-
the following basic specifications will result in opti- linity in lubricating oil is known as its Total Base
mum engine performance and durability. Number (TBN). TBN is essential to neutralize the
DOOSAN strongly encourages the use of fuels that acids from combustion gases and to minimize cor-
meet the Preferred Fuels specification. rosive wear.
The permissible fuels are crude oils or blended fuels. Any API classification performance of oil should
Use of these fuels can result in higher main- have sufficient TBN for fuels with less than 0.5%
tenance costs and reduced engine service life. sulfur. For fuels with 0.5% to 1.5% sulfur by weight,
engine oil must have a TBN of 20 times the per-
centage of fuel sulfur as measured by the ASTM
(American Society of Testing Materials) D-2896
method. (ASTM D-2896 can normally be found at
your local technological society, library or college).
DOOSAN recommends infrared analysis (in con-
junction with wear metal analysis) of used oil in
determining the effectiveness of oil TBN and acid
neutralization.
116
Maintenance Section
For fuel with sulfur exceeding 1.5% by weight, use

an oil with a TBN of 30 and reduce the oil change Gasoline Specifications
interval by one half. Also, infrared analysis and wear
Only unleaded gasoline should be used for
metal analysis should be used to establish oil
DOOSAN forklift trucks. The gasoline in which
change intervals. methanol is contained, is not recommended. The
Periodically request fuel sulfur content information gasoline in which ethanol is contained, is not
from your fuel supplier. Fuel sulfur content can recommended, either.
change with each bulk delivery.
LP-Gas Specifications
LP-Gas is Liquefied Petroleum Gas. The exact
composition of LP-Gas varies slightly between dif-
ferent parts of the country and different refineries.
HD5 or HD10 is recommended for DOOSAN forklift
trucks.
Composition of HD5
Propane (C3H8) 90.0 %
Propylene up to 5 %
Butane (C4H10) 2.0 %
iso-Butane 1.5 %
Methane (CH4) 1.5 %
Total 100 %
WARNING
Remember LP-Gas is heavier than air and will sink
to the lowest spot possible. Avoid areas near floor
drains or lubrication pits where escaped fuel may
collect.
117
Maintenance Section
Lubricant Specifications
Lubricant Information Hydraulic Oil (HYDO)

Certain abbreviations follow Society of Automotive The following commercial classifications can be
Engineers (SAE) J754 nomenclature and some used in the hydraulic system.
classifications follow SAE J183 abbreviations.
The MILspecifications are U.S.A. Military ISO 6743/4 HM
Specifications. AFNOR NFE 48-603 HM
The recommended oil viscosities can be found in the DIN 51524 TEIL 2 H-LP
Lubricant Viscosities chart in this publication. HAGGLUNDS DENISON HFO-HF2
Grease is classified by the National Lubricating CINCINNATI P68,69,70
Grease Institute (NLGI) based on ASTM D217-68
Worked Penetration characteristics which are given Viscosity : ISO VG32
a defined consistency number.
Industrial premium hydraulic oils that have passed
the Vickers vane pump test (35VQ25).
Engine Oil (DEO and EO) These oils should have antiwear, antifoam, antirust
and antioxidation additives for heavy duty use as
The following oil specifications provide guidelines for stated by the oil supplier. ISO viscosity grade of 32
the selection of commercial products : would normally be selected.
z Gasoline/LP-Gas Engine : API SJ or higher
z Diesel Engine : API CH-4 Grade or ACEA E5
NOTICE
NOTICE Make-up oil added to the hydraulic tanks must

mix with the oil already in the systems. Use only
Failure to follow the oil recommendations can petroleum products unless the systems are
cause shortened engine lift due to carbon equipped for use with special products. If the
deposits or excessive wear. hydraulic oil becomes cloudy, water or air is
entering the system. Water or air in the system
will cause pump failure. Drain the fluid, retighten
Consult the EMA Lubricating Oils Data Book for a all hydraulic suction line clamps, purge and refill
listing of oil brands. the system. Consult your DOOSAN Lift Truck
dealer for purging instructions.
NOTE : The percentage of sulfur in the fuel will
affect the engine oil recommendations. For
fuel sulfur effects, the Infrared Analysis or
the ASTM D2896 procedure can be used
to evaluate the residual neutralization
properties of an engine oil. The sulfur
products formation depends on the fuel
sulfur content, oil formulation, crankcase
blowby, engine operating conditions and
ambient temperature.
118
Maintenance Section
Transmission Oil (TDTO) Drive Axle Oil

NOTE : Failure to follow the recommendation will
cause shortened life due to excessive gear
NOTICE wear.
This oil is formulated for transmissions and Shoe Brake

drive trains only, and should not be used in Select oil that meets below specifications.
engines. Shortened engine life will result. z API GL-5
z MIL-L-2105 C, D
NOTE : Multi-grade oils are not blended by DOO- Gear Oil offers maximum protection against the
SAN for use in transmissions. Multi-grade scoring and pitting of gear teeth and rolling element
oils which use high molecular weight bearings.
polymers as viscosity index improvers lose Gear Oil can also provide excellent stability under
their viscosity effectiveness by permanent high temperature conditions and has superior low
and temporary shear of the viscosity index temperature performance. It will also give protection
improver and therefore, are not against rust and corrosion.
recommended for transmission and drive
train compartments. Oil Cooled Disc Brake (OCDB)
Select oil that meets below specifications.
NOTE : Failure to follow this recommendation can The API CD/TO - 2 specification or MIL - L 2104D or
cause shortened transmission life due to E oil could be used.
material incompatibility, inadequate friction-
al requirements for disk materials and/or
excessive gear wear.
The API CD/TO - 2 specification or MIL - L 2104D or

E oil could be used.
119
Maintenance Section
Brake Fluid Lubricating Grease (MPGM)

Use Multipurpose Molybdenum Grease (MPGM) for
all lubrication points. If MPGM grease can not be
used, a multipurpose type grease which contains
3% to 5% molybdenum disulfide can be used.
NLGI No.2 grade is suitable for most tempera-

tures.
Use NLGI No.1 or No.0 grade for extremely low
temperature.
Shoe Brake
Use heavy duty hydraulic brake fluid. It must be cer-
tified by the oil supplier to meet SAE J1703f latest
revision, DOT 3 or 4 specifications.
Oil Cooled Disc Brake

Use heavy duty hydraulic brake fluid certified by oil
supplier to meet the latest version of following clas-
sifications.
ISO 6743/4 HM
AFNOR NFE 48-603 HM
DIN 51524 TEIL2 H-LP
HAGGLUNDS DENISON HFO-HF2
CINCINNATI P68,69,70
Viscosity : ISO VG10

ISO Viscosity Grade of 10 would normally be
selected. The following products are authorized for
use.
Supplier Product Name

TOTAL AZOLLAZS 10
AGIP ACER 10
BP ENERGOLHP 10, HLP 10
CALTEX SPINDURN 10
ELF SPINELF 10
NUTO H 10
ESSO
SPINESSO 10
FINA HYDRAN 10
VELOCITE OILNO.5
MOBIL
VELOCITE OILE
120
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities
LUBRICANT VISCOSITIES Refill Capacities (Approximate)
FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment Oil C F Compartment
or System Liters U.S. Gal.
or System Viscosities Min Max Min Max
Engine SAE Engine Crankcase w/Filter G420F &
Crankcase -20 +40 -4 +104
10W30 4.2 1.11
G420F(E) 2.0 liter
[G420F(E)] and
Lift Chains SAE 5W30 -30 +30 -22 +86 Gasoline & LP-Gas
API SJ Engine Crankcase
Engine 6.5 1.7
w/Filter A2300 Diesel
Crankcase
SAE Cooling System
(Diesel) -15 +50 +5 +122
15W40
API CH4 or w/Coolant Recovery
ACEA E5 8.5 2.25
Bottle G420F & G420F(E) 2.0 liter
Power Shift SAE 10W -20 +22 -4 +72 Gasoline & LP-Gas
Transmission
SAE 30 +10 +50 +50 +122 Cooling System
API CD/TO-2
w/Coolant Recovery 9.8 2.55
Hydraulic and ISO VG32 -20 +30 -4 +86
Power Steering ISO VG46 -10 +40 +14 +104 Bottle A2300 Diesel
System Fuel Tank-G Series, D Series
42 11.0
ISO 6743/4 HM ISO VG68 0 +50 +32 +122 Gasoline, Diesel
Shoe
Brake SAE LP-Gas-G-Series 15.2Kg 33.5 Ib
-20 +50 -4 +122
API 80W90
GL-5 Power Shift Transmission 10.0 2.7
Drive
Disc Hydraulic & Power
Axle
Brake SEA 10W -20 +22 -4 +72 30 7.9
Housing Steering System
(OCDB)
API Drive Axle 5.0 1.3
CD/TO- SAE 30 +10 +50 +50 +122
2 Brake System 1.0 0.26
Shoe
Brake SAE
-30 +50 -22 +122
Brake DOT3 J1703f
Reserv DOT4
oir Disc
(Only Brake
for (OCDB)
ISO VG10 -20 +30 -4 +86
OCDB) ISO
6743/
4 HM
The SAE grade number indicates the viscosity of oil.

A proper SAE grade number should be selected
according to ambient temperature.
121
Maintenance Section
Engine Valve Lash (Diesel Engine Only) - Check,
Adjust ...................................................................... 143
NOTICE
All maintenance and repair, except every 10 service
Every 250 Service Hours or Monthly
hours or daily, on the lift truck must be performed by
qualified and authorized personnel only. Air Intake System - Check, Clean ......................... 144
Hydraulic Oil Level - Check ................................... 146
Drive Axle Oil Level - Check.................................. 146
NOTICE Mast, Carriage, Lift Chains & Attachments - Inspect,
Lubricate ................................................................. 147
Careless disposal of waste oil can harm the Steering Mechanism - Check, Lubricate............... 147
environment and can be dangerous to persons. Battery Terminal - Clean, Inspect ......................... 148
Always dispose of waste oil to an authorized Brake Oil Level - Check......................................... 148
personnel only. Engine Oil & Filter - Change.................................. 149
PCV Valve System - Inspect, Clean ..................... 150
Wheel Bolts & Nuts - Inspect................................. 150
Fuel Filter (Diesel Engine Only) - Change............ 151
When Required
Every 500 Service Hours or 3 Months
Priming the Fuel System (Diesel Engine Only) ....126
Fuel Tank Filler Cap and Screen (If Equipped) - Belts - Check, Adjust.............................................. 152
Clean .......................................................................127 Tilt Cylinders - Check, Adjust, Lubricate............... 152
Seat, Hood Latch & Support Cylinder - Check, Mast Hinge Pin - Lubricate .................................... 153
Lubricate..................................................................128 Crosshead Roller - Inspect.................................... 153
Fuses, Bulbs and Circuit Breaker - Change, Reset Parking Brake - Test, Adjust.................................. 154
.................................................................................128 Inching & Braking Control Shaft - Lubricate ......... 154
Fuse & Relay (G420F(E) Only) .............................129 Drive Axle Oil (OCDB) - Change........................... 154
Test Fuel System for Leaks (LP and Dual Fuel Horn & Lights (If Equipped) - Check ..................... 154
Engines Only) .........................................................131 Overhead Guard - Inspect ..................................... 154
Tires and Wheels - Inspect, Check .......................131 Inspect Vacuum Lines and Fittings (G420F(E)
Carriage Roller Extrusion - Adjust.........................132 Engine Only)........................................................... 155
Fuel Trim Valve(FTV) Inspection (G420F(E) Engine
Every 10 Service Hours or Daily Only)........................................................................ 155
Inspect Electrical System (G420F(E) Engine Only)
Inspect Engine for Fluid Leaks ..............................133 ................................................................................. 155
Engine Oil Level - Check........................................133
Coolant Level - Check, Clean................................133 Every 1000 Service Hours or 6 Months
Air Cleaner Indicator - Check.................................134
Inspect Foot Pedal Operation (G420F(E) Only)...134 Hydraulic Return Filter, Breather & Strainer - Check,
Inspect Engine for Exhaust Leaks.........................134 Change.................................................................... 156
Walk-Around Inspection - Inspect .........................135 Engine Valve Lash (Diesel Engine Only) Check,
Mast Channels - Lubricate.....................................136 Adjust ...................................................................... 156
Transmission Oil Level - Check.............................136 Lift Chains - Test, Check, Adjust........................... 157
Transmission Oil & Strainer- Clean, Change ....... 159
First 50-100 Service Hours or a Week Air Intake System - Change................................... 159
Inspect Coolant Hoses (LP, Dual Fuel Engines Only)
Engine Oil & Filter (Diesel Engine Only) - Change ................................................................................. 160
.................................................................................137 LP Regulator/Converter Inspection (LP, Dual Fuel
Transmission Oil & Strainer - Change, Clean ......138 Engine Only)........................................................... 160
Drive Axle Oil - Change..........................................139 Fuel Lines & Fittings - Check ................................ 160
Parking Brake - Test, Adjust ..................................140 Inspect Mixer Assembly (G420F(E) Engine Only)160
Inspect Throttle Assembly (G420F(E) Engine Only)
First 250 Service Hours or a Month ................................................................................. 160
Hydraulic Return Filter Change ..........................143
122
Maintenance Section
Drive Axle Oil (Shoe Brake) - Change ..................161

Inspect Ignition System (LP-Gas, Gasoline & Dual
Fuel Engines Only) .................................................161
Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
Engine Only) ...........................................................161
Fuel Filter (LP - Gas Engine Only) ........................162
Testing Fuel Lock-off Operation (LP-Gas Engine
Only) ........................................................................162
Every 2000 Service Hours or Yearly
Steer Wheel Bearings Reassemble ...................163

Drive Wheel Bearing - Reassemble ......................164
Cooling System Clean, Change .........................165
Fork - Inspect..........................................................167
Hydraulic Oil - Change, Check, Clean ..................169

Inspect Battery System ..........................................170
Replace Oxygen Sensor (G420F(E) Engine Only)
.................................................................................170
Checking the TMAP Sensor (G420F(E) Engine
Only) ........................................................................171
Inspect for Intake Leaks (G420F(E) Engine Only)
.................................................................................171
Replace Spark Plugs (G420F(E) Engine Only)....172
Timing Belt (G420F(E) LP-Gas, Gasoline & Dual

Fuel Engine Only) - Change ..................................173
123
Maintenance Section
Quick Reference to Maintenance Schedule FIRST EVERY
2500 Service Hours or 15 Months


50-100 Service Hours or a Week
250 Service Hours or a Monthly
2000 Service Hours or a Yearly

250 Service Hours or a Month
10 Service Hours or a Daily

ITEMS SERVICES PAGE
When Required
Air Cleaner Indicator Check 134 O
Air Intake System Change 159 O
Air Intake System Check, Clean 144 O
Battery Terminal Clean, Inspect 148 O
Belts Check, Adjust 152 O
Brake Oil Level Check 148 O
Carriage Roller Extrusion Adjust 132 O
Checking the TMAP Sensor (G420F(E) Engine Only) 171 O
Coolant Level Check, Clean 133 O
Cooling System Clean, Change 165 O
Crosshead Roller Inspect 153 O
Drive Axle Oil Change 139 O
Drive Axle Oil (Shoe Brake) Change 161 O
Drive Axle Oil Level Check 146 O
Drive Wheel Bearing Reassemble 164 O
Engine Oil & Filter Change 149 O
Engine Oil & Filter (Diesel Engine Only) Change 137 O
Engine Oil Level Check 133 O
Engine Valve Lash (Diesel Engine Only) Check, Adjust 143 O
Fork Inspect 167 O
Fuel Filter (Diesel Engine Only) Change 151 O
Fuel Filter (LP - Gas Engine Only) 162 O
Fuel Lines & Fittings Check 160 O
Fuel Tank Filler Cap and Screen (If Equipped) Clean 127 O
155 O
Only)
Fuse & Relay (G420F(E) Only) 129 O
Fuses, Bulbs and Circuit Breaker Change, Reset 128 O
Horn & Lights (If Equipped) Check 154 O
Change, Check,
Hydraulic Oil 169 O
Clean
Hydraulic Oil Level Check 146 O
Hydraulic Return Filter Change 143 O
Hydraulic Return Filter, Breather & Strainer Check, Change 156 O
Inching & Braking Control Shaft Lubricate 154 O
Inspect Battery System 170 O
124
Maintenance Section
Quick Reference to Maintenance Schedule FIRST EVERY


50-100 Service Hours or a Week
250 Service Hours or a Monthly
2000 Service Hours or a Yearly

250 Service Hours or a Month
10 Service Hours or a Daily

ITEMS SERVICES PAGE
When Required
Inspect Coolant Hoses (LP, Dual Fuel Engines Only) 160 O
Inspect Electrical System (G420F(E) Engine Only) 155 O
Inspect Engine for Exhaust Leaks 134 O
Inspect Engine for Fluid Leaks 133 O
Inspect Foot Pedal Operation (G420F(E) Only) 134 O
Inspect for Intake Leaks (G420F(E) Engine Only) 171 O
Inspect Ignition System (LP-Gas, Gasoline & Dual Fuel
161 O
Engines Only)
Inspect Mixer Assembly (G420F(E) Engine Only) 160 O
Inspect Throttle Assembly (G420F(E) Engine Only) 160 O
Inspect Vacuum Lines and Fittings (G420F(E) Engine
155 O
Only)
Test, Check,
Lift Chains 157 O
Adjust
LP Regulator/Converter Inspection (LP, Dual Fuel
160 O
Engine Only)
Mast Channels Lubricate 136 O
Mast Hinge Pin Lubricate 153 O
Mast, Carriage, Lift Chains & Attachments Inspect, Lubricate 147 O
Overhead Guard Inspect 154 O
Parking Brake Test, Adjust 140 O
PCV Valve System Inspect, Clean 150 O
Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
161 O
Engine Only)
Replace Oxygen Sensor (G420F(E) Engine Only) 170 O
Replace Spark Plugs (G420F(E) Engine Only) 172 O
Seat, Hood Latch & Support Cylinder Check, Lubricate 128 O
Steer Wheel Bearings Reassemble 163 O
Steering Mechanism Check, Lubricate 147 O
Test Fuel System for Leaks (LP and Dual Fuel Engines
131 O
Only)
Testing Fuel Lock-off Operation (LP-Gas Engine Only) 162 O
Tilt Cylinders - Check, Adjust, Lubricate 152 O
Timing Belt (G420F(E) LP-Gas, Gasoline & Dual Fuel
Change 173 O
Engine Only)
Tires and Wheels Inspect, Check 131 O
Transmission Oil & Strainer Change, Clean 138 O
Transmission Oil Level Check 136 O
Walk-Around Inspection Inspect 135 O
Wheel Bolts & Nuts Inspect 150 O
125
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.
Draining the Water From the Fuel Filter

Priming the Fuel System (Diesel
Engine Only) 1. Check "Diesel Engine Water in fuel filter indicator
light" in instrument panel. Refer to, "Diesel
Bleeding the Fuel System Engine Water in Fuel Filter Indicator Light" in
After changing the fuel filter cartridge assembly, or section.
after having serviced any part of the fuel system,
make sure that the air is bled from the system.
2. Turn the wing nut (1) counter clockwise more

1. Loosen one of four bleeding screws on overflow
than two turns. The wing nut (1) is located near
pipes to injection nozzles.
fuel's inlet side. Some times later, "w" marking
will be added as illustrated in Top View below.
2. Push the priming pump on top of the fuel filter 3. Turn the wing nut (2) counter clockwise more than
housing against the spring to allow air mixed with six turns to open the drain valve on the bottom of
fuel to escape through the bleeding screw. the fuel filter.
Ensure that excess fuel is collected in a
container or rag to prevent fuel from getting onto
engine parts.
3. Repeat the pumping action until no bubbles are
visible in the flowing fuel.
4. Tighten the bleed screw.
5. Start the engine and check fuel system for leaks.
126
Maintenance Section
Fuel Tank Filler Cap and Screen (If

Equipped) - Clean
Park the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
engine stopped.
4. Drain some fuel (and any water) until the clean

fuel flows out from the filter.
1. Remove the filler cap assembly. Clean in clean,

nonflammable solvent.
2. Dry cap assembly.
3. Install filler cap assembly.
WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
4. Drain moisture and sediment from fuel tank as

required by prevailing conditions.
127
Maintenance Section
Seat, Hood Latch & Support Fuses, Bulbs and Circuit Breaker -
Cylinder - Check, Lubricate 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.
1. Check the operation of the seat adjuster rod.

Make sure that the seat slides freely on its track.
Lightly oil the seat slider tracks if necessary.
Remove the front cover of fuse box. The

fuses are located under the cover.
2. Pull the latch to raise the hood and seat assem-
Fuse - Protects an electrical circuit from an over-
bly. Make certain the support cylinder will hold
load. Opens (filament separates) if an overload
the hood open.
occurs.
128
Maintenance Section
Fuse & Relay (G420F(E) Only)

Fuse
<G15/18/20SC-5>
Fuses are identified as follows :

1. Horn - 10 amp.
2. Head Lamp, Clearance Lamp, Tail Lamp. - 15 amp.
3. Lamp Relay Coil, Fwd/Rev Solenoid, Rear Lamp
/Alarm - 10 amp Located on the top of Engine
4. Instrument Panel, Hour Meter, Preheat Controller, Fuel
Shut-off Solenoid - 15 amp Relay
5. Stop Lamp, Turn Signal Lamp, Strobe Lamp - 15 amp
6. Starter Relay - 10 amp
Bulbs
Bulbs are identified as follows :
1. Bulb-head lamp halogen (12V-35W)
*2. Bulb-back up (12V-8W)
*3. Bulb-turn signal (12V-23W)
*4. Bulb-stop & tail (12V-23/8W) Located rear side of valve mounting bracket
*OPTIONALLAMP OR LIGHT
Circuit Breaker
1. Raise the hood and seat assembly. Make sure

the support cylinder securely holds the hood
open.
129
Maintenance Section
Typical Example
2. The main circuit breaker is located on the rear of

the support for the controls.
NOTE : To reset circuit breakers push in on the
button. The button should stay in if the
breaker is reset. If the button will not stay
in, or comes out shortly after reset, have
the circuits checked.
130
Maintenance Section
Test Fuel System for Leaks (LP Tires and Wheels - Inspect, Check
and Dual Fuel Engines Only)
WARNING
Servicing and changing tires and rims can be
dangerous and should be done only by trained
personnel using proper tools and procedures.
Deflate tire before removing wheel nuts from the
truck.
If correct procedures are not followed while ser-
vicing tires and rims, the assemblies could burst
with explosive force and cause serious physical
Check injury or death.
Points
Follow carefully the specific information provid-
ed by your tire servicing man or dealer.
1. Obtain a leak check squirt bottle or pump spray
bottle.
Check Inflation and Damage
2. Fill the bottle with an approved leak check
solution. Inspect tires for wear, cuts, gouges and foreign
objects. Look for bent rims and correct seating of
3. Spray a generous amount of the solution on the locking ring.
fuel system fuel lines and connections, starting at Check tires for proper inflation. See Tire Inflation
the storage container. Pressures.
To inflate tires always use a clip-on chuck with a
4. Wait approximately 15-60 seconds then perform a minimum 60 cm (24 inches) length of hose to an in-
visual inspection of the fuel system. Leaks will line valve and gauge.
cause the solution to bubble. Always stand behind the tread of the tire. NOT in
front of the rim.
5. Repair any leaks before continuing.
6. Crank the engine through several revolutions.

This will energize the fuel lock-off and allow fuel
to flow to the pressure regulator/converter.
Apply additional leak check solution to the
regulator/converter fuel connections and housing.
Repeat leak inspection as listed above.
7. Repair any fuel leaks before continuing.
WARNING
Prior to any service or maintenance activity, Test Do not reinflate a tire that has been run while flat or
Fuel System for Leaks underinflated, without first checking to make sure
the rim is not damaged and is in the correct position.
When tires are changed, be sure to clean all rim
parts and, if necessary, repaint to stop detrimental
effects of corrosion. Sand blasting is recommended
for removal of rust.
131
Maintenance Section
WARNING Carriage Roller Extrusion - Adjust

Deflate tire before removing wheel nuts from the 1. Set the mast vertical.
truck.
2. Lower the carriage completely.
3. On full free lift and full free triple lift models, the
Check all components carefully and replace any
bottom of the inner mast must be flush with the
cracked, badly worn, damaged and severely rusted
bottom of the stationary mast.
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts.
Do NOT, under any circumstances, attempt to
rework, weld, heat or braze any rim components.

inner upright to the bottom of carriage bearing.
The safety disc wheel has designed to prevent loos-
5. The measurement (A) must be as follows in
ening of the rim bolt on the two-piece rim where the
Chart below.
tire is attached to the truck. The rim nut is attached
to the inner side. The bolt head is rounded. For that
Height of carriage roller extrusion (A)
reason, the tire must first be removed from the truck
when the rim is taken apart. STD mast FF mast FFT mast
22 36 36
132
Maintenance Section
Every 10 Service Hours or Daily

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

1. Raise the hood and seat assembly.
Coolant Level - Check, Clean
Checking Coolant Level
WARNING
Hot oil and components can cause personal WARNING
injury. Do not allow hot oil or components to At operating temperature, the engine coolant is
contact skin. hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
Gasoline and LP-Gas Engines been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali.
Avoid contact with the skin and eyes to prevent
personal injury.
2. Maintain oil level between the Max. and Min.

marks on the dipstick.
Typical Example
1. Observe the coolant level with engine cold.

Maintain coolant level to the proper line on
expansion bottle. If the expansion bottle has no
coolant, it will be necessary to check coolant at
the radiator filler neck.
133
Maintenance Section
2. Remove the radiator cap. Fill radiator to the top of

the filler neck. Inspect radiator cap. Replace if Air Cleaner Indicator - Check
damaged. Install the radiator cap.
Checking Service Indicator
3. Start and run the engine to stabilize the coolant 1. Observe the air cleaner service indicator.
level in the filler neck. If low add coolant until it
reaches the top of the filler neck. Install the radi- 2. Service the air cleaner when the RED band in
ator cap. Observe coolant level in the expansion the service indicator, lock in the visible position.
bottle. If necessary, add coolant to bring the See topic, Air Intake System - Check, Clean in
coolant to the appropriate line on the expansion Every 250 Service Hours or Monthly.
bottle.
NOTE : Service the element more frequently, as
4. Stop the engine. required, in severe dust or lint conditions.
Also, service it more frequently where the
5. Inspect the cooling system for leaks, hose cracks
operator is required to wear a respirator.
or loose connections.
3. Close hood and seat assembly.
WARNING
Inspect Foot Pedal Operation
Pressure air can cause personal injury. (G420F(E) Only)
When using pressure air for cleaning, wear a 1. Verify foot pedal travel is smooth without sticking.
protective face shield, protective clothing and
protective shoes.
Maximum air pressure must be less than 205 WARNING
kPa (30 psi) for cleaning purposes.
When the acceleration pedal harness is connected
or disconnected, should be worked KEY OFF
condition.
6. Blow any dust and lint from the radiator fins.
If not, occurred malfunction, can cause the personal
injury.

temperatures.
2. Perform visual inspection of exhaust system.

Repair any/all leaks found.
134
Maintenance Section
Walk-Around Inspection - Inspect

For maximum service lift 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 gouged tires.
Have any repairs made and debris removed, as
needed.
Typical Example
8. Inspect the cooling system for leaks, worn hoses

and debris buildup.
9. Inspect engine compartment for oil, coolant and
fuel leaks.
10.Inspect the forks.
z Visually inspect forks for cracks, especially in the
heel section, around the mounting brackets, and
1. Inspect the tires and wheels for cuts, gouges,
all weld areas.
foreign objects, inflation pressure and loose or
missing bolts.
z Inspect for broken or jagged fork tips, bent or
2. Inspect the mast and lift chains for wear, broken twisted blades and shanks. Make sure positioning
links, pins and loose rollers. lock is in place and working. Lock the forks in
position before using the truck. See Every 2000
3. Inspect the hydraulic system for leaks, worn Service Hours or Yearly.
4. Look for transmission and differential leaks on z Remove all defective forks from service.
the lift truck and on the ground.

6. Inspect the instrument panel for broken gauges
and indicator lights.
7. Test the horn and other safety devices for prop-
er operation.
135
Maintenance Section
Mast Channels - Lubricate Transmission Oil Level - Check

Checking Oil Level
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.
The channels on the roller-type mast require a 2. Park the lift truck level with the forks lowered,
break-in period. Apply a light film of lubricant on the parking brake applied and the transmission con-
channels where the rollers ride. This will prevent trols in NEUTRAL.
metal peel until the rollers set a pattern.
3. With the service brake applied and the engine at
low idle, shift the directional control lever to for-
ward and then to reverse, to fill the clutches.
4. Shift the direction control lever to the NEUTRAL
position.
5. Open the floor plate.
6. Remove the dip stick. Observe the oil level.

7. Maintain the oil level between the MIN and MAX
marks on the dip stick.
136
Maintenance Section
First 50-100 Service Hours or a Week

4. Remove and discard oil filter element.

Engine Oil & Filter (Diesel Engine
5. Wipe sealing surface of oil filter element mount-
Only) - Change ing base. Make sure the entire old gasket is
removed.
Diesel Engine Crankcase
6. Before installing a new filter element, apply a
The percentage of sulfur in the fuel will affect the
small amount of clean engine oil to the filter ele-
engine oil recommendations. If the fuel has over
ment gasket.
0.5% sulfur content, the CD engine oil have a TBN
of 20 times the percentage of fuel sulfur (TBN as 7. Install the new filter element. When the gasket
measured by the ASTM D-2896 method). Your oil contacts the base, tighten it 11/4 of a turn more.
supplier should be able to furnish the correct oils. Do not overtighten.
1. Operate lift truck a few minutes to warm oil. Park 8. Raise the lift truck, remove the blocking and
the lift truck with the forks lowered, parking brake lower the lift truck.
applied, Transmission in neutral and the engine 9. Raise the hood and seat assembly.
stopped.
10.Fill the crankcase. See Refill Capacities.
2. Raise rear of lift truck off ground and block
securely.
WARNING
contact skin.
11.Start the engine and allow the oil to fill the filter
and passages.
12.Check for oil leaks.
3. Remove the crankcase drain plug and allow oil to

drain. Clean and install drain plug.
137
Maintenance Section
Transmission Oil & Strainer -

Change, Clean
Power Shift Transaxle(PTA18)
WARNING
contact skin.
13. Stop the engine and measure the oil level.

Maintain the oil level between the MAX. and MIN. Park the lift truck level, with the forks lowered, park-
marks on dip stick. ing brake engaged, transmission in NEUTRAL and
the engine stopped.
14. Close hood and seat assembly. Component is shown removed from the lift truck for
illustrative purposes.
NOTICE 1. Remove drain plug (1). Allow the oil to drain.

Check O-ring seal and replace if necessary.
Servicing of the engine oil and oil filter element
Remove the strainer.
will largely affect on the engine performance as
well as the engine life. Engine oil and filter ele-
ment must be changed initially 50 hours.
Normal
Oil gauge
Drain plug (1)
Strainer
IPMO060I
2. Wash the strainer in clean, nonflammable sol-

vent and dry it. Install the strainer, and the drain
plug.
3. Remove the filler cap. Fill the compartment with
oil. See Refill Capacities. Install the dip
stick/filler cap.
4. Start the engine.
5. With the service brake applied and engine at low
idle, shift the transmission to forward and reverse
to fill the clutches.
138
Maintenance Section
6. Shift the transmission into NEUTRAL. Engage the

parking brake. Drive Axle Oil - Change
7. Remove the dip stick. Observe the oil level. Park the lift truck on a level surface. Apply the park-
ing brake. Place the directional control lever in
8. Maintain the oil level between the MIN and MAX NEUTRAL.
9. Check for oil leaks at the strainer and drain plug.
10.Stop the engine. Install the floor plate.
1. Raise the carriage high enough to access the

drain plug and level/fill plug.
2. Block the bottom of the mast with a block of
wood to hold the carriage in the raised position.
4. Place an appropriate container under the axle to
catch the oil as it drains. Remove the drain plug
and the level/fill plug.
5. Allow the oil to drain completely out. Discard the

old oil according to federal, state, and local
regulations.
6. Clean and reinstall the drain plug.
7. Add sufficient fresh oil through the level/fill open-
ing until it reaches the bottom of the hole. See
the section Lubricant Viscosities and Refill
Capacities for the type and amount of oil to use.
139
Maintenance Section
8. Clean and reinstall the level/fill plug.

