D25-30-33S-3 B3.3 MOTOR

For use in service manual
form SB4133E01
SB4134E01
Nov. 2004
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 listed with mark (*) are, they are not available for the initial
release of the manual. When items are updated, or supplements added, they
will be announced in preview and should be ordered as they become available.
TITLE FORM NUMBER
Service Manual Contents SB4134E01

Safety SB2003E00
Torque Specifications SB2004E00
ENGINE
3.3 Liter (B3.3) Diesel Engine SB4135E00

G420E/G424E Tier Ⅱ Engine SB4136E00
G430E/G643E Tier Ⅱ Engine SB4137E00
DAC CS-121 Series Alternator SB2007E02
Bosch K1 Series Alternator SB2008E01
POWER TRAIN
Power Train SB2102E01

Power Train D & A SB2103E01
VEHICLE SYSTEMS
Vehicle Systems SB4138E00

Vehicle Systems D & A SB4139E00
Vehicle Systems - Supplement SB4156E00
Hydraulic System Schematic SB4140E00
Hydraulic System Schematic - G424E/G430E Tier Ⅱ Engine SB4157E00
Electric Systems Schematic SB4141E00
Electric Systems Schematic - G424E/G430E Tier Ⅱ Engine SB4158E00
OPERATION & MAINTENANCE
Operation & Maintenance Manual SB2302E06
Models ; D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3), D32S-3(B3.3), D33S-3(B3.3)

SB2003E00
O c t. 1 9 9 6
WARNING
SAFETY
WARNING WARNING
The proper and safe lubrication and maintenance Do not operate this machine unless you have
for this machine, recommended by DAEWOO, 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
The serviceman or mechanic may be 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. Read and 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 DAEWOO 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 way
invisible close to the hose. This oil can penetrate 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 45±15 lb i in
3/8-24 12 ± 2 110±20 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 359û. 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 37û Flared, 45û 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
37û FLARED AND STRAIGHT THREAD O-RING FITTINGS
37û FLARED O-RING SWIVEL NUTS

FITTING-PLUG
IDAS004B
37û 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
45û FLARED AND 45û INVERTED FLARE FITTINGS
INVERTED
45û FLARED 45û FLARED
IDAS007B
45û FLARED AND 45û 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 45û FLARE
IDAS010B
AIR CONDITIONING FITTINGS

O-RING FITTING END 45û FLARE FITTING END
STEEL TUBES ALUMINUM TUBES
THREAD
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
SB4135E00
Jan. 2004
Service Manual
B3.3 Diesel Engine
Lift Trucks
D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3),
D32S-3(B3.3), D33S-3(B3.3)
Skid Steer Loaders

450/450Plus, 460/460Plus
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 or 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.
DAEWOO 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 DAEWOO 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. DAEWOO dealers have the most
current information available.
1
Index Engine Testing
Introduction Complete Engine.................................................. 89

Measuring Compression Pressure..................... 89
About the Manual................................................... 4 Testing and Adjusting the Fan Belt Tansion ....... 91
How to Use the Manual ......................................... 4 Fuel System ......................................................... 92
Illustrations............................................................. 6 Checking and Adjusting Fuel Injection Timing ... 92
Symbols ................................................................. 5 Injector ................................................................. 95
Assembly ........................................................... 98
Engine Identification Disassembly....................................................... 97
Testing................................................................ 95
Lubricating System............................................. 100
Engine Diagrams ................................................... 9
Measuring Oil Pressure ................................... 100
Engine Views ....................................................... 9
Rocker Levers ...................................................... 87
Engine Identification .............................................. 7
Adjusting Valve Clearance ................................. 87
Engine Dataplate ................................................. 7
Specifications......................................................... 8
Specifications
Troubleshooting Symptoms
Camshaft and Camshaft Bushing ...................... 105
Capscrew Markings and Torque Values - Metric 115
Procedures and Techniques .................................20
Capscrew Markings and Torque Values - U.S.
Troubleshooting Symptoms Charts.......................20
Customary.......................................................... 116
Coolant Contamination .......................................34
Capscrew Markings and Torque Values ............. 115
Coolant Loss.......................................................35
Connecting Rod, Piston Ring and Piston Pin..... 111
Coolant Temperature above Normal...................38
Crankshaft.......................................................... 106
Engine Cranks But Will Not Start
Cylinder Block .................................................... 104
(No Exhaust Smoke) ..........................................22
Cylinder Head .................................................... 103
Engine Difficult to Start or Will Not Start
Cylinder .............................................................. 109
(Exhaust Smoke) (Continued) ............................24
Flywheel ............................................................. 108
Engine Difficult to Start or Will Not Start
Fraction, Decimal, Millimeter Conversions......... 117
(Exhaust Smoke) ................................................23
Newton-Meter to Foot-Pound Conversion
Engine Has Poor Respones ...............................25
Chart .................................................................. 118
Engine Power Output Low (Continued) ..............29
Oil Pump ............................................................ 112
Engine Power Output Low..................................28
Pipe Plug Torque Values .................................... 118
Engine Runs Rough or Misfires..........................27
Piston ................................................................. 110
Engine Stops During Operation ..........................26
Regulator Valve.................................................. 113
Engine Vibration Excessive ................................41
Rocker Arm Shaft, Push Rod and Tappets......... 102
Engine Will Not Crank or Cranks Slowly ............21
Tap-Drill Chart - U.S. Customary and Metric...... 119
Excessive Exhaust (Black Smoke) .....................30
Thermostat ......................................................... 114
Excessive Noise (Continued) .............................40
Timing Gear........................................................ 107
Excessive Noise .................................................39
Valves, Valve Guides, and Springs .................... 101
Fuel consumption Is Excessive ..........................33
Weight and Measures - Conversion Factors...... 120
Lubricating Oil Consumption Excessive .............31
Lubricating Oil Contaminated .............................32
Lubricating Oil Pressure Is Low..........................36 Special Tool
Oil Level Rises....................................................37
Special Tool List ................................................. 121
Complete Engine
Complete Engine ..................................................42
Engine Assembly ................................................61
Engine Disassembly ...........................................42
Diesel Engine 3 Index

About the Manual
This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related problems
and to provide recommended repair procedures.
The material in this manual covers all Signature engines. The manual is divided into sections. Each section is
equivalent to a group used in Cummins filmcard system. Some sections contain reference numbers and
procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools
where applicable. Procedure numbers are used to identify and reference specific repair procedures for correcting
the problem.
This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The
troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section
are in numerical order. However, the repair steps within a given procedure are organized in the order the repair
must be performed, regardless of the numerical order of the steps. The user must use the Section Contents pages
or the Index at the back of the manual to locate specific topics when not using the troubleshooting trees.
How to Use the Manual

This manual is organized to provide an easy flow from problem identification to problem correction. A list of
troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms,
Section TS. The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and
directing the end user to the correct procedure for making the repair. Complete the following steps to locate and
correct the problem.
(Step 1) Locate the symptom on the Section Contents pages of Section TS.
Reference to the page number where the Troubleshooting Symptom Tree is
found is made to the right of the symptom tree title.
(Step 2) The left column of boxes in the Troubleshooting Symptom Charts indicates a
probable cause of the problem, starting at the top with the simplest and easiest to
repair, and continuing downward to the most difficult.
The right column of boxes provides a brief description of the corrective action
with a reference number to the correct procedure used to make the repair.
(Step 3) Locate the probable cause in the left column; then turn to the procedure
referenced in the right column.
(Step 4) The Troubleshooting Symptom Charts are based on the following assumptions:
1. The engine has been installed according to the manufacturer's specifications.
2. The easiest repairs are done first.
3. "Generic" solutions cover problems with the most common applications and
original equipment manufacturer (OEM).
Diesel Engine 4 Introduction

Symbols
The following symbols have 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.
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.
The component weighs 23kg [50lb] or more. To avoid personal injury, use a hoist or get
assistance to lift the component.

Illustrations
Some of the illustrations throughout this manual are
generic and will not look exactly like the engine or
parts used in your application. The illustrations can
contain symbols to indicate an action required and an
acceptable or not acceptable condition.
th8sesa
The illustrations are intended to show repair or

replacement procedures. The procedure will be the
same for all applications, although the illustration can
differ.
Ca8vagc

Engine Identification
Engine Dataplate
The engine dataplate shows specific information
about the engine. The engine serial number (ESN)
and control parts list (CPL) provide information for
ordering parts and for service needs.
NOTE: The engine dataplate must not be changed

unless approved by Cummins Engine 00900248
Company, Inc.
00900249
Diesel Engine 7 Engine Identification

Specifications
Performance D20/25/30/32/33S-3 450/450Plus,460/460Plus
Standard - SAEJ1995
Air Cleaner - without but with 3.0kPa intake restriction
Test Condition Muffler - without but with 10.0kPa exhaust restriction
Alternator - without
Fan - without
Rated Power kW(PS) 43.4 (59) @ 2200 rpm 48.5 (65) @ 2600 rpm
Max Torque Nm(kgf-m) 202 (20.6) @ 1600 rpm 214 (21.8) @ 1600 rpm
Torque Rising 7.4 % for 2200rpm rating 20.0% for 2600rpm rating
@Rated Power g/kWh 227 @2200rpm 236 @ 2600rpm
BSFC
@Max Torque g/kWh 219 @1600rpm 226 @ 1600rpm
General Engine Data Naturally Aspirated

Engine Weight (Dry) Less Flywheel and Electronics 245 kg [540 lb]
Compression Ratio 18.8
Bore 95 mm [3.74 in]
Stroke 115 mm [4.528 in]
Displacement 3.26 liters [199 in³]
Firing Order 1-2-4-3
Intake 0.35 mm [0.014 in]
Valve Clearance:
Exhaust 0.50 mm [0.020 in]
Rotation Viewed from the Front of the Engine Clockwise
Lubrication System Naturally Aspirated

Regulating Valve Opening Pressure 490 kPa [71 psi]
Total System 7.5 liters [8.0 qt] 8.0 liters [8.5 qt]
Lubricating Oil Capacity:
Standard Oil Pan Only 7.0 liters [7.4 qt]
Lubricating Oil Pressure at Idle (Minimum Allowable) 69 kPa [10 psi]
Lubricating Oil Pressure at Rated (Minimum 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 1.5 liters [1.6 qt]
Cooling System Naturally Aspirated

Coolant Capacity (Engine Only ) 4.5 liters [4.75 qt]
Standard Modulating Thermostat Start 82° C [180° F]
Range: Fully Open 95° C [203° F]
Maximum Pressure Cap @ Sea Level 50 kPa [7 psi]
Air Induction System Naturally Aspirated

Maximum Allowable Intake Restriction at Rated Speed and 762 mm H2O
Load with Dirty Filter Element [30 in H2O]
Exhaust System Naturally Aspirated

Maximum Allowable Exhaust Restriction at Rated Speed and 75 mm Hg
Load with Dirty Filter Element [3 in Hg]
Fuel System Naturally Aspirated

Maximum Allowable Restriction to the Fuel Transfer Pump 75 mm Hg
or Filter Head Must Not Exceed [3 in Hg]
Maximum Allowable Return Line Restriction Must Not 190.5 mm Hg
Exceed [7.5 in Hg]
Inlet Pressure to the Injection Pump Range 0.00 kPa [0.00 psi] to 39.0 kPa [5.00 psi]
Electrical System Naturally Aspirated

Minimum Recommended Battery
12-VDC Starter 550 CCA
Capacity with Light Accessories*:
Minimum Recommended Battery
Capacity with Heavy 12-VDC Starter 730 CCA
Accessories**:
Maximum Allowable Resistance
12-VDC Starter 0.0012 ohms
of the Starting Circuit:
*Typical light accessories include: Alternator, small steering pump, and disengaged clutch.
**Typical heavy accessories include: Hydraulic pump and torque converter.

Engine Diagrams
Engine Views
The following illustrations show the locations of the major external engine components, filters, and other service
and maintenance points. Some external components will be at different locations for different engine models.
Intake Side
(Naturally Aspirated)
00900138
1. Intake Manifold 5. Fan

2. Starting Motor 6. Fuel Filter
3. Fuel Injection Pump 7. Oil Fill Cap.
4. Crankshaft Pulley

Exhaust Side
00900139
1. Oil Fill Cap 4. Dipstick

2. Thermostat Housing 5. Oil Filter
3. Alternator 6. Exhaust Manifold.

Front View
00900140
Rear View
00900141

Exhaust Side
00900146
1. Oil Strainer 8. Camshaft

2. Oil Pump 9. Piston
3. Oil Cooler (Optional) 10. Intake and Exhaust Valve
4. Regulator Valve 11. Rocker Arm
5. Oil Filter 12. Timing Gear
6. Safety Valve 13. Cooling Water.
7. Crankshaft

Oil Pump
00900148
1. Bushing 8. Regulator Valve

2. Gear Drive (number of teeth: 7) 9. Valve Spring.
3. Pump cover
4. Oil Pump Drive Gear (number of teeth: 22) Oil pump
5. Driveshaft • Type: Gear Type
6. Drivenshaft • Pump Speed: Engine Speed x 1.182.
7. Driven Gear (number of teeth: 7)
Regulator Valve
• Set Pressure: 490 ± 50kPa [71 ± 7psi].

Fuel System
00900149
1. Fuel Injection Pump 5. Fuel Tank

2. Overflow Valve 6. Water-in-Fuel Sensor (WIF)
3. Fuel Solenoid 7. Fuel Filter
4. Fuel Injection Nozzle 8. Hand Priming Pump.

Fuel Injection Pump
00900150
1. Pump Holder A. Fuel Inlet (from Fuel Tank)

2. Fuel Injection Pump Drive Gear B. To. Fuel Tank
(number of teeth: 52) C. To Fuel Injection Pump
3. Drive Shaft D. To Fuel Injection Nozzle.
4. Fuel Injection Pump (Body)
5. Fuel Filter Fuel Injection Pump
6. Fuel Injection Pipe (No. 1) • Maker: Zexel
7. Fuel Injection Pipe (No. 2) • Type: VE
8. Fuel Injection Pipe (No. 3) • Lubrication Method: Forced Lubrication with Fuel
9. Fuel Injection Pipe (No. 4)
10. Spill Tube Governor
• Type: Mechanical, All-speed Type.

Fuel Injection Nozzle
00900151
1. Fuel Drain Line Connector A. Fuel Inlet (from injection pump)

2. Nozzle Holder B. Fuel Injection (to cylinder)
3. Adjusting Shim C. Fuel Return (to fuel tank).
4. Nozzle spring
5. Spring seat Fuel Injection Nozzle
6. Intermadiate Plate • Maker: Zexel
7. Nozzle Body • Injection Pressure: 40 MPa
8. Retaining Nut • Adjustment of Injection Pressure: By Shim.
9. Needle.

Cooling System
00900147
1. Radiator 6. Cylinder Head

2. Thermostat 7. Piston
3. Water Temperature Gauge 8. Cylinder Block
4. Water Pump 9. Oil Cooler (optional).
5. Water Manifold A. From Oil Pump (oil).

Air Intake System
00900227
1. Filtered Air
2. Intake Manifold
3. Intake Valve Port.

Exhaust System
00900232
1. Exhaust Valve Port

2. Exhaust Manifold

Procedures and Techniques
A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information
known about a complaint, the faster and easier the problem can be solved.
The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the
easiest and most logical things first. Complete all steps in the sequence shown from top to bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts are designed to
stimulate a thought process that will lead to the cause and correction of the problem.
Follow these basic troubleshooting steps:
• Get all the facts concerning the complaint

• Analyze the problem thoroughly
• Relate the symptoms to the basic engine systems and components
• Consider any recent maintenance or repair action that can relate to the complaint
• Double-check before beginning any disassembly
• Solve the problem by using the symptom charts and doing the easiest things first
• Determine the cause of the problem and make a thorough repair
• After repairs have been made, operate the engine to make sure the cause of the complaint has been
corrected
Troubleshooting Symptoms Charts

Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each
row of blocks from top to bottom. Follow through the chart to identify the corrective action.
Diesel Engine 20 Troubleshooting Symptoms

Engine Will Not Crank or Cranks Slowly
This is symptom tree T-002.
Cause Correction
Troubleshoot and repair starting circuit wiring
Defective wiring of starting circuit
including relays and switches.
OK
Specific gravity of battery electrolytr is low, or Check the alternator. If the alternator checks
Battery voltage is low Out, replace the battery.
OK
Staring motor is malfunctioning Replace the staring motor.
OK
Ring gear tooth surface is chipped or damaged Replace ring gear.