Parking Brake - Test, Adjust
9. Remove the wood blocking and lower the car-
riage.
Parking Brake Testing
10.Operate the lift truck for a few minutes and check
oil level again. See the topic, Drive Axle Oil NOTICE
Level - Check in Every 250 Service Hours or
OSHA requires the parking brake to hold the lift
Monthly section.
truck, with capacity load, on a 15% grade.
Testing requires a test load equal to the capacity of
the truck and a 15% grade.
If the maximum grade in the workplace is less than
its capacity, use the Parking Brake inspection
procedure covered in Inspection from Operators
Seat, Engine On in Every 10 Service Hours or
Daily section.
1. Pick up capacity load and drive over to a 15%

grade.
2. Remove your thumb from the release button.

The lever should resist movement when pulled
fully back and a clicking sound should be heard.
The lever should remain fully back until you
press the release button with your thumb.
3. Engage the parking brake and slowly release

the service brake.
4. Engage the parking brake and shift the

transmission to NEUTRAL. Slowly release the
service brakes.
5. The parking brake adjustment is proper if it

holds the lift truck on the grade. The parking
brake needs adjusting if it does not hold the lift
truck on the grade.
6. If the lift truck starts to move in reverse down

the grade with the parking brake engaged, stop
it with the service brakes, disengage the
parking brake and reverse slowly down the
grade controlling your speed with the service
brakes.
140
Maintenance Section
WARNING
To prevent personal injury, the operator MUST
be ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck
starts to move.
Parking Brake Adjusting
1. Park the lift truck on a level surface, lowered the

forks, shift the transmission to NEUTRAL and
shut OFF the engine and block the wheels
securely. 7. Loosen lock nut (5). Tighten screw (6) to 6 to 7
Nm (50 to 60 lbin). Loosen the screw (6) 1 1/6
2. Chock the lift truck's tires to prevent turns and tighten the lock nut (5).
unintentional movement.
NOTICE
Turn the adjustment screw (6) clockwise to tighten.
Turning the screw (6) too far counterclockwise could
allow parts to fall into the bottom of the transmission.
The transmission would than require disassembly to
remove the parts.
8. Reinstall the floor plate and floor mat.
9. Engage the parking brake, remove the tire

chocks and test the parking brake. Refer to
3. Remove the floor mat and floor plate. Parking Brake Testing in the preceding section.
4. Make sure the parking brake lever is released.
5. Make sure the brake lever (1) is held against

stop pin (2). If the brake lever (1) is held against
the stop pin (2), go to step 7. If the brake lever
(1) is NOT held against the stop pin (2), go to
step 6.
6. Remove the pin (3) and the cotter pin (4).

Tighten the nut (6) to compress the spring (7)
further and pull downward and turn the clevis
(5) until the pin (3) fits into the brake lever when
the lever (1) is held against the stop pin (2).
Then install the pin (3) and the cotter pin (4)
and return the nut (6) to the clevis (5).
141
Maintenance Section
To Adjust (Oil Cooled Disc Brake Only)

Park the lift truck on the level, with forks lowered,
transmission in NEUTRAL, the engine stopped and
the wheels securely blocked.
1. Turn the knob(1) clockwise to increase the

levers tension or counterclockwise to decrease it
Adjustment is correct when the lever requires an
. .
effort 196 to 245 N m (20 to 25 kgf m) [142 to 178
lbf.ft].
3. The distance(3) must be sustained. Do not adjust

it freely. If you cannot get the sufficient perfor-
mance of parking by above two steps, please
contact DOOSAN lift truck service personnel.
2. If it is difficult to get the desired levers tension by

the knob control, you can get it by locating the
middle of the cable bolt thread.
z At the front of the bracket(2)
: increase the levers tension.
z At the rear of the bracket(2)

: decrease the levers tension.
142
Maintenance Section
First 250 Service Hours or a Month

Hydraulic Return Filter Change Engine Valve Lash (Diesel Engine

Only) - Check, Adjust
WARNING
injury. Do not allow hot oil or component to con- NOTICE
tact skin.
The valve clearances are to be adjusted at the times
of the following situations.
Park the lift truck level with the forks lowered, park-
ing brake engaged, transmission in NEUTRAL and z When the engine is overhauled and the cylinder
the engine stopped. heads are disassembled.
z When severe noise comes from valve train.
z When the engine is not normally operated even
though there is no trouble in the fuel system.
WARNING
To prevent possible injury when adjusting diesel
engines, do not use the starter motor to turn the
flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring valve clearance.
1. Loosen the bolts of the hydraulic tank top plate
assembly.
NOTICE
2. Remove the return filter from tank top plate
assembly. Measure the valve lash with the engine stopped. To
obtain an accurate measurement, allow at least 20
3. Change the return filter. minutes for the engine cylinder head and block to
4. Install the tank top plate assembly and fasten the cool.
bolts.
Set the clearance to the nominal appropriate clear-
ance given in the Valve Clearances chart shown
below.
Valve Clearances
Engine Valve Clearance
2.3 Liter Exhaust Valves 0.3 mm(0.012 in)
(A2300)Diesel Intake Valves 0.3 mm(0.012 in)
Refer to the Service Manual for the complete valve

adjustment procedure.
NOTE : In case of Gasoline or LPG engine, no valve

adjustment is necessary.
143
Maintenance Section

3. Clean and inspect the element or replace with a

Air Intake System - Check, Clean new element. See topic, Cleaning Primary Filter
Element.
Servicing Filter Element
4. Clean the inside of air cleaner housing and the
cover. Inspect all connections between the air
cleaner and carburetor. Check intake hose for
NOTICE cracks, damage necessary to prevent leakage.
Never service filter with the engine running.
NOTICE
Do not allow dirty air to enter the intake hose

when cleaning the inside of the cleaner hous-
ing.
5. Check the air cleaner housing for loose retain-

ing bolts.
6. Reset the air cleaner service indicator.
7. Install the air filter element.
8. Install the cover and tighten the cover latches.
Service the air cleaner when the red target in the
service indicator stays locked in the visible position 9. Start the engine and observe the position of the
with the engine stopped. indicator. If the indicator shows RED after the
installation of the primary element, install anoth-
1. To service the air cleaner, raise the hood and er clean or a new element or, replace the sec-
seat assembly. Make certain the support cylinder ondary element. See topic, Air Intake System -
securely holds the hood open. Loosen the cover Change in Every 1000 Service Hours or 6
latches and remove the cover. months section.
10.Stop the engine and close the hood and seat
assembly.
2. Rotate the element slightly to separate it from its

base and remove it from the air cleaner housing.
144
Maintenance Section
Cleaning Primary Filter Elements Air-205 kPa (30 psi) Maximum Pressure
WARNING
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a
protective shoes.
The maximum air pressure must be below 205
NOTICE Direct air on the inside and outside of the element

along the length of the pleats. Check the element for
Do not clean the elements by bumping or tap- any tears, rips or damage.
ping them.
Inspect filter elements after cleaning. Do not use Checking Element
a filter with damaged pleats, gaskets or seals.
When cleaning with pressure air, use 205 kPa
(30 psi) maximum pressure to prevent filter
element damage.
When cleaning with pressure water, use 280 kPa
(40 psi) maximum pressure to prevent filter
element damage.
Have spare elements on hand to use while cleaning

used elements.
The primary element should be replaced after 6
months service or after cleaning no more than 3 1. Insert a light inside the clean dry element and
times. examine it. Discard the element if tears, rips or
damage are found.
2. Wrap and store good elements in a clean, dry
place.
145
Maintenance Section
Hydraulic Oil Level - Check Drive Axle Oil Level - Check

Park the lift truck on a level surface. Apply the park-
WARNING ing brake. Place the directional control lever in
NEUTRAL.
At operating temperature, the hydraulic tank is
hot and under pressure.
Hot oil can cause burns.
Remove the fill cap only when the engine is
stopped, and the cap is cool enough to touch
with your bare hand. Remove the fill cap slowly
to relieve pressure.
1. Operate the lift truck for a few minutes to warm

the oil. Park the lift truck on a level surface, with
the forks lowered, mast tilted back, parking brake
engaged, transmission in NEUTRAL and the 1. Raise the carriage high enough to access the
engine stopped. level/fill plug.
2. Pull the latch and raise the hood and seat 2. Block the bottom of the mast with a block of
assembly. Make sure the air lift cylinder securely wood to hold the carriage in the raised position.
holds the hood open.
4. Remove the level/fill plug. The oil level should

3. Remove the breather/dip stick. Maintain the oil
reach the bottom of the hole. Maintain the oil
level to the FULLmark on the breather/dip stick.
level, to the bottom of the hole.
5. Clean off the level/fill plug and put it back in
place.
6. Remove the wood blocking and lower the load
backrest.
146
Maintenance Section
Mast, Carriage, Lift Chains & Steering Mechanism - Check,

Attachments - Inspect, Lubricate Lubricate
1. Operate the lift, tilt and attachment controls.
Listen for unusual noises. These may indicate a
need for repair.
2. Inspect for loose bolts and nuts on the carriage.
Remove any debris from the carriage and mast.
3. Inspect the forks and attachments for free opera-
tion and damage. Have repairs made if neces-
sary.
1. Lubricate the steer axle king pins, total of four fit-

tings. Two on the right side and two on the left
side.
2. Lubricate the steering link bearings, total of four
fittings. Two on the right side and two on the left
side.
3. Check for any worn or loose components of the
steering mechanism. Remove any debris or trash
4. Brush a film of oil on all links of the chain. as required.
5. Raise and lower the carriage a few times to work
lubricant into the chain links.
NOTICE
Lubricate chains more frequently than normal in

applications where the lift truck is operating in a
atmosphere which could cause corrosion of
components or when lift truck must work in
rapid lift cycles.
6. Inspect the chain anchors and individual links for

wear, loose pins or cracked leaves.
147
Maintenance Section
Battery Terminal - Clean, Inspect Brake Oil Level - Check

WARNING
Batteries give off flammable fumes that can
explode.
Do not smoke when observing the battery elec-
trolyte levels.
Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes.
Always wear protective glasses when working
with batteries.
The brake reservoir is located on the left side of the

steering column.
1. Remove the filler cap.

2. Maintain the brake fluid level to the fluid level
mark on the brake system reservoir.
3. Clean and install the filler cap.
Typical Example
1. Clean the top of the battery and terminals.

2. Check terminals for corrosion. Coat terminals with
heavy grease.
148
Maintenance Section
Engine Oil & Filter - Change

Diesel Engine Crankcase
See topic, Engine Oil & Filter (Diesel Engine Only) -
Change in First 50 - 100 Service Hours
Gasoline, LP-Gas Engine Crankcase

1. Operate lift truck a few minutes to warm oil. Park
the lift truck with the forks lowered, parking brake
applied, transmission in neutral and the engine
stopped. 5. Remove and discard oil filter element.
2. Raise rear of lift truck off ground and black 6. Wipe sealing surface of oil filter element mount-
securely. ing base. Make sure the entire old gasket is
removed.
WARNING 7. Before installing a new filter element, apply a

small amount of clean engine oil to the filter ele-
Hot oil and components can cause personal ment gasket.
contact skin. 8. Install the new filter element. When the gasket
contacts the base, tighten it 3/4 of a turn more.
Do not overtighten.
9. Raise the lift truck, remove the blocking and
lower the lift truck.
10.Fill the crankcase. See Refill Capacities.
11.Start the engine and allow the oil to fill the filter
and passages.
12.Check for oil leaks.
3. Remove the crankcase drain plug and allow oil to

drain. Clean and install drain plug.
13.Stop the engine and measure the oil level.

Maintain the oil level to the FULL mark on the dip
stick.
14.Close hood and seat assembly.
149
Maintenance Section
PCV Valve System - Inspect, Clean Wheel Bolts & Nuts - Inspect
G420F(E) Gasoline, LP-GAS and Dual Inspect Tightness
Fuel Engine
Steer Wheels
1. Loosen the hose clamps and remove the PCV

valve. Typical Example
2. Shake the PCV valve. If it rattles, reinstall it. If it 1. Inspect tightness of wheel bolts in a sequence
does not rattle, replace it. opposite each other 110 Nm (81 lbft).
3. Tighten the hose clamps. Drive Wheels
2. Inspect tightness of wheel nuts in a sequence

opposite each other to 180 Nm (133 lbft).
150
Maintenance Section
Fuel Filter (Diesel Engine Only) -

Change
Diesel Engine (A2300)
Park lift truck with the forks lowered, parking brake
applied, transmission in neutral, engine stopped and
cool.
WARNING
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire.
Turn the disconnect switch OFF if fitted or dis-
connect the battery when changing fuel filters.
2. Remove fuel filter cartridge assembly.

3. Remove sensor assembly from cartridge assem-
bly.
4. Before installing a new cartridge assembly,
assemble existing sensor assembly, apply a
small amount
NOTICE
Do not fill fuel filters with fuel before installing

them. Contaminated fuel will cause accelerated
wear to fuel system parts.
5. Install the new fuel filter cartridge assembly.

6. Turn the new fuel filter cartridge assembly until
the filter gasket is fitted against the sealing face.
7. Turn the fuel filter cartridge assembly an addi-
tional 2/3 of turn.
151
Maintenance Section

Belts - Check, Adjust Tilt Cylinders - Check, Adjust,

Lubricate
Chassis Pivot Eyebolts - Lubricate
1. Remove floor plates.
Typical Example
1. Check the condition and adjustment of the belt.

Correct adjustment allows 12mm (0.47 inch)
deflection under 98N(22lb) of force.
2. Lubricate two fittings for the pivot eyebolts, one
on each tilt cylinder.
3. Check the pivot eye pins for loose retainer bolts
and wear.
Mast Pivot Eyes-Lubricate
Typical Example
NOTICE
Failure to loosen the alternator mounting bolt

will cause excessive stress and break the alter-
nator mounting ear. 1. Lubricate two fittings for the mast pivot eyes, one
on each side of the mast.
2. To adjust the alternator drive belt, loosen adjust- 2. Check the pivot eye pins for loose retainer bolts
ing bracket bolt and mounting bolt. Move the and wear.
alternator in or out as required. Tighten bolts.
152
Maintenance Section
Cylinder Rod Extension-Adjust

Mast Hinge Pin - Lubricate
NOTE : The following description is for forward tilt.
For cylinder rod back tilt, the collar should
be stationary by the tilt eye. If it is not, the
O-ring inside the collar may need to be
replaced. To adjust back tilt, spacers must
be added or removed.
1. Lower the forks and tilt the mast forward.

2. Lubricate the two fittings for the mast hinge pins,
one on each side of the mast.
1. Check to make sure the tilt cylinders extend and

retract evenly. Crosshead Roller - Inspect
2. If one cylinder continues to move after the other 1. Operate the mast through a lift cycle. Watch the
cylinder has stopped in full forward or backward chains move over the crosshead rollers. Make
tilt, an adjustment must be made to one cylinder. sure the chain is tracking over the rollers proper-
ly.
3. To adjust the cylinder rod extension, move the
spacer to the rear and loosen the pinch bolt on
the clevis.
4. Turn the cylinder rod in or out of the clevis to
obtain the proper adjustment. Turning the rod
into the clevis shortens the stroke. Turning the
rod out of the clevis lengthens the stroke.
5. Tighten the pinch bolts to a torque of 9515 Nm
(7010 lbft). Check the cylinder rods again for
even travel.
Typical Example
2. Check for damaged crosshead rollers, guards

and retainer rings.
153
Maintenance Section
Parking Brake - Test, Adjust

Horn & Lights (If Equipped) -
See topic, Parking Brake - Test, Adjust in First Check
50-100 Service Hours.
Inching & Braking Control Shaft -

Lubricate
1. Press horn button, to determine if horn is opera-

tional.
2. Check and replace all defective gauges.
3. Check all lights such as warning, directional,
1. Lubricate three fittings for the inching and brake
backup, driving and flood lights for correct oper-
pedal control shaft.
ation. Replace all burned out bulbs. Have repairs
made if needed.
Drive Axle Oil (OCDB) - Change
See topic, Drive Axle Oil - Change in the First 50 -
100 Service Hours.
Overhead Guard - Inspect
1 2
1. Check tightness of overhead guard mounting

bolts at 105 Nm (77 lbft)(1) & 60 Nm (44
lbft)(2).
2. Check overhead guard for bent or cracked sec-
tions. Have repairs made if needed.
154
Maintenance Section
Inspect Vacuum Lines and Fittings Inspect Electrical System

(G420F(E) Engine Only) (G420F(E) Engine Only)
1. Visually inspect vacuum lines and fittings for 1. Check for loose, dirty or damaged connectors
physical damage such as bittleness, cracks and and wires on the harness including: Fuel
kinks. Repair/replace as required. lock-off, TMAP sensor, O2 sensor, Electronic
throttle, Control Relays, Fuel Trim Valve, Foot
2. Slovent or oil damage may cause vacuum lines Pedal, and crank sensor.
to become soft resulting in a collapsed line while
the engine is running.
2. Repair and/or replace as necessary.
3. If abnormally soft lines are detected, replace as
necessary.
(1) Fuel Trim Valve(FTV) (2) Vacuum lines
Fuel Trim Valve(FTV) Inspection

(G420F(E) Engine Only)
1. Visually inspect the Fuel trim valve for

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

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

connector to the FTV.
4. Disconnect the vacuum lines form the FTV to

the pressure regulator/converter, at the
converters tee connection.
5. Lightly blow through the vacuum line connected

to the FTV. Air should not pass through the FTV
when de-energized. If air leaks past the FTV
when de-energized replace replace the FTV.
155
Maintenance Section


Hydraulic Return Filter, Breather & assembly.
Strainer - Check, Change 5. Change the return filter.
6. Remove the suction strainer from the tank.
WARNING 7. Install a new strainer by hand.
Hot oil and components can cause personal 8. Install the tank top plate assembly and fasten the
injury. Do not allow hot oil or components to bolt.
contact skin.
9. Start the engine and operate the hydraulic con-
trols, and the steering system, through a few
Park the lift truck level with the forks lowered, park- cycles to fill the lines. Look for oil leaks.
ing brake engaged, transmission in NEUTRAL and
10.Stop the engine and check the oil level. With all
the engine stopped.
cylinders retracted, maintain the oil level to the
FULLmark on the dip stick/filler cap assembly.
Engine Valve Lash (Diesel Engine Only)

Check, Adjust
See topic, Engine Valve Lash (Diesel Engine Only)
Check, Adjust in First 250 Service Hours or a
Month.
1. Remove and discard the air breather.

2. Install a new air breather.
assembly.
156
Maintenance Section
Check for Equal Tension

Lift Chains - Test, Check, Adjust
Lift Chain Wear Test
Inspect the part of the chain that is normally oper-
ated over the cross head roller. When the chain
bends over the roller, the movement of the parts
against each other causes wear. Inspect to be sure
that chain link pins do not extend outside of the link
hole. If any single link pin is extended beyond its
connecting corresponding link, it should be
suspected of being broken inside of its link hole. Lift
chains are required to check for wear about every
1,000 service hours or 6 months.
Chain wear test is a measurement of wear of the Typical example
chain links and pins. Take the following steps to
check chain wear.
Lift the carriage and the mast high enough for get-
ting tension on lift chains. Check the chains, and
1. Lift the mast and carriage enough for getting ten-
make sure the tension is the same. Lift chains are
sion on lift chains.
required to check for equal tension about every
1,000 service hours or 6 months.
WARNING
Personal injury can be caused by sudden move-
ment of the mast and carriage. Keep hands and
feet clear of any parts that can move.
Lift Chain Adjustment
Typical example
2. Measure precisely ten links of chain distance at

the center of pins in millimeter.
3. Calculate chain wear rate*.
4. If the chain wear rate is 2% or more, replace the
lift chain.
*Chain wear rate (%)
= Actual measurement - Pitch** X 10 X 100
Pitch** X 10 Typical example for carriage equal tension
**Chain Pitch for G15/18S-5, G20SC-5, D15/18S-5, If the tension is not the same on both chains, take
D20SC-5 = 15.88mm(0.63 in) the procedure as follows.
NOTE : If carriage height is not correct, make

adjustments by following procedures.
157
Maintenance Section
4. Set the mast vertical and raise the carriage and

Carriage Chain Adjustment
check equal chain tension. If not equal, repeat
Make sure that carriage height is correct. If correct, the same procedure as step 1 through step 3.
adjust the chain for equal tension. If not, adjust the
chain for correct carriage height by adjusting anchor 5. Put LOCTITE No. 242 Tread lock on the threads
nuts(1),(2). of the anchor nuts(1),(2) after the adjustment is
completed.
NOTE : See the previous section, Carriage Roller
Extrusion in When Required. for proper Mast Chain Adjustment - FF,FFT Mast
height of carriage.
1. Fully lower the carriage and tilt mast forward or lift

the carriage and put blocks under the carriage to
release the tension from the lift chains.
2. Loosen nut(1) and adjust nut(2) to get proper dis-
tance from bottom of inner upright to the bottom
of carriage bearing.
Typical example for FF mast
Typical example for carriage chain of STD mast
Typical example for FFT mast
Make sure that mast height is correct. If correct,

adjust chain for equal tension. If not, adjust mast
chain for correct mast height by adjusting anchor
nuts(3),(4).

Extrusion in When Required. for proper
Typical example for carriage chain of FF,FFT mast inner mast height.
3. Make adjustment anchor nut(1),(2) for equal 1. Lift the inner mast and put blocks under the inner
chain tension. mast to release the tension from the lift chains.
2. Loosen nut(3) and adjust nut(4) to make inner
mast rail flush with outer mast rail bottom.
158
Maintenance Section
3. Make adjustment anchor nuts(3),(4) for equal

chain tension. Air Intake System - Change
4. Raise the inner mast and check equal chain ten- Changing Primary Element
sion. If not equal, repeat the same procedure as
step 1 through step 3. See topic, Air Intake System - Check, Clean in
Every 250 Service Hours or Monthly.
5. Put LOCTITE No. 242 tread lock on the threads
of the anchor nuts(3),(4) after the adjustment is Changing Secondary Element
completed.
Replace the secondary element after the primary
element has been cleaned three times or 6 months.
Transmission Oil & Strainer- Clean,
Change 1. Remove the primary air cleaner element. See
topic Servicing Filter Element. Clean the inside
See topic, Transmission Oil & Strainer - Clean, of the air cleaner housing and cover.
Change in First 50-100 Service Hours.
2. Remove the secondary element. Inspect the gas-

ket between the air cleaner housing and the
engine inlet. Replace the gasket if it is damaged.
NOTICE
Always replace the secondary element. Do not

attempt to reuse it by cleaning.
3. Install a new secondary element. Install a new or

cleaned primary element. Install the cover.
Tighten the latches.
4. Start the engine and observe the air cleaner ser-
vice indicator. If the indicator shows RED after
installing a new secondary element and a
cleaned primary (outer) element, replace the
cleaned primary filter with a new element.
5. Stop the engine. Close the hood and seat
assembly.
159
Maintenance Section
Inspect Coolant Hoses (LP, Dual Fuel Lines & Fittings - Check
Fuel Engines Only) Visually inspect fuel lines and fittings for physical
1. Visually inspect coolant hoses and clamps. damage. Replace as required.
connect to the pressure regulator/converter.
1 2
2. Replace any hose that shows signs of swelling,
cracking, abrasion or deterioration.
2
(1) Fuel line
1 (2) LP mixer
(3) Throttle Assembly
(1) LP Regulator/Converter Inspect Mixer Assembly (G420F(E)

(2) Coolant hose Engine Only)
Refer to the LP mixer section of the engine service
LP Regulator/Converter Inspection manual for procedures.
(LP, Dual Fuel Engine Only)

1. Visually inspect the pressure regulator/converter
Inspect Throttle Assembly
housing for coolant leaks. Refer to the pressure (G420F(E) Engine Only)
regulator/converter section of the service manual
1. Visually inspect the throttle assembly motor
if maintenance is required.
housing for coking, cracks and missing
cover-retaining clips. Repair and/or replace as
NOTE : For pressure testing and internal inspection necessary.
of the pressure regulator/converter, refer to
the pressure regulator/converter section of
the service manual. NOTE : Refer to the LP mixer and throttle section of
the service manual for procedures on
removing the mixer and inspecting the
throttle plate.
160
Maintenance Section

Drive Axle Oil (Shoe Brake) - Replace LP Fuel Filter Element

Change (LP-Gas, Dual Fuel Engine Only)
See topic, Drive Axle Oil - Change in First 50 -
100 Service Hours Park the lift truck in an authorized refueling area with
the forks lowered, parking brake applied and the
transmission in Neutral.
Inspect Ignition System (LP-Gas,
Gasoline & Dual Fuel Engines 1. Close the fuel shutoff valve on the LP-Fuel tank.
Run the engine until the fuel in the system runs
Only) out and the engine stops.
1. Disconnect Battery Cables.
2. Remove and inspect the spark plugs. Replace
as required. 3. Scribe a line across the filter housing covers,
3. Inspect the ignition coil for cracks and heat which will be used for alignment purposes when
deterioration. Visually inspect the coil heat sink re-installing the filter cover.
fins. If any fins are broken replace as required.
G420F(E) Engine 1
(1) screws
161
Maintenance Section
Fuel Filter (LP - Gas Engine Only) Testing Fuel Lock-off Operation
(LP-Gas Engine Only)
Disassembly
1. Start engine.
4
2 1
5 2. Locate the electrical connector for the fuel lock
3
6 3. Disconnect the electrical connector.
7
5. Remove top cover (2), magnet (3), spring (4), and 4. The engine should run out of fuel and stop within
filter element (7) from bottom cover (5). a short period of time.
6. Replace the filter element (7).

5. Turn the ignition key switch off and re-connect the
fuel lock-off connector.
1. Check bottom cover O-ring seal (6) for damage.
Replace if necessary. NOTE : The length of time the engine runs on
trapped fuel vapor increases with any
2. Re-assemble the filter assembly aligning the increase in distance between the fuel
scribe lines on the top and bottom covers. lock-off and the pressure
regulator/converter.
3. Install the cover retaining screws, tightening the
1
4. Open the fuel valve by slowly turning the valve
counterclockwise. 2
3

(1) LP fuel lock-off

(2) Regulator / couverter
(3) Fuel Trim valve (FTV)
162
Maintenance Section

Steer Wheel Bearings

Reassemble
the engine stopped.
4. Remove the locknut, lockwasher and flat washer.