Engine Cranks But Will Not Start (No Exhaust Smoke)
Cause Correction
Fuel level low in the tank Fill the supply tank.
OK
Improper fuel is being used Drain fuel and replace with correct fuel.
OK
Clogged fuel tank air breather hole Clean the fuel tank breather.
OK
Engine does start when voltage is applied to

Troubleshoot and repair the circuit wiring.
the fuel cut solenoid valve
OK
Engine does not start when voltage is applied

Replace the fuel cut solenoid valve.
to the fuel cut solenoid valve
OK
Clogged prefilter Clean the prefilter.
OK
Clogged fuel filter or strainer Clean or replace the fuel filter or strainer.
OK
Clogged or leaking fuel piping Clean and repair the fuel piping.
OK
Feed pump is damaged or seized Replace the feed pump.
OK
Injector are plugged Replace the injectors.
OK
Injection pump driveshaft or driveshaft key is

Repair or replace the injection pump.
damaged

Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Cause Correction
Starting aid malfunctioning or heater mount
Replace the starting aid.
Does not become warm
OK
Crank speed is too slow (minimum crank Verify drive units are not engaged. Check the
Speed: 150 rpm) Battery and recharge or replace.
OK
Improper fuel is being used Drain fuel and replace with correct fuel.
OK
Clogged air cleaner element Clean or replace the air cleaner element.
OK
OK
OK
Leakage, clogging, air in fuel system Repair and clean the fuel filter or strainer.
OK
Injection pump timing is incorrect Retime the injection pump.
OK
(Continued)

Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued)
Cause Correction
Overhead adjustments are not correct Measure and adjust the overhead settings.
OK
Inspect the rocker levers, rocker shafs, and

Overhead components are damaged valve for excessive damage. Replace as
necessary.
OK
Replace the defective or clogged injection

Defective or clogged injection nozzle
nozzle
OK
Injection pump is malfunctioning Repair or replace the injection pump.
OK
Worn piston ring or cylinder resulting in low

Replace the worn piston ring or cylinder.
compression

Engine Has Poor Respones
Cause Correction
Clogged air cleaner element Clean or replace the air cleaner element
OK
OK
Clogged prefilter Clean or replace the fuel filter or strainer.
OK
Clogged fuel filter or strainer Clean and repair the fuel piping
OK
Clogged or leaking fuel piping Clean and adjust the overhead settings.
OK
OK
Defective contact of valve or valve seat

Replace the cylinder head.
Resulting in low compression
OK
Turbocharger does not rotate freely Replace the turbocharger.
OK

nozzle.
OK
Injection pump is malfunctioning Repair or replace the injection pump.
OK

Compression

Engine Stops During Operation
Cause Correction
Chassis powertrain is damaged or overloaded Refer to the OEM’s service manuals.
OK
OK
OK
OK
Clogged fuel filter or strainer Clean and or replace the fuel filter or strainer.
OK
OK
Feed pump piston is damaged or seized Replace the feed pump.
OK
Inspect the rocker levers, rocker shafts, and

Overhead components are damaged valves for excessive damage. Replace as
necessary.
OK
Injection pump is malfunctioning Replace the injection pump.
OK
Gear train damaged or seized Refer to OEM’s service manuals.
OK
Piston or connecting rod is damaged Replace damaged piston or connecting rod.
OK
Crankshaft bearing is damaged Replace damaged crankshaft bearing.

Engine Runs Rough or Misfires
Cause Correction
OK
OK
Low idle speed is adjusted too low Adjust the low idle speed.
OK
OK
OK
Line between the fuel tank and feed pump

Clean and repair the lines.
are clogged or have air in them
OK
Line between the feed pump and the injector

Clean and repair the lines.
nozzle are clogged or have air in them
OK

Engine Power Output Low
Cause Correction
Improper fuel is being used Drain and replace the fuel with the correct fuel.
OK
OK
OK
Full throttle can not be achieved because the

fuel lever linkage is bent or not adjusted Repair or adjust the fuel lever linkage.
correctly
OK
OK
Clogged fuel filter or strainer Clean and or replace the fuel filter or strainer.
OK
OK
Feed pump is defective Replace the feed pump.
OK
OK
(Continued)

Engine Power Output Low (Continued)
Cause Correction
Defective contact of valve or seat
Replace the cylinder head.
Resulting in low compression
OK
OK

nozzle.
OK
OK

compression

Excessive Exhaust (Black Smoke)
Cause Correction
Engine is bring lugged down Use lower gear.
OK
OK
Replace the muffler. Refer to the OEM’s

Muffler is crushed or clogged
service manual.
OK
Tighten the clamp between turbocharger and

Air leakage between the turbocharger and
head. Repair leaks between turbocharger and
head
head.
OK
Exhaust leak between turbocharger and

Inspect and change gaskets.
Exhaust manifold
OK
OK
Defective or clogged injection nozzle Adjust or replace the injection pump.
OK
Worn piston ring or cylinder (blue smoke) Replace the worn piston ring or cylinder.
OK
Incorrect injection timing Adjust injection timing.
OK

Lubricating Oil Consumption Excessive
Cause Correction
Inspect the engine the external oil leaks.
Lubricating oil leak (external) Tighten the capscrews, pipe plugs, and fittings.
Replace the gaskets if necessary.
OK
Intake system is contaminated with dust Remove and clean intake manifold.
OK
Dipstick is not calibrated correctly Verify the dipstick is correctly marked.
OK
Breather or breather hose is clogged Clean the breather and breather hose.
OK
Turbocharger compressor or turbine oil seal is

Replace the compressor or turbine seal.
Leaking
OK
Rear crankshaft seal or seal surface is

Repair or replace seal and surface.
damaged
OK
Valve stem, guide, or seal is damaged Repair or replace the damaged component.
OK
Replace the worn or broken piston ring or

Worn or broken piston ring or cylinder
cylinder.

Lubricating Oil Contaminated
Cause Correction
Breather or breather hose is clogged Clean the breather and breather hose.
OK
Lubricating oil filter is clogged Replace the filter.
OK
Turbocharger turbine oil seal is damaged Replace the turbine seal.
OK
Turbocharger turbine oil seal is damaged Replace the turbine seal.
OK
Turbocharger turbine oil seal is

Replace the turbine seal.
Damaged
OK
Refer to Exhaust Gas Is Black (Incomplete

Exhaust gas is black
Combustion).
OK
Defective contact of valve or valve seat

Repair the valve or valve seat.
resulting in low compression
OK

Compression

Fuel consumption Is Excessive
Cause Correction
Check and repair the accessories. Refer to the
Overloading from malfunctioning accessories
OEM’s service manuals.
OK
Refer to the operation and maintenance

Operator technique is not correct
manual for proper operating speeds and loads.
OK
Check the fuel lines, fuel connections, and fuel

filters for leaks. Check the fuel lines to the
Fuel leaks (external)
supply tanks. Refer to the OEM’s service
manual.
OK
Assure good-quality No.2 diesel fuel is being

Poor-quality fuel or No.1 fuel is being used
used.
OK
Refer to troubleshooting logic for Exhaust Gas

Intake or exhaust restriction
is Blake.
OK

nozzle.
OK
Incorrect injection timing Adjust injection timing.
OK
Injection pump is adjusted incorrectly causing

Adjust or replace the injection pump.
excessive injection

Coolant Contamination
Cause Correction
Review the coolant change interval. Drain and
Coolant is rusty flush the system. Fill the system with the
Correct mixture of coolant and water.
OK
Lubricating oil cooler for powertrain is damaged Refer to the OEM’s service manual.
OK
Cylinder head gasket is cracked or damaged Replace the cylinder head or gasket.
OK
Cylinder block is cracked or porous Replace the cylinder block.

Coolant Loss
This is symptom tree T-013.1
Cause Correction
Inspect the radiator heater, hoses, and
connection to locate the leak. If oil is present in
Radiator or cab heater is leaking
the coolant, check for a transmission or
lubricating oil cooler leak.
OK
Inspect the engine and components for seal,

External engine leak
gasket, or drain cock leaks.
OK
Review the operation for overheating and low

Overheating or compression gases are leaking
power. Refer to troubleshooting logic for
Resulting in loss through the radiator overflow
Coolant Temperature Above Normal.
OK
Check for mixing of coolant and transmission

Transmission cooler is leaking (if equipped)
fluid.
OK
Cylinder head gasket is leaking Check or replace the head gasket.
OK
Cylinder head is cracked or porous Check or replace the cylinder head.
OK
Cylinder block coolant passages are leaking Check or replace the cylinder block.

Lubricating Oil Pressure Is Low
Cause Correction
Check the oil level. Verify the dipstick
Lubricating oil lever is below specification calibration and the oil pan capacity. Fill the
system to the specified level.
OK
Oil level or pressure sensor is damaged Replace the oil lever or oil pressure sensor.
OK
Lubricating oil filter is clogged Replace the filter
OK
Fuel or coolant is in the lubricating oil. Refer to Oil Level Rises symptom tree.
OK
Regulator or relief valve is not adjusted

Adjust the regulator or relief valve.
Correctly
OK
Lubricating oil pan strainer is clogged Clean the strainer.
OK
Lubricating oil suction tube is damaged Repair or replace the suction tube.
OK
Lubricating oil pump is damaged Replace the oil pump.
OK
Main or rod bearing is worn or damaged Replace the bearing

Oil Level Rises
Cause Correction
Rear crankshaft seal or seal surface is
Repair or replace seal and surface
damaged
OK
Replace the auxiliary pump. Refer to the OEM’s

Auxiliary equipment has damaged pump seal
service manual.
OK
Injector sleeve is damaged Replace the injector sleeve.
OK
Fuel injector is leaking inside cylinder head Replace the injector.
OK
Injector pump seal is leaking Remove and repair the injection pump.
OK
Cylinder head or head gasket is cracked or

Replace the cylinder head or gaeket.
damaged
OK
Cylinder block is cracked or porous Replace the cylinder block.

Coolant Temperature above Normal
Cause Correction
Inspect the engine and radiator for external
Coolant level is below specification
coolant leaks.
OK
Fan belt is slipping or the fan pulley is worn Replace the fan belt or pulley.
OK
Water temperature gauge is malfunctioning Replace the water temperature gauge.
OK
Radiator fin is clogged or crushed Clean, repair, or replace the radiator.
OK
Radiator core is clogged Clean and repair the radiator.
OK
Thermostat is defective and does not open Replace the thermostat.
OK
Water pump is damaged Replace the water pump.
OK
Cylinder head or head gasket is cracked or

Replace the cylinder head or graket.
damaged

Excessive Noise
Cause Correction
Belt is squeaking due to insufficient tension or Check and adjust belt tension. Make sure all
abnormally high loading the pulleys rotate freely.
OK
Tighten the clamp between turbocharger and

Air leakage between the turbocharger and
head. Repair leaks between turbocharger and
head
head.
OK
Refer to Exhaust Gas is Black troubleshooting

Exhaust leaks
tree.
OK
OK
Gear train backlash is not adjusted correctly Adjust the backlash for the gear train.
OK
Idler gear bushing is damaged or missing Replace the idler gear bushing.
OK

nozzle.
OK
OK

Overhead components are damaged
valves for excessive damage.
OK
(Continued)

Excessive Noise (Continued)
Cause Correction
Injection pump is adjusted incorrectly Adjust or replace the injection pump.
OK

compression

Engine Vibration Excessive
Cause Correction
Engine mounting bolts are loose or the engine
Replace the engine mounting bolts or cushion.
mounting cushion is broken
OK
Repair the alignment. Refer to the OEM’s

Engine and powertrain is out of alignment
service manual.
OK
Gear train backlash is not adjusted correctly Adjust the backlash for the gear train.
OK

Overhead components are damaged valves for excessive damage. Replace as
necessary.
OK
Cam bushing is worn Replace the cam bushing.
OK
Injection pump is adjusted incorrectly Adjust or replace the injection pump.
OK
Main bearing or connecting rod is worn or

Replace the connecting rod or main bearing.
damaged

Complete Engine
Engine Disassembly
Service Tool
Part No. Part Name Quantity

3375193 Unit Repair Stand or Engine Overhaul Stand
or 1
3375194
3163625 Bracket 1
3163292 Valve Spring Compressor 1
3397890 Flange Puller 1
3823137 Piston Ring Expansion Tool 1
Engine Removal
NOTE: Put tag on all hoses, lines, linkage, and

electrical connections as they are removed
to identify location and aid the installation
process.
fp8hola
WARNING
Always disconnect the negative (-) cable first.
Disconnect the battery cables.
WARNING
Allow the engine to cool before draining to avoid
ea8wrha burns from hot liquid.
WARNING
Coolant is toxic. Keep away from children and
animals. Save for reuse or dispose of in
accordance with local regulations.
Drain the engine coolant.
Diesel Engine 42 Complete Engine

WARNING
Some state and federal agencies in the United

States of America have determined that used oil
is carcinogenic and can cause reproductive
toxicity. Avoid inhalation of vapors, ingestion, and
prolonged contact with used engine oil. Always
use the proper procedures to dispose of the oil.
Drain the lubricating oil.

op800li
Engine Oil: 7.5 liters [1.98 U.S.gal]
Disconnect the starter cable, engine ground straps,

cab or chassis to engine hoses, tubing, electrical
wires and hydraulic lines.
Disconnect the intake and exhaust system pipes.
oi400hc
Disconnect the drive units from the flywheel housing

and flywheel.
tr400wa
Remove all chassis components necessary to

remove the engine from the equipment.
ra400ha

Prepare a stable stand, Part No. 3375193 or 3375194,
which will prevent the engine from falling over.
Engine Weight (approx.): 255 kg [562 lb]
00900154
Remove the starting motor.
00900156
Install the bracket, Part No. 3163625, on the engine.
00900207
WARNING
This component weighs 23 kg [50 lb] or more. To
avoid personal injury, use a hoist or get
assistance to lift this component. The engine
lifting equipment must be designed to lift the
engine without causing personal injury.
Put the engine on the stand.
00900208

Cover all the engine openings to prevent dirt and
debris from entering the engine.
00900209
Fan Pulley
WARNING
Be careful not to injure your fingers or damage
the alternator when moving the alternator toward
the cylinder block.
Loosen the mounting capscrew of the adjustment

plate (1). Loosen the alternator mounting capscrew
and nut.
00900158 Move the alternator toward the cylinder block, and
remove the belt (2).
Remove the fan pulley.
Fan
Remove the four capscrews, retainer plate, fan, and

spacer.
00900157
Alternator
Remove the adjusting capscrew and washer.

Remove the capscrew, adjustment plate, and spacer.
Remove the remaining capscrew and alternator.
00900159

Lubricating Oil Filter
Remove the lubricating oil filter.
00900155
Dipstick Guide
Remove the dipstick and dipstick guide.
00900160
Water Pump
Remove the mounting capscrews, water pump,

gasket, and o-ring.
Discard the gasket and o-ring.
00900161
Thermostat
Remove the two mounting capscrews, thermostat

housing, thermostat and seal.
18900025

Exhaust Manifold
Remove the eight capscrews, exhaust manifold, and

gasket.
Discard the gasket.
00900162
Fuel Injection Tubing
Remove the clamp.

Remove the sleeve nuts and the fuel injection tubing
from the fuel injection pump and the cylinder head.
00900163
Intake Manifold
Remove the eight capscrews, intake manifold, and air

inlet connection. Remove the grid heated, if equipped.
Remove the four capscrews, air inlet connection, and
o-ring. Discard the o-ring.
00900164

Spill Tube
Remove the spring hose clamps and hose.