Remove the outer wheel bearing.
1. Lift the steer wheels off the ground. Place stands

or blocking under the frame and steer axle to
support the lift truck.
2. Remove the hub cap which is pressed into the
wheel hub.
5. Remove the wheel assembly. Examine the wheel

for damage and wear. Replace the wheel if nec-
essary.
NOTE : Deflate tire before removing wheel nuts

from the truck.
6. Remove the inner bearing. Clean and lubricate

the steering knuckle. Reassemble both the inner
and outer bearing cones.
7. Install the inner bearing. Lubricate the seal and
install the wheel assembly on the knuckle.
3. Straighten the lockwasher tangs.
8. Install the outer wheel bearing and the outer
washer. Install the lockwasher and locknut.
163
Maintenance Section
Drive Wheel Bearing - Reassemble

Consult your DOOSAN lift truck dealer for the prop-
er wheel bearing reassembling procedure.
Reassembling of bearings and adjustment proce-
dure must be made by a trained mechanic or deal-
er personnel.
9. Tighten the locknut to 135 Nm (100 lbft), while

turning wheel hub to seat the bearing.
10.Loosen the locknut. Retorque it to 505Nm
(374 lbft). Bend the lockwasher tang to secure
locknut.
11.Install the hub cap.
12.Raise the lift truck and remove the blocking
Lower the lift truck to the ground. 1. Apply Loctite No.271 Thread Lock to threads of
spindle bolts. Torque for bolts that hold spindle to
drive axle housing is 100.5 12.3 Nm (74.2 9.1
lbft).
2. Tighten nut slowly until torque required to turn
bearings is 10.8 2.0 Nm (8.0 1.5 lbft).
drive shaft bolts. Torque for bolts that hold drive
shaft to hub is 71 12 Nm (52.5 9 lbft).
stud bolts. Torque for stud bolts is 88 10 Nm
(65 7.4 lbft).
stopping bolts. Torque for bolts that hold nut and
plate is 9.8 2.0 Nm (7.2 1.5 lbft).
164
Maintenance Section
Cooling System Clean, Change
WARNING
At operating temperature, the engine coolant is
Check the coolant level only after the engine has
been stopped and the filler cap is cool enough to
touch with your bare hand.
Remove the filler cap slowly to relieve pressure. A2300 Diesel Engine
Coolant is included antifreeze for forbidding

corrosion. Avoid contact with the skin and eyes
to prevent personal injury.
Use all cleaning solution with care.
The Lift truck must be level, the forks lowered, the

parking brake engaged, the transmission in
NEUTRAL and the engine stopped and cool.
1. Turn the radiator cap slowly to relieve the

pressure, and then remove the cap. G420F(E) 2.0L LPG/Gasoline Engine
3. Open the radiator drain valve. Allow the coolant to

drain into a suitable container.
Drain the recovery bottle.
2. Remove the drain plug or water hose on engine

block.
165
Maintenance Section
NOTICE
Hold the drain port when the radiator drain valve is
turned because the tank and the drain port are
separated.
4. After draining the coolant completely, close the

radiator drain valve and the block drain plug, fill
the engine and the radiator full with a radiator
cleaner, and clean the engine and the radiator.
5. Start and run the engine for 30 minutes.
6. Stop the engine and drain the cleaning solution

into a suitable container.
7. Flush the system with clean water, until draining

water is clear.
8. Close the drain valve and install the block drain

plug. Fill coolant to top of the filler neck.
9. Start and run the engine to stabilize the coolant

level. See topic, Coolant Level Check in
Every 10 Service hours or Daily.
166
Maintenance Section
degrees from an original angle other than 90

Fork - Inspect degrees, as may be found in some special appli-
cation forks.
Forks should be inspected, at a minimum, every 12

months. If the truck is being used in a multi-shift or 3. Check the straightness of the upper face of blade
heavy duty operation, they should be checked every (D) and the front face of shank (E) with a straight
six months. edge.
The fork should be withdrawn from service if the
1. Inspect the forks carefully for cracks. Special
deviation from straightness exceeds 0.5 percent
attention should be given to the heel section (A),
of the length of the blade and/or the height of the
all weld areas and mounting brackets (B).
shank respectively 5 mm/1000 mm (0.18"/36").
Inspect the top and bottom hooks on forks used
on hook type carriages and tubes on shaft
mounted forks.
Forks with cracks should be removed from ser-
vice.
"Wet Test" magnetic particle inspection is gener-

ally preferred due to its sensitivity and the ease
of interpreting the results. Portable equipment is
usually recommended so it can be moved to the
lift truck.
Inspectors should be trained and qualified in

accordance with The American Society for Non
Destructive Testing, Level II Qualifications. 4. Check the difference in height of one fork tip to
the other when mounted on the fork carrier. A
difference in fork tip height can result in uneven
support of the load and cause problems with
entering loads.
The maximum recommended difference in fork
tip elevation (F) is 6.5 mm (0.25") for pallet forks
and 3 mm (0.125") for fully tapered forks. The
maximum allowable difference in fork tip eleva-
tion between the two or more forks is 3 percent of
blade length (L).
Replace one or both forks when the difference in

fork tip height exceeds the maximum allowable
difference. Contact your local DOOSAN Lift
Truck Dealer for further information.
2. Check the angle between the upper face of the
blade and the front face of the shank. The fork
should be withdrawn from service if angle (C)
exceeds 93 degrees or deviates by more than 3
167
Maintenance Section
Shaft mounted forks may use set collars or spac-

ers on the shaft to either side of the fork. They
may also use U bolts, pins, or similar devices
which engage the fork through the top structure
of the carriage.
5. Check the fork blade (J) and shank (H) for wear
with special attention to the heel (G). The fork
should be withdrawn from service if the thickness
is reduced to 90 percent or less of the original
thickness.
Fork blade length may also be reduced by wear,
especially on tapered forks and platens. Remove 8. Check fork markings (N) for legibility. Renew
the forks from service when the blade length is markings as required to retain legibility.
no longer adequate for the intended loads.
9. a. Lift the mast and operate the tilt control lever,
until the top surface of the forks is parallel with
the floor. Place two straight bars that are the
same width as the carriage, across the forks
as shown.
b. Measure the distance from the bottom of each
end of the two bars to the floor. The forks must
be parallel within 3 mm (.12 in) for Full
Tapered and Polished (FTP) forks, all other
forks 6.4 mm (.25 in), for their complete length.
c. Put one fork, one third from the tip, under a

fixture that will not move. Then operate the tilt
control with caution until the rear of the truck
6. Check the fork mountings (K) for wear, crushing lifts just off the floor. Follow the same proce-
and other local deformation, which can cause dure with the second fork. Repeat Step a.
excessive side to side wobble of the forks.
Excessive clearance on hook type forks may
allow them to fall from the carrier. Forks which
show visible signs of such damage should be
removed from service.
7. Check the positioning lock and other fork
retention devices to make sure they are in place
and working.
Hook type forks use a spring loaded pin (M),
located in the top hook, to engage notches in the
top carriage bar to hold the fork in place.
When adjusting the fork spacing, the forks are

prevented from sliding off the end of the carriage
by stop blocks. These stop blocks are at both
ends of the carriage and in the path of the bottom
fork hook. The load backrest extension may be
used in place of the stop blocks in some cases.
168
Maintenance Section


Hydraulic Oil - Change, Check, trols, and the steering system, through a few
Clean cycles to fill the lines. Look for oil leaks.
6. Stop the engine and check the oil level. With all
WARNING
Hot oil and components can cause personal FULL mark on the breather/dip stick.
contact skin.
the engine stopped.
1. Remove the hydraulic tank drain plug. Allow the

oil to drain. Clean and install the plug.
2. Remove the breather/dip stick.
3. Remove the strainer. Wash the breather and

strainer in clean, nonflammable solvent and dry
4. Install the strainer. Fill the hydraulic tank. See

topic Refill Capacities. Install the breather/dip
stick.
169
Maintenance Section
Inspect Battery System Replace Oxygen Sensor (G420F(E)

1. Clean battery outer surfaces with a mixture of Engine Only)
baking soda and water. G420F(E) Engine
2. Inspect battery outer surfaces for damage and
3. Remove battery cable and clean, repair and/or

When indicated by MIL, replace oxygen seasor on

the exhaust manifold and oxygen sensor on muffler
assembly.
1. Stop engine and wait until the exhaust pipe and

exhaust pipe is cooled.
2. Disconnect the electrical connector of oxygen

sensor
3. Remove oxygen sensor
4. Assemble new oxygen sensor

Tightening torque : 45 Nm (32.5 lbft)
5. Connect the electrical connector of oxygen

sensor
WARNING
When assembling the filters, check the arrow
mark on the filter surface.
The arrow mark position is same as fuel flow
direction.
170
Maintenance Section
Checking the TMAP Sensor Inspect for Intake Leaks (G420F(E)

(G420F(E) Engine Only) Engine Only)
1. Verify that the TMAP sensor (F) is mounted tightly 1. Visually inspect the intake manifold, throttle
into the manifold adapter (E), with no leakage. assembly (2), and manifold adapters (3), for
looseness and leaks. Repair as necessary.
2. If the TMAP is found to be loose, remove the
TMAP retaining screw and the TMAP sensor from Replace PCV Valve and breather
the manifold adapter.
element (LP-Gas, Gasoline and Dual
3. Visually inspect the TMAP O-ring seal for damage. Fuel Engines) - Change
Replace as necessary.
4. Apply a thin coat of an approved silicon lubricant

to the TMAP o-ring seal.
5. Re-install the TMAP sensor into the manifold

adapter and securely tighten the retaining screw.

valve.
2. Assemble new PCV valve and hose.
3. Tighten the hose clamps
171
Maintenance Section
Replace Spark Plugs (G420F(E)

Engine Only)
2. Remove the ignition wiring harness.
3. Remove the ignition coil assy.
4. Remove spark plugs.
5. Gap the new spark plugs to the proper

specifications.
G420F(E) Engine : 0.7 ~ 0.8
6. Apply anti-seize compound to the spark plug

threads and install.
G420F(E) Engine : 25 Nm (18 Ibft)
WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.
(1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug
172
Maintenance Section

Timing Belt (G420F(E) LP-Gas,

Gasoline & Dual Fuel Engine Only)
- Change
See the Service Manual for the procedure and
specifications.
WARNING
G420F(E) is dual over-head CAM engine. If
timing belt is not replaced on time, engine could
be damaged.
173
Index Section
Index
# Checking the TMAP Sensor (G420F(E) Engine

Only)........................................................................ 171
12 Months Inspection .............................................110 Circuit Breaker..................................................45, 129
Cleaning Primary Filter Elements ......................... 145
Coolant Information................................................ 114
A
Coolant Level - Check, Clean................................ 133
Coolant Water......................................................... 115
Accelerator Pedal .....................................................49
Cooling System Clean, Change......................... 165
Advanced Diagnostics..............................................77
Cooling System Specifications.............................. 114
After Starting the Engine..........................................61
Crosshead Roller - Inspect.................................... 153
Air Cleaner Indicator - Check.................................134
Crushing or Cutting Prevention ............................... 14
Air Intake System - Change...................................159
Cylinder Rod Extension-Adjust ............................. 153
Air Intake System - Check, Clean .........................144
Antifreeze ................................................................115
Attachment Abbreviations (includes Special Forks) D
...................................................................................41
Avoiding Lift Truck Tipover ......................................21 Daily Inspection ...................................................... 109
Diesel Engine ........................................................... 57
Diesel Engine (A2300)........................................... 151
B
Diesel Engine Crankcase ..............................137, 149
Diesel Engines........................................................ 133
Basic Troubleshooting (Gasoline) ...........................71
Diesel Specifications.............................................. 116
Basic Troubleshooting(LP).......................................64
Direction Control Lever ............................................ 48
Battery Terminal - Clean, Inspect..........................148
Disassembly ........................................................... 162
Before Operating the Lift Truck ...............................12
Displaying Fault Codes (DFC) from SECM Memory
Before Starting the Engine.......................................54
................................................................................... 77
Before Starting the Lift Truck...................................11
Draining the Water From the Fuel Filter ............... 126
Before Storage........................................................104
Drive Axle Oil.......................................................... 119
Belts - Check, Adjust..............................................152
Drive Axle Oil - Change ......................................... 139
Bent or Twisted Forks ............................................108
Drive Axle Oil (OCDB) - Change........................... 154
Bleeding the Fuel System ......................................126
Drive Axle Oil (Shoe Brake) - Change.................. 161
Brake Fluid ..............................................................120
Drive Axle Oil Level - Check.................................. 146
Brake Oil Level - Check .........................................148
Drive Wheel Bearing - Reassemble...................... 164
Bulbs........................................................................129
Burn Prevention ........................................................15
E
C
Electrical Disconnect Switch (If Equipped)............. 44
Electronic Controlled Spark-Ignition Engines......... 62
Capacity Chart - With Sideshift................................38
Engine Compartment............................................... 45
Capacity Chart - Without Sideshift ..........................37
Engine Oil & Filter - Change.................................. 149
Carriage Roller Extrusion - Adjust.........................132
Engine Oil & Filter (Diesel Engine Only) - Change
Causes of Fork Failure...........................................108
................................................................................. 137
Center of Gravity (CG) .............................................21
Engine Oil (DEO and EO)...................................... 118
Changing From Gasoline to LP - Gas.....................59
Engine Oil Level - Check ....................................... 133
Changing From LP - Gas to Gasoline.....................59
Engine Valve Lash (Diesel Engine Only) - Check,
Changing LP-Gas Tanks..........................................52
Adjust ..............................................................143, 156
Changing Primary Element....................................159
Environment Management ........................................ 3
Changing Secondary Element...............................159
Environment Protection ......................................... 107
Chassis Pivot Eyebolts - Lubricate........................152
Every 10 Service Hours or Daily ........................... 133
Check for Equal Tension........................................157
Every 1000 Service Hours or 6 Months................ 156
Check Inflation and Damage .................................131
Every 1500 Service Hours or 9 Months................ 161
Checking Coolant Level .........................................133
Every 2000 Service Hours or Yearly..................... 163
Checking Oil Level..................................................136
Every 250 Service Hours or Monthly .................... 144
Checking Service Indicator ....................................134
174
Index Section
Every 3000 Service Hours or 18 Months ..............173 I

Every 500 Service Hours or 3 Months ..................152
Identification, Lift Capacity and Attachment Plate . 40
F If Optional Suspension Seat (Weight Adjusting
Type) Equipped ........................................................ 18
Fatigue.....................................................................108 Important Safety Information ..................................... 4
Fire or Explosion Prevention....................................15 Improper Modification or Repair............................ 108
First 250 Service Hours or a Month ......................143 Inching....................................................................... 96
First 50-100 Service Hours or a Week..................137 Inching & Braking Control Shaft - Lubricate ......... 154
First Installation.......................................................109 Inching into Loads .................................................... 98
Fluid Penetration.......................................................14 Inspect Battery System.......................................... 170
Foreword .....................................................................2 Inspect Coolant Hoses (LP, Dual Fuel Engines Only)
Fork - Inspect..........................................................167 ................................................................................. 160
Fork Inspection .......................................................109 Inspect Electrical System (G420F(E) Engine Only)
Fuel Filter (Diesel Engine Only) - Change............151 ................................................................................. 155
Fuel Filter (LP - Gas Engine Only) ........................162 Inspect Engine for Exhaust Leaks ........................ 134
Fuel Lines & Fittings - Check.................................160 Inspect Engine for Fluid Leaks.............................. 133
Fuel Selector Switch (If Dual Fuel Equipped).........45 Inspect Foot Pedal Operation (G420F(E) Only)... 134
Fuel Specifications .................................................116 Inspect for Intake Leaks (G420F(E) Engine Only)
Fuel Sulfur Content.................................................116 ................................................................................. 171
Fuel Tank Filler Cap and Screen (If Equipped) - Inspect Ignition System (LP-Gas, Gasoline & Dual
Clean .......................................................................127 Fuel Engines Only)................................................. 161
Fuel Trim Valve(FTV) Inspection (G420F(E) Engine Inspect Mixer Assembly (G420F(E) Engine Only)160
Only) ........................................................................155 Inspect Throttle Assembly (G420F(E) Engine Only)
Fuel Types ..............................................................116 ................................................................................. 160
Fuse.........................................................................129 Inspect Tightness ................................................... 150
Fuse & Relay (G420F(E) Only) .............................129 Inspect Vacuum Lines and Fittings (G420F(E)
Fuses, Bulbs and Circuit Breaker - Change, Reset Engine Only)........................................................... 155
.................................................................................128 Inspection, Maintenance and Repair of Lift Truck
Forks ....................................................................... 107
G Instrument Panel ...................................................... 42
G420F Dual Fuel System (If Equipped)..................59 L

G420F Engine...........................................................63
G420F(E) Gasoline, LP-GAS and Dual Fuel Engine Lift Chain Adjustment............................................. 157
.................................................................................150 Lift Chain Wear Test .............................................. 157
G420FE Engine ........................................................62 Lift Chains - Test, Check, Adjust........................... 157
Gasoline and LP-Gas Engines ..............................133 Lift Control................................................................. 49
Gasoline Engine .......................................................56 Lift Fork Adjustment ............................................... 103
Gasoline or Diesel Engine Equipped ......................51 Lift Truck Capacity Rating ....................................... 40
Gasoline Specifications..........................................117 Lift Truck Controls .................................................... 48
Gasoline, LP-Gas Engine Crankcase ...................149 Lift Truck Operation.................................................. 95
General Fuel Information .......................................116 Lift Truck Parking ..................................................... 13
General Hazard Information ....................................10 Lift Truck Shipping ................................................. 105
General Warnings to Operator ..................................6 Lift Truck Stability ..................................................... 21
Lift Truck Stability Base ........................................... 22
H Lifting Drums or Round Objects............................ 101
Lifting the Load......................................................... 98
Hand Placement Warning ..........................................7 Literature Information................................................. 2
Hook-on type Fork..................................................103 Load Backrest Must Be In Place Warning................ 7
Horn & Lights (If Equipped) - Check .....................154 Long Time Storage................................................. 104
How to Survive in a Tipover.....................................29 LP Regulator/Converter Inspection (LP, Dual Fuel
Hydraulic Oil - Change, Check, Clean ..................169 Engine Only)........................................................... 160
Hydraulic Oil (HYDO) .............................................118 LP-Gas Engine ......................................................... 57
Hydraulic Oil Level - Check....................................146 LP-Gas Specifications............................................ 117
Hydraulic Return Filter Change ..........................143 Lubricant Information ............................................. 118
Hydraulic Return Filter, Breather & Strainer - Check, Lubricant Specifications......................................... 118
Change....................................................................156 Lubricant Viscosities .............................................. 121
Lubricant Viscosities and Refill Capacities........... 121
175
Index Section
Lubricating Grease (MPGM)..................................120 R

M Reading Diagnostic Fault Codes............................. 77
Refill Capacities...................................................... 121
Machine Lifting and Tiedown Information .............105 Refueling................................................................... 51
Maintenance................................................................3 Relay ....................................................................... 129
Maintenance and Repair........................................110 Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
Maintenance Information..........................................14 Engine Only)........................................................... 161
Maintenance Intervals ....................................... 3, 122 Replace Oxygen Sensor (G420F(E) Engine Only)
Make proper antifreeze additions..........................115 ................................................................................. 170
Mast Abbreviations ...................................................41 Replace PCV Valve and breather element (LP-Gas,
Mast Channels - Lubricate.....................................136 Gasoline and Dual Fuel Engines) - Change......... 171
Mast Hinge Pin - Lubricate.....................................153 Replace Spark Plugs (G420F(E) Engine Only).... 172
Mast Pivot Eyes-Lubricate .....................................152
Mast, Carriage, Lift Chains & Attachments - Inspect, S
Lubricate..................................................................147
Metric Hardware .....................................................112 Safety ...................................................................... 2, 5
Mounting and Dismounting ......................................11 Safety Rules ............................................................. 24
Moving Fan Warning ..................................................8 Seat ........................................................................... 46
Seat Adjustment....................................................... 18
N Seat Switch System(If Equipped) ........................... 47
Seat, Hood Latch & Support Cylinder - Check,
No Riders Warning .....................................................8 Lubricate ................................................................. 128
No Standing On Forks Warning, No Standing Under Serial Number........................................................... 39
Forks Warning.............................................................7 Serial Number Locations ......................................... 39
Noise and Vibration ..................................................36 Service Brake Pedal................................................. 49
Servicing Filter Element......................................... 144
O Sideshift Attachment Control (If Equipped) ............ 50
Specifications ........................................ 30, 31, 32, 34
Operating in Hot Weather ......................................101 Stability and Center of Gravity................................. 22
Operating Techniques..............................................98 Starting a Cold Diesel Engine ................................. 57
Operating the Lift Truck............................................12 Starting a Warm Diesel Engine ............................... 57
Operation.....................................................................2 Starting From a 12 Volt External Source................ 58
Operation Information...............................................11 Starting the Engine................................................... 56
Operator Restraint System (If Equipped)........... 2, 17 Starting the Lift truck ................................................ 12
Operator's Station and Monitoring Systems ...........42 Steer Wheel Bearings Reassemble................... 163
Operator's Warning and Identification Plate ...........40 Steering Knob (If Equipped) .................................... 97
Operator's Warning Plate.........................................40 Steering Mechanism - Check, Lubricate............... 147
Overhead Guard - Inspect .....................................154 Storage Information................................................ 104
Overhead Guard Must Be In Place Warning ............8
Overloading.............................................................108 T
P Test Fuel System for Leaks (LP and Dual Fuel

Engines Only) ......................................................... 131
Packing brake .............................................................8 Test Operation........................................................ 140
Parking Brake - Test, Adjust ......................... 140, 154 Testing Fuel Lock-off Operation (LP-Gas Engine
Parking Brake Lever.................................................49 Only)........................................................................ 162
Parking the Lift Truck .............................................102 Tilt Control................................................................. 50
PCV Valve System - Inspect, Clean......................150 Tilt Cylinders - Check, Adjust, Lubricate............... 152
Power Shift Transaxle ..............................................95 Tilting Steering Column ........................................... 46
Power Shift Transaxle(PTA18) ..............................138 Timing Belt (G420F(E) LP-Gas, Gasoline & Dual
Pressure Air ..............................................................14 Fuel Engine Only) - Change.................................. 173
Pressure Warning.......................................................7 Tire Inflation ............................................................ 111
Prestart Conditions ...................................................56 Tire Inflation Information ........................................ 111
Priming the Fuel System (Diesel Engine Only) ....126 Tire Inflation Press9ures Adjustment.................... 111
Tires and Wheels - Inspect, Check....................... 131
176
Index Section
To Adjust (Oil Cooled Disc Brake Only)................142

To Adjust (Shoe Brake Only).................................141
To Operate the Lift Truck After a Long Time Storage
.................................................................................104
Torque for Metric Fasteners ..................................113
Torque for Standard Bolts, Nuts, and Taperlock
Studs .......................................................................112
Torque for Standard Hose Clamps - Worm Drive 112
Torque Specifications.............................................112
Torques for Bolts and Nuts With Standard Threads
.................................................................................112
Torques for Taperlock Studs .................................113
Training Required To Operate or Service Warning..5
Transmission Inching Control Pedal .......................48
Transmission Oil & Strainer - Change, Clean ......138
Transmission Oil & Strainer- Clean, Change........159
Transmission Oil (TDTO) .......................................119
Transmission Oil Level - Check.............................136
Traveling with the Load............................................99
Turning ....................................................................100
U
Unloading ..................................................................99
W
Walk-Around Inspection ...........................................54
Walk-Around Inspection - Inspect .........................135
Warning Signs and Labels.................................. 5, 17
Wheel Bolts & Nuts - Inspect.................................150
When Required.......................................................126
177
SB2354E00
Operation &
Maintenance Manual
LIFT TRUCKS
GC15S-5, GC18S-5, GC20SC-5
0703
Table of Contents
Table of Contents
Information Section Maintenance Section
Foreword ....................................................................2 Inspection, Maintenance and Repair of Lift Truck

Forks ........................................................................ 92
Torque Specifications ............................................. 96
Safety Section Cooling System Specifications............................... 98
Fuel Specifications................................................ 100
Important Safety Information ....................................4 Lubricant Specifications ....................................... 101
Safety .........................................................................5 Lubricant Viscosities and Refill Capacities ......... 104
Warning Signs and Labels ................................5
Maintenance Intervals .......................................... 105
Operation Information..................................... 11
Maintenance Information................................ 14 When Required ..................................................... 107
Pressure Air..................................................... 14 Every 10 Service Hours or Daily.......................... 111
Fluid Penetration ............................................. 14 First 50-100 Service Hours or a Week ................ 115
Crushing or Cutting Prevention...................... 14 First 250 Service Hours or a Month..................... 118
Burn Prevention .............................................. 15 Every 250 Service Hours or Monthly................... 119
Operator Restraint System (If Equipped) ...... 17
Every 500 Service Hours or 3 Months................. 125
Avoiding Lift Truck Tipovers........................... 22
Safety Rules .................................................... 24 Every 1000 Service Hours or 6 Months .............. 129
How to Survive in a Tipover ........................... 29 Every 1500 Service Hours or 9 Months .............. 134
Every 2000 Service Hours or Yearly ................... 136
Every 2500 Service Hours or 15 Months ............ 141
General Section Every 3000 Service Hours or 18 Months ............ 145
Every 4500 Service Hours or two Years ............. 145
Specifications.......................................................... 31
Noise and Vibration ................................................ 33
Serial Number ......................................................... 34 Index Section
Operator's Warning and Identification Plate ......... 35
Index ...................................................................... 146
Operation Section
Operator's Station and Monitoring Systems ......... 37

Seat Switch System (If Equipped)......................... 40
Lift Truck Controls .................................................. 43
Refueling ................................................................. 46
Before Starting the Engine..................................... 48
Starting the Engine ................................................. 50
After Starting the Engine........................................ 53
Lift Truck Operation................................................ 81
Operating Techniques............................................ 83
Parking the Lift Truck ............................................. 87
Lift Fork Adjustment................................................ 88
Storage Information................................................ 89
Transportation Hints ............................................... 90
Towing Information ................................................. 91
1
Information Section
Foreword
Literature Information Photographs or illustrations guide the operator
through correct procedures of checking, operation
This manual should be stored in the operator's and maintenance of the DOOSAN operator restraint
compartment in the literature holder or seat back system.
literature storage area.
SAFE and EFFICIENT OPERATION of a lift truck
This manual contains safety, operation, transportation, depends to a great extent on the skill and alertness
lubrication and maintenance information. on the part of the operator. To develop this skill the
operator should read and understand the Safe
Some photographs or illustrations in this publication Driving Practices contained in this manual.
show details or attachments that can be different
from your lift truck. Guards and covers might have Forklift trucks seldom tipover, but in the rare event
been removed for illustrative purposes. they do, the operator may be pinned to the ground
by the lift truck or the overhead guard. This could
Continuing improvement and advancement of result in serious injury or death.
product design might have caused changes to your
lift trucks which are not included in this publication. Operator training and safety awareness is an
Read, study and keep this manual with the lift truck. effective way to prevent accidents, but accidents
can still happen. The DOOSAN operator restraint
Whenever a question arises regarding your lift truck, system can minimize injuries. The DOOSAN
or this publication, please consult your DOOSAN operator restraint system keeps the operator
dealer for the latest available information. substantially within the confines of the operators
compartment and the overhead guard.
This manual contains information necessary for

Safety
Safe Operation. Before operating a lift truck make
The Safety Section lists basic safety precautions. In sure that the necessary instructions are available
addition, this section identifies the text and and understood.
locations of warning signs and labels used on the
lift truck. Read and understand the basic
precautions listed in the Safety Section before
Operation
operating or performing lubrication, maintenance
and repair on this lift truck. The Operation Section is a reference for the new
operator and a refresher for the experienced one.
This section includes a discussion of gauges,
Operator Restraint System (If Equipped) switches, lift truck controls, attachment controls,
transportation and towing information.
This manual contains safety, operation and
maintenance information for the DOOSAN operator
Photographs and illustrations guide the operator
restraint system. Read, study and keep it handy.
through correct procedures of checking, starting,
operating and stopping the lift truck.
WARNING Operating techniques outlined in this publication are

basic. Skill and techniques develop as the operator
Your DOOSAN truck comes equipped with an
gains knowledge of the lift truck and its capabilities.
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DOOSAN
2
Information Section
Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without
specific intervals are listed under When Required
topics. Items in the Maintenance Intervals chart
are referenced to detailed instructions that follow.
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating

conditions, more frequent lubrication than is specified
in the Maintenance Intervals chart might be
necessary.
Perform service on items at multiples of the original

requirement. For example, at Every 500 Service
Hours or 3 Months, also service those items listed
under Every 250 Service Hours or Monthly and
Every 10 Service Hours or Daily.
Environment Management
Note that DOOSAN Infracore VHEICLE B.G. is ISO
14001 certified which is harmonized with ISO 9001.
Periodic ENVIRONMENTAL AUDITS &
ENVIRONMENTAL PERFORMANCE EVALUATIONS
have been made by internal and external inspection
entities. LIFE-CYCLE ANALYSIS has also been
made through out the total product life.
ENVIRONMENT MANAGEMENT SYSTEM includes

DESIGN FOR ENVIRONMENT from the initial
stage of the design.
ENVIRONMENT MANAGEMENT SYSTEM considers

environmental laws & regulations, reduction or
elimination of resource consumption as well as
environmental emission or pollution from industrial
activities, energy saving, environment-friendly product
design (lower noise, vibration, emission, smoke,
heavy metal free, ozone depleting substance free,
etc.), recycling, material cost reduction, and even
environmentally oriented education for the employee.
3
Safety Section

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 precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as WARNING
as shown below.
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is
used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
4
Safety Section
Safety
The safety rules and regulations in this section are Warning Signs and Labels
representative of some, but not all rules and
regulations noted under the Occupational Safety Warning Signs and Labels
and Health Act (OSHA) and are paraphrased There are several specific safety signs on your lift
without representation that the OSHA rules and truck. Their exact location and description of the
regulations have been reproduced verbatim. hazard are reviewed in this section. Please take the
time to familiarize yourself with these safety signs.
Please refer to 1910. 178 in Federal Register Vol. Make sure that you can read all safety signs. Clean
37, No. 202, the National Fire Protection or replace these if you cannot read the words or
Association No. 505 (NFPA), American National see the pictures. When cleaning the labels use a
Standard, ANSI B56. 1 Safety Standard for Low lift cloth, water and soap. Do not use solvent, gasoline,
and High Lift Trucks and subsequent revisions for a etc.
complete list of OSHA rules and regulations as to You must replace a label if it is damaged, missing
the safe operation of powered industrial lift trucks. or cannot be read. If a label is on a part that is
Since regulations vary from country to country replaced, make sure a new label is installed on the
outside in U.S.A., operate this lift truck in replaced part. See your dealer for new labels.
accordance with local regulations.
Training Required To Operate or
DOOSAN lift trucks are manufactured according to
the regulations and standards laid down in EU Service Warning
Machinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives
89/655/EC and 89/391/EC and its amendments for
the safe use of DOOSAN lift trucks.

injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.
Do not operate a lift truck if in need of repair,

defective or in any way unsafe. Report all defects Located on the right of the steering wheel.
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so. WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DOOSAN LIFT TRUCK dealers.
5
Safety Section
General Warnings to Operator 9. Do not allow anyone to stand or pass under the
elevated portion of any machine.
10. Be sure operating surface can safely support

machine.
11. Operate machine and attachments only from

operator's position.
12. Do not handle unstable or loosely stacked

loads.
13. Use minimum tilt when picking up or depositing

a load.
Located on the right side of the operator's seat.
14. Use extreme care when handling long, high, or
wide loads.
WARNING 15. Forks should be completely under load and

Only trained and authorized personnel may spread apart as far as load permits.
operate this machine. For safe operation, read
and follow the operation and maintenance 16. Machine should be equipped with overhead
Manual furnished with this lift truck and guard or equivalent protection. Where load
observe the following warnings: requires it, use load backrest extension. Use
extreme caution if operating without these
1. Before starting machine. Check all controls and devices.
warning devices for proper operation.
17. Parking - Lower lifting mechanism to floor. Put
2. Refer to machine identification plate for directional control or shift lever in neutral. Set
allowable machine capacity. Do not overload. parking/secondary brake. Turn ON - OFF
Operate machines equipped with attachments switch off. Chock wheels if machine is on
as partially loaded machines when not incline. Disconnect battery when storing
handling a load. electric machines.
3. Put directional control or shift lever in neutral 18. Observe safety rules when handling fuel for
before ON - OFF switch is turned on. engine powered machine and when changing
batteries for electric machines.
4. Start, turn and brake smoothly. Slow down for
turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid
running over loose objects or holes in the
roadway surfaces. Use extreme caution when
turning on inclines.
5. Travel with load as low as possible and tilted

back. If load interferes with visibility, travel with
load trailing.
6. On grade operations travel with load up grade.
7. Watch out for pedestrians and obstructions.

Check overhead clearances.
8. Do not permit riders on forks or machine at any

time.
6
Safety Section
Pressure Warning No Standing On Forks Warning, No

Standing Under Forks Warning
WARNING
Contents under pressure may be hot. Allow to WARNING
cool before opening. Do not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do not
stand or walk under the forks.
Located on the radiator top tank by the radiator cap.
Hand Placement Warning Located on the lift cylinder.
WARNING Load Backrest Must Be In Place

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

Located on the mast.
7
Safety Section
Overhead Guard Must Be In Place Moving Fan Warning

Warning
WARNING
WARNING To avoid personal injury, stay clear of moving
Operation without this device in place may be fan.
hazardous. This guard conforms to A.N.S.I.
B56.1 and F.E.M. Section 4.
This design has been tested with an impact of
appropriate value.
Located inside the engine compartment cover.
Packing brake
Located on the Overhead Guard.
No Riders Warning
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
Pull the lever BACK to engage the

parking brake.
Push the lever FORWARD to release

the parking brake.
Located beside the operator's station.
8
Safety Section
Applying the parking brake puts the transmission in

NEUTRAL. The parking brake must be applied
when leaving the lift truck and when starting the
engine. If the operator leaves the seat without
applying the parking brake, an audible alarm will
sound.
WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied. Alarm
will sound if parking brake is not applied.
WARNING
Correct adjustment is necessary to provide
adequate braking. See the MAINTENANCE section
for adjustment procedures. The lift truck may creep
at engine idle and can cause damage, injury or
death. Always apply the parking brake when
leaving the lift truck. The parking brake is NOT
automatically applied.
9
Safety Section
General Hazard Information Always use the overhead guard. The overhead
guard is intended to protect the lift truck operator
from overhead obstructions and from falling objects.
A truck that is used for handing small objects or

uneven loads must be fitted with a load backrest.
If the lift truck must be operated without the overhead

guard in place due to low overhead clearance, use
extreme care. Make sure there is no possibility of
falling objects from any adjacent storage or work
area. Make sure the load is stable and fully supported
by the carriage and the load backrest extension (if
equipped).
Attach a Do Not Operate or similar warning tag to Do not raise loads any higher than necessary and
start switch or controls before servicing or repairing never raise a load higher than 1830 mm (72 in) with
the lift truck. the overhead guard removed.
Do not start or service the lift truck when a DO Always use load backrest extension when the carriage
NOT OPERATE or similar warning tag is attached or attachment does not fully support the load. The
to the start switch or controls. load backrest extension is intended to prevent the
load or any part of the load from falling backwards
Wear a hard hat, protective glasses and other into the operator's station.
protective equipment as required by job conditions.
When operation the lift truck, do not depend only on
Know the width of your attachments so proper flashing lights or back-up alarm (if equipped) to
clearance can be maintained when operating near warn pedestrians.
fences, boundary obstacles, etc.
Always be aware of pedestrians and do not proceed
Do not wear loose clothing or jewelry that can catch until the pedestrians are aware of your presence
on controls or other parts of the lift truck. and intended actions and have moved clear of the
lift truck and/or load.
Keep the lift truck, especially the deck and steps,
free of foreign material such as debris, oil tools and Do not drive lift truck up to anyone standing in front
other items which are not part of the lift truck. of an object.
Secure all loose items such as lunch boxes, tools Obey all traffic rules and warning signs.
and other items which are not part of the lift truck.
Keep hands, feet and head inside the operator
Know the appropriate work-site hand signals and station. Do not hold onto the overhead guard while
who gives them. Accept signals from one person operating the lift truck. Do not climb on any part of
only. the mast or overhead guard or permit others to do
so.
Do not allow unauthorized personnel to ride on the

forks or any other part of the lift truck, at any time.
When working in a building or dock, observe floor

load limits and overhead clearances.
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.
10
Safety Section
Never put maintenance fluids into glass containers. Operation Information

Use all cleaning solutions with care.
Do not use steam, solvent, or high pressure to clean Mounting and Dismounting
electrical components.
Report all needed repairs. Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before

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

and dismounting.
Use the handgrips for mounting and dismounting.
Do not try to climb on or off the lift truck when

carrying tools or supplies.
Inspect the part of the chain that is normally Never get on or off a moving lift truck.
operated over the crosshead roller. When the chain
bends over the roller, the movement of the parts Do not use any controls as handholds when
against each other causes wear. entering or leaving the operator's station.
Inspect to be sure that chain link pins do not extend Never get on or off a moving lift truck. Never jump
outside of the bore hole. off the lift truck.
If any single link pin is extended beyond its connecting Keep hands and steering wheel free of slippery
corresponding link, it should be suspected of being material.
broken inside of its bore hole.
Inspect the chain anchor and the anchor links for Before Starting the Lift Truck
wear. Perform a walk-around inspection daily and at the
start of each shift. Refer to the topic Walk-around
Do not change any factory set adjustment values Inspection in Every 10 Service Hours or Daily
(including engine rpm setting) unless you have both section of this manual.
authorization and training. Especially Safety equipment
and switches may not be removed or adjusted Adjust the seat so that full brake pedal travel can be
incorrectly. Repairs, adjustments and maintenances obtained with the operator's back against the seat
that are not correct can make a dangerous operating back.
condition.
Make sure the lift truck is equipped with a lighting
For any checkup, repair, adjustments, maintenance system as required by conditions.
and all other work concerning your forklift truck,
please contact your DOOSAN dealer. We would like to Make sure all hydraulic controls are in the HOLD
draw your attention to the fact that any secondary position.
damages due to improper handling, insufficient
maintenance, wrong repairs or the use of other than Make sure the direction control lever is in the
original DOOSAN spare parts waive any liability by NEUTRAL position.
DOOSAN.
Make sure the parking brake is engaged.
Make sure no one is standing and/or working on,

underneath or close to the lift truck before operating
the lift truck.
11
Safety Section
Operate the lift truck and controls only from the Operating the Lift Truck
operator's station.
Always keep the lift truck under control.
Make sure the lift truck horn, lights, backup alarm (if
equipped) and all other devices are working Obey all traffic rules and warning signs.
properly.
Never leave the lift truck with the engine operating,
Check for proper operation of mast and or with the parking brake disengaged.
attachments. Pay particular attention to unusual
noises or erratic movement which might indicate a Operate the engine only in a well ventilated area.
problem.
Lower mast, with or without load, before turning or
Make sure service and parking brakes, steering, traveling. Tip over could result. Watch out for
and directional controls are operational. overhead obstructions.
Make sure all personnel are clear of lift truck and
travel path. Always observe floor load limits and overhead
Refer to the topic Lift Truck Operation in the clearance.
Operation Section of this manual for specific
starting instructions. Start, turn, and brake smoothly, slow down for turns,
grades, slippery or uneven surfaces.
Starting the Lift truck
Use special care when operation on grades. Do not

Do not start the engine or move any of the controls angle across or turn on grades. Do not use lift truck
if there is a DO NOTOPERATE or similar warning on slippery grades. Travel with forks downgrade
tag attached to the start switch or controls. when unloaded. Travel with load upgrade.
Before Operating the Lift Truck Do not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plate
Test brakes, steering controls, horn and other devices on the lift truck. Use extreme caution when handing
for proper operation. Report faulty performance. Do
suspended, long, high or wide load.
not operate lift truck until repaired.
Learn how your lift truck operates. Know its safety

devices. Know how the attachments work.
Before moving the lift truck, look around. Start, turn

and brake smoothly.
An operator must constantly observe his lift truck

for proper operation.
12
Safety Section
Loading or Unloading Trucks/Trailers
Do not operate lift trucks on trucks or trailers which

are not designed or intended for that purpose.
Be certain truck or trailer brakes are applied and

wheel chocks in place (or be certain unit is locked
to the loading dock) before entering onto trucks or
trailers.
If trailer is not coupled to tractor, make sure the

trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
Tilt elevated load forward only when directly over prevent upending or corner dipping.
unloading area and with load as low as possible.
Be certain dock plates are in good condition and
Do not stunt ride or indulge in horseplay. properly placed and secured. Do not exceed the
rated capacity of dock boards or bridge plates.
Always look and keep a clear view of the path of
travel. Lift Truck Parking
Travel in reverse if load or attachment obstructs When leaving the operator station, park the lift truck
visibility. Use extreme caution if visibility is in authorized areas only. Do not block traffic.
obstructed.
Stay in designated travel path, clear of dock edges,

ditches, other dropoffs and surfaces which cannot
safely support the lift truck.
Slow down and use extra care through doorways,

intersections and other location where visibility is
reduced.
Slow down for and avoid pedestrians, other

vehicles, obstruction, pot holes and other hazards
or objects in the path of travel.
Always use overhead guards except where z Park the lift truck level, with the forks lowered
operation conditions do not permit. Do not operate and the mast tilted forward until the fork tips
lift truck in high stacking areas without overhead touch the floor.
guards. z Move the direction control lever to NEUTRAL.
When stacking, watch for falling objects. Use load z Engage the parking brake.
backrest extension and overhead guard. z Turn the key switch off and remove the key.
Refer to the topic Operation Techniques in the z Turn the disconnect switch to OFF and remove
Operation Section of this manual. the key (if equipped).
z Block the drive wheels when parking on an
incline.
13
Safety Section
Maintenance Information Stay clear of all rotating and moving parts.

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

Pressure Air operator's compartment and secured to the lift truck.
Pressure air can cause personal injury. When using
pressure air for cleaning, wear a protective face To avoid possible weakening of the Falling Objects
shield, protective clothing and protective shoes. Protective Structure (FOPS), consult a DOOSAN
dealer before altering, by adding weight to, welding
The maximum air pressure must be below 205 kPa on, or cutting or drilling holes into the structure.
(30 psi) for cleaning purposes.
The overhead guard is not intended to protect
against every possible impact. The overhead guard
may not protect against some objects penetrating
Fluid Penetration into the operator's station from the sides or ends of
Always use a board or cardboard when checking the lift truck.
for a leak. Escaping fluid under pressure, even a
pin- hole size leak, can penetrate body tissue, The lift truck is equipped with an overhead guard
causing serious injury, and possible death. If fluid is and FOPS as standard. If there is a possibility of
injected into your skin, it must be treated by a overhead objects falling through the guard, the
doctor familiar with this type of injury immediately. guard must be equipped with smaller holes or a
plexiglass cover.
Any altering done that is not specifically authorized

Crushing or Cutting Prevention by DOOSAN invalidates DOOSAN's FOPS
certification. The protection offered by this FOPS will be
Support equipment and attachments properly when
impaired if it has been subjected to structural
working beneath them. Do not depend on hydraulic
damage. Structural damage can be caused by an
cylinders to hold it up. Any attachment can fall if a
overturn accident, by falling objects, etc.
control is moved, or if a hydraulic line breaks.
Do not mount any item such as fire extinguishers,
Never attempt adjustments while the lift truck is
first aid kits and lights by welding brackets to or
moving or the engine is running unless otherwise
drilling holes in any FOPS structure. See your
specified.
DOOSAN dealer for mounting guidelines.
Where there are attachment linkages, the clearance
in the linkage area will increase or decrease with
movement of the attachment.
14
Safety Section
Burn Prevention Fire or Explosion Prevention

Coolant All fuels, most lubricants and some coolant
mixtures are flammable.
At operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines to Fuel leaked or spilled onto hot surfaces or electrical
heaters or the engine contain hot water or steam. components can cause a fire.
Any contact can cause severe burns.
Do not smoke while refueling or in a refueling area.
Do not smoke in areas where batteries are charged,
Check the coolant level only after engine has been or where flammable materials are stored.
stopped and the fill cap is cool enough to remove
with your bare hand. Batteries in series can be located in separate
Remove the cooling system fill cap slowly to relieve compartments. When using jumper cables always
pressure. connect positive(+) cable to positive(+) terminal of
battery connected to starter solenoid and negative(-)
Cooling system additive contains alkali that can cable from external source to starter negative(-)
cause personal injury. Avoid contact with the skin terminal.
and eyes and do not drink. (If not equipped with starter negative(-) terminal,
Allow cooling system components to cool before connect to engine block.)
draining.
See the Operation Section of this manual for
Oils specific starting instructions.
Hot oil and components can cause personal injury. Clean and tighten all electrical connections. Check
Do not allow hot oil or components to contact the daily for loose or frayed electrical wires. Have all
skin. At operation temperature, the hydraulic tank is loose or frayed electrical wires tightened, repaired
hot and can be under pressure. or replaced before operation the lift truck.
Remove the hydraulic tank fill cap only after the Keep all fuels and lubricants stored in properly
engine has been stopped and the fill cap is cool marked containers and away from all unauthorized
enough to remove with your bare hand. persons.
Remove the hydraulic tank fill cap slowly to relieve Store all oily rags or other flammable material in a
pressure. protective container, in a safe place.
Relieve all pressure in air, oil fuel or cooling Do not weld or flame cut on pipes or tubes that
systems before any lines, fittings or related items contain flammable fluids. Clean them thoroughly
are disconnected or removed. with nonflammable solvent before welding or flame
cutting on them.
Batteries
Remove all flammable materials such as fuel, oil
Batteries give off flammable fumes which can and other debris before they accumulate on the lift
explode. truck.
Do not smoke when observing the battery electrolyte Do not expose the lift truck to flames, burning brush,
levels. etc., if at all possible.
Electrolyte is an acid and can cause personal injury Shields, which protect hot exhaust components
if it contacts skin or eyes. from oil or fuel spray in the event of a line, tube or
seal failure, must be installed correctly.
Always wear protective glasses when working with
batteries. Do not operate in areas where explosive gases
exist or are suspected.
15
Safety Section
Fire Extinguisher End fittings damaged or leaking.

Have a fire extinguisher-type BC and 1.5KG minimum Outer covering chafed or cut and wire reinforcing
capacity-on rear overhead guard leg with latch and exposed.
know how to use it. Inspect and have it serviced as
recommended on its instruction plate. Outer covering ballooning locally.
Ether Evidence of kinking or crushing of the flexible part
of hose.
Ether is poisonous and flammable.
Armouring embedded in the outer cover.
Breathing ether vapors or repeated contact of ether
with skin can cause personal injury. End fittings displaced.
Use ether only in well-ventilated areas. Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
Do not smoke while changing ether cylinders. against other parts, and excessive heat during
operation.
Use ether with care to avoid fires.
Tire Information
Do not store replacement ether cylinders in living
areas or in the operator's compartment. Explosions of air-inflated tires have resulted from
heat-induced gas combustion inside the tires. The
Do not store ether cylinders in direct sunlight or at heat, generated by welding or heating rim components,
temperatures above 39C (102F). external fire, or excessive use of brakes can cause
gaseous combustion.
Discard cylinders in a safe place. Do not puncture
or burn cylinders. A tire explosion is much more violent than a blowout.
The explosion can propel the tire, rim and axle
Keep ether cylinders out of the reach of unauthorized components as far as 500 m (1500 ft) or more from
personnel. the lift truck. Both the force of the explosion and the
flying debris can cause personal injury or death,
Lines, Tubes and Hoses and property damage.
Do not bend or strike high pressure lines. Do not

install bent or damaged lines, tubes or hoses.
Repair any loose or damaged fuel and oil lines,

tubes and hoses. Leaks can cause fires. Contact
your DOOSAN dealer for repair or replacement.
Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or
cardboard to check for leaks. See Fluid Penetration
in the Safety Section for more details. Tighten all
connections to the recommended torque. Replace if
any of the following conditions are found.
Do not approach a warm tire closer than the outside
of the area represented by the shaded area in the
above drawing.
16
Safety Section
Dry nitrogen(N2) gas is recommended for inflation Operator Restraint System (If
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure. Equipped)
Nitrogen mixes properly with air.
Warning Signs and Labels
Nitrogen inflated tires reduce the potential of a tire Your DOOSAN lift truck has the following tipover
explosion, because nitrogen does not support warning decals.
combustion. Also, nitrogen helps prevent oxidation
and the resulting deterioration of rubber and Make sure that you can read all safety signs. Clean
corrosion of rim components. or replace these if you cannot read the words or
see the pictures. When cleaning the labels use a
Proper nitrogen inflation equipment and training in cloth, water and soap. Do not use solvent, gasoline,
its use are necessary to avoid overinflation. A tire etc. You must replace a label if it is damaged,
blowout or rim failure can result from improper or missing or cannot be read. If a label is on a part
misused equipment. that is replaced, make sure a new label is installed
on the replaced part. See you DOOSAN Lift Truck
Stand behind the tread and use a self-attaching dealer for new labels.
chuck when inflation a tire.
Servicing, changing tires and rims can be dangerous injury or death to yourself or others is to familiarize
and should be done only by trained personnel using yourself with the proper operation of the lift truck, to
proper tools and procedures. If correct procedures be alert, and to avoid actions or conditions which
are not followed while servicing tires and rims, the can result in an accident.
assemblies could burst with explosive force and
cause serious personal injury or death. Follow
carefully the specific information provided by your WARNING
tire or rim servicing personnel or dealer.
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.
17
Safety Section
WARNING
Do not place your hand or fingers under the

seat. Injury may occur as the seat moves up
and down.
The Survive in tipover warning is located on the

overhead guard. It shows the proper use of the
Seat Adjustment
Move the lever, slide the seat to the desired

position, and release the lever.

motion.
18
Safety Section
If Optional Suspension Seat (Weight Weight adjustment

Adjusting Type) Equipped Pull the weight adjustment lever upwards and move
Forward and Backward Adjustment right or left side.
Adjust to drivers weight in 7 steps (50 ~ 110 kg)
The seat can be adjusted by pushing the lever on
the right side of seat.
NOTICE
Do NOT place your hand or fingers under the seat.

Injury may occur as the seat moves up and down.
Forward and Backward

Adjustment
Backrest Inclination
The backrest angle can be adjusted by using the

lever on the left side of seat.

motion.
19
Safety Section
Seat Belt
The Operator Restraint System, Prevents the
operator from jumping from the operator's
compartment in the event of 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 tipover.
Inspection
3. In the event of tipover, the seat and restraint

system should be inspected for damage and
replaced, if necessary.
NOTE: Operator restraints shall be examined at

the regular truck service intervals. It is
recommended that they be replaced if any
of the following conditions are found:
1. If the seat belt is torn, if pulling motion is

Cut or frayed strap
interrupted during extension of the belt, or if the
Worn or damaged hardware including anchor
points
belt cannot be inserted into the buckle properly,
replace the seat belt assembly.
Buckle or retractor malfunction
Loose stitching
WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.
Fasten the Seat Belt
2. Belt Maintenance Every 500 service hours.

Check that the belt fastening works properly
and that winding device is free from run lock
when jerked. Check that the belt is suitably
fastened to the seat. Check that the seat is
correctly secured to the hood and the chassis.
On visual inspection, fastenings must be intact,
otherwise, contact the safety manager.
WARNING
Your DOOSAN truck comes equipped with a 1. Grip the plate (connector) of the belt and insert
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any the plate into the slot of the buckle until a snap
reason, it should only be replaced with another is heard. Adjust the belt to fit snugly acreoss
DOOSAN operator restraint system. your hips. Pull on the belt to confirm it is latched.
2. Make sure the belt is not twisted.
20
Safety Section
The belt will automatically retract when released.

WARNING Hold the plate of the belt and allow the belt to
If you fasten the belt across your abdomen, the slowly retract.
belt may injure your abdomen in an accident.
1. Be sure to fasten the belt across your hips, not

across your abdomen.
NOTE: The belt is designed to automatically

adjust to your size and movement. A quick
pull on the belt will confirm that the
automatic adjuster will hold the belt
position in the event of an accident.
Release the Seat Belt
Push the button of the buckle to release the belt.
21
Safety Section
Avoiding Lift Truck Tipovers 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
Counterbalanced lift truck design is based on the bal- combined CG of the truck and load. The lift truck
ance of two weights on opposite sides of a fulcrum has moving parts and, therefore, has a CG that
(the front axle). The load on the forks must be bal- moves. The CG moves forward or backward as the
anced by the weight of the lift truck. The location of mast is tilted forward or backward. The CG moves
the center of gravity of both the truck and the load up or down as the mast moves up or down. The CG
is also a factor. This basic principle is used for and, therefore, the stability of the loaded lift truck, is
picking up a load. The ability of the lift truck to affected by a number of factors such as :
handle a load is dis-cussed in terms of center of
gravity and both forward and sideways stability. the size, weight, shape and position of the load
the height to which the load is lifted
Center of Gravity (CG) the amount of forward or backward tilt
tire pressure
dynamic forces created when the lift truck is
accelerated, braked or turned
condition and grade of surfaces on which the lift
truck is operated
The point within an object, at which the whole weight of

the object may be regarded as being concentrated,
is called the center of gravity or CG. If the object is uni-
form, its geometric center will coincide with its CG.
If it is not uniform, the CG could be at a point outside of
the object. When the lift truck picks up a load, the
truck and load have a new combined CG.
These same factors are also important for unloaded
lift trucks. They tip over sideways easier than a
loaded lift truck carrying its load in the lowered
position.
22
Safety Section
Lift Truck Stability Base Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
mast, and having no special-purpose attachment. In
addition, the capacity load assumes that the load
center is no further from the top of the forks than it
is from the face of the backrest. If these conditions
do not exist, the operator may have to reduce the
safe operating load because the truck stability may
be reduced. The lift truck should not be operated if
its capacity/nameplate does not indicate capacity
load.
NOTE : If the load is not uniform, the heaviest

portion should be placed closer to the
backrest and centered on the forks.
For the lift truck to be stable (not tip over forward or
to the side), the CG must stay within the area of the
lift truck stability base a triangular area between
the front wheels and the pivot of the steer wheels. If
the CG moves forward of the front axle, the lift truck
will tip forward. If the CG moves outside of the line 1. Capacity/Nameplates originally attached to
on either side of the stability base, the lift truck will forklifts sold by DOOSAN shall not be
tip to the side. removed, altered or replaced without DOO-
SANs approval.
2. DOOSAN assumes no responsibility for lift
WARNING trucks placed in service without a valid
Dynamic forces (braking, acceleration, turning) DOOSAN Nameplate.
also affect stability and can produce tipover 3. If necessary to change your specification,
even when the CG is within the stability triangle. contact your DOOSAN lift truck dealer.
Capacity Load (Weight and Load

Center)
The capacity load of the lift truck is shown on the

capacity/nameplate riveted to the truck. It is
determined by the weight and load center. The load
center is determined by the location of the CG of
the load. The load center shown on the nameplate
is the horizontal distance from the front face of the
forks, or the load face of an attachment, to the CG
of the load. The location of the CG in the vertical
direction is the same as the horizontal dimension.
23
Safety Section
Safety Rules
Do not operate a lift truck unless you are in the

operators seat. Keep hands and feet inside the
operators compartment. Do not put any part of the
body outside of the operators compartment.
Only properly trained and authorized personnel
Never put any part of body into the mast structure
should operate forklift trucks. Wear a hard hat and
or between the mast and the truck
safety shoes when operating a lift truck. Do not
wear loose clothing.
Do not start, stop, turn or change direction suddenly

or at high speed. Sudden movement can cause the
Inspect and check the condition of your forklift truck
lift truck to tip over. Slow the speed of your truck
using the operator's check list before starting work.
and use the horn near corners, exits, entrances,
Immediately report to your supervisor any obvious
and near people.
defects or required repairs.
Never operate a lift truck with wet hands or shoes.

Do not operate your truck in unauthorized areas.
Never hold any controls with grease on your hands.
Know your forklift truck and think safety.
Your hands or feet will slide off of the controls and
Do not compromise safety.
cause an accident.
Follow all safety rules and read all warning signs.
24
Safety Section
Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the
Do not let other people ride on the truck. rated capacity shown on the capacity plate.
Lift trucks are designed to carry loads, not people. Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.
Do not operate your truck without the load backrest

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

pick up an off center load. Such a load increases
the possibility of a tipover to the side. Make sure
loads are correctly stacked and positioned across
both forks. Always use the proper size pallet.
Position the forks as wide as possible under the Do not drive on slippery surfaces.
load. Position loads evenly on the forks for proper Sand, gravel, ice or mud can cause a tipover.
balance. Do not lift a load with one fork. If unavoidable, slow down.
25
Safety Section
Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward.
load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards.
cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
Look out for overhead obstructions when raising or Do not jump off if your truck starts to tip over.
stacking loads. Do not travel with a raised load. Do Stay in your seat to survive.
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.
Go up ramps in forward direction and down ramps

in reverse direction when moving loads.
Never elevate a load with the forklift truck on an
Do not move loose loads that are higher than the incline.
load backrest. Go straight off and straight down. Use an assistant
Be alert for falling loads when stacking. when going up or down a ramp with a bulky load.
Travel with the load tilted back and the forks as low
as possible.
This will increase stability to the truck and load and
permit better visibility for you.
26
Safety Section
Do not stack or turn on ramps. Do not drive in forward direction when loads restrict
Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to
the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
an incline.
Be careful when operating a lift truck near the edge

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

Avoid running over loose objects. support the weight of the truck and load.
Look in the direction of travel. Look out for other Make sure that they are correctly positioned.
persons or obstructions in your path of travel. Put blocks on the vehicle you enter to keep it from
An operator must be in full control of his lift truck at moving.
all times.
27
Safety Section
Do not operate your truck close to another truck. Mop up spilt fuel and do not forget to close the fuel
Always keep a safe distance from other trucks and tank before restarting the engine.
make sure there is enough distance to stop safely. Park your lift truck in authorized areas only. Fully
Never overtake other vehicles. lower the forks to the floor, put direction lever in
NEUTRAL position, engage the parking brake, and
turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work.
Do not use your lift truck to push or tow another

truck.
Do not let another push or tow your truck.
If a truck will not move, call a service technician.
Exhaust from all internal combustion engines

contains carbon monoxide, a colorless, odorless,
tasteless, poisonous gas. Exposure to carbon
monoxide can cause serious injury or health
problems, including death. and avoid unnecessary
idling of the engine. If nausea, dizziness or
headaches are experienced stop the truck and seek
fresh air.
Forklift trucks may only be refueled at specially

reserved locations. Switch off the engine when
refueling.
Smoking and handling of naked flames during
refueling are strictly prohibited. This prohibition also
applies during the changing of the LPG (liquefied
propane gas) tank.
28
Safety Section
How to Survive in a Tipover
WARNING
Hold on tight.
In the event of a tipover, the risk of serious injury or

death will be reduced if the operator is using the
operator restraint system and follows the
instructions provided.
Always use operator restraint system.
Brace your feet and keep them within the operators

compartment.
DONT jump.
29
Safety Section
Lean away from the direction of fall.
Lean forward.
30
General Section
Specifications
CHARACTERISTICS
1 Manufacturer DOOSAN DOOSAN DOOSAN
2 Model GC15S-5(TIER-3) GC18S-5(TIER-3) GC20SC-5(TIER-3)
3 Capacity at rated load center lb/kg 3000/1500 3500/1750 4000/2000
4 Load center distance inch/mm 24/500 24/500 24/500
5 Power type electric, diesel, gasoline, lp-gas LP LP LP
6 Operator type stand-on, rider-seated Rider - seated Rider - seated Rider - seated
7 Tire c=cushion, p=pneumatic C C C
8 Wheels(x=driven) number, front/rear X 2/2 X 2/2 X 2/2
DIMENSIONS
9 Lift with STD maximum fork height with rated load inch/mm 118/3000 118/3000 118/3000
10 two-stage mast free lift inch/mm 5.1/130 5.1/130 5.3/135
12 Fork carriage ISO class ll II II
thickness X width X length inch 1.4 x 4 x 41 1.4 x 4 x 41 1.6 x 4 x 41
13 Forks
mm 35x100x1050 35x100x1050 40x100x1050
14 Tilt of mast forward/backward deg 6/8 6/8 6/8
15 length without forks inch/mm 80.8/2051.5 82.9/2106.5 84.1/2138.5
16 width inch/mm 37/940 39/991 39/991
17 Overall mast lowered height inch/mm 78/1980 78/1980 78/1980
18 dimensions mast extended height inch/mm 159/4045 159/4045 159/4050
19 overhead guard height inch/mm 81/2060 81/2060 81/2060
20 seat height inch/mm 39.3/1000 39.3/1000 39.3/1000
21 Outside turning radius inch/mm 71.5/1816 74/1881 76/1932
22 Load moment constant inch/mm 15.5/394 15.5/394 15.7/399
23 90 stacking aisle inch/mm 86/2184 88/2235 89/2261
23a 90 intersecting aisle inch/mm 63.1/1603 64.7/1643 65.1/1653
PERFORMANCE
24 travel, loaded/unloaded mph 11.3/11.6 11.3/11.6 11.3/11.6
kph 18.0/18.5 18.0/18.5 18.0/18.5
25 lift, loaded/unloaded fpm 118.1/128 118.1/128 118.1/128
Speeds
mm/s 600/650 600/650 600/650
26 lowering, loaded/unloaded fpm 98.4/88.6 98.4/88.6 98.4/88.6
mm/s 500/450 500/450 500/450
28 Drawbar pull at 1.0 mph, loaded lb/kg 3086/1400 3086/1400 3086/1400
30 Gradeability at 1.6 mph, loaded % 37 32 30
31 Acceleration traveling loaded/unloaded s
WEIGHT
32 Total weight unloaded lb/kg 5940/2695 6510/2955 6800/3085
33 Axle load with loaded, front/rear lb 7840/1100 8345/1450 9400/1400
kg 3685/510 4035/670 4435/650
34 without loaded, front/rear lb 2370/3570 2190/4320 2095/4695
kg 1075/1620 995/1960 955/2130
CHASSIS
35 number of front/rear 2/2 2/2 2/2
36 Tires front size inch 18 X 6 X 12.12 18 X 7 X 12.12 18 X 7 X 12.12
37 rear size inch 14 X 5 X 10 14 X 5 X 10 14 X 5 X 10
38 Wheel base inch/mm 48.2/1225 48.2/1225 48.2/1225
39 Tread front/rear inch 31/31 32/31 32/31
mm 787/787 813/787 813/787
40 at loaded, the lowest point inch/mm 3/75 3/75 3/75
Ground clearance
41 at loaded, the center of wheelbase inch/mm 4.3/110 4.3/110 4.3/110
42 Service brake foot/hydraulic foot/hydraulic foot/hydraulic
43 Parking brake hand/mech hand/mech hand/mech
DRIVE
45 Battery voltage/capacity V/AH 12 / 45 12 / 45 12 / 45
49 manufacturer/model G420FE G420FE G420FE
50 rated output (at rpm) hp/rpm 45.5@2300 45.5@2300 45.5@2300
ps/rpm 46.1@2300 46.1@2300 46.1@2300
51 Engine max. torque lb-ft 112@1600 112@1600 112@1600
kg.m/rpm 15.5@1600 15.5@1600 15.5@1600
52 cycle/cylinders/displacement cc 1975 1975 1975
55 type Powershift Powershift Powershift
Transmission
56 no. speeds forward/reverse 1/1 1/1 1/1
31
General Section
32
General Section
Noise and Vibration
Sound Pressure Level at Whole-body Vibration

Operators ear (Leq.) Level
according to EN12053 according to EN13059
Model Guaranteed Sound
2
(m/s )
dB(A) Mean Uncertainty
GC15/18S-5, GC20SC-5 82 1.8 0.5
33
General Section
Serial Number
Serial Number Locations
For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.
Power Shift Transaxle Serial Number

______________________________
Lift Truck Serial Number

______________________________
Side Shift Serial Number (If Equipped)

______________________________
2.0 liter Spark Ignition Engine Serial Number

(G420F(E))
______________________________
2.3 liter Diesel Engine Serial Number

______________________________
34
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 Lift Truck Capacity Rating

Do not exceed allowable lift truck working capacity
load ratings.
The capacity of the lift truck is given by weight and
distance to the load center. For example: a capacity
of 1500kg(3300 lb) at 500mm(24in) means that the
lift truck can lift 1500kg(3300lb) if the load center is
500 mm (24in) from both the vertical and horizontal
faces of the forks.
Before attempting to lift any load, ensure that the
weight and load center combination is within the
capacity of the lift truck as shown on the capacity
rating plate. To determine the load center measure
the distance from the face of the carriage to the
Located by the right side of the operator's seat on
gravitational center of the load.
the engine compartment cover.
The rated capacity on the plate refers to the
capacity of the lift truck as it left the factory.
Subsequent changes of any form to the equipment
Identification, Lift Capacity and or battery can alter the lift trucks rating.
Attachment Plate The rated capacity of the lift truck applies to
operating conditions where the lift truck is on level
ground. The capacity of the lift truck is reduced on
inclines.
Below are abbreviations that may appear on the
IDENTIFICATION, LIFT CAPACITY and
ATTACHMENTPLATES and their meanings.
Located on the cowl to the right side of the steering

column.
35
General Section
Mast Abbreviations Attachment Abbreviations

STD - Standard Mast (single inner member, (includes Special Forks)
low free lift)
Special Carriage - increased width,
SC-
FF - Full Free Lift Mast (single inner member height or outreach
with high free lift duplex cylinder)
SSS - Shaft-type Sideshift Carriage
FFT - Triple Lift Mast (two inner members) with
either low or full free lift characteristics. HSS - Hook-type Sideshift Carriage (ITA)
QUAD - Quadruple (Quad) Mast (with three CW - Counterweight

inner members)
SF - Special Forks
NOTE : When only a mast-type is listed on the SWS - Swing Shift, Sideshift
Nameplate, a standard carriage and forks
are used. RAM - Ram or Boom
DBCBH - Double Cube Block Handler
HFP - Hydraulic Fork Positioner
CR - Crane Arm or Crane Boom
TH - Tire Handler
CTH - Container Handler
LPP - Load Push-Pull Device
CC - Carton Clamp
RC - Roll Clamp
LS - Load Stabilizer
PWH - Pulp Wood Handler
SS-ST - Sideshift-Side Tilt Carriage
36
Operation Section