Remove the spill tube.
00900166
Injector
CAUTION
Be careful not to damage the tip of the injector
when removing.
Remove the mounting capscrew, washer, and injector.
NOTE: When removing the injector, clean around

00900167 the injector, and insert a blind plug to
prevent dust or dirt from entering the engine.
NOTE: Mark the injectors with tags showing the

cylinder number, and keep it in a safe place.
If there is no abnormality in the injector,
install it in the same position during
assembly.
Rocker Lever Cover
Remove the three capscrews, isolator assemblies,

rocker lever cover, and o-ring.
03900075

00900251
Rocker Arm Assembly
1. Rocker Shaft 7. Cup Plug

2. Adjusting Screw Lock Nut 8. Snap Ring
3. Pedestal Mounting Capscrews 9. Thrust Washer (if equipped)
4. Separating Spring 10. Rocker Lever Pedestal
5. Rocker Shaft Indexing Screw 11. Rocker Lever
6. Pedestal Mounting Stud 12. Adjusting Screw.
Rocker Arm Assembly
Remove the mounting capscrews and the rocker arm

assembly.
NOTE: When removing the rocker arm, loosen the

locknut, and turn the adjustment screw
counterclockwise 2 to 3 turns.
00900169

Pushrods
Remove the pushrods from the cylinder head.
NOTE: Mark the pushrods with tags showing the

cylinder number, and keep it in a safe place.
If there is no abnormality in the push rod,
assembly.
00900170
Cylinder Head Assembly
WARNING
assistance to lift this component.
Remove the mounting capscrews, cylinder head

assembly, and gasket.
00900171 Discard the gasket.
Cylinder Head Assembly - Disassembly
Using the spring pusher, Part No. 3398179, compress

the valve spring, and remove the valve collets.
00900172
Loosen the spring, and remove the spring seat and

valve spring.
00900173

Raise the cylinder head, and remove the valve.
NOTE: Mark the valves with tags to show the place

of installation and keep in a safe place.
00900174
Fuel Injection Pump
CAUTION
Do not allow dirt or dust to enter the oil and fuel
inlet and outlet ports. Severe engine damage will
occur if contaminants are allowed to enter the
engine.
Remove the fuel supply tube from the fuel injection

pump.
00900176 Remove the mounting capscrew from the bracket and
fuel injection pump.
NOTE: The fuel injector pump, adapter plate, and

gear are removed as an assembly. The gear
can then be removed from the pump if
necessary.
Remove the mounting capscrews of the fuel injector

pump adapter plate.
Remove the fuel injector pump assembly, adapter
plate, and o-ring from the gear housing.
Discard the o-ring.
00900211
Remove the nut and washer from the fuel injection

pump.
Remove the fuel injection pump gear from the fuel
injection pump.
00900210

Remove the two mounting nuts, fuel injection pump,
and o-ring from the adapter plate.
Discard the o-ring.
00900246
PTO Shaft (if applicable)
Remove the two capscrews, flange, o-ring, and PTO

shaft.
00900177
Lubricating Oil Pan
Remove the 24 capscrews, lubricating oil pan, and

gasket.
Discard the gasket.
00900178
Lubricating Oil Suction Tube
Remove the two mounting capscrews, lubricating oil

suction tube, and o-ring.
Discard the o-ring.
00900179

Crankshaft Pulley
Remove the capscrew and mounting plate.
00900180
Remove the crankshaft pulley using flange puller,

Part No. 3397890.
00900212
Gear Housing Cover
Remove the 17 capscrews and the gear housing

cover.
00900181
NOTE: A noise damper is installed on some

engines. The noise damper must be
removed prior to removing the front oil seal.
Remove the front oil seal from the gear housing cover.
00900182

Lubricating Oil Pump
Remove the five capscrews and the lubricating oil

pump.
00900183
Idler Gear
Remove the capscrew, retainer plate, and idler gear.

NOTE: If a PTO is installed, the idler gear uses a
bearing.
00900184
Camshaft Assembly
Remove the two mounting capscrews through the

casting holes in the camshaft gear.
00900185
Remove the thrust plate and camshaft assembly.
NOTE: When removing the camshaft, lightly rotate

the shaft while being careful not to damage
the bushing.
00900186

Flywheel
WARNING
WARNING
00900187 The pilot is short, so the flywheel can come off
suddenly.
Remove the six capscrews, retaining plate, coupling,

and flywheel.
Flywheel Housing
WARNING
Remove the nine capscrews, rear oil seal, and

flywheel housing.
00900188
Remove the rear oil seal.
00900189
Block Water Heater
NOTE: Be sure the engine coolant has been

drained.
Disconnect the block heater electrical cord.
cs900wf

Loosen the block heater retaining nut.
Remove the block heater from the block.
cs900mb
Piston, Connecting Rod Assembly
Turn the cylinder block on its side with cylinders

positioned horizontally.
00900190
CAUTION
Be careful not to damage the inside of the
cylinder.
Remove the carbon at the top of the cylinder using

fine sandpaper.
00900191
Measure the side clearance of the connecting rod

with a dial gauge before removing the piston and
connecting rod assembly.
Side Clearance
mm in
0.20 MIN 0.0079
0.40 MAX 0.016
00900192

Rotate the camshaft to set the piston at bottom dead
center.
Remove the mounting capscrews of the connecting
rod cap.
Check the number stamped on the connecting rod
cap and the cylinder. The numbers must match.
NOTE: If there is no number stamped on the
connecting rod cap, stamp the correct
number on the camshaft end of the cap.
Tap the cap with a plastic hammer, and remove the
connecting rod cap and bearing.
00900193
Push a wooden bar or hammer handle through the

cylinder from the lubricating oil pan side of the block.
Support the piston at the cylinder head side of the
block, and push the bar in far enough to remove the
piston and connecting rod assembly.
00900195
Piston and Connecting Rod Assembly -

Disassembly
Remove the snap ring on one side of the piston using

pliers.
00900196
Remove the piston pin, and separate the piston and

connecting rod.
NOTE: If the pin does not come out, place the

assembly in hot water prior to disassembly.
00900197

Remove the snap ring on the other side of the piston
using pliers.
00900198
Remove the piston ring from the piston using piston

ring tool, Part No. 3823137.
00900199
If the bushing is worn, the connecting rod must be

replaced.
Inside Diameter: 30.00 mm [1.18 in]
NOTE: Keep the pistons, connecting rods, bearings,
piston rings, piston pins, and bushings in
sets for each cylinder number.
00900200
Main Bearing Cap
Rotate the cylinder block so that the bottom of the

block is facing up.
00900201

Measure the end play of the crankshaft using a dial
gauge.
NOTE: The end play measurement is necessary for
determining the wear of the thrust bearing
and abnormal wear of the crankshaft.
Crankshaft End Play

mm in
0.131 MIN 0.0052
0.351 MAX 0.0138
00900202
Remove the mounting capscrews of the main bearing

cap.
Remove the main bearing cap and lower bearing.
NOTE:
• Mark the thrust bearings so that they can be
installed into the correct position.
• The main bearing cap mounting capscrews must
be replaced after each use.
00900203
Crankshaft
CAUTION
Be careful not to hit the crankshaft against the
cylinder block and damage the sliding surface.
Remove the crankshaft.
00900204
Remove the upper main bearing.

NOTE: Mark the main bearings and thrust bearing
so that they can be installed into the correct
position.
00900205

Tappet
Remove the tappet.
00900205

Engine Assembly
Service Tools
Part No. Part Name Quantity

3375193
or Unit Repair Stand or Engine Overhaul Stand 1
3375194
3163625 Bracket 1
3163292 Valve Spring Compressor 1
3823137 Piston Ring Expansion Tool 1
3397773 Piston Ring Compressor 1
Setting the Unit in the Repair Stand
Install bracket, Part No. 3163625, to the cylinder

block.
00900213
WARNING
Put the engine block on the stand.
00900214

Tappet
NOTE: Rotate the engine block so that the cylinder

head side is down.
Coat the tappet with engine oil and install into the
block.
00900215
Crankshaft
CAUTION
Confirm that there is no dirt or dust stuck to the
rear face of the bearing before installation. Debris
behind the bearing can cause severe engine
damage.
NOTE: Coat the inside face of the bearing with

engine oil (SAE 30) before installation.
Align the protrusion of the upper main bearing with
00900216
the notch in the cylinder block.
Install the upper main bearings.
CAUTION
Do not hit the crankshaft against the cylinder
block. Damage to the block or crankshaft can
occur.
Position the crankshaft and gear in the cylinder block.
00900204
Main Bearing Cap
CAUTION
Confirm that there is no dirt or dust stuck to the
rear face of the bearing before installation. Debris
behind the bearing can cause severe engine
damage.
NOTE: Coat the inside face of the bearing with

engine oil (SAE 30) before installation. The
number stamped on the main bearing cap
00900217
must be the same as the number stamped
on the cylinder block.
Align the protrusion in the lower main bearing with the
notch in the cap.
Install the lower main bearing into the main bearing
cap.

• Casting number or cast arrow on the main
bearing cap must face toward the front of the
engine.
• New main bearing mounting capscrews must be
used.
• Coat the capscrew threads and seat face with
engine oil.
Position the main bearing caps and capscrews.
00900218
CAUTION
Install each thrust bearing with the oil groove on
the outside. Failure to do so will cause engine
damage or failure.
CAUTION
Do not let the thrust bearings slip out of place.
Engine damage or failure will result if the thrust
bearings are not properly installed.
00900219
NOTE: Casting number or cast arrow on the main
bearing cap must face toward the front of
the engine. The thrust bearing is located on
the main bearing closest to the rear of the
engine (No. 5). Align the lower thrust
bearing with the dowel pin.
Install the upper thrust bearing.
Tighten the mounting capscrews in the order shown.
Torque Value:
Main Bearing
Capscrews Step 1 113 N•m [83 ft-lb]
2 Loosen all capscrews
completely
3 132 N•m [98 ft-lb]
00900220
After tightening the mounting capscrews, make sure

the crankshaft rotates smoothly
NOTE:
00900222

Measure the crankshaft end play using a dial indicator.
Crankshaft End Play

mm in
0.131 MIN 0.0052
0.351 MAX 0.0138
00900202
Piston, Connecting Rod Assembly - Assemble
CAUTION
Be careful not to damage the piston or break the
piston rings.
Install the piston rings on the piston using piston ring

tool, Part No. 3823137.
NOTE: The rings must be set with the stamped
mark near the end facing up. The oil ring
00900223 (bottom ring) must be set with matching part
of the expander coil and the end gap of the
ring 180 degrees apart.
Install one snap ring on one side of the piston into the
snap ring groove.
00900198
NOTE: The stamped “F” mark on the piston and the

match mark (or cast part number) on the
connecting rod must face in the same
direction.
Assemble the piston on the connecting rod by
installing the piston pin.
NOTE: Pistons do not need to be heated prior to
installing the piston pin. However, placing
the piston in hot water prior to installing the
pin will ease the installation.
00900197

Install the other snap ring into the snap ring groove.
NOTE: Make sure the connecting rod moves freely
forward and backward after installing the
last snap ring.
00900196
Locate the end gaps of the piston rings as shown.

1. Top Ring
2. Second Ring
3. Oil Ring
4. Part Number Mark - “EXXXX”
- XXXX = Last Four Digits of the Part Number
- “NA” or “T”
- NA = Naturally Aspirated
- T = Turbocharged
00900225
NOTE: Align the notch of the upper bearing with the

notch of the connecting rod.
Install the upper connecting rod bearing into the
connecting rod.
00900226
NOTE: Coat the inside face of the cylinder, the

piston rings, and the surface of the
connecting rod bearing with engine oil (SAE
30). Install the piston and connecting rod
assembly with the “F” mark on the piston
facing the front of the engine.
NOTE: The connecting rods are stamped with the
number of the cylinder in which they are to
be installed. This match mark must be on
the camshaft side of the engine after
installation.
00900228 Set the crankshaft pin to bottom dead center.
Install the piston and connecting rod assembly from
the top of the cylinder block using piston holder, Part
No. 3397773.

Align the notch of the lower bearing with the notch of
the connecting rod cap.
Install the lower connecting rod bearing into the
connecting rod cap.
00900229
NOTE: Coat the lower bearing with engine oil (SAE

30). The connecting rod cap is stamped with
a number that must match both the number
on the connecting rod and the cylinder in
which it is being installed.
Install the connecting rod cap and capscrews.
NOTE: Coat the connecting rod capscrew threads
and seat face with engine oil (SAE 30).
Tighten the capscrews.
Torque Value:
Main Bearing
00900230 Capscrews Step 1 39 N•m [29 ft-lb]
2 Rotate 90 degrees
NOTE: The connecting rod capscrews can be

reused five times. Make a punch mark on
the capscrew head each time the capscrew
is used. If there are already five marks on
the capscrew head, the capscrew must be
replaced.
After installing the piston and connecting rod

assemblies, check the crankshaft for smooth rotation.
00900231
Measure the side clearance of the connecting rod cap.
Connecting Rod Cap Side Clearance

mm in
0.20 MIN 0.0079
0.40 MAX 0.0160
00900192

Flywheel Housing
Install the rear seal using oil seal installer, Part No.
ST 972.
Fill 40 to 60 percent of the space in the seal lip with
grease.
00900189
WARNING
CAUTION
Do not apply excessive force to the seal lip
00900188 surface when aligning and installing the flywheel.
Damage to the engine will occur if the seal is
damaged.
NOTE: Apply gasket sealant to the flywheel housing

mounting surface.
Align the flywheel housing with the dowel pins.
Install the flywheel housing and capscrews. Tighten
the capscrews.
Torque Value: 69 N•m [50 ft-lb]
Measure the distance in height between the

lubricating oil pan mounting surface and the flywheel
housing flange.
Maximum Height Difference: 0.15 mm [0.0059 in]
00900235

Measure the radial and face runout of the flywheel
housing.
Radial Runout
mm in
0.35 MAX 0.014
Face Runout
mm in
0.30 MAX 0.012
00900236
Flywheel
WARNING
Install the flywheel, coupling, retaining plate, and six

capscrews. Tighten the capscrews.
00900187 Torque Value:

Main Bearing
Flywheel
2 191 N•m [141 ft-lb]
Measure the radial and face runout of the flywheel.
Radial Runout
mm in
0.20 MAX 0.0079
Face Runout
mm in
0.15 MAX 0.0059
00900237
Camshaft Assembly
NOTE: When installing the camshaft, lightly rotate

the shaft while being careful not to damage
the bushing.
Install the thrust plate, camshaft assembly, and two
capscrews.
Tighten the capscrews through the casting holes in
the camshaft gear.
00900238

Measure the end play (1) of the camshaft.
Camshaft End Play

mm in
0.150 MIN 0.0059
0.350 MAX 0.0138
00900239
Oil Pump
Install the lubricating oil pump and five capscrews.
00900183
Measure the end play of the lubricating oil pump drive

gear.
Lubricating Oil Pump Drive Gear End Play

mm in
0.020 MIN 0.0008
0.070 MAX 0.0028
00900240
Idler Gear
Align the match marks of the idler gear, crankshaft

gear, and camshaft gear. The match marks are
identified as follows:
• Crankshaft Gear and Idler Gear: A
• Idler Gear and Camshaft Gear: B
• Fuel Pump and Idler Gear: C
• Lower case letters identify oil pump and
accessory drive, which are not timed.
00900241

Install the retainer plate and capscrew.
Tighten the capscrew.
00900184
Measure the end play of the idler gear.
00900243
Match mark alignment:
Turbocharged and Naturally Aspirated

Crankshaft gear 0.08 mm to 0.19 mm
A
and idler gear [0.0031 in to 0.007 in]
Camshaft gear 0.08 mm to 0.19 mm
B
and idler gear [0.0031 in to 0.007 in] Aspirated
Replacement
Injection pump
0.07 mm to 0.29 mm Limit:
Backlash C gear and idler
[0.003 in to 0.011 in] 0.40 mm
gear
[0.0157 in]
a
and oil pump gear [0.006 in to 0.012 in]
Camshaft gear 0.03mm to 0.050mm
b
and PTO gear [0.0012 in 0.0035 in]
Replacement
Clearance Between Bushing and Shaft
[0.0006 in to 0.002 in] 0.10 mm
[0.0039 in]
Replacement
End Play of Idler Gear
[0.0012 in to 0.0035 in] 0.20 mm
[0.0079 in]