Instrument Panel
Your lift truck may not have the same indicator or warning lights as shown in the illustrations.
Due to the various options available, typical instrument panels are shown.
However, the symbols on the indicators and lights on your panel identify what those particular items are.
Also, the symbol for each of the items is identified and an explanation of their function and location is
described on the following pages.
Diesel (12V)
LPG/GAS (12V)
37
Operation Section
1. Engine Oil Pressure Indicator Light - Check the cooling system for a malfunction. Both
Indicates insufficient engine oil pressure. tenth & ninth will flash out of phase when the coolant
The light will come on when the ignition temperature reaches approximately 106C (223F)
switch is turned to the ON position. The on all engines.
light should go off after the engine is started. If the
light turns on while operating the lift truck, 7. Transmission Oil Temperature
insufficient engine oil pressure is indicated. Park the Gauge - Indicates transmission oil
lift truck and stop the engine. temperature. If both tenth & ninth flash
Check the system for a malfunction. The light will out of phase while operating the lift truck,
turn on when the oil pressure drops to approximately excessive transmission oil temperature is indicated.
70kPa (10psi). Park the lift truck and stop the engine.
Check the system for a malfunction. Both tenth &
2. Alternator Indicator Light - Indicates if ninth will flash out of phase when the transmission
the battery charging system is operational. oil temperature reaches approximately 80 to 100 C
The light will come on when the ignition (175 to 220 F).
switch is turned to the ON position.
The light should go off after the engine is started, 8. G420F(E) LP Engine Malfunction
indicating the alternator is producing sufficient Indicator Lamp (MIL) - G420F(E) engine
voltage to charge the battery. If the light turns on control system is equipped with built-in
with the engine running, check the alternator fault diagnostics. Detected system faults
charging system for a malfunction. can be displayed by the Malfunction Indicator Lamp
(MIL) as Diagnostic Fault Codes(DFC) or flash
3. Diesel Engine Start Preheat Indicator codes, and viewed in detail with the use of service
Light (Diesel Engine Only) - The light will tool software. When the ignition key is turned ON
come ON when the key is turned to the the MIL will perform a self-test, illuminate once and
ON position from the OFF position. This then go OFF. If a detected fault condition exists, the
indicates that the glow plugs are preheating the pre- fault or faults will be stored in the memory of the
combustion chambers for easier starting. engine control module(ECM). Once a fault occurs
The amount of time needed to preheat the pre- the MIL will illuminate and remain ON. This signals
combustion chambers is approximately seven the operator that a fault has been detected by the
seconds, depending on the surrounding air SECM.
temperature. When the light goes OFF the
maximum pre-combustion chamber temperature has 9. Seat Belt Warning Light - Indicates
been reached and the key can be turned to the when the seat belt does not fastened by
START position to start the engine. operator. The light will come on when the
ignition switch is turned to the on position
4. Diesel Engine Water in Fuel Filter the light should go off often engine is started.
Indicator Light - Indicates when the
engine is running, there is water in the 10. Service Hour Meter - Indicates the
fuel filter exceeds 100cc. total number of hours the engine and the
The light will come ON when the ignition switch is lift truck have operated. The hour meter
turned to the ON position. The light should go off will operate when the ignition switch is in
after the engine is started. If the light turns on with the ON position, whether the engine is running or
the engine running, park the lift truck and stop the not. The hour meter is used to determine lubrication
engine. and maintenance intervals.
Drain some fuel (and any water) until clean fuel
flows from the filter which approximately takes 5 to 6 11. Parking indicator light - The light will
seconds. come ON when the parking lever is
applied.
5. Fuel Level Gauge - Indicates fuel level
(Gas, Diesel, or Dual Fuel Trucks Only)
12. Front Floodlights - Push down on
6. Engine Coolant Temperature Gauge the switch(17), to the first step, to turn the
- Indicates coolant temperature. If both front floodlights on.
tenth & ninth flash out of phase while Front and Rear Floodlights - Push down on the
operating the lift truck, overheating is switch(17), to the second step, to turn both the front
indicated. Park the lift truck and stop the engine. and rear floodlights on. The floodlights are optional.
38
Operation Section
13. Transmission Neutral Position Light Electrical Disconnect Switch (If

- Indicates the neutral position of
transmission. Equipped)
14. Brake Fluid Oil Light (If Equipped) -

The light is ON when the brake fluid oil of
brake reservoir comes down to low level
position. Refill the proper brake fluid oil if
its light is ON.
15. Low Level Light of LP GAS -

Indicates the low Level of LP GAS (LP or
DUAL only)
16. Directional Turning Indicator Light
17. Front and Rear Floodlishts Switch -

The front floodright is ON when push 1. ON - Connects the battery for electrical
down switch to the first step. power to all electrical circuits.
The front and rear floodlights are ON when push
down switch to the second step.
2. OFF - Disconnects the battery from all
electrical circuits.
18. Horn Switch - Push on the horn button

to sound the horn.
39
Operation Section
Seat Switch System (If Equipped)
NOTICE
1. Prior to operating the lift truck, be sure to
understand and check the SEAT SWITCH
SYSTEM.
2. While in normal operation and on level ground,

select a direction with the derectional lever and
with the park brake released. You will note that
the truck will move slowly in the selected
direction. If you lift yours hips off of the seat,
within three seconds, the SEAT SWITCH
SYSTEM will desengage the transmission
The lift truck is equipped with a SEAT SWITCH allowing the truck to coast but not automatically
SYSTEM. In normal operation if the direction lever stop.
is placed in either forward or reverse, the lift truck
will move at a speed proportional to the accelerator 3. To restore the lift truck to normal operation,
pedal's position. If the operator leavers the seat while sitting in the operator's seat depress the
without setting the parking brake, within three brake pedal to hold the lift truck, return the
seconds after leaving the seat, the SEAT SWITCH directional lever to the neutral position, and
SYSTEM will automatically disengage the then reselect a direction of travel (either
transmission. The directional lever, however, will forward or reverse). The transmission will then
remain in that forward or reverse location although re-engage.
internally the transmission will have shifted into
neutral. 4. If seat or seat switch replacement becomes
necessary, be sure to use genuine DOOSAN
Before exiting the lift truck, the parking brake Infracore lift truck parts. Lift trucks should
should always be applied. never be operated without an operational
SEAT SWITCH SYSTEM.
WARNING
WHEN LEAVING MACHINE APPLY PARKING
BRAKE!
PARKING BRAKE IS NOT AUTOMATICALLY
APPLIED.
NOTE: Some trucks may be equipped (ask your

dealer if this applies to your truck) with an
alarm that will sound if the parking brake is
not applied when leaving the machine.
40
Operation Section
Engine Compartment Circuit Breaker
1. The engine compartment is accessible by

Circuit Breaker - Protects the main
pulling the latch and raising the hood and seat
electrical circuits. To reset the circuit
assembly.
breaker, push the button in. It is Located in
the engine compartment.
2. The hood and seat assembly is held up by a

support cylinder. Make certain the air cylinder is
operating properly and will hold the hood up
before doing anything in the engine compartment.
41
Operation Section
Seat
NOTE : Seat arrangements may vary. Basic
operation will be similar.
Seat adjustment should be checked at the

beginning of each shift and when operators change.
Lock the seat into position before operating, to
prevent an unexpected seat change.
Adjust seat to allow full brake pedal travel with

operator's back against seat back.
NOTE : The seat can only be correctly adjusted

with the operator fully seated.
Tilting Steering Column
To adjust the steering column, push down the

knob(1) and move the steering column to the
desired position, then release the knob(1)
42
Operation Section
Lift Truck Controls

Direction Control Lever Transmission Inching Control
Pedal
1. Forward - Push the lever forward for

FORWARD direction travel. Inching Control Pedal - Pushing down on
the inching pedal, modulates the hydraulic
2. Neutral - Move the lever to center pressure to the clutch packs, permitting
position for NEUTRAL. disc slippage.
Further pushing on the pedal completely relieves

3. Reverse - Pull the lever back for
clutch pack pressure and applies the service
REVERSE direction travel.
brakes to stop and hold the lift truck.
NOTE : The purpose of the inching control pedal is

to provide precise inching control at slow
travel speed, with high engine rpm. This is
used for fast hydraulic lift during load
approach, pickup or positioning.
43
Operation Section
Service Brake Pedal Parking Brake Lever
Push DOWN on the brake pedal to slow Pull the lever BACK to engage the parking
or stop the lift truck. brake.
RELEASE the brake pedal to allow the lift Push the lever FORWARD to release the
truck to move. parking brake.
Accelerator Pedal Lift Control
NOTE : To prevent a sudden change of position of

Push DOWN on the pedal to increase the load, operate all lift, tilt and attachment controls
engine rpm (speed). smoothly.
RELEASE the pedal to decrease engine 1. Lower Position - Push the lever
rpm (speed). FORWARD smoothly to lower the load.
2. Hold Position - When the lever is

released it will return to the HOLD or
center position Lifting or lowering action
will stop.
3. Lift Position - Pull the lever BACK

smoothly to lift the load.
44
Operation Section
Tilt Control Sideshift Attachment Control (If

Equipped)
1. Mast Tilt Back - Pull the lever BACK

smoothly to tilt the mast backward. 1. Sideshift Left - Push the lever FOR-
WARD to shift the carriage to the left.
2. Mast Hold - When the lever is released
it will return to the HOLD or center 2. Sideshift Hold - When the lever is
position. Tilting action will stop. released it will return to the HOLD or
center position. Sideshifting action will
3. Mast Tilt Forward - Push the lever stop.
FORWARD smoothly to tilt the mast
forward. 3. Sideshift Right - Pull the lever BACK
to shift the carriage to the right.
45
Operation Section
Refueling
WARNING Changing LP-Gas Tanks
1. Park the lift truck on level ground, with the
Only trained, authorized personnel should fill or parking brake applied, the transmission in
exchange LP-Gas tanks. NEUTRAL, the forks lowered and the engine
running at low idle.
Personnel engaged in filling of LP-Gas containers
should wear protective clothing such as face
shield, long sleeves and gauntlet gloves.
Do not refuel or store LP-Gas powered lift trucks

near any underground entrance, elevator shafts
or any other place where LP-Gas could collect
in a pocket causing a potentially dangerous
condition.
Examine all LP-Gas containers before filling

and again before reuse, for damage to various
valves, liquid gauge, fittings and hand valve
wheels.
2. Close the fuel shutoff valve at the LP-Gas tank.
All defective or damaged LP-Gas containers must Run the engine until it stops, then turn off the
be removed from service. ignition switch.
3. Disconnect the fuel supply line.
Explosive fumes may be present during refueling.
Do not smoke in refueling areas.

safe locations. Safe outdoor locations are preferable
to indoor locations.
Stop the engine and get off the lift truck during
refueling.
The careless handling of LP-Gas containers can

result in a serious accident.
Use extreme care when transporting containers

to prevent damage to them. 4. Loosen the retaining clamps and remove the
tank.
5. Check the mounting to be sure the locating pin
(dowel) is not missing or broken.
NOTICE
If the locating pin (dowel) is missing or broken,

be sure the pin is replaced.
46
Operation Section
11. Position the replacement tank so that the

locating pin(dowel) is in place.
The LP-Gas tank must not extend past the

counterweight.
12. Clamp the tank securely

13. Connect the fuel supply line.
6. Check to be sure that the LP-Gas warning plate 14. Open the fuel valve by slowly turning the
is in position on the lift truck and is legible. valve counterclockwise. If the fuel valve is
opened too quickly, a back pressure check
7. Check to be sure the replacement tank is of the
valve will shut off the fuel supply. If this
correct type.
happens, close the fuel valve completely. Wait
8. Inspect the replacement tank for damage such five seconds and then open the fuel valve very
as dents, scrapes or gouges and for indication slowly.
of leakage at valves or threaded connections.
15. Inspect the LP-Gas fuel lines and fittings with a
soap solution after filling the tank or when
looking for leaks.
9. Check for debris in the relief valve, for damage

to various valves and liquid level gauge.
10. Inspect the quick-disconnect couplings for deter-
ioration, damage or missing flexible seals.
47
Operation Section
Before Starting the Engine

Walk-Around Inspection 5. Inspect the carriage, forks or attachments for
wear, damage and loose or missing bolts.
Make a thorough walk-around inspection before
mounting the lift truck or starting the engine. Look 6. Inspect the tires and wheels for cuts, gouges,
for such items as loose bolts, debris buildup, oil or foreign objects, inflation pressure and loose or
coolant leaks and cut or gouged tires. Check missing bolts.
condition of tires, mast, carriage, forks or
attachments. Have repairs made as needed and all
debris removed.
Before starting the gas engine, push the
accelerator pedal all the way down once and then
slowly it to set the automatic choke.
7. Inspect the overhead guard for damage and

loose or missing mounting bolts.
9. Look for transmission and drive axle leaks on
the lift truck and on the ground.
2. Inspect the instrument panel for broken or
damaged indicator lights or gauges.
3. Test the horn and other safety devices for
proper operation.
Typical Example
10. Inspect the engine compartment for oil, coolant

and fuel leaks.
4. Inspect the mast and lift chains for wear, broken

links, pins and loose rollers.
48
Operation Section
Typical Example
13. Observe the fuel level gauge after starting the
11.Measure the engine crankcase oil level with the truck. Add fuel if necessary.
dip stick. Maintain the oil level between the MAX.
and MIN., (or FULL and ADD) notches on the
dip stick.
WARNING
Personal injury may occur from accidents
caused by improper seat adjustment. Always
adjust the operator's seat before starting the lift
truck engine.
Seat adjustment must be done at the beginning
Typical Example
12.Observe the engine coolant level in the coolant

recovery bottle. With the engine cold, maintain
the level to the COLD mark. If the recovery
bottle is empty, also fill the radiator at the top
tank.
14. To position the seat, PUSH the lever away from

the seat track and move the seat forward or
backward to a comfortable position.
49
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

ignition switch to the START position.

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

1. Engage the parking brake, if not already
engaged. Place the directional control lever in 4. If engine coolant is cold, engine speed could be
the NEUTRAL position. higher than low idle speed. Dont drive forklift
until engine speed becomes normal low idle
speed.
NOTICE
If the inside of engine cylinder is wet by gasoline,
the engine could not start. In this case, press
accelerator pedal fully and turn the ignition switch
to ON position for 10 seconds. The inside of
cylinder would be dry because ECM does not allow
gasoline fuel injection. Repeat it three times. Dont
press accelerator pedal and turn the ignition switch
2. Lift trucks equipped with electrical disconnect to the START position to start engine.
switches ; the engine will not start unless the
disconnect switch is in the ON (closed) position.
Before starting, turn the disconnect switch to the
OFF (open) position.
50
Operation Section
LP-Gas Engine Diesel Engine

Starting a Cold Diesel Engine
WARNING 1. Turn the key to the ON position. The start
preheat light will come ON. The preheat light will
LP - Gas fuel is flammable and can cause
stay ON approximately seven seconds,
personal injury.
depending on the surrounding air temperature.
Inspect LP - Gas fuel lines and fitting for leaks.
Inspect tank for secure mounting.
NOTICE
Do not engage the starter for more than 10
seconds.
2. When the preheat light goes OFF, turn the key

to the START position, with the accelerator
pedal fully depressed.
position.
4. If the engine stalls or does not start, turn the key
1. Turn the tank fuel valve ON by slowly turning to the OFF position, then repeat steps 1 thru 3.
the valve counterclockwise. Observe the LP
Gas gauge (if equipped).
Starting a Warm Diesel Engine
ignition switch to the START position. 1. Turn the key to the ON position and then to
START position, without waiting for the preheat
3. Once the engine starts, release the ignition light to go OFF. At the same time fully depress
switch. the accelerator.
4. If the engine does not start, repeat step 2. release the accelerator pedal to a low idle
position.
5. If engine coolant is cold, engine speed could be
higher than normal low idle speed. Dont drive
forklift until engine speed becomes normal low
idle speed.
51
Operation Section
Starting From a 12 Volt External

Source
WARNING
Sparks occurring near the battery could cause
vapors to explode.
ground cable to a point away from and below
the battery, and well clear of fuel system
components.
Typical Example
NOTICE
Do not reverse battery cables. It can cause
damage to the alternator.
cables in parallel with the lift truck battery
cables : POSITIVE(+) to POSITIVE(+) and
NEGATIVE(-) to NEGATIVE(-).
Attach ground cable last, remove first. All lift
trucks equipped with DOOSAN built internal
combustion engines are NEGATIVE(-) ground.
52
Operation Section
4. The diesel engine water in fuel filter indicator

After Starting the Engine light(4), will not come ON with the engine
running, unless water in fuel filter exceeds
Observe all indicator lights and gauges frequently 100cc. Stop the engine immediately and drain
during operation, to make sure all systems are the water if the light comes ON.
working properly. All of the indicator lights will come
ON with the ignition switch in the ON position 5. Observe the fuel level gauge (5) for fuel level in
before the engine is started. the tank.
6. The engine coolant temperature gauge pointer
Diesel (12V)
running, unless the coolant temperature is
1 4 2 excessive.
7. The transmission oil temperature gauge pointer
running, unless the oil temperature is excessive.
8
5 6 7
LPG/GAS (12V)
8. Observe the hour meter(8) make sure it is

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

not come ON with the engine running, unless
there is low or no oil pressure. Stop the engine
immediately, if the light comes ON.
2. The alternator indicator light (2), should not
come ON during normal operation. The
alternator is not producing the sufficient voltage
to charge the battery if the light comes ON with
the engine running.
3. The Spark-ignition G420F(E) engine MIL
(Malfunction Indicator Light) (3) will not come
ON with the engine running, unless the fault or
faults are stored in the memory of the engine
control module (ECM). Stop the engine and
check the electric engine control system if the
light comes ON. Refer G420E Engine of this
section.
53
Operation Section
Electronic Controlled Spark-Ignition Engines

G420FE Engine
EMS (Engine management system) of G420F(E) (SECM) uses two heated exhaust gas oxygen
engine engine is a closed loop system utilizing a 3- sensors (HEGO) in the exhaust system to monitor
way catalytic muffler to reduce the emission level in exhaust gas content. One HEGO is installed in front
the exhaust gas. In order to obtain maximum effect of the catalytic muffler and one is installed after the
from the catalyst, an accurate control of the air fuel catalytic muffler.
ratio is required. A small engine control module
EMS schematic of G420FE Dual fuel engine
The SECM makes any necessary corrections to the pressure are monitored by the SECM. The SECM
air fuel ratio by controlling the inlet fuel pressure to controller has full adaptive learning capabilities,
the air/fuel mixer by modulating the dual fuel trim allowing it to adapt control function as operating
valves (FTV) connected to the regulator. Reducing conditions change. Factors such as ambient
the fuel pressure leans the air/fuel mixture and temperature, fuel variations, ignition component
increasing the fuel pressure enriches the air/fuel wear, clogged air filter, and other operating
mixture. To calculate any necessary corrections to variables are compensated.
the air fuel ratio, the SECM uses a number of
different sensors to gain information about the MPI (multi-point injection) is used for this system.
engines performance. Engine speed is monitored Fuel injection pressure and flow rate depend on
by the SECM through a variable reluctance (VR) or engine-specific fuel injection requirements. A
Hall Effect sensor. Intake manifold air temperature variety of regulators and injectors can be used to fit
and absolute pressure are monitored with a TMAP individual needs. The gasoline fuel pressure
sensor. MI-07 is a drive-by-wire (DBW) system regulator is a one-way, non-return configuration. All
connecting the accelerator pedal to the electronic gasoline specific components are automotive
throttle through the electrical harness; mechanical production parts and validated to strict automotive
cables are not used. A throttle position sensor standards. Four (4) sequential injection channels
(TPS) monitors throttle position in relation to the are supported.
accelerator pedal position sensor (APP) command.
Even engine coolant temperature and adequate oil
54
Operation Section
G420F Engine
EMS (Engine management system) of G420F engine engine is an open loop LP system and/or closed loop
gasoline system. 3-way catalytic muffler is not used for this system.
LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM.
Manifold pressure from the TMAP, rpm from the crank position sensor and throttle position is used by the
SECM to calculate load. Feedback from the electronic throttle is still provided to the SECM by the throttle
position sensors (TPS).
EMS schematic of G420F Dual Fuel engine
55
Operation Section
Basic Troubleshooting(LP)
The MI-07 systems are equipped with built-in fault basic checks that should be made before referring
diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or
displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
and are covered in the Advanced Diagnostics
section. Items such as fuel level, plugged fuel Locating a problem in a propane engine is done
lines, clogged fuel filters and malfunctioning exactly the same way as with a gasoline engine.
pressure regulators may not set a fault code by the Consider all parts of the ignition and mechanical
Small Engine Control Module (SECM). Below are systems as well as the fuel system.

Fuel container empty Fill fuel container
Engine Cranking z Do not exceed 80% of liquid
but Will Not Start capacity
Liquid valve closed Slowly open liquid valve
z Slowly open liquid valve
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Leak test
Broken Fuse - SECM Replace Fuse for SECM
z See Maintenance Section, Fuses
replacement
Filter replacement
collapsed hose
Incorrect air/fuel or ignition/spark See Advanced Diagnostics
control
56
Operation Section

Difficult to Start z Fill fuel container
Filter replacement
z Leak test
collapsed hose
z Fill fuel container
57
Operation Section

Will Not Run z Fill fuel container
Continuously z Do not exceed 80% of liquid capacity
Filter replacement

test
z -35F minimum
Check coolant hoses
return hose
problem
Will Not z Fill fuel container
Accelerate/Hesita z Do not exceed 80% of liquid capacity
tion During
Acceleration Excess flow valve closed Reset excess flow valve
58
Operation Section

Will Not z See Maintenance
Accelerate/Hesita Section, LP Fuel Filter replacement
tion During
Acceleration Faulty vapor connection between Check connection
collapsed hose
or sticking
Foot Pedal signal incorrect or
intermittent
Incorrect air/fuel or ignition control
Engine Stalls z Fill fuel container
Filter replacement
test
59
Operation Section

Engine Stalls z See Engine Service Manual
collapsed hose
z -35F minimum
z Check coolant hoses
return hose
manifold
head
Engine Mechanical See Engine Manufacturers Service Manual

Rough Idle z Verify no holes in hose
the pressure regulator/converter
collapsed hose

manifold
head
60
Operation Section

Rough Idle
Incorrect timing or spark control Service Manual
High Idle Speed
Throttle sticking Service Manual
pedal signal z See Advanced Diagnostics
Poor High Speed z See Maintenance section, Fuel Filter
Performance replacement

test
collapsed hose
Restricted exhaust system Check exhaust system
z Measure exhaust back pressure
Incorrect ignition control
See Advanced Diagnostics & See Engine
Incorrect air/fuel control
Service Manual
61
Operation Section
Excessive Fuel Air/Fuel Mixer malfunction Check mixer

Consumption/LP Air filter clogged Check air filter
G Exhaust Smell z Clean/replace as required
Vacuum leak Check system vacuum hoses from
regulator to FTV and mixer
z Repair/replace as necessary
Pressure regulator malfunction/fuel Test pressure regulator operation
pressure too high z See Engine Service Manual
Faulty FTV Check FTV for housing cracks or
obstructions
z See Advanced Diagnostics FTV
operation
z Repair and/or replace as necessary
Weak ignition and/or spark control See Advanced Diagnostics
Incorrect air/fuel control See Advanced Diagnostics
Exhaust system leaks Repair exhaust system
Oxygen sensor failure Replace as necessary
62
Operation Section
Advanced Diagnostics Displaying Fault Codes (DFC) from

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

EXAMPLE: A code 461 (ETCSticking) has been

(1) Malfunction Indicator Lamp(MIL) for Engine control system
63
Operation Section
Table 2. MI-07 Diagnostic Fault Codes (Flash Codes)

NONE
identification
Inj1Open
ohms (cold)
Inj2Open
ohms (cold)
Inj3Open
ohms (cold)
Inj4Open
Check Injector 4 Resistance, 12 to 14
ohms (cold)
Check ECT sensor connector and wiring
ECTRangeLow for a short to GND
141
Coolant Sensor failure or TurnOnMil SECM (Signal) Pin B15 To ECT Pin 3
(14)
shorted to GND SECM (Sensor GND) Pin B1 to ECT Pin 1
(1) TurnOnMil Check if ECT sensor connector is
ECTRangeHigh
151 (2) DelayedEngine disconnected or for an open ECT circuit
or open circuit
(3) CheckEngineLight SECM (Sensor GND) Pin B1 to ECT Pin 1
64
Operation Section


ECTOverTempFault
leaks in the system.
Engine coolant temperature is (1) TurnOnMil
Possible ECT short to GND, check ECT
161 high. The sensor has (2) DelayedEngine
signal wiring
(16) measured an excessive Shutdown
SECM (Signal) Pin B15 to ECT Pin 3
coolant temperature typically (3) CheckEngineLight
SECM (Sensor GND) Pin B1 to ECT Pin 1
due to the engine overheating.
Check regulator for coolant leaks
ECT_IR_Fault
Check for coolant system problems, e.g.
defective or stuck thermostat
FuelSelectConflict Check fuel select switch connection for a
Conflict in fuel select signals, short to GND
CamEdgesFault SECM (SIGNAL) Pin B10 to CAM sensor
No CAM signal when engine is Pin 2
191 known to be rotating, broken None SECM (Sensor GND) Pin B1 to CAM
crankshaft sensor leads or sensor Pin 3
defective CAM sensor Switched 12V to CAM sensor Pin 1
CamSyncFault
SECM (SIGNAL) Pin B10 to CAM sensor
Pin 2
CAM sensor, normally due to
noise on the signal or an
sensor Pin 3
intermittent connection on the
Switched 12V to CAM sensor Pin 1
CAM sensor
CrankEdgesFault
Pin 3
engine is known to be rotating,
broken crankshaft sensor
sensor Pin 2
leads or defective crank
sensor
CrankSyncFault
Pin 3
crankshaft sensor, normally
194 None SECM (Sensor GND) Pin B1 to Crank
sensor Pin 2
65
Operation Section

221 range low, normally set if the GND
TurnOnMil
range low, normally set if the GND
222 TurnOnMil
TPS1RangeHigh
231 range high, normally set if the wiring for a shorted circuit
TurnOnMil
power or the ground for the SECM Pin B1 (sensor GND) to ETC Pin 2
sensor has opened
TPS2RangeHigh
range high, normally set if the wiring for a shorted circuit
232 TurnOnMil
power or the ground for the SECM pin B1 (sensor GND) to ETC Pin 2
sensor has opened
corrosion.
None
TPS Pin 3 (PWR) to
corrosion.
242 None
TPS PIN 3 (PWR) to
TPS1AdaptHiMax
251 Learned WOT end of TPS1
None N/A
expected
TPS2AdaptHiMax
252 None N/A
sensor range higher than
expected
TPS1AdaptHiMin
271 None N/A
expected
66
Operation Section

TPS2AdaptHiMin
272 None N/A
expected
TPS1AdaptLoMax
281 None N/A
than expected
TPS2AdaptLoMax
Learned closed throttle end of
282 None N/A
TPS2 sensor range higher
than expected
NOTE: The TPS is not a (1) TurnOnMil
291 Perform checks for DFCs 241 & 242
serviceable item and can (2) Engine Shutdown
only be repaired by
assembly.
MAPTimeRangeLow
Vdc)
331 set if the TMAP pressure
None Check the MAP sensor by disconnecting
(33) signal wire has been
sensor:
TMAP Pin 1(GND) to
opened to the SECM
MAPRangeLow
Vdc)
set if the TMAP pressure (1) TurnOnMil
332 Check the MAP sensor by disconnect-ing
signal wire has been (2) CutThrottle
sensor:
TMAP Pin 1(GND) to
opened to the SECM
67
Operation Section

MAPTimeRangeHigh Check TMAP connector and MAP signal wiring
341
shorted to power, shorted to None Check the MAP sensor by disconnect-ing the
(34)
failed or the SECM has failed. TMAP Pin 1(GND) to
MAPRangeHigh Check TMAP connector and MAP signal wiring
(1) TurnOnMil
342 shorted to power, shorted to Check the MAP sensor by disconnecting the
(2) CutThrottle
failed or the SECM has failed TMAP Pin 1(GND) to
MAP_IR_HI Check for vacuum leaks. Check that TMAP
351 MAP sensor indicates higher None sensor is mounted properly. Possible defective
pressure than expected TMAP sensor.
MAP_IR_LO
MAP_STICKING
Check that TMAP sensor is mounted properly.
353 MAP sensor not changing as None
Possible defective TMAP sensor.
expected
IATRangeLow for a shorted circuit
Sensor Input is Low normally TMAP Pin 1 to SECM Pin B1 (sensor GND)
371
(37)
sensor wire has shorted to disconnect the TMAP connector and measure
chassis ground or the sensor the IAT resistance
has failed. Resistance is approx 2400 ohms at room
temperature.
68
Operation Section

IATRangeHigh for a shorted circuit
Sensor Input is High normally TMAP Pin 1 to SECM Pin B1 (sensor GND)
381
(38)
sensor wire has been disconnect the TMAP connector and measure
disconnected or the circuit has the IAT resistance
opened to the SECM. Resistance is approx 2400 ohms at room
temperature.
IAT_IR_Fault Check connections to TMAP sensor. Check
391 Intake Air Temperature not None that TMAP sensor is properly mounted to
changing as expected manifold.
circuit
421 TurnOnMil
details.
circuit
EST2_Open system. See application note.
422 TurnOnMil
details.
circuit
423 TurnOnMil
details.
69
Operation Section

open circuit
EST4_Open system. See application manual.
424 TurnOnMil
engine details.
EST5_Open
None N/A
spark module
EST6_Open
None N/A
spark module
EST7_Open
427 None N/A
spark module
EST8_Open
428 None N/A
spark module
shorts
EST1_Short
spark module
engine details.
70
Operation Section

shorts
EST2_Short
spark module
engine details.
shorts
EST3_Short
spark module
engine details.
shorts
EST4_Short
spark module
engine details.
EST5_Short
spark module
EST6_Short
spark module
71
Operation Section

EST7_Short
spark module
EST8_Short
spark module
Check for debris or obstructions inside
ETC_Sticking
the throttle body
Electronic Throttle Control is
Perform the throttle test using the
sticking. This can occur if the
Service Tool and re-check for fault
inside the throttle bore is
wear
sticking. The plate sticking can
be due to some type of (1) TurnOnMil
461 open circuit
obstruction, a loose throttle (2) EngineShutdown
(26) SECM Pin A17 to ETC + Pin 1
plate, or worn components shaft (3) CutThrottle
bearings.
the throttle
assembly.
Pin 4 (-DRIVER) ~3.0-4.0
Check the ETC driver wiring for an open
circuit
ETC_Open_Fault
has failed, normally set if either
471 of the ETC driver signals have None
opened or become
disconnected, electronic throttle
the throttle
or SECM is defective.
Pin 4 (-DRIVER) ~3.0-4.0
ETCSpringTest
Spring Return Test has failed.
The SECM will perform a safety
test of the throttle return spring
following engine shutdown. If
(1) TurnOnMil
481 this spring has become weak Perform throttle spring test by cycling
(2) EngineShutdown
(28) the throttle will fail the test and the ignition key and re-check for fault
set the fault.
assembly.
72
Operation Section

Check ETC driver wiring for a shorted circuit
HbridgeFault_ETC SECM Pin A17 to ETC + Pin 1
Electronic Throttle Control SECM Pin A18 to ETC - Pin 4
Driver has failed. Perform the throttle test using the Service
Indeterminate fault on Tool and re-check for fault
491
Hbridge driver for TurnOnMil Check the ETC internal motor drive by
(29)
electronic throttle control. disconnecting the throttle connector and
Possibly either ETC+ or measuring the motor drive resistance at the
ETC- driver signals have throttle
been shorted to ground TPS Pin 1 (+DRIVER) to
Pin 4 (-DRIVER) ~3.0-4.0
Perform maintenance check on electrical
connections to the battery and chassis
ground
with the engine running to verify charging
531 SysVoltRangeLow
TurnOnMil system and alternator function
(53) System voltage too low
SECM Pin A16 (DRVG)
SECM Pin B17 (DRVG)
Check battery and charging system voltage
with the engine running
Check voltage regulator, alternator, and
charging system
Check battery and wiring for overheating
541 SysVoltRangeHigh
TurnOnMil and damage
(54) System voltage too high
SECM Pin A16 (DRVG)
SECM Pin B17 (DRVG)
73
Operation Section

TMAP Pin 1 XDRG GND
SensVoltRangeLow (1) TurnOnMil
551 SECM Pin B24 +5 Vdc to SECM
(55) Pin B1 XDRG GND
XDRP too low
Verify transducer power at
ETC with a multimeter
GND
multimeter.
TMAP Pin 1 XDRG GND
SensVoltRangeHigh (1) TurnOnMil
561 SECM Pin B24 +5 Vdc to
(56) SECM Pin B1 XDRG GND
XDRP too high
Verify transducer power at ETC with a
multimeter
GND
multimeter.
HardOverspeed Usually associated with additional ETC faults
571 (1) TurnOnMil
exceeded the third level (3 Verify if the lift truck was motored down a steep
(57) (2) HardRevLimit
protection
MediumOverspeed Usually associated with additional ETC faults
(1) TurnOnMil
572 exceeded the second level Verify if the lift truck was motored down a steep
(2) MediumRevLimit
(2 of 3) of overspeed grade
protection
SoftOverspeed Usually associated with additional ETC faults
(1) TurnOnMil
573 exceeded the first level (1 Verify if the lift truck was motored down a steep
(2) SoftRevLimit
protection
APP1RangeLow
APP1 sensor voltage out
of range low, normally set (1) TurnOnMil
611 Check foot pedal connector
if the APP1 signal has (2)
(61) Check APP1 signal at SECM PIN B7
shorted to ground, circuit CheckEngineLight
has opened or sensor has
failed
74
Operation Section