Temporarily position the fuel injection pump assembly
and measure the backlash of the gears.
Measure the backlash of all the gears with a dial
indicator.
00900244
Gear Housing Cover
NOTE: A noise damper is installed on some

engines. The noise damper must be
installed prior to installing the front oil seal.
Install the front oil seal using tool, Part No. 3824498.
Fill 40 to 60 percent of the space in the seal lip with
grease.
00900182
CAUTION
Do not apply excessive force to the seal lip
surface when aligning and installing the gear
housing cover. Damage to the engine will occur if
the seal is damaged.
NOTE: Apply gasket sealant, Part No. 3823494, to

the gear housing cover mounting surface.
Install the gear housing cover and 17 capscrews.
00900181 Tighten the capscrews.
Measure the distance in height between the cylinder

block and the gear housing cover.
Maximum Height Difference: 0.15 mm [0.0059 in]
00900247

Crankshaft Pulley
Align the crankshaft pulley with the crankshaft key.

Install the crankshaft pulley, mounting plate, and
capscrew.
00900180
Lubricating Oil Suction Tube
Install a new o-ring, oil suction tube, and two

capscrews.
00900179
Lubricating Oil Pan
NOTE: Apply a 1-mm [0.039-in] bead of gasket

sealant, Part No. 3823494, to the mounting
surface of the lubricating oil pan.
Install a new gasket, lubricating oil pan, and 24
capscrews.
If the oil drain plug was removed, install the drain plug.
00900178
PTO Shaft (if applicable)
Align the gear of the PTO shaft with the surface teeth
of the camshaft gear.
Install the o-ring, flange, and two capscrews.
00900177

Fuel Injection Pump
CAUTION
Do not allow dirt or dust to enter the oil and fuel
inlet and outlet ports. Severe engine damage will
occur if contaminants are allowed to enter the
engine.
Install new o-ring, fuel injection pump, and two

mounting nuts on the adapter plate.
Tighten the nuts.
00900246
Install the fuel injection pump gear, washer, and nut

on the fuel injection pump.
Tighten the nut.
00900210
NOTE: Align the fuel injection pump gear match

mark “C” with the idler gear match mark “C”.
Install new o-ring, adapter plate, fuel injection pump
assembly, and mounting capscrews to the gear
housing.
Tighten the mounting capscrews.
00900211
Install the mounting capscrew on the fuel injection

pump support bracket.
NOTE: The fuel supply tube has a 12-mm and 14-
mm banjo fitting. The 12-mm banjo fitting
connects to the fuel injection pump. The 14-
mm banjo fitting connects to the fuel filter
head, which is installed later in the
assembly process.
Install the fuel supply tube to the fuel injection pump.
00900176 Torque Value: 20 N•m [15 ft-lb]

Cylinder Head Assembly
NOTE: Coat the stems of the intake and exhaust

valves and the inside of the valve guides
with engine oil.
Install the valves.
00900174
Install the valve spring and spring seat on the valve

stem.
00900173
Install the valve cotter into the valve stem groove

while compressing the valve spring with spring pusher,
Part No. 3398179.
00900172
After releasing the valve spring, tap the top of the

valve stem with a plastic hammer to make certain the
cotter is completely fitted.
00900252

CAUTION
Remove all carbon and dirt from the contact

surfaces of the cylinder block and the cylinder
head. Remove all burrs and damage, and clean
out all the dirt from inside the cylinder block.
Failure to follow these steps will result in severe
engine damage.
Install a new cylinder head gasket with the TOP mark

00900253 facing up.
WARNING
NOTE: Coat the capscrew threads with antifriction

compound, Part No. 3824879.
Install the cylinder head using four head capscrews
as guides.
00900254
Install the capscrews. Tighten the capscrews in the

sequence shown.
Torque Value:
Cylinder Head
2 108 N•m [80 ft-lb]
3 Rotate 90 degrees
NOTE: The cylinder head capscrews can be reused

five times. Make a punch mark on the
00900245 capscrew head each time the capscrew is
used. If there are already five marks on the
capscrew head, the capscrew must be
replaced.
Push Rods
NOTE: If there is no abnormality in the pushrods,

install them in the same position that they
were removed from during disassembly.
00900170

00900251
Rocker Arm Assembly
1. Rocker Shaft 7. Cup Plug

2. Adjusting Screw Lock Nut 8. Snap Ring
3. Pedestal Mounting Capscrews 9. Thrust Washer (only used on some engines)
4. Separating Spring 10. Rocker Lever Pedestal
5. Rocker Shaft Indexing Screw 11. Rocker Lever
6. Pedestal Mounting Stud 12. Adjusting Screw.
Rocker Arm Assembly
NOTE: Check that the ball of the adjustment screw

is fitted properly into the socket of the
pushrod before tightening the capscrews. If
the valve spring tension pushes against the
rocker arm, loosen the locknut, and turn the
adjustment screw back to prevent strain on
the pushrod.
Install the rocker arm assembly and eight capscrews.
00900169 Torque Value: 25 N•m [18 ft-lb]

Adjusting Valve Clearance
Adjust the valve clearance. Refer to Section 14.
03900077
Rocker Lever Cover
Install the o-ring into the rocker lever cover.

Install the rocker lever cover, three capscrews, and
isolator assemblies.
03900075
Injector
Coat the injectors with anti-sieze compound, Part No.

3824879, before installation.
fi9slwb
CAUTION
Be careful not to damage the tip of the injector
when installing.
NOTE: When installing the injector, clean around

the injector, and do not allow dust or dirt to
enter the engine.
NOTE: If there is no abnormality in the injector,
00900167 assembly.
Install the injector, washer, and mounting capscrew.

Spill Tube
Install the spill tube.
00900166
Intake Manifold
NOTE: Apply a 1-mm [0.039-in] bead of gasket

sealant, Part No. 3823494, to the mounting
surface of the intake manifold.
Install the air inlet connection, intake manifold, and
seven capscrews.
00900164
Fuel Injection Tubing
NOTE: Before installing the fuel injection tubing,

blow compressed air through it to clean it.
Position the fuel injection tubing, and loosely install
the sleeve nuts on the fuel injection pump and the
cylinder head.
Tighten the clamp.
Tighten the banjo fittings
00900163
Exhaust Manifold
Install a new gasket, the exhaust manifold, and the

eight capscrews.
00900162

Thermostat
Install seal, thermostat, thermostat housing, and two

mounting capscrews.
18900025
Water Pump
Install the o-ring, gasket, water pump, and mounting

capscrews.
00900161
Dipstick
NOTE: Apply Loctite™ sealant, Part No. 3375068,

or equivalent, to the outside of the dipstick
tube.
CAUTION
Excessive sealant can run back into the engine
and cause damage to other components.
00900160 Install the dipstick guide.

Install the dipstick.

Lubricating Oil Filter
Install the lubricating oil filter.

NOTE: Some engines will have an oil filter cooler
mounted between the oil filter and the
engine block.
00900155
Block Water Heater
Clean the core plug hole thoroughly. Make sure there

are not burrs or sharp edges that might cut the o-ring.
cs9pxea
Lubricate the new heater o-ring with clean engine oil.
cs9orwa
The locking channel (T-Bar) should be threaded out

to the end of the bolt. If so equipped, do not remove
the retaining wire used to position the channel (T-Bar).
cs900wg

Hook the element and one leg of the channel (T-Bar)
into the hole as illustrated.
cs900wh
Hook the other leg of the channel in the hole and

push the heater into the hole as far as possible by
hand.
cs900wi
CAUTION
Do not pull the heater into location with the
locking bolt as the channel (T-Bar) can bend or
cause the threads to strip.
If necessary, use a plastic hammer to tap the heater

in until the shoulder contacts the block.
cs900hb
Tighten the locking bolt.