CHECK
APP2RangeLow
612
low, normally set if the APP2 signal TurnOnMil Check APP2 signal at SECM PIN
(65)
has shorted to ground, circuit has B16
APP1RangeHigh
APP1 sensor voltage out of range (1) TurnOnMil Check foot pedal connector
621
high, normally set if the APP1 signal (2) CheckEngine Check APP1 signal at SECM PIN
(62)
has shorted to power or the ground Light B7
APP2RangeHigh
622
high, normally set if the APP2 signal TurnOnMil Check APP2 signal at SECM PIN
(66)
has shorted to power or the ground B16
631
(63)
B7
632
(67)
B16
APP1AdaptHiMax
641
(64)
APP2AdaptHiMax
642
(68)
APP1AdaptHiMin
APP2AdaptHiMin
APP1AdaptLoMax
APP2AdaptLoMax
corrosion
APP_Sensors_Conflict Cycle the pedal several times and
691 APP position sensors do no not track (1) TurnOnMil check APP1 signal at SECM Pin
(69) well, intermittent connections to APP (2) Level1PowerLimit B7
or defective pedal assembly Cycle the pedal several times and
check APP2 signal at SECM Pin
B16
75
Operation Section

LSDFault_Dither1 being disconnected
711
has opened or shorted to TurnOnMil FTV1 Pin 2 (power) to SECM (DRVP) Pin A23
(71)
resistance (~26 2 )
LSDFault_Dither2 being disconnected or signal shorted to GND
712 has opened or shorted to TurnOnMil FTV2 Pin 2 (power) to SECM (DRVP) Pin A23
resistance (~26 2 )
Check Check Engine Lamp for an open wire or
shorted to GND
crank disable relay
Check fuel lock off valve for an open wire or
connector being disconnected or signal shorted
LSDFault_LockOff
to GND
Fuel lock off Valve Fault,
Lockoff Pin B (signal) to SECM Pin A11 Lockoff
717 signal has opened or shorted TurnOnMil
Pin A (power) to SECM (DRVP) Pin A23
Check CSV for an open coil by disconnecting
defective Fuel lock off valve
the CSV connector and measuring the
resistance (~26 3)
LSDFault_MIL
Check MIL lamp for an open wire or short to
GND.
GasFuelAdaptRangeLo Check for vacuum leaks.
721 In LPG mode, system had to Check dual dither valves, e.g. leaking valve or
TurnOnMil
(72) adapt rich more than hose
expected Check for missing orifice(s).
76
Operation Section
GasFuelAdaptRangeHi Check dual dither valves, e.g. plugged valve or

731 In LPG mode, system had hose.
TurnOnMil
(73) to adapt lean more than Check for plugged orifice(s).
expected
are OK.
GasO2NotActive
741 inactive on LPG, open O2
(2) DisableGas O2 Pin 1 (HEATER PWR) to SECM (DRVP +
(74) sensor signal or heater
O2Ctrl 12V) Pin A23
leads, defective O2
sensor
PWR)
connections are OK.
GNG) Pins A16, B17
GasPostO2NotActive
after engine has been running for some time
(1) TurnOnMil and SECM has calculated that water
inactive on LPG, open O2
742 (2) DisableGasPost condensation in exhaust has been removed by
sensor signal or heater
O2Ctrl exhaust heat. Post O2 Heater Relay has
leads, defective O2
SECM (DRVP + 12V) applied to the relay coil
sensor.
power. The relay coil ground is controlled by
SECM Pin A20 to activate the relay to flow
current through the post O2 heater.
PWR)
GasO2FailedLean Check for vacuum leaks.
(1) TurnOnMil
Pre-catalyst O2 sensor Check dual dither valves, e.g. leaking valve or
751 (2) DisableGas
indicates extended lean hose.
O2Ctrl
operation on LPG Check for missing orifice(s).
(e.g. faults pertaining to dither valves, Pre-Cat
GasPostO2FailedLean O2, Post Cat O2 sensor)
(1) TurnOnMil
Pre-catalyst O2 sensor Check for vacuum leaks
752 (2) DisableGasPost
indicates extended lean Check for leaks in exhaust, catalytic converter,
O2Ctrl
operation on LPG HEGO sensors; repair leaks.
GasO2FailedRich Check dual dither valves, e.g. plugged valve or
(1) TurnOnMil
771 Pre-catalyst O2 sensor hose.
(2) DisableGas
(77) indicates extended rich Check for plugged orifice(s).
O2Ctrl
operation on LPG
77
Operation Section

(e.g. faults pertaining to FTVs, Pre-Cat O2, Post
GasPostO2FailedRich
(1) TurnOnMil Cat O2 sensor)
772 (2) DisableGasPost Look for leaks in exhaust, catalytic converter,
operation on LPG
LiqFuelAdaptRangeHi
Low gasoline fuel pressure, perform gasoline
In Gasoline mode,
821 TurnOnMil pressure test.
system had to adapt lean
Injector problems, e.g. plugged, defective
more than expected
injector.
LiqFuelAdaptRangeLo Low gasoline fuel pressure, perform gasoline
w pressure test
831 In Gasoline mode, TurnOnMil Injector problems, e.g. leaking, defective
system had to adapt rich injector.
more than expected
are OK.
LiqO2NotActive
841 (2) DisableLiquid O2 Pin 1 (HEATER PWR) to SECM (DRVP +
O2Ctrl 12V) PIN A23
O2 sensor
PWR)
Check that Post-catalyst O2 sensor connections
are OK.
GNG) Pins A16, B17
LiqPostO2NotActive
after engine has been running for some time and
(1) TurnOnMil SECM has calculated that water condensation in
842 (2) DisableLiqPost exhaust has been removed by exhaust heat.
O2Ctrl Post O2 Heater Relay has SECM (DRVP + 12V)
applied to the relay coil power. The relay coil
O2 sensor.
ground is controlled by SECM Pin A20 to
activate the relay to flow current through the
post O2 heater.
PWR)
LiqO2FailedLean
(1) TurnOnMil Low gasoline fuel pressure, perform gasoline
851 (2) DisableLiquid pressure test.
O2Ctrl Injector problems, e.g. plugged, defective
injector
78
Operation Section

Correct other faults that may contribute to
852 (e.g. faults pertaining to Injectors, MAP,
LiqPostO2FailedLean
(1) TurnOnMil IAT, Pre-Cat O2, Post Cat O2 sensor)
Pre-catalyst O2 sensor indicates
852 (2) DisableLiqPost Look for leaks in exhaust, catalytic converter,
extended lean operation on
gasoline
LiqO2FailedRich High gasoline fuel pressure, perform gasoline
Pre-catalyst O2 sensor indicates (1) TurnOnMil pressure test
871
extended rich operation on (2) DisableLiquid O2Ctrl Injector problems, e.g. leaking, defective
gasoline injector
Correct other faults that may contribute to
872 (e.g. faults pertaining to Injectors, MAP,
LiqPostO2FailedRich
(1) TurnOnMil IAT, Pre-Cat O2, Post Cat O2 sensor)
Pre-catalyst O2 sensor indicates
872 (2) DisableLiq Look for leaks in exhaust, catalytic converter,
extended rich operation on
PostO2Ctrl HEGO sensors; repair leaks.
gasoline
Check if O2 sensor installed before the
O2RangeLow
(1) TurnOnMil catalyst is shorted to GND or sensor GND.
Pre-catalyst O2 sensor voltage
911 (2) DisableLiquid O2Ctrl O2 (signal) Pin 3 to SECM Pin B13
out of range low, sensor signal
(3) DisableGas O2Ctrl SECM (DRVG GND) Pins A16, B17
shorted to ground
SECM (XDRG sensor GND) Pin B1
Check if O2 installed after the catalyst sensor
(1) TurnOnMil
O2_PostCatRangeLow is shorted to GND or sensor GND.
(2) Disable asoline
Post-catalyst O2 sensor voltage O2 (signal) Pin 3 to SECM Pin B19
912 Post-catalyst O2Ctrl
out of range low, sensor signal Possible sources: SECM (DRVG GND) Pins
(3) Disable LPG
shorted to ground A16, B17 and SECM (XDRG sensor GND)
Post-catalyst O2Ctrl
Pin B1
Check if O2 sensor installed before catalyst
O2RangeHigh
(1) TurnOnMil is shorted to +5Vdc or battery.
Pre-catalyst O2 sensor voltage
921 (2) DisableLiquid O2Ctrl O2 (signal) Pin 3 to SECM Pin B13
out of range high, sensor signal
(3) DisableGas O2Ctrl SECM (XDRP + 5V) Pin B24
shorted to power
SECM (DRVP + 12V) Pin A23
(1) TurnOnMil Check if O2 sensor installed after catalyst is
O2_PostCatRangeHigh
(2) Disable asoline shorted to +5Vdc or battery.
Post-catalyst O2 sensor voltage
922 Post-catalyst O2Ctrl O2 (signal) Pin 3 to SECM Pin B19 Possible
out of range low, sensor signal
(3) Disable LPG voltage sources: SECM (XDRP + 5V) Pin
shorted to ground
Post-catalyst O2Ctrl B24 and SECM (DRVP + 12V) Pin A23
FuelTempRangeLow
Check fuel temp sensor connector and wiring
Fuel Temperature Sensor Input
for a short to GND
is Low normally set if the fuel
931 TurnOnMil SECM (signal) Pin B14 to FTS Pin 1
temperature sensor wire has
SECM (sensor GND) Pin B1 to FTS Pin 2
shorted to chassis ground or the
sensor has failed.
FuelTempRangeHigh
Fuel Temperature Sensor Input Check if fuel temp sensor connector is
is High normally set if the fuel disconnected or for an open FTS circuit
932 TurnOnMil
temperature sensor wire has SECM (signal) Pin B14 to FTS Pin 1
been disconnected or the circuit SECM (sensor GND) Pin B1 to FTS Pin 2
79
Operation Section

933 Excessive transmission oil (2) DelayedEngine
transmission service procedures.
ServiceFault4
994 TurnOnMil
reached-replace HEGO Replace Post-catalyst HEGO sensor
sensors
ServiceFault5
reached-replace timing belt
80
Operation Section
Lift Truck Operation

Power Shift Transaxle
1. Start the engine. See topic "Starting the WARNING
Engine." A lift truck with the engine running but without
an operator can move slowly (creep) if the
transmission is engaged.
This could result in personal injury.
Always place the transmission control lever in
the NEUTRAL (center) position and apply the
parking brake before dismounting the lift truck.
5. Release the service brake.

6. Push down on the accelerator pedal to obtain
the desired travel speed. Release the pedal to
decrease travel speed.
2. Push down on the service brake pedal to hold
the lift truck until ready to move it.
3. Release the parking brake.
NOTE : The parking brake must be released
before the directional control can be used.
WARNING
Sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift
truck to tip over.
Stop the loaded lift truck completely, before
4. Select the direction of travel by pushing the shifting to reverse.
directional lever FORWARD for forward Failure to comply could result in personal injury.
direction or by pulling the lever BACK for
reverse direction.
NOTE : Where conditions permit, directional
changes can be made under full power at
speeds up to 8 km/h (5 mph). A speed of 8
km/h (5 mph) is a fast walk. Directional
shift changes at speeds above 8 km/h (5
mph) are considered abusive. Bring the lift
truck to a complete stop where load
stability or other factors prevent safe
operation under full power shifts safe
operation under full power shifts.
81
Operation Section
Inching
NOTE : The purpose of the inching pedal is to
provide precise lift truck inching control at
very slow travel speed and high engine
rpm. This is used for fast hydraulic lift,
during load approach, pick up or load
positioning.
7. To change the lift truck direction of travel,

release the accelerator pedal.
8. Push down on the service brake pedal to reduce
the lift truck speed as necessary.
1. To inch (creep) in either direction, slowly push

down on the inching pedal. This will start to
apply the service brakes and allow the
transmission clutch discs to slip.
2. Vary the position of the inching pedal and the
accelerator pedal to control the inching speed
and distance.
3. Pushing down further on the inching pedal will
9. Move the directional lever to the desired disengage the transmission completely and
direction of travel. Slowly push down on the apply the service brakes fully to stop and hold
accelerator pedal as the lift truck changes the lift truck. This will provide full engine power
direction. for fast hydraulic lift.
10.When the direction change is completed,
continue to push down on the accelerator pedal
to obtain the desired travel speed.
11.To stop the lift truck when traveling in either

direction, release the accelerator pedal.
12.Push down on the service brake pedal and bring
the lift truck to a smooth stop.
82
Operation Section
Operating Techniques
Inching into Loads Lifting the Load
1. Lift the load carefully and tilt the mast back a
short distance.
1. Move the lift truck slowly FORWARD into

position and engage the load. The truck should
be square with load, forks spaced evenly
between pallet stringers and as far apart as 2. Tilt the mast further back to cradle the load
load permits.
3. Operate the lift truck in reverse until the load is

clear of the other material.
2. Move the lift truck FORWARD until the load
touches the carriage. 4. Lower the cradled load to the travel position.
NOTE : Lift and tilt speeds are controlled by engine

rpm.
83
Operation Section
Traveling with the Load Unloading
NOTICE
Travel with the load as low as possible, while

still maintaining ground clearance.
1. Move the lift truck into the unloading position.
1. Travel with the load uphill on upgrades and

downgrades.
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
2. For better vision, travel in reverse with bulky
power is off.
loads.
84
Operation Section
Turning
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.
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
counterweight swing.
85
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 the

overheating. Clean them out regularly with a
blast of compressed air. Also, check the
leakage of water.
2. Check the fan belt tension and adjust to proper
tension
3. Even if the engine overheats and the coolant
boils over, let the engine idle for a while with
opening engine hood until temperature falls
1. Block drums or round objects. Tilt the mast
before shut off the engine.
FORWARD and side the fork tips along the
floor to get under the load.
2. Before lifting, tilt the mast BACK slightly until

the load is cradled on the forks.
86
Operation Section
Parking the Lift Truck

Park the lift truck level, with the forks lowered and
floor. Block the drive wheels when parking on an
incline.
5. Turn the key in the ignition switch to the OFF

position and remove the key.
1. Park in an authorized area only. Do not block

traffic. If LP - Gas equipped, do not park near
elevator shafts or any other area where LP-Gas
could collect in a pocket (low area), causing a
potentially dangerous condition.
NOTE : If an LP- Gas equipped lift truck is stopped

or parked for an indefinite or prolonged
period of time, shut off the LP-Gas fuel
tank valve.
6. Actuate each loading lever several times to

remove the residual pressure in the respective
2. Place the transmission controls in NEUTRAL. cylinders and hoses.
3. Engage the parking brake. 7. Block the drive wheels if parking on an incline.
4. Lower the forks to the ground.
WARNING
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.
87
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. After adjustment, set the fork locks to keep the
forks in place.
WARNING
Make sure the forks are locked before carrying
a load.
88
Operation Section
Storage Information
Before Storage The machine should be operated at least once a
week. Fill the cooling system, if cooling water is
Before storing your lift truck, clean and inspect as discharged, and mount the battery. Start the
the following procedures. engine and warm up thoroughly. Move the
machine a little forwards and backwards.
Wipe away grease, oil, etc. adhering to the body Operate the hydraulic controls several times.
of the truck with waste cloth, and use water, if
needed.
To Operate the Lift Truck after a
While cleaning the truck, check general
condition of the truck. Especially check the truck Long Time Storage
body for recess or damge and tires for wear or Remove covers and antirust from each of the
nails or stones in the tread. components and exposed parts.
Fill the fuel tank with fuel specified. Drain the engine crankcase, transmission
Check for leakage of hydraulic oil, engine oil, (clutch type machine), differential and final
fuel, or coolant, etc. reduction gear, clean the inside of them and add
new oil.
Apply grease, where needed.
Drain off foreign matter and water from the
Check for looseness of nuts and bolts, especial- hydraulic oil tank and fuel tank.
ly hub nuts.
Remove the head cover from the engine
Check mast rollers to see that they rotate smoothly. cylinder. Oil valves and rocker shaft and check
Prime the oil into the lift cylinders by actuating each valve for proper operation.
the lift lever all the way several times. Add cooling water to the specified level.
Drain off coolant completely in water of cold Charge the battery and mount it on the machine.
weather, if antifreeze is not used. Connect the cables.
Perform pre-operational checks carefully. (refer
Long Time Storage to Before Starting the Engine)
Perform the following service and checks in Warm up the machine.
addition to the Parking the lift truck services.
Taking the rainy season into consideration, park

the machine at a higher and hard ground.
Avoid parking on soft grounds such as an
asphalt ground in summer.
Dismount the battery from the machine. Even
though the machine is parked indoors, if the
place is hot or humid, the battery should be kept
in a dry, cool place. Charge the battery once a
month.
Apply antirust to the exposed parts which tend
to rust.
Cover components such as the breather and air
cleaner which may be caught with humidity.
Storage Information
89
Operation Section
Transportation Hints
Lift Truck Shipping Machine Lifting and Tiedown
Check travel route for overpass clearances. Make Information
sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
overhead guard or cab. NOTICE
To prevent the lift truck from slipping while loading Improper lifting or tiedowns can allow load to
or shifting in transit, remove ice, snow or other shift and cause injury and/or damage.
slippery material from the loading dock and the
truck bed before loading.
1. Weight and instructions given herein apply to
lift trucks as manufactured by DOOSAN.
NOTICE 2. Use proper rated cables and slings for lifting.
Position the crane for level lift truck lift.
Obey all state and local laws governing the
weight, width and length of a load. 3. Spreader bar widths should be sufficient to
Observe all regulations governing wide loads. prevent contact with the lift truck.
4. Use the tiedown locations provided for lift truck
tiedown.
NOTICE
Check the state and local laws governing weight,
Remove ice, snow or other slippery material width and length of a load.
from the shipping vehicle and the loading dock.
Contact your DOOSAN Lift Truck dealer for
shipping instructions for your lift truck.
Always block the trailer or the rail car wheels before

loading the lift truck. Position the lift truck on the
truck bed or the rail car.
Apply the parking brake and place the directional

control lever in NEUTRAL.
Turn the ignition switch to the OFF position and

remove the key. If LP-Gas equipped, shut off the
LP Gas fuel tank.
Block the wheels and secure the lift truck with
tiedowns.
90
Operation Section
To provide sufficient control and braking when

Towing Information moving a disabled lift truck downhill, a larger towing
lift truck or additional lift trucks connected to the
rear could be required. This will prevent
WARNING uncontrolled rolling. The different situation
Personal injury or death could result when requirements cannot be given, as minimal towing lift
towing a disabled lift truck incorrectly. truck capacity is required on smooth level surfaces
to maximum on inclines or poor surface conditions.
Block the lift truck wheels to prevent movement Consult your DOOSAN Lift Tuck dealer for towing a
before releasing the brakes. The lift truck can disabled lift truck.
roll free if it is not blocked.
Follow the recommendations below, to properly
perform the towing procedure.
These towing instructions are for moving a disabled

lift truck a short distance, at low speed, no faster
than 2 km/h (1.2 mph), to a convenient location for
repair. These instructions are for emergencies only.
Always haul the lift truck if long distance moving is
required.
Shield must be provided on the towing lift truck to
protect the operator if the tow line or bar should
break.
Do not allow riders on the lift truck being towed 1. Release the parking brake.
unless the operator can control the steering and/or
braking.
Before towing, make sure the tow line or bar is in NOTICE
good condition and has enough strength for the
towing situation involved. Use a towing line or bar Release the parking brake to prevent excessive
with a strength of at least 1.5 times the gross wear and damage to the parking brake system.
weight of the towing lift truck for a disabled lift truck
stuck in the mud or when towing on a grade.
Keep the tow line angle to a minimum. Do not 2. Check that the service brake pedal is released.
exceed a 30 angle from the straight ahead position. 3. Key switch is in the OFF position.
Connect the tow line as low as possible on the lift
truck that is being towed. 4. Direction control lever is in neutral.
Quick lift truck movement could overload the tow
5. Fasten the tow bar to the lift truck.
line or bar and cause it to break. Gradual and
smooth lift truck movement will better. 6. Remove the wheel blocks. Tow the lift truck
Normally, the towing lift truck should be as large as slowly. Do not tow any faster than 2 km/h (1.2
the disabled lift truck. Satisfy yourself that the mph).
towing lift truck has enough brake capacity, weight
and power, to control both lift trucks for the grade
and the distance involved. WARNING
Be sure all necessary repairs and adjustments
have been made before a lift truck that has been
towed to a service area is put back into
operation.
91
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck Forks
The following section gives practical guidelines for Users may also refer to the International
inspection, maintenance and repair of lift truck forks. Organization For Standardization - ISO Technical
It also provides general information on the design Report 5057 - Inspection and Repair of Fork Arms
and application of forks and the common cause of and ISO Standard 2330 - Fork Arms-Technical
fork failures. Characteristics and Testing.
Lift truck forks can be dangerously weakened by While there are no specific standards or
improper repair or modification. They can also be regulations in the United States, users should be
damaged by the cumulative effects of age, abrasion, familiar with the requirements for inspection and
corrosion, overloading and misuse. maintenance of lift trucks as provided by the 29
Code Federal Register 1910.178 Powerd Industrial
A fork failure during use can cause damage to the Truck, and ANSI/ASME Safety Standard(s) B56.1,
equipment and the load. A fork failure can also B56.5 or B56.6 as applicable to the type of
cause serious injury. machine(s) in use.
A good fork inspection and maintenance program Environment Protection Section

along with the proper application can be very
effective in preventing sudden failures on the job. When servicing this lift truck, use an authorized
servicing area and an approved container to collect
Repairs and modifications should be done only by coolant, oil, fuel, grease, electrolyte and any other
the fork manufacturer or a qualified technician who potential environmental pollutant before any lines,
knows the material used and the required welding fittings or related items are disconnected or
and heat treatment process. removed.
Users should evaluate the economics of returning After servicing, dispose of those materials in an
the forks to the manufacturer for repairs or authorized place and container. When cleaning the
purchasing new forks. This will vary depending on lift truck, be sure to use an authorized area.
many factors including the size and type of fork.
Forks should be properly sized to the weight and

length of the loads, and to the size of the machine
on which they are used. The general practice is to
use a fork size such that the combined rated
capacity of the number of forks used is equal to or
greater than the Standard(or rated) Capacity of
the lift truck.
The individual load rating, in most cases, will be

stamped on the fork in a readily visible area. This is
generally on the top or side of the fork shank.
A fork rated at 1500 pounds at 24 inch load

center will be stamped 1500B24.
A fork rated at 2000 kg at 600 mm load center
will be stamped 2000B600.
The manufacturer identification and year and date

of manufacture is also usually shown.
Some countries have standards or regulations which

apply specifically to the inspection and repair of forks.
92
Maintenance section
Causes of Fork Failure Repetitive Overloading

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

which starts in an area of high stress concentration
This is usually in the heel section or on the fork
mounting.
As the crack progresses under repetitive load

cycling, the load bearing cross section of the
remaining metal is decreased in size until it
becomes insufficient to support the load and
complete failure occurs.
Fatigue failure is the most common mode of fork

failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.
93
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

Establish a daily and 12 month inspection routine within acceptable tolerances. See Forks, Step
by keeping a record for the forks on each lift truck. 4, in the 2000 Service Hours or Yearly in
Initial information should include the machine serial
number on each the forks are used, the fork 3. Make sure positioning lock is in place and
manufacturer, type, original section size, original working Lock forks in position before using
length and capacity. Also list any special truck. See Forks, Step 7, in the 2000 Service
characteristics specified in the fork design. Hours or Yearly in Maintenance Intervals
Record the date and results of each inspection, Daily Inspection

making sure the following information is included.
1. Visually inspect forks for cracks, especially in
Actual wear conditions, such as percent of the heel section, around the mounting brackets,
original blade thickness remaining. and all weld areas. Inspect for broken or jagged
fork tips, bent or twisted blades and shanks.
Any damage, failure or deformation which might
impair the use of the truck.
2. Make sure positioning lock is in place and
Note any repairs or maintenance. working. Lock the forks in position before using
the truck. See 2000 Service Hours or Yearly
in Maintenance Intervals.
An ongoing record of this information will help in
identifying proper inspection intervals for each
3. Remove all defective forks from service.
operation, in identifying and solving problem areas
and in anticipating time for replacement of the forks.
94
Maintenance section
12 Months Inspection 4. A fork should be load tested before being

returned to service on completion of repairs
authorized and done in accordance with the
Forks should be inspected, at a minimum, every 12 manufacturers recommendations.
months. If the truck is being used in a multi-shift or
heavy duty operation, they should be checked Most manufacturers and standards require the
every six months. See Forks in the 2000 Service repaired fork to be tested with a load 2.5 times
Hours or Yearly in Maintenance Intervals. the specified capacity and at the load center
marked on the fork arm.
With the fork restrained in the same manner as

Maintenance and Repair its mounting on the lift truck, apply the test load
1. Repair forks only in accordance with the twice, gradually and without shock. Maintain
manufacturers recommendations. the test for 30 seconds each time.
Most repairs or modifications should be done Check the fork arm before and after the second
only by the original manufacturer of the forks or application of the test load. It shall not show
an expert knowledgeable of the materials, any permanent deformation.
design, welding and heat treatment process.
Consult the fork manufacturer for further infor-
2. The following repairs or modifications SHOULD mation as may be applicable to the specific fork
NOT be attempted. involved.
Flame cutting holes or cutouts in fork Testing is not required for repairs to the
blades. positioning lock or the markings.
Welding on brackets or new mounting
hangers.
Repairing cracks or other damage by
welding.
Bending or resetting.
3. The following repairs MAY be performed.
Forks may be sanded or lightly ground, to

remove rust, corrosion or minor defects from
the surfaces.
Heel sections may be ground with a carbon
stone to remove minor surface cracks or
defects. Polish the inside radius of the heel
section to increase the fatigue life of the
fork. Always grind or polish in the direction
of the blade and shank length.
Repair or replace the positioning locks on
hook type forks.
Repair or replace most fork retention
devices used with other fork types.
95
Maintenance section
Torque for Standard Bolts, Nuts,

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

metric hardware. Non-metric tools might Torques for Bolts and Nuts With
slip and cause injury. Standard Threads
Torque for Standard Hose Clamps

Thread Size Standard Nut and Bolt Torque
- Worm Drive Inch
1
Nm lbft
NOTICE
1/4 12 + 4 9+3
The chart below gives the torques for initial 5/16 25 + 7 18 + 5
installation of hose clamps on new hose and for
reassembly or retightening of hose clamps on 3/8 45 + 7 33 + 5
existing hose.
7/16 70 + 15 50 + 11
1/2 100 + 15 75 + 11
Initial Installation Torque On New
Clamp Width Hose 9/16 150 + 20 110 + 15
1
Nm lbin 5/8 200 + 25 150 + 18
16 mm (.625 in) 7.5 + 0.5 65 + 5 3/4 360 + 50 270 + 37
7/8 570 + 80 420 + 60
13.5 mm (.531 in) 4.5 + 0.5 40 + 5
1 875 + 100 640 + 75
8 mm (.312 in) 0.9 + 0.2 8+2
1 1/8 1100 + 150 820 + 110
Reassembly Or 1 1/4 1350 + 175 1000 + 130
Clamp Width Retightening Torque
1
1 3/8 1600 + 200 1180 + 150
Nm lb in
1 1/2 2000 + 275 1480 + 200
16 mm (.625 in) 4.5 + 0.5 40 + 5 1
kg.m.
13.5 mm (.531 in) 3.0 + 0.5 25 + 5
8 mm (.312 in) 0.7 + 0.2 6+2

1
kg.m.
96
Maintenance section
Torques for Taperlock Studs Torque for Metric Fasteners
Standard Taperlock Stud NOTICE

Thread Size Torque
Inch Be very careful never to mix metric with U.S.
customary (standard) fasteners. Mismatched or
Nm1 lbft
incorrect fasteners will cause lift truck damage
1/4 8+3 6+2 or malfunction and may even result in personal
injury.
5/16 17 + 5 13 + 4
3/8 35 + 5 26 + 4
Original fasteners removed from the lift truck should
7/16 45 + 10 33 + 7 be saved for reassembly whenever possible. If new
fasteners are needed, they must be of the same size
1/2 65 + 10 48 + 7 and grade as the ones that are being replaced.
5/8 110 + 20 80 + 15
The material strength identification is usually shown
3/4 170 + 30 125 + 22 on the bolt head by numbers (8.8, 10.9, etc.). This
chart gives standard torques for bolts and nuts with
7/8 260 + 40 190 + 30 Grade 8.8.
1 400 + 60 300 + 45
NOTE : Metric hardware must be replaced with
1 1/8 500 + 700 370 + 50 metric hardware. Check parts book.
1 1/4 650 + 80 480 + 60

1 3/8 750 + 90 550 + 65 Standard Torque
Thread Size
1 1/2 870 + 100 640 + 75 Metric
1 Nm1 lbft
kg.m. M6 12 + 4 9+3
M8 25 + 7 18 + 5
M10 55 + 10 41 + 7
M12 95 + 15 70 + 11
M14 150 + 20 110 + 15
M16 220 + 30 160 + 22

M20 450 + 70 330 + 50
M24 775 + 100 570 + 75
M30 1600 + 200 1180 + 150
M36 2700 + 400 2000 + 300

1
kg .m.
2
ISO - International Standards Organization.
97
Maintenance section
Cooling System Specifications

Coolant Information Check the specific gravity of the coolant solution
frequently in cold weather to ensure adequate
protection.
NOTE : The following information is generic and Clean the cooling system if it is contaminated, if the
valid for lift trucks. engine overheats or if foaming is observed in the
radiator.
Engine operating temperatures have increased to
improve engine efficiency. This means proper cool Old coolant should be drained, the system cleaned
ing system maintenance is especially important. and new coolant added every 2000 service hours or
Overheating, overcooling, pitting, cavitation erosion, yearly.
cracked heads, piston seizures, and plugged
radiators are classic cooling system failures. In fact, Refer to topic, Cooling System-Clean, Change in
coolant is as important as the quality of fuel and every 2000 service hours or yearly section.
lubricating oil.
Filling at over 20 liters (5 U.S. gallons) per minute
can cause air pockets in the cooling system.
NOTICE
After draining and refilling the cooling system,
DOOSAN recommends that the coolant mixture operate the engine with the radiator cap removed
contain a minimum of 30% antifreeze or equivalent. until the coolant reaches normal operating
temperature and the coolant level stabilizes. Add
Never add coolant to an overheated engine, coolant as necessary to fill the system to the proper
engine damage can result. Allow the engine to level.
cool first.
Never operate without a thermostat in the cooling
All water is corrosive at engine operating system. Cooling system problems can arise without
temperature. The cooling system should be a thermostat.
protected with a 3 to 6% concentration of liquid
supplemental coolant additive at all times,
regardless of the concentration of antifreeze.
Excessive supplemental coolant additive greater

than the recommended 6%, together with concen-
tration of antifreeze greater than 65% can cause
deposits to form and can result in radiator tube
blockage, overheating, and/or water pump seal
damage.
If the machine is to be stored in, or shipped to,

an area with freezing temperatures, the cooling
system must be protected to the lowest expected
outside (ambient) temperature.
The engine cooling system is normally protected

to 28C (20F) with antifreeze, when shipped
from the factory unless special requirements are
defined.
98
Maintenance section
Coolant Water Antifreeze

Hard water, or water with high levels of calcium and Make proper antifreeze additions.
insoluble chemical compounds by combining with Adding pure antifreeze as a makeup solution for
cooling system additives such as silicates and cooling system top-up is an unacceptable practice. It
phosphates. increases the concentration of antifreeze in the
cooling system which increase the concentration of
The tendency of silicates and phosphates to pre- dissolved solids and undissolved chemical inhibitors
cipitate out-of-solution increases with increasing in the cooling system. Add antifreeze mixed with
water hardness. Hard water, or water with high lev- water to the same freeze protection as your cooling
els of calcium and magnesium ions encourages the system.
formation of insoluble chemicals, especially after a
number of heating and cooling cycles. Use the chart below to assist in determining the
concentration of antifreeze to use.
deionized water to reduce the potential and severi-
Antifreeze Concentrations
ty of chemical insolubility.
Protection Temperature Concentration

MINIMUM ACCEPTABLE WATER
Protection to -15C (5F) 30% antifreeze and 70% water
Water Content Limits gr/gal(ppm)
Chlorides (Cl) 2.4(40) maximum
Sulfates (SO4) 5.9(100) maximum
Total hardness 10(170) maximum
Total solids 20(340) maximum
PH 5.5 to 9.0
Using water that meets the minimum acceptable

water requirement may not prevent drop-out of
these chemical compounds totally, but should mini-
mize the rate to acceptable levels.
99
Maintenance section
Fuel Specifications
LP-Gas Specifications
LP-Gas is Liquefied Petroleum Gas. The exact
composition of LP-Gas varies slightly between
different parts of the country and different refineries.
HD5 is recommended for DOOSAN forklift trucks.
Remember LP-Gas is heavier than air and will sink
to the lowest spot possible. Avoid areas near floor
drains or lubrication pits where escaped fuel may
collect.
Composition of HD5
Propane (C3H8) 90.0 %
Propylene up to 5 %
Butane (C4H10) 2.0 %
iso-Butane 1.5 %
Methane (CH4) 1.5 %
Total 100 %
100
Maintenance section
Lubricant Specifications
Lubricant Information Hydraulic Oil (HYDO)
Certain abbreviations follow Society of Automotive The following commercial classifications can be
Engineers (SAE) J754 nomenclature and some used in the hydraulic system.
classifications follow SAE J183 abbreviations.
ISO 6743/4 HM
The MILspecifications are U.S.A. Military AFNOR NFE 48-603 HM
Specifications. DIN 51524 TEIL 2 H-LP
The recommended oil viscosities can be found in the CINCINNATI P68,69,70
Lubricant Viscosities chart in this publication.
Grease is classified by the National Lubricating
Grease Institute (NLGI) based on ASTM D217-68 Industrial premium hydraulic oils that have passed
Worked Penetration characteristics which are given the Vickers vane pump test (35VQ25).
a defined consistency number. These oils should have antiwear, antifoam, antirust
and antioxidation additives for heavy duty use as
Engine Oil (DEO and EO) stated by the oil supplier. ISO viscosity grade of 32
would normally be selected.
The following oil specifications provide guidelines for
the selection of commercial products :
NOTICE
LP-Gas Engine : API SJ or higher
Make-up oil added to the hydraulic tanks must
mix with the oil already in the systems. Use only
petroleum products unless the systems are
NOTICE
equipped for use with special products.
Failure to follow the oil recommendations can
If the hydraulic oil becomes cloudy, water or air is
cause shortened engine lift due to carbon
entering the system. Water or air in the system
deposits or excessive wear.
will cause pump failure. Drain the fluid, retighten all
hydraulic suction line clamps, purge and refill
the system. Consult your DOOSAN Lift Truck
Consult the EMA Lubricating Oils Data Book for a
listing of oil brands. dealer for purging instructions.
NOTE : The percentage of sulfur in the fuel will

affect the engine oil recommendations. For
fuel sulfur effects, the Infrared Analysis or
the ASTM D2896 procedure can be used to
evaluate the residual neutralization
properties of an engine oil. The sulfur
products formation depends on the fuel
sulfur content, oil formulation, crankcase
blowby, engine operating conditions and
ambient temperature.
101
Maintenance section
Transmission Oil (TDTO) Drive Axle Oil

NOTE : Failure to follow the recommendation will
cause shortened life due to excessive gear
NOTICE wear.
This oil is formulated for transmissions and
drive trains only, and should not be used in Shoe Brake
engines. Shortened engine life will result. Select oil that meets below specifications.
API GL-5
MIL-L-2105 C, D
NOTE : Multi-grade oils are not blended by DOO-
SAN for use in transmissions. Multi-grade Gear Oil offers maximum protection against the
oils which use high molecular weight scoring and pitting of gear teeth and rolling element
polymers as viscosity index improvers lose bearings.
their viscosity effectiveness by permanent Gear Oil can also provide excellent stability under
and temporary shear of the viscosity index high temperature conditions and has superior low
improver and therefore, are not temperature performance. It will also give protection
recommended for transmission and drive against rust and corrosion.
train compartments.
Oil Cooled Disc Brake (OCDB)
NOTE : Failure to follow this recommendation can Select oil that meets below specifications.
cause shortened transmission life due to The API CD/TO - 2 specification or MIL - L 2104D or
material incompatibility, inadequate friction- E oil could be used.
al requirements for disk materials and/or
excessive gear wear.
The API CD/TO - 2 specification or MIL - L 2104D or

E oil could be used.
102
Maintenance section
Brake Fluid Lubricating Grease (MPGM)

Use Multipurpose Molybdenum Grease (MPGM) for
all lubrication points. If MPGM grease can not be
used, a multipurpose type grease which contains
3% to 5% molybdenum disulfide can be used.
NLGI No.2 grade is suitable for most tempera-

tures.
Use NLGI No.1 or No.0 grade for extremely low
temperature.
Shoe Brake
Use heavy duty hydraulic brake fluid. It must be
certified by the oil supplier to meet SAE J1703f
latest revision, DOT 3 or 4 specifications.
Oil Cooled Disc Brake

Use heavy duty hydraulic brake fluid certified by oil
supplier to meet the latest version of following clas-
sifications.
ISO 6743/4 HM
AFNOR NFE 48-603 HM
DIN 51524 TEIL2 H-LP
CINCINNATI P68,69,70

ISO Viscosity Grade of 10 would normally be
selected. The following products are authorized for
use.
Supplier Product Name

TOTAL AZOLLAZS 10
AGIP ACER 10
BP ENERGOLHP 10, HLP 10
CALTEX SPINDURN 10
ELF SPINELF 10
NUTO H 10
ESSO
SPINESSO 10
FINA HYDRAN 10
VELOCITE OILNO.5
MOBIL
VELOCITE OILE
103
Maintenance section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities
LUBRICANT VISCOSITIES Refill Capacities (Approximate)
FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment Oil C F Compartment
Liters U.S. Gal.
or System Viscosities Min Max Min Max or System
Engine Crankcase SAE Engine Crankcase w/Filter

-20 +40 -4 +104 4.0 1.1
(LP-Gas)and Lift 10W30 G420E LP-Gas
chains Cooling System
SAE 5W30 -30 +30 -22 +86 w/Coolant Recovery
API SH/SG/SJ
9.5 2.5
Bottle G420E Gasoline & LP-
Power Shift SAE 10W -20 +22 -4 +72 Gas
Transmission
API CD/TO-2 SAE 30 +10 +50 +50 +122 Fuel Tank LP-Gas-G-Series 15.2Kg 33.5 Ib
ISO VG32 -20 +30 -4 +86 Power Shift Transmission 10.0 2.7
Hydraulic and
Power Steering Hydraulic & Power
ISO VG46 -10 +40 +14 +104 25 6.25
System Steering System
ISO 6743/4 HM
ISO VG68 0 +50 +32 +122 Drive Axle 5.0 1.3
Shoe
SAE Brake System 1.0 0.26
Brake -20 +50 -4 +122
80W90
API GL-5
Drive
Disc
Axle SEA 10W -20 +22 -4 +72
Brake
Housing
(OCDB)
API
SAE 30 +10 +50 +50 +122
CD/TO-2
Shoe
Brake SAE
-30 +50 -22 +122
DOT3 J1703f
DOT4
Brake Disc
Reservoir Brake
(OCDB)
ISO VG10 -20 +30 -4 +86
ISO
6743/
4 HM
The SAE grade number indicates the viscosity of oil.

A proper SAE grade number should be selected
according to ambient temperature.
104
Maintenance section
Drive Axle Oil Level - Check ................................ 121

Maintenance Intervals Mast, Carriage, Lift Chains & Attachments - Inspect,
Lubricate................................................................ 122
Steering Mechanism - Check, Lubricate ............. 122
NOTICE Battery Terminal - Clean, Inspect ........................ 123
Brake Oil Level - Check........................................ 123
All maintenance and repair, except every 10 Engine Oil Filter - Change.................................... 124
service hours or daily, on the lift truck must be
performed by qualified and authorized personnel
only.
Belts - Check, Adjust ............................................ 125
Tilt Cylinders - Check, Adjust, Lubricate ............. 125
Mast Hinge Pin - Lubricate................................... 126
NOTICE
Crosshead Roller - Inspect................................... 126
Inching & Braking Control Shaft - Lubricate........ 127
Careless disposal of waste oil can harm the
Horn & Lights (If Equipped) - Check.................... 127
environment and can be dangerous to persons.
Overhead Guard - Inspect.................................... 127
Always dispose of waste oil to an authorized
Inspect Vacuum Lines and Fittings (G420F(E)
personnel only.
Engine Only).......................................................... 128
Only) ...................................................................... 128
Inspect Electrical System (G420F(E) Engine Only)
When Required ............................................................................... 128
Operator's Seat, Hood Latch and Support Cylinder - Every 1000 Service Hours or 6 Months
Check, Lubricate................................................... 107
Fuses & Relay Change ........................................ 107 Hydraulic Return Filter, Breather & Strainer - Check,
Tire and Wheels - Inspect, Check ....................... 108 Change .................................................................. 129
Test Fuel System for Leaks ................................. 109 Lift Chains - Test, Check, Adjust ......................... 130
Wheel Bolts - Inspect ........................................... 110 Transmission Oil & Strainer - Clean, Change..... 132
Carriage Roller Extrusion Adjust ...................... 110 Inspect Coolant Hoses (LP, Dual Fuel Engines
Only) ...................................................................... 133
Every 10 Service Hours or Daily LP Regulator/Converter Inspection (LP, Dual Fuel
Engine Only).......................................................... 133
Walk-Around Inspection Inspect....................... 111 Fuel Lines & Fittings - Check............................... 133
Inspect Engine for Fluid Leaks ............................ 112 Inspect Mixer Assembly (G420F(E) Engine Only)
Engine Oil Level Check..................................... 112 ............................................................................... 133
Coolant Level - Check.......................................... 112 Inspect Throttle Assembly (G420F(E) Engine Only)
Air Intake System - Check ................................... 113 ............................................................................... 133
Mast Channels - Lubricate................................... 114
Transmission Oil Level - Check........................... 114 Every 1500 Service Hours or 9 Months
First 50-100 Service Hours or a Week Drive Axle Oil (Shoe Brake) - Change................. 134
Inspect Ignition System (LP-Gas, Gasoline & Dual
Parking Brake - Test, Adjust ................................ 115 Fuel Engines Only) ............................................... 134
Transmission Oil & Strainer - Change, Clean .... 115 Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
Drive Axle Oil - Change........................................ 116 Engine Only).......................................................... 134
Fuel Filter (LP - Gas Engine Only) ...................... 135
First 250 Service Hours or a Month Testing Fuel Lock-off Operation (LP-Gas Engine
Only) ...................................................................... 135
Hydraulic Return Filter - Change......................... 118
Steer Wheel Bearings - Repack .......................... 136
Air Intake System - Check, Clean ....................... 119 Cooling System Clean, Change ....................... 137
Hydraulic Oil Level - Check.................................. 121 Fork - Inspect ........................................................ 139
105
Maintenance section
Hydraulic Oil - Change, Check, Clean ................ 141

Inspect Battery System ........................................ 142
Replace Oxygen Sensor (G420F(E) Engine Only)
............................................................................... 142
Checking the TMAP Sensor (G420F(E) Engine
Only) ...................................................................... 143
Inspect for Intake Leaks (G420F(E) Engine Only)
............................................................................... 143
Replace Spark Plugs (G420F(E) Engine Only).. 144

Timing Belt - Change............................................ 145
Timing Belt for Counterbalance Shaft - Change 145
Every 4500 Service Hours or two Years
Replace Oxygen Sensor ...................................... 145
106
Maintenance section
When Required
Operator's Seat, Hood Latch and Fuses & Relay Change

Support Cylinder - Check, NOTE : If a fuse filament separates, use only the
Lubricate 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.
Fuse - Protects an electrical circuit from an

overload. Opens (filament separates) if an
overload occurs.
1. Check the operation of the seat adjuster rod. Check the fuses. Use a flashlight, if necessary.
Make sure that the seat slides freely on its track.
Lightly oil the seat slider tracks if necessary.
2. Pull the latch to raise the hood and seat

assembly. Make certain the support cylinder
will hold the hood open.
3. Lightly oil the hood latch mechanism and the
rod for the hood support cylinder.
107
Maintenance section
Circuit Breaker
1. Raise the hood and seat assembly. Make sure
the support cylinder securely holds the hood
open.
Fuses are identified as follows :

1. Horn - 10 amp.
2. Head Lamp, Clearance Lamp, Tail Lamp. - 15 amp.
Typical Example
3. Lamp Relay Coil, Fwd/Rev Solenoid, Rear Lamp
/Alarm - 10 amp
2. The main circuit breaker is located on the rear of
4. Instrument Panel, Hour Meter, Preheat Controller, the support for the controls.
Fuel Shut-off Solenoid - 15 amp
NOTE : To reset circuit breakers push in on the
5. Stop Lamp, Turn Signal Lamp, Strobe Lamp - 15 amp button. The button should stay in if the
6. Starter Relay - 10 amp breaker is reset. If the button will not stay
in, or comes out shortly after reset, have
the circuits checked.
Bulbs
Bulbs are identified as follows : Tire and Wheels - Inspect, Check
1. Bulb-head lamp halogen (12V-35W)
*2. Bulb-back up (12V-8W)
*3. Bulb-turn signal (12V-23W)
*4. Bulb-stop & tail (12V-23/8W)
*OPTIONALLAMP OR LIGHT
1. Inspect the thickness of the tread area. It

should be more than 25 mm (1 inch). If the
thickness is less than 25 mm (1 inch), the tire
must be replaced.
Consult your DOOSAN dealer. Do not try to

replace the tire yourself.
2. Inspect the wheels. They should have no

cracks or distortion.
108
Maintenance section
Test Fuel System for Leaks
Check
Points
1. Obtain a leak check squirt bottle or pump spray

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

solution.
3. Spray a generous amount of the solution on the

fuel system fuel lines and connections, starting
at the storage container.
4. Wait approximately 15-60 seconds then

perform a visual inspection of the fuel system.
Leaks will cause the solution to bubble.
5. Repair any leaks before continuing.
6. Crank the engine through several revolutions.

This will energize the fuel lock-off and allow fuel
to flow to the pressure regulator/converter.
Apply additional leak check solution to the
regulator/converter fuel connections and
housing. Repeat leak inspection as listed above.
7. Repair any fuel leaks before continuing.
WARNING
Prior to any service or maintenance activity,

Test Fuel System for Leaks
109
Maintenance section
Wheel Bolts - Inspect Carriage Roller Extrusion Adjust

Inspect Tightness - Drive Wheels
1. Set the mast vertical.
2. Lower the carriage completely.
3. On full free lift and full free triple lift models, the
bottom of the inner mast must be flush with the
bottom of the stationary mast.
1. Inspect the tightness of the wheel bolts in a

sequence opposite each other 135 + 15 Nm
(100lbft.).

inner upright to the bottom of carriage bearing.
5. The measurement (A) must be as follows in
Chart below.
Height of carriage roller extrusion (A)
STD mast FF mast FFT mast
-6 11 11
110
Maintenance section
Every 10 Service Hours or Daily

Walk-Around Inspection Inspect 5. Inspect the operator's compartment for loose

For maximum service lift of the lift truck, make a
6. Inspect the instrument panel for broken gauges
thorough walk-around inspection. Look around and
and indicator lights.
under the truck for such items as loose or missing
bolts, debris or dirt buildup, fuel, oil or coolant leaks 7. Test the horn and other safety devices for
and cut gouged tires. proper operation.
Have any repairs made and debris removed, as

needed.
8. Inspect the cooling system for leaks, worn

hoses and debris buildup.
9. Inspect engine compartment for oil, coolant and
fuel leaks.
1. Inspect the tires and wheels for cuts, gouges,
foreign objects, inflation pressure and loose or 10. Inspect the forks.
missing bolts.
2. Inspect the mast and lift chains for wear, Visually inspect forks for cracks, especially in
broken links, pins and loose rollers. the heel section, around the mounting brackets,
and all weld areas.
hoses or damaged lines. Inspect for broken or jagged fork tips, bent or
twisted blades and shanks.
4. Look for transmission and differential leaks on
the lift truck and on the ground. Make sure positioning lock is in place and
working. Lock the forks in position before using
the truck. See Every 2000 Service Hours or
Yearly.
Remove all defective forks from service.
111
Maintenance section
Inspect Engine for Fluid Leaks Coolant Level - Check

temperatures. WARNING
2. Turn the engine off. At operating temperature, the engine coolant is
3. Inspect the entire engine for oil and/or coolant
leaks.
4. Repair as necessary before continuing.
Check the coolant level only after the engine
has been stopped and the fill cap is cool
Engine Oil Level Check enough to touch with your bare hand.
1. Raise the hood and seat assembly. Remove the fill cap slowly to relieve pressure.
WARNING Cooling system conditioner contains alkali.

Avoid contact with the skin and eyes to prevent
Hot oil and components can cause personal personal injury.
contact skin.
1. Observe the coolant level with engine cold.

2. Measure the crankcase oil level. Maintain the Maintain coolant level to the proper line on
level to FULL mark on the dip stick. expansion bottle. If the expansion bottle has no
coolant, it will be necessary to check coolant at
the radiator filler neck.
2. Remove the radiator cap. Fill radiator to the top
of the filler neck. Inspect radiator cap. Replace
if damaged. Install the radiator cap.
level in the filler neck. If low add coolant until it
reaches the top of the filler neck. Install the
radiator cap. Observe coolant level in the
expansion bottle. If necessary, add coolant to
bring the coolant to the appropriate line on the
expansion bottle.
4. Stop the engine.
5. Inspect the cooling system for leaks, hose
cracks or loose connections.
112
Maintenance section
WARNING Inspect Foot Pedal Operation

Pressure air can cause personal injury. Verify foot pedal travel is smooth without
sticking.
protective shoes.
WARNING
Maximum air pressure must be less than 205 When the acceleration pedal harness is connected
kPa (30 psi) for cleaning purposes. or disconnected, should be worked KEY OFF
condition.
6. Blow any dust and lint from the radiator fins. If not, occurred malfunction, can cause the
personal injury.
Air Intake System - Check
Checking Service Indicator

temperatures.
2. Perform visual inspection of exhaust system.
Repair any/all leaks found.
1. Observe the air cleaner service indicator.

2. Service the air cleaner when the RED band in
the service indicator, lock in the visible position.
See topic, Air Intake System - Check, Clean in
Every 250 Service Hours or Monthly.
NOTE : Service the element more frequently, as

required, in severe dust or lint conditions.
Also, service it more frequently where the
operator is required to wear a respirator.
3. Close hood and seat assembly.
113
Maintenance section
Mast Channels - Lubricate Transmission Oil Level - Check

Checking Oil Level
WARNING
contact skin.
1. Start and operate the lift truck until the engine

reaches normal operating temperature.
2. Park the lift truck level with the forks lowered,
The channels on the roller-type mast require a
parking brake applied and the transmission con-
break-in period. Apply a light film of lubricant on the
trols in NEUTRAL.
channels where the rollers ride. This will prevent
metal peel until the rollers set a pattern. 3. With the service brake applied and the engine at
low idle, shift the directional control lever to for-
ward and then to reverse, to fill the clutches.
4. Shift the direction control lever to the NEUTRAL
position.
5. Open the floor plate.
6. Remove the dip stick. Observe the oil level.

7. Maintain the oil level between the MIN and MAX
114
Maintenance section
First 50-100 Service Hours or a Week

Parking Brake - Test, Adjust Transmission Oil & Strainer -

NOTE : Be sure area around the lift truck is clear Change, Clean
of personnel and obstructions.
Power Shift Transaxle(PTA18)
Test Operation WARNING
1. Drive the lift truck, with a capacity load, forward
up a 15% incline [a slope that increases 1.5
meters in 10 meters (1.5 ft increase in 10 ft)].
contact skin.
Park the lift truck level, with the forks lowered, park-
the engine stopped.
Component is shown removed from the lift truck for
illustrative purposes.
1. Remove drain plug (1). Allow the oil to drain.

Check O-ring seal and replace if necessary.
Remove the strainer.
2. Halfway up the incline, stop the lift truck with the

service brake.
IPMO060I
2. Wash the strainer in clean, nonflammable sol-

vent and dry it. Install the strainer, and the drain
plug.
3. Engage the parking brake. Slowly release the 3. Remove the filler cap. Fill the compartment with
service brake. oil. See Refill Capacities. Install the dip
stick/filler cap.
4. The parking brake should hold the lift truck. If
the lift truck starts to move, immediately apply 4. Start the engine.
the service brakes. Have the parking brake
5. With the service brake applied and engine at
adjusted.
low idle, shift the transmission to forward and
reverse to fill the clutches.
115
Maintenance section
6. Shift the transmission into NEUTRAL. Engage Drive Axle Oil - Change
the parking brake.
Park the lift truck on a level surface. Apply the
7. Remove the dip stick. Observe the oil level. parking brake. Place the directional control lever in
8. Maintain the oil level between the MIN and MAX NEUTRAL.
9. Check for oil leaks at the strainer and drain plug.
10. Stop the engine. Install the floor plate.
1. Raise the carriage high enough to access the

drain plug and level/fill plug.
2. Block the bottom of the mast with a block of
wood to hold the carriage in the raised position.
4. Place an appropriate container under the axle to
catch the oil as it drains. Remove the drain plug
and the level/fill plug.
5. Allow the oil to drain completely out. Discard the

old oil according to federal, state, and local
regulations.
6. Clean and reinstall the drain plug.
7. Add sufficient fresh oil through the level/fill
opening until it reaches the bottom of the hole.
See the section Lubricant Viscosities and
Refill Capacities for the type and amount of oil
to use.
116
Maintenance section
8. Clean and reinstall the level/fill plug.

9. Remove the wood blocking and lower the
carriage.
10.Operate the lift truck for a few minutes and
check oil level again. See the topic, Drive Axle
Oil Level - Check in Every 250 Service Hours
or Monthly section.
117
Maintenance section
First 250 Service Hours or a Month

Hydraulic Return Filter - Change
WARNING
injury. Do not allow hot oil or component to
contact skin.
Park the lift truck level with the forks lowered,

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

assembly.
assembly.
3. Change the return filter.
4. Install the tank top plate assembly and fasten
the bolts.
118
Maintenance section

Air Intake System - Check, Clean 3. Clean and inspect the element or replace with a
new element. See topic, Cleaning Primary Filter
Servicing Filter Element Element.
4. Clean the inside of air cleaner housing and the
cover. Inspect all connections between the air
NOTICE cleaner and carburetor. Check intake hose for
Never service filter with the engine running. cracks, damage necessary to prevent leakage.
NOTICE
Do not allow dirty air to enter the intake hose
when cleaning the inside of the cleaner hous-
ing.
5. Check the air cleaner housing for loose retain-

ing bolts.
6. Reset the air cleaner service indicator.
7. Install the air filter element.
8. Install the cover and tighten the cover latches.
Service the air cleaner when the red target in the
service indicator stays locked in the visible position 9. Start the engine and observe the position of the
with the engine stopped. indicator. If the indicator shows RED after the
installation of the primary element, install
1. To service the air cleaner, raise the hood and another clean or a new element or, replace the
seat assembly. Make certain the support secondary element. See topic, Air Intake
cylinder securely holds the hood open. Loosen System - Change in Every 1000 Service Hours
the cover latches and remove the cover. or 6 months section.
10. Stop the engine and close the hood and seat
assembly.
2. Rotate the element slightly to separate it from its

base and remove it from the air cleaner housing.
119
Maintenance section
Cleaning Primary Filter Elements Air-205 kPa (30 psi) Maximum Pressure
WARNING
Pressure air can cause personal injury.
protective shoes.
The maximum air pressure must be below 205
NOTICE Direct air on the inside and outside of the element

along the length of the pleats. Check the element
Do not clean the elements by bumping or tap-
for any tears, rips or damage.
ping them.
Inspect filter elements after cleaning. Do not Checking Element
use a filter with damaged pleats, gaskets or
seals.
When cleaning with pressure air, use 205 kPa
(30 psi) maximum pressure to prevent filter
element damage.
When cleaning with pressure water, use 280
kPa (40 psi) maximum pressure to prevent fil-
ter element damage.
Have spare elements on hand to use while cleaning

used elements.
The primary element should be replaced after 6
months service or after cleaning no more than 3 1. Insert a light inside the clean dry element and
times. examine it. Discard the element if tears, rips or
damage are found.
2. Wrap and store good elements in a clean, dry
place.
120
Maintenance section
Hydraulic Oil Level - Check Drive Axle Oil Level - Check

Park the lift truck on a level surface. Apply the
parking brake. Place the directional control lever in
WARNING
NEUTRAL.
At operating temperature, the hydraulic tank is
Hot oil can cause burns.
Remove the fill cap only when the engine is
stopped, and the cap is cool enough to touch
with your bare hand. Remove the fill cap slowly
to relieve pressure.
1. Operate the lift truck for a few minutes to warm

the oil. Park the lift truck on a level surface, with
the forks lowered, mast tilted back, parking
brake engaged, transmission in NEUTRAL and
the engine stopped. 1. Raise the carriage high enough to access the
level/fill plug.
2. Pull the latch and raise the hood and seat
assembly. Make sure the air lift cylinder 2. Block the bottom of the mast with a block of
securely holds the hood open. wood to hold the carriage in the raised position.
3. Remove the breather/dip stick. Maintain the oil

4. Remove the level/fill plug. The oil level should
level to the FULLmark on the breather/dip stick.
reach the bottom of the hole. Maintain the oil
level, to the bottom of the hole.
5. Clean off the level/fill plug and put it back in
place.
6. Remove the wood blocking and lower the load
backrest.
121
Maintenance section
Mast, Carriage, Lift Chains & Steering Mechanism - Check,

Attachments - Inspect, Lubricate Lubricate
1. Operate the lift, tilt and attachment controls.
Listen for unusual noises. These may indicate a
need for repair.
2. Inspect for loose bolts and nuts on the carriage.
Remove any debris from the carriage and mast.
3. Inspect the forks and attachments for free
operation and damage. Have repairs made if
necessary.
1. Lubricate the steer axle king pins, total of four

fittings. Two on the right side and two on the
left side.
2. Lubricate the steering link bearings, total of four
fittings. Two on the right side and two on the left
side.
3. Check for any worn or loose components of the
steering mechanism. Remove any debris or
4. Brush a film of oil on all links of the chain. trash as required.
5. Raise and lower the carriage a few times to

work lubricant into the chain links.
NOTICE
Lubricate chains more frequently than normal in
applications where the lift truck is operating in a
atmosphere which could cause corrosion of
components or when lift truck must work in
rapid lift cycles.
6. Inspect the chain anchors and individual links

for wear, loose pins or cracked leaves.
122
Maintenance section
Battery Terminal - Clean, Inspect Brake Oil Level - Check

WARNING
Batteries give off flammable fumes that can
explode.
Do not smoke when observing the battery elec-
trolyte levels.
Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes.
Always wear protective glasses when working
with batteries.
The brake reservoir is located on the left side of the

steering column.
1. Remove the filler cap.

2. Maintain the brake fluid level to the fluid level
mark on the brake system reservoir.
3. Clean and install the filler cap.
Typical Example
1. Clean the top of the battery and terminals.

2. Check terminals for corrosion. Coat terminals
with heavy grease.
123
Maintenance section
Engine Oil Filter - Change 7. Before installing a new filter element, apply a
small amount of clean engine oil to the filter
1. Operate lift truck a few minutes to warm oil.
element gasket.
Park the lift truck with the forks lowered,
parking brake applied, transmission in neutral 8. Install the new filter element. When the gasket
and the engine stopped. contacts the base, tighten it 3/4 of a turn more.
Do not overtighten.
2. Raise rear of lift truck off ground and block
securely. 9. Raise the lift truck, remove the blocking and
lower the lift truck.
10. Fill the crankcase. See Refill Capacities.
WARNING 11. Start the engine and allow the oil to fill the filter
and passages.
12. Check for oil leaks
contact skin.
13. Stop the engine and measure the oil level.

3. Remove the crankcase drain plug and allow oil Maintain the oil level to the FULL mark on the
to drain. Clean and install drain plug. dip stick.
4. Raise the hood and seat assembly. 14. Close hood and seat assembly.
5. Remove and discard oil filter element.

6. Wipe sealing surface of oil filter element
mounting base. Make sure all of the old gasket
is removed.
124
Maintenance section

Belts - Check, Adjust Tilt Cylinders - Check, Adjust,

Lubricate
Chassis Pivot Eyebolts - Lubricate
1. Remove floor plates.
Typical Example
1. Check the condition and adjustment of the belt.

Correct adjustment allows 12mm (0.47 inch)
deflection under 98N(22lb) of force.
2. Lubricate two fittings for the pivot eyebolts, one
on each tilt cylinder.
3. Check the pivot eye pins for loose retainer bolts
and wear.
Mast Pivot Eyes-Lubricate
Typical Example
NOTICE
Failure to loosen the alternator mounting bolt
will cause excessive stress and break the alter-
nator mounting ear.
1. Lubricate two fittings for the mast pivot eyes,
2. To adjust the alternator drive belt, loosen
adjusting bracket bolt and mounting bolt. Move 2. Check the pivot eye pins for loose retainer bolts
the alternator in or out as required. Tighten bolts. and wear.
125
Maintenance section
Cylinder Rod Extension-Adjust Mast Hinge Pin - Lubricate

NOTE : The following description is for forward tilt.
For cylinder rod back tilt, the collar should be
stationary by the tilt eye. If it is not, the O-ring inside
the collar may need to be replaced. To adjust back
tilt, spacers must be added or removed.
1. Lower the forks and tilt the mast forward.

2. Lubricate the two fittings for the mast hinge pins,
1. Check to make sure the tilt cylinders extend and Crosshead Roller - Inspect
retract evenly.
1. Operate the mast through a lift cycle. Watch the
2. If one cylinder continues to move after the other chains move over the crosshead rollers. Make
cylinder has stopped in full forward or backward sure the chain is tracking over the rollers
tilt, an adjustment must be made to one cylinder. properly.
3. To adjust the cylinder rod extension, move the
spacer to the rear and loosen the pinch bolt on
the clevis.
4. Turn the cylinder rod in or out of the clevis to
obtain the proper adjustment. Turning the rod
into the clevis shortens the stroke. Turning the
rod out of the clevis lengthens the stroke.
5. Tighten the pinch bolts to a torque of 9515
Nm (7010 lbft). Check the cylinder rods again
for even travel.
Typical Example
2. Check for damaged crosshead rollers, guards

and retainer rings.
126
Maintenance section
Parking Brake - Test, Adjust Horn & Lights (If Equipped) -

See topic, Parking Brake - Test, Adjust in First Check
50-100 Service Hours.
Inching & Braking Control Shaft -

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

operational.
2. Check and replace all defective gauges.
1. Lubricate three fittings for the inching and brake 3. Check all lights such as warning, directional,
pedal control shaft. backup, driving and flood lights for correct
operation. Replace all burned out bulbs. Have
repairs made if needed.
Drive Axle Oil (OCDB) - Change
See topic, Drive Axle Oil - Change in the First 50 Overhead Guard - Inspect
- 100 Service Hours.
2
1
1. Check tightness of overhead guard mounting

bolts at 105 Nm (77 lbft)(1) & 60 Nm (44
lbft)(2).
2. Check overhead guard for bent or cracked
sections. Have repairs made if needed.
127
Maintenance section
Inspect Vacuum Lines and Inspect Electrical System

Fittings (G420F(E) Engine Only) (G420F(E) Engine Only)
1. Visually inspect vacuum lines and fittings for 1. Check for loose, dirty or damaged connectors
physical damage such as bittleness, cracks and and wires on the harness including: Fuel lock-
kinks. Repair/replace as required. off, TMAP sensor, O2 sensor, Electronic
throttle, Control Relays, Fuel Trim Valve, Foot
2. Slovent or oil damage may cause vacuum lines
Pedal, and crank sensor.
to become soft resulting in a collapsed line
while the engine is running.
2. Repair and/or replace as necessary.
3. If abnormally soft lines are detected, replace as
necessary.
(1) Fuel Trim Valve(FTV) (2) Vacuum lines
Fuel Trim Valve(FTV) Inspection

(G420F(E) Engine Only)
1. Visually inspect the Fuel trim valve for

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

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

connector to the FTV.
4. Disconnect the vacuum lines form the FTV to

the pressure regulator/converter, at the
converters tee connection.
5. Lightly blow through the vacuum line

connected to the FTV. Air should not pass
through the FTV when de-energized. If air
leaks past the FTV when de-energized replace
replace the FTV.
128
Maintenance section

Hydraulic Return Filter, Breather 4. Remove the return filter from tank top plate
assembly.
& Strainer - Check, Change
5. Change the return filter.
6. Remove the suction strainer from the tank.
WARNING
7. Install a new strainer by hand.
injury. Do not allow hot oil or components to 8. Install the tank top plate assembly and fasten
contact skin. the bolt.
Park the lift truck level with the forks lowered, trols, and the steering system, through a few
parking brake engaged, transmission in NEUTRAL cycles to fill the lines. Look for oil leaks.
and the engine stopped. 10. Stop the engine and check the oil level. With all
FULLmark on the dip stick/filler cap assembly.
1. Remove and discard the air breather.

2. Install a new air breather.
assembly.
129
Maintenance section
Lift Chains - Test, Check, Adjust Check for Equal Tension

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 wear.
Inspect to be sure that chain link pins do not extend
outside of the link hole. If any single link pin is
extended beyond its connecting corresponding link,
it should be suspected of being broken inside of its
link hole. Lift chains are required to check for wear
about every 1,000 service hours or 6 months.
Chain wear test is a measurement of wear of the Lift the carriage and the mast high enough for get-
chain links and pins. Take the following steps to ting tension on lift chains. Check the chains, and
check chain wear. make sure the tension is the same. Lift chains are
required to check for equal tension about every
1. Lift the mast and carriage enough for getting 1,000 service hours or 6 months.
tension on lift chains.
WARNING
Personal injury can be caused by sudden
movement of the mast and carriage.
Keep hands and feet clear of any parts that can
move.
Lift Chain Adjustment
2. Measure precisely ten links of chain distance at

the center of pins in millimeter.
3. Calculate chain wear rate*.
4. If the chain wear rate is 2% or more, replace
the lift chain.
*Chain wear rate (%)

= Actual measurement - Pitch** X 10
X 100 Typical example for carriage equal tension
Pitch** X 100
**Chain Pitch for GC15/18S-5, GC20SC-5 If the tension is not the same on both chains, take
= 15.88mm(0.63 in) the procedure as follows.
NOTE : If carriage height is not correct, make

adjustments by following procedures.
130
Maintenance section
Carriage Chain Adjustment 4. Set the mast vertical and raise the carriage and
check equal chain tension. If not equal, repeat
Make sure that carriage height is correct. If correct, the same procedure as step 1 through step 3.
adjust the chain for equal tension. If not, adjust the
5. Put LOCTITE No. 242 Tread lock on the
chain for correct carriage height by adjusting
threads of the anchor nuts(1),(2) after the
anchor nuts(1),(2).
adjustment is completed.
Extrusion in When Required. for proper Mast Chain Adjustment - FF,FFT Mast
height of carriage.
1. Fully lower the carriage and tilt mast forward or

lift the carriage and put blocks under the
carriage to release the tension from the lift
chains.
2. Loosen nut(1) and adjust nut(2) to get proper
distance from bottom of inner upright to the
bottom of carriage bearing.
Typical example for FF mast
Typical example for carriage chain of STD mast
Typical example for FFT mast
Make sure that mast height is correct. If correct,

adjust chain for equal tension. If not, adjust mast
chain for correct mast height by adjusting anchor
nuts(3),(4).

Extrusion in When Required. for proper
inner mast height.
Typical example for carriage chain of FF,FFT mast
1. Lift the inner mast and put blocks under the
3. Make adjustment anchor nut(1),(2) for equal
inner mast to release the tension from the lift
chain tension.
chains.
2. Loosen nut(3) and adjust nut(4) to make inner
mast rail flush with outer mast rail bottom.
131
Maintenance section
3. Make adjustment anchor nuts(3),(4) for equal

chain tension.
4. Raise the inner mast and check equal chain
tension. If not equal, repeat the same
procedure as step 1 through step 3.
5. Put LOCTITE No. 242 tread lock on the threads
of the anchor nuts(3),(4) after the adjustment is
completed.
Transmission Oil & Strainer -

Clean, Change
See topic, Transmission Oil & Strainer - Clean,
Change in First 50-100 Service Hours.
132
Maintenance section
Inspect Coolant Hoses (LP, Dual Fuel Lines & Fittings - Check
Fuel Engines Only) Visually inspect fuel lines and fittings for physical
1. Visually inspect coolant hoses and clamps. damage. Replace as required.
connect to the pressure regulator/converter.
1 2
2. Replace any hose that shows signs of swelling,
cracking, abrasion or deterioration.
2
(1) Fuel line
1 (2) LP mixer
(3) Throttle Assembly
Inspect Mixer Assembly (G420F(E)

(1) LP Regulator/Converter Engine Only)
(2) Coolant hose
Refer to the LP mixer section of the engine service
manual for procedures.
LP Regulator/Converter
Inspection (LP, Dual Fuel Engine Inspect Throttle Assembly
Only) (G420F(E) Engine Only)
1. Visually inspect the pressure regulator/converter 1. Visually inspect the throttle assembly motor
housing for coolant leaks. Refer to the
housing for coking, cracks and missing cover-
pressure regulator/converter section of the
retaining clips. Repair and/or replace as
service manual if maintenance is required.
necessary.
NOTE : For pressure testing and internal inspection NOTE : Refer to the LP mixer and throttle section of
of the pressure regulator/converter, refer to the service manual for procedures on
the pressure regulator/converter section of removing the mixer and inspecting the
the service manual. throttle plate.
133
Maintenance section

Drive Axle Oil (Shoe Brake) - Replace LP Fuel Filter Element

Change (LP-Gas, Dual Fuel Engine Only)
See topic, Drive Axle Oil - Change in First 50 - Park the lift truck in an authorized refueling area
100 Service Hours with the forks lowered, parking brake applied and
the transmission in Neutral.
Inspect Ignition System (LP-Gas, 1. Close the fuel shutoff valve on the LP-Fuel tank.
Gasoline & Dual Fuel Engines Run the engine until the fuel in the system runs
Only) out and the engine stops.

2. Remove and inspect the spark plugs. Replace 3. Scribe a line across the filter housing covers,
as required. which will be used for alignment purposes when
re-installing the filter cover.
3. Inspect the ignition coil for cracks and heat
deterioration. Visually inspect the coil heat sink
fins. If any fins are broken replace as required. 1
G420F(E) Engine
(1) screws
134
Maintenance section
Fuel Filter (LP - Gas Engine Only) Testing Fuel Lock-off Operation
(LP-Gas Engine Only)
Disassembly
1. Start engine.
4 2 1
5 2. Locate the electrical connector for the fuel lock
3
6 3. Disconnect the electrical connector.
7
4. The engine should run out of fuel and stop within
a short period of time.
5. Turn the ignition key switch off and re-connect the

fuel lock-off connector.
1. Check bottom cover O-ring seal (6) for damage. NOTE: The length of time the engine runs on
Replace if necessary. trapped fuel vapor increases with any
increase in distance between the fuel lock-
2. Re-assemble the filter assembly aligning the off and the pressure regulator/converter.
scribe lines on the top and bottom covers.
3. Install the cover retaining screws, tightening the

1
2
4. Open the fuel valve by slowly turning the valve
counterclockwise. 3


(1) LP fuel lock-off
(2) Regulator / couverter
(3) Fuel Trim valve (FTV)
135
Maintenance section

Steer Wheel Bearings - Repack 11. Install the inner bearing.

12. Install the wheel assembly on the steering
knuckle.
13. Install the outer wheel bearing.
14. Install the flat washer, lockwasher and locknut.
15. Tighten the locknut to 135 Nm (100 lbft), while
turning wheel hub to seat the bearing.
16. Loosen the locknut. Torque the locknut to 50
Nm (37 lbft). Bend the lockwasher tang to
secure lock-nut.
17. Install the hub cap.
1. Raise the steer wheels off the ground. Block 18. Raise the lift truck and remove the blocking.
the lift truck up with blocking under the frame Lower the lift truck to the ground.
and steer axle.
2. Remove the hub cap.
3. Straighten the lockwasher tangs.
4. Remove the locknut, lockwasher and flat washer.
5. Remove the outer wheel bearing.
6. Remove the wheel assembly.
7. Examine the seal for damage and wear.

Replace the seal, if necessary.
8. Remove the inner bearing.
9. Clean and lubricate the steering knuckle.
10. Repack the inner and outer bearings.
136
Maintenance section
Cooling System Clean, Change
WARNING
At operating temperature, the engine coolant is
Check the coolant level only after the engine
has been stopped and the filler cap is cool
enough to touch with your bare hand.
Remove the filler cap slowly to relieve pressure. G420F(E) 2.0L LPG/Gasoline Engine
Coolant is included antifreeze for forbidding
corrosion. Avoid contact with the skin and eyes
to prevent personal injury. 3. Open the radiator drain valve. Allow the coolant
to drain into a suitable container.
Use all cleaning solution with care.
Drain the recovery bottle.
The Lift truck must be level, the forks lowered, the

parking brake engaged, the transmission in
NEUTRAL and the engine stopped and cool.
1. Turn the radiator cap slowly to relieve the

pressure, and then remove the cap.
2. Remove the drain plug or water hose on engine

block.
137
Maintenance section
NOTICE
Hold the drain port when the radiator drain valve is
turned because the tank and the drain port are
separated.
4. After draining the coolant completely, close the

radiator drain valve and the block drain plug, fill
the engine and the radiator full with a radiator
cleaner, and clean the engine and the radiator.
5. Start and run the engine for 30 minutes.
6. Stop the engine and drain the cleaning solution

into a suitable container.
7. Flush the system with clean water, until draining

water is clear.
8. Close the drain valve and install the block drain

plug. Fill coolant to top of the filler neck.

level. See topic, Coolant Level Check in
Every 10 Service hours or Daily.
138
Maintenance section
Fork - 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 The fork should be withdrawn from service if
months. If the truck is being used in a multi-shift or the deviation from straightness exceeds 0.5
heavy duty operation, they should be checked percent of the length of the blade and/or the
every six months. height of the shank respectively 5 mm/1000
mm (0.18"/36").
1. Inspect the forks carefully for cracks. Special
attention should be given to the heel section (A), all
weld areas and mounting brackets (B). Inspect the
top and bottom hooks on forks used on hook type
carriages and tubes on shaft mounted forks.
Forks with cracks should be removed from service.

"Wet Test" magnetic particle inspection is generally
preferred due to its sensitivity and the ease of inter-
preting the results. Portable equipment is usually
recommended so it can be moved to the lift truck.
Inspectors should be trained and qualified in

accordance with The American Society for Non
Destructive Testing, Level II Qualifications. 4. Check the difference in height of one fork tip to
the other when mounted on the fork carrier. A
difference in fork tip height can result in uneven
support of the load and cause problems with
entering loads.
The maximum recommended difference in fork

tip elevation (F) is 6.5 mm (0.25") for pallet
forks and 3 mm (0.125") for fully tapered forks.
The maximum allowable difference in fork tip
elevation between the two or more forks is 3
percent of blade length (L).
Replace one or both forks when the difference

in fork tip height exceeds the maximum
2. Check the angle between the upper face of the blade allowable difference. Contact your local
and the front face of the shank. The fork should be DOOSAN Lift Truck Dealer for further
withdrawn from service if angle (C) exceeds 93 information.
degrees or deviates by more than 3 degrees from an
original angle other than 90 degrees, as may be found
in some special application forks.
139
Maintenance section
at both ends of the carriage and in the path of

the bottom fork hook. The load backrest
extension may be used in place of the stop
blocks in some cases.
Shaft mounted forks may use set collars or

spacers on the shaft to either side of the fork.
They may also use U bolts, pins, or similar
devices which engage the fork through the top
structure of the carriage.
5. Check the fork blade (J) and shank (H) for wear
with special attention to the heel (G). The fork
should be withdrawn from service if the
thickness is reduced to 90 percent or less of the
original thickness.
Fork blade length may also be reduced by wear,

especially on tapered forks and platens.
Remove the forks from service when the blade
length is no longer adequate for the intended
loads.
8. Check fork markings (N) for legibility. Renew
markings as required to retain legibility.
9. a. Lift the mast and operate the tilt control lever,
until the top surface of the forks is parallel
with the floor. Place two straight bars that
are the same width as the carriage, across
the forks as shown.
b. Measure the distance from the bottom of

each end of the two bars to the floor. The
forks must be parallel within 3 mm (.12 in)
for Full Tapered and Polished (FTP) forks,
all other forks 6.4 mm (.25 in), for their
complete length.
6. Check the fork mountings (K) for wear, crushing
and other local deformation, which can cause
c. Put one fork, one third from the tip, under a
excessive side to side wobble of the forks.
fixture that will not move. Then operate the
Excessive clearance on hook type forks may
tilt control with caution until the rear of the
allow them to fall from the carrier. Forks which
truck lifts just off the floor. Follow the same
show visible signs of such damage should be
procedure with the second fork. Repeat Step
removed from service.
a.
7. Check the positioning lock and other fork
retention devices to make sure they are in place
and working.
Hook type forks use a spring loaded pin (M),

located in the top hook, to engage notches in
the top carriage bar to hold the fork in place.
When adjusting the fork spacing, the forks are

prevented from sliding off the end of the
carriage by stop blocks. These stop blocks are
140
Maintenance section

Hydraulic Oil - Change, Check, 5. Start the engine and operate the hydraulic con-
trols, and the steering system, through a few
Clean cycles to fill the lines. Look for oil leaks.
WARNING 6. Stop the engine and check the oil level. With all
Hot oil and components can cause personal cylinders retracted, maintain the oil level to the
injury. Do not allow hot oil or components to FULL mark on the breather/dip stick.
contact skin.
the engine stopped.
1. Remove the hydraulic tank drain plug. Allow the

oil to drain. Clean and install the plug.
2. Remove the breather/dip stick.
3. Remove the strainer. Wash the breather and

strainer in clean, nonflammable solvent and dry
4. Install the strainer. Fill the hydraulic tank. See

topic Refill Capacities. Install the breather/dip
stick.
141
Maintenance section
Inspect Battery System Replace Oxygen Sensor

1. Clean battery outer surfaces with a mixture of (G420F(E) Engine Only)
baking soda and water. G420F(E) Engine
2. Inspect battery outer surfaces for damage and
3. Remove battery cable and clean, repair and/or

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.

sensor


sensor
WARNING
When assembling the filters, check the arrow
mark on the filter surface.
The arrow mark position is same as fuel flow
direction.
142
Maintenance section
Checking the TMAP Sensor Inspect for Intake Leaks (G420F(E)

(G420F(E) Engine Only) Engine Only)
1. Verify that the TMAP sensor (F) is mounted 1. Visually inspect the intake manifold, throttle
tightly into the manifold adapter (E), with no assembly (2), and manifold adapters (3), for
leakage. looseness and leaks. Repair as necessary.
2. If the TMAP is found to be loose, remove the Replace PCV Valve and breather
TMAP retaining screw and the TMAP sensor
from the manifold adapter.
element (LP-Gas, Gasoline and Dual
Fuel Engines) - Change
3. Visually inspect the TMAP O-ring seal for
damage. Replace as necessary.
4. Apply a thin coat of an approved silicon lubricant

to the TMAP o-ring seal.
5. Re-install the TMAP sensor into the manifold

adapter and securely tighten the retaining screw.

valve.
2. Assemble new PCV valve and hose.
3. Tighten the hose clamps
143
Maintenance section
Replace Spark Plugs (G420F(E)

Engine Only)
2. Remove the ignition wiring harness.
3. Remove the ignition coil assy.
4. Remove spark plugs.
5. Gap the new spark plugs to the proper

specifications.
G420F(E) Engine : 0.7 ~ 0.8
6. Apply anti-seize compound to the spark plug

threads and install.
G420F(E) Engine : 25 Nm (18 Ibft)
WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.
(1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug
144
Maintenance section

Timing Belt - Change

specifications.
Timing Belt for Counterbalance

Shaft - Change
specifications.
Every 4500 Service Hours or two Years

Replace Oxygen Sensor
(1) Oxygen Sensor
1. Stop engine and wait until the exhaust pipe and

exhaust pipe is cooled.
sensor
sensor
145
Index Section
Index
# Circuit Breaker ..................................................... 108

Cleaning Primary Filter Elements ....................... 120
12 Months Inspection .............................................95 Coolant Information ............................................... 98
Coolant Level - Check ......................................... 112
A Coolant Water ........................................................ 99
Cooling System Clean, Change ...................... 137
Accelerator Pedal ...................................................44 Cooling System Specifications.............................. 98
Advanced Diagnostics............................................63 Crosshead Roller - Inspect.................................. 126
After Starting the Engine........................................53 Crushing or Cutting Prevention............................. 14
Air Intake System - Check .................................. 113 Cylinder Rod Extension-Adjust ........................... 126
Air Intake System - Check, Clean ...................... 119
Antifreeze ................................................................99 D
Attachment Abbreviations (includes Special Forks)
.................................................................................36 Daily Inspection...................................................... 94
Avoiding Lift Truck Tipovers ..................................22 Diesel Engine ......................................................... 51
Direction Control Lever.......................................... 43
B Disassembly......................................................... 135
Displaying Fault Codes (DFC) from SECM Memory
Basic Troubleshooting(LP).....................................56 ................................................................................ 63
Battery Terminal - Clean, Inspect....................... 123 Drive Axle Oil........................................................ 102
Before Operating the Lift Truck .............................12 Drive Axle Oil - Change....................................... 116
Before Starting the Engine.....................................48 Drive Axle Oil (OCDB) - Change ........................ 127
Before Starting the Lift Truck.................................11 Drive Axle Oil (Shoe Brake) - Change................ 134
Before Storage........................................................89 Drive Axle Oil Level - Check ............................... 121
Belts - Check, Adjust........................................... 125
Bent or Twisted Forks ............................................93 E
Brake Fluid ........................................................... 103
Brake Oil Level - Check ...................................... 123 Electrical Disconnect Switch (If Equipped) .......... 39
Bulbs..................................................................... 108 Electronic Controlled Spark-Ignition Engines ...... 54
Burn Prevention ......................................................15 Engine Compartment............................................. 41
Engine Oil (DEO and EO) ................................... 101
C Engine Oil Filter - Change................................... 124
Engine Oil Level Check.................................... 112
Capacity Load (Weight and Load Center) ............23 Environment Management...................................... 3
Carriage Roller Extrusion Adjust ..................... 110 Environment Protection Section ........................... 92
Causes of Fork Failure...........................................93 Every 10 Service Hours or Daily......................... 111
Center of Gravity (CG) ...........................................22 Every 1000 Service Hours or 6 Months ............. 129
Changing LP-Gas Tanks........................................46 Every 1500 Service Hours or 9 Months ............. 134
Chassis Pivot Eyebolts - Lubricate..................... 125 Every 2000 Service Hours or Yearly .................. 136
Check for Equal Tension..................................... 130 Every 250 Service Hours or Monthly.................. 119
Checking Oil Level............................................... 114 Every 2500 Service Hours or 15 Months ........... 141
Checking Service Indicator ................................. 113 Every 3000 Service Hours or 18 Months ........... 145
Checking the TMAP Sensor (G420F(E) Engine Every 4500 Service Hours or two Years ............ 145
Only) ..................................................................... 143 Every 500 Service Hours or 3 Months................ 125
Circuit Breaker ........................................................41
146
Index Section
F Inching into Loads.................................................. 83

Inspect Battery System........................................ 142
Fasten the Seat Belt...............................................20 Inspect Coolant Hoses (LP, Dual Fuel Engines
Fatigue.....................................................................93 Only) ..................................................................... 133
Fire or Explosion Prevention..................................15 Inspect Electrical System (G420F(E) Engine Only)
First 250 Service Hours or a Month ................... 118 .............................................................................. 128
First 50-100 Service Hours or a Week............... 115 Inspect Engine for Exhaust Leaks...................... 113
First Installation.......................................................94 Inspect Engine for Fluid Leaks............................ 112
Fluid Penetration.....................................................14 Inspect Foot Pedal Operation ............................. 113
Foreword ...................................................................2 Inspect for Intake Leaks (G420F(E) Engine Only)
Fork - Inspect....................................................... 139 .............................................................................. 143
Fork Inspection .......................................................94 Inspect Ignition System (LP-Gas, Gasoline & Dual
Fuel Filter (LP - Gas Engine Only) ..................... 135 Fuel Engines Only) .............................................. 134
Fuel Lines & Fittings - Check.............................. 133 Inspect Mixer Assembly (G420F(E) Engine Only)
Fuel Specifications .............................................. 100 .............................................................................. 133
Fuel Trim Valve(FTV) Inspection (G420F(E) Engine Inspect Throttle Assembly (G420F(E) Engine Only)
Only) ..................................................................... 128 .............................................................................. 133
Fuses & Relay Change ....................................... 107 Inspect Tightness - Drive Wheels....................... 110
Inspect Vacuum Lines and Fittings (G420F(E)
G Engine Only)......................................................... 128
Inspection, Maintenance and Repair of Lift Truck
G420F Engine.........................................................55 Forks ....................................................................... 92
G420FE Engine ......................................................54 Instrument Panel.................................................... 37
Gasoline Engine .....................................................50
General Hazard Information ..................................10 L
General Warnings to Operator ................................6
Lift Chain Adjustment .......................................... 130
H Lift Chain Wear Test............................................ 130
Lift Chains - Test, Check, Adjust ........................ 130
Hand Placement Warning ........................................7 Lift Control .............................................................. 44
Hook-on type Fork..................................................88 Lift Fork Adjustment............................................... 88
Horn & Lights (If Equipped) - Check .................. 127 Lift Truck Capacity Rating ..................................... 35
How to Survive in a Tipover...................................29 Lift Truck Controls.................................................. 43
Hydraulic Oil - Change, Check, Clean ............... 141 Lift Truck Operation ............................................... 81
Hydraulic Oil (HYDO) .......................................... 101 Lift Truck Parking................................................... 13
Hydraulic Oil Level - Check................................. 121 Lift Truck Shipping ................................................. 90
Hydraulic Return Filter - Change........................ 118 Lift Truck Stability................................................... 22
Hydraulic Return Filter, Breather & Strainer - Check, Lift Truck Stability Base......................................... 23
Change................................................................. 129 Lifting Drums or Round Objects............................ 86
Lifting the Load....................................................... 83
I Literature Information .............................................. 2
Load Backrest Must Be In Place Warning ............. 7
Identification, Lift Capacity and Attachment Plate35
Long Time Storage ................................................ 89
If Optional Suspension Seat (Weight Adjusting
LP Regulator/Converter Inspection (LP, Dual Fuel
Type) Equipped ......................................................19
Engine Only)......................................................... 133
Important Safety Information ...................................4
LP-Gas Engine....................................................... 51
Improper Modification or Repair ............................93
LP-Gas Specifications ......................................... 100
Inching .....................................................................82
Lubricant Information........................................... 101
Inching & Braking Control Shaft - Lubricate ...... 127
Lubricant Specifications ...................................... 101
147
Index Section
Lubricant Viscosities............................................ 104 Parking Brake - Test, Adjust .......................115, 127

Lubricant Viscosities and Refill Capacities ........ 104 Parking Brake Lever .............................................. 44
Lubricating Grease (MPGM)............................... 103 Parking the Lift Truck............................................. 87
Power Shift Transaxle ........................................... 81
M Power Shift Transaxle(PTA18) ........................... 115
Pressure Air............................................................ 14
Machine Lifting and Tiedown Information .............90 Pressure Warning .................................................... 7
Maintenance .............................................................3 Prestart Conditions ................................................ 50
Maintenance and Repair........................................95
Maintenance Information .......................................14 R
Maintenance Intervals ..................................... 3, 105
Make proper antifreeze additions..........................99 Reading Diagnostic Fault Codes .......................... 63
Mast Abbreviations .................................................36 Refill Capacities ................................................... 104
Mast Channels - Lubricate.................................. 114 Refueling ................................................................ 46
Mast Hinge Pin - Lubricate.................................. 126 Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
Mast Pivot Eyes-Lubricate .................................. 125 Engine Only)......................................................... 134
Mast, Carriage, Lift Chains & Attachments - Inspect, Replace Oxygen Sensor ..................................... 145
Lubricate............................................................... 122 Replace Oxygen Sensor (G420F(E) Engine Only)
Metric Hardware .....................................................96 .............................................................................. 142
Mounting and Dismounting ....................................11 Replace PCV Valve and breather element (LP-Gas,
Moving Fan Warning ................................................8 Gasoline and Dual Fuel Engines) - Change ...... 143
Replace Spark Plugs (G420F(E) Engine Only) . 144
N
S
No Riders Warning ...................................................8
No Standing On Forks Warning, No Standing Under Safety.................................................................... 2, 5
Forks Warning...........................................................7 Safety Rules........................................................... 24
Noise and Vibration ................................................33 Seat......................................................................... 42
Seat Adjustment..................................................... 18
O Seat Switch System (If Equipped)........................ 40
Serial Number ........................................................ 34
Operating in Hot Weather ......................................86 Serial Number Locations ....................................... 34
Operating Techniques............................................83 Service Brake Pedal .............................................. 44
Operating the Lift Truck..........................................12 Servicing Filter Element ...................................... 119
Operation...................................................................2 Sideshift Attachment Control (If Equipped).......... 45
Operation Information.............................................11 Specifications ......................................................... 31
Operator Restraint System (If Equipped)......... 2, 17 Stability and Center of Gravity .............................. 22
Operator's Seat, Hood Latch and Support Cylinder - Starting a Cold Diesel Engine ............................... 51
Check, Lubricate.................................................. 107 Starting a Warm Diesel Engine............................. 51
Operator's Station and Monitoring Systems .........37 Starting From a 12 Volt External Source.............. 52
Operator's Warning and Identification Plate .........35 Starting the Engine ................................................ 50
Operator's Warning Plate.......................................35 Starting the Lift truck.............................................. 12
Overhead Guard - Inspect .................................. 127 Steer Wheel Bearings - Repack ......................... 136
Overhead Guard Must Be In Place Warning ..........8 Steering Mechanism - Check, Lubricate ............ 122
Overloading.............................................................93 Storage Information ............................................... 89
P T
Packing brake ...........................................................8 Test Fuel System for Leaks ................................ 109
148
Index Section
Test Operation ..................................................... 115

Testing Fuel Lock-off Operation (LP-Gas Engine
Only) ..................................................................... 135
Tilt Control...............................................................45
Tilt Cylinders - Check, Adjust, Lubricate............ 125
Tilting Steering Column..........................................42
Timing Belt - Change........................................... 145
Timing Belt for Counterbalance Shaft - Change 145
Tire and Wheels - Inspect, Check ...................... 108
To Operate the Lift Truck after a Long Time
Storage....................................................................89
Torque for Metric Fasteners ..................................97
Torque for Standard Bolts, Nuts, and Taperlock
Studs .......................................................................96
Torque for Standard Hose Clamps - Worm Drive 96
Torque Specifications.............................................96
Torques for Bolts and Nuts With Standard Threads
.................................................................................96
Torques for Taperlock Studs .................................97
Training Required To Operate or Service Warning5
Transmission Inching Control Pedal .....................43
Transmission Oil & Strainer - Change, Clean ... 115
Transmission Oil & Strainer - Clean, Change ... 132
Transmission Oil (TDTO) .................................... 102
Transmission Oil Level - Check.......................... 114
Traveling with the Load..........................................84
Turning ....................................................................85
Unloading ................................................................84
Walk-Around Inspection .........................................48

Walk-Around Inspection Inspect...................... 111
Warning Signs and Labels................................ 5, 17
Wheel Bolts - Inspect .......................................... 110
When Required.................................................... 107
149

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SERVICE MANUAL CONTENTS

TITLE FORM NUMBER

Service Manual Contents SB4240E01

A2300 Diesel Engine SB4106E01

Power Train SB4243E00

Vehicle Systems SB4365E00

OPERATION & MAINTENANCE

Operation & Maintenance Manual SB2353E00

Models ; D(G)15/18S-5, D(G)20SC-5, GC15/18S-5, GC20S-5

20. Relieve all pressure in air, oil or water systems

METRIC NUTS AND BOLTS

METRIC TAPERLOCK STUDS

Exceptions to these torques are given in the Service

INCH NUTS AND BOLTS

INCH TAPERLOCK STUDS

O-RING FACE SEAL FITTING

STRAIGHT THREAD O-RING

STRAIGHT THREAD O-RING

O-RING FACE SEAL FITTING NUT

ASSEMBLY OF FITTINGS WITH STRAIGHT

This type of fitting is used in many applications. The tube

4 CLAMP TORQUE ON RETIGHTENING

37 FLARED O-RING SWIVEL NUTS

37 FLARED AND STRAIGHT THREAD O-RING FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

TIGHTENING OTHER FITTINGS

45 FLARED AND 45 INVERTED FLARE FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

TIGHTENING OTHER FITTINGS

AIR CONDITIONING FITTINGS

THREAD STEEL TUBES ALUMINUM TUBES

TAPERED PIPE THREAD FITTINGS

Introduction Air System

A Series Diesel Engine 3 Index

A Series Diesel Engine 4 Index

About the Manual

How to Use the Manual

The logic charts reflect three basic considerations:

A Series Diesel Engine 5 Introduction

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque

PERFORM an electrical MEASUREMENT.

A Series Diesel Engine 6 Introduction

Test Check or compare the performance of a component or system to established

Visually Look for any obvious damage or problem.

Remove Take off a component or assembly

Clean Remove dirt, grease or other contamination.

Disassemble Take the component or assembly apart.

Repair Restore a component or assembly to a serviceable condition within the established

Install Place a component or assembly in the correct position.

A Series Diesel Engine 7 Introduction

A Series Diesel Engine 8 Introduction

External Engine Components

Exhaust Side [Naturally Aspirated] Intake Side [Naturally Aspirated]

A Series Diesel Engine 9 General Engine Information

A Series Diesel Engine 10 General Engine Information

Engine Model A2300

Lubrication System Naturally Aspirated