Torque Value: 2.0 N•m [18 in-lb]
Do not over-tighten the locking bolt.
cs9bona

Insert the power cord into the socket being careful to
align the pins with the sockets of the power cord.
Tighten the retaining nut by hand.
Do not apply power until the cooling system is filled,
and run the engine long enough for the thermostats to
open and ensure all the air has escaped.
cs900hc
Alternator
Install the alternator and capscrew.

Install the spacer, mounting capscrew, and
adjustment plate.
Loosely install the washer and adjustment capscrew.
00900159
Fan Pulley
Install the fan pulley.
00900255
Position the fan belt (2) into the fan pulley groove,
and loosely tighten the adjustment capscrew (1).
00900158

WARNING
Be careful not to injure your fingers or damage
the alternator when adjusting the belt tension.
Insert a bar or pipe between the alternator and the

cylinder block. Raise the alternator to adjust the fan
tension.
NOTE: The belt must deflect 7 mm to 10 mm [0.28
in to 0.39 in] when pushed with finger-
pressure of 6 kg [13 lb] at a point midway
00900257 between the fan pulley and the crankshaft
pulley.
Tighten the adjustment capscrew (1).
Torque Value:
Mounting
31 N•m [23 ft-lb]
Capscrew
Adjustment
31 N•m [23 ft-lb]
Capscrew
Fan
Install the spacer, fan, four capscrews.

00900157
Remove the covers on all the engine openings that

were installed to prevent dirt and debris from entering
the engine.
00900209

WARNING
Engine Weight (approx.) 330 kg [660 lb]

Remove the engine from the stand.
00900208
Remove the bracket, Part No. 3163625, from the

engine.
00900207
Install the starting motor.

NOTE: The o-ring is used only on wet flywheel
housings.
00900156
Install all the chassis components that were removed

during removal of the engine from the equipment.

Connect the drive units to the flywheel housing and
flywheel.
tr400wa `
Connect the intake and exhaust system pipes.
oi400ha
Connect the starter cable, engine ground straps, cab

or chassis to engine hoses, tubing, electrical wires,
and hydraulic lines.
WARNING
Always connect the negative (-) cable last.
Connect the battery cables.
sb8coma
WARNING
Some state and federal agencies in the United
States of America have determined that used oil
is carcinogenic and can cause reproductive
toxicity. Avoid inhalation of vapors, ingestion, and
prolonged contact with used engine oil. Always
use the proper procedures to dispose of the oil.
Fill the engine with lubricating oil.

07900034 Engine Oil 6.5 liters [1.7 u.s.gal]

WARNING
Coolant is toxic. Keep away from children and
animals. Save for reuse or dispose of in
accordance with local regulations.
Fill the engine with engine coolant.
ra800wn
NOTE: Remove all tags that were put on all hoses,

lines, linkage, and electrical connections as
they were removed to identify location
during the removal process.
fp8hola

Rocker Levers
Adjusting Valve Clearance
Remove the cylinder head cover.
03900075
Rotate the crankshaft in the normal direction.

While watching the movement of the intake valve of
No. 4 cylinder, bring the No.1 cylinder into
compression top dead center position
Align the TOP engraved mark on the crankshaft
pulley (1) with pointer (2).
NOTE:
• The engraved mark on the crankshaft pulley will
read “1.4 TOP.”
• The No. 4 intake valve will start to open when the
0390076 No. 1 cylinder comes near compression top
dead center.
Loosen the lock nut (3) on the adjustment screw (4).

Insert the feeler gauge (5) between the valve stem (6)
and the rocker arm (7).
Adjust the clearance with the adjustment screw until
slight drag is felt on the feeler gauge.
Valve Clearance (Engine Hot or Cold)

Intake Valve Exhaust Valve
0.35 mm 0.50 mm
0.014 in 0.020 in
0390077
Diesel Engine 87 Engine Testing

NOTE: Adjust intake and exhaust clearances in the
following firing order by rotating the
crankshaft 180 degrees in the normal
direction: 1-2-4-3.
0390078
Adjust the valve clearances for intake valves No. 1

and No. 3.
Adjust the valve clearances for exhaust valves No. 1
and No. 2.
0390079
Rotate the crankshaft in the normal direction one

revolution.
Adjust the valve clearances for intake valves No. 2
and No. 4.
Adjust the valve clearances for exhaust valves No. 3
and No. 4.
0390078
Tighten the locknut to secure the adjustment screw.
Locknut Torque Value

N•m ft-lb
39.2 MIN 28.9
49 MAX 36.1
0390080

Complete Engine
Measuring Compression Pressure
WARNING WARNING
Exhaust manifold and muffler are hot. Do not To avoid personal injury, keep hands, long hair,
touch the exhaust manifold or muffler or personal jewelry, and loose fitting or torn clothing away
injury will occur. from fans and other moving parts.
Adjust the overhead. Refer to Adjusting Valve

Clearance procedure.
0390077
Remove the spill tube.
0390166
Disconnect the fuel injection tubing.

NOTE: Disconnect the fuel shut-off solenoid.
0390163

CAUTION
Do not allow dirt or foreign matter to get into the
cylinder. Foreign objects in the cylinder can
cause severe engine damage.
Remove the nozzle holder assembly for each cylinder.

Remove the injector.
0390167
Lubricate the sealing lips of the sleeve with anti-seize

compound. Assemble the injector, sealing sleeve, a
new copper sealing washer, and the hold-down clamp.
Use only one washer.
NOTE: A light coat of clean 15W-40 engine oil
between the washer and injector can help
hold the washer in place during installation.
fi9slwb
Install the adapter to the nozzle holder mounting

section of the cylinder to be measured. Tighten the
adapter.
Adapter Capscrews
N•m ft-lb
39 MIN 29
49 MAX 36
14900059
Connect the compression gauge to the adapter.

NOTE: Most compression leakage can be
prevented by applying a small amount of oil
to the mounting section of the adapter.
14000060

Crank the engine with the starting motor. Read the
gauge when the pointer is stabilized.
Engine Compression
kPa psi
1965 MIN 285
2944 NOM 427
14000062
Testing and Adjusting the Fan Belt

Tansion
Testing the Fan Belt Tension
Check the amount the fan belt deflects when pushed

with a force of 6 kg [13.2 lb] at a point midway
between the fan pulley and the alternator pulley.
Fan Belt Deflection

mm in
7.0 MIN 0.28
10.0 MAX 0.39
fa9blsh
Adjusting the Fan Belt Tension
Loosen the mounting capscrew of the alternator (1)

and belt tension adjustment capscrew (2).
14000068
Using a bar, raise the alternator, and adjust the fan

belt tension.
Tighten the adjustment capscrew and the mounting
capscrew.
Torque Value:
Adjustment
31 N•m [23 ft-lb]
Capscrew
Mounting
66 N•m [49 ft-lb]
Capscrew
00900257

Fuel System
Checking and Adjusting Fuel
Injection Timing
There are two methods for checking and adjusting the

fuel injection timing of an injection pump.
• The “MATCH MARK ALIGNMENT” method,
which is used when the injection pump is
installed on the original engine and the pump is
not being repaired.
• The “MEASURING DEVICE” method, which is
used when a repaired or replaced injection
pump is installed on the engine.
Checking and Adjusting with the Match Mark

Alignment Method
NOTE: Set the No. 1 cylinder at compression top

dead center (TDC) by aligning the pointer
on the gear cover with the TDC line on the
crankshaft pulley. Confirm that the mark “C”
can be seen on the idler gear. If the mark
“C” can not be seen, rotate the crankshaft
one complete revolution and confirm that
“C” can be seen.
14900070
NOTE: Align the match mark “C” on the injection

pump gear with the match mark “C” on the
idler gear during installation for correct
alignment. Align the stamped line “a” on the
injection pump with the stamped line “b” on
the timing gear case during installation for
correct alignment.
Install the injection pump.
14900071

If the stamp lines are out of alignment, loosen nut (7).
Align the stamp lines by rotating the coupling.
Tighten the nut.
14900072
Checking and Adjusting with the Measuring

Device Method
NOTE: Set the No. 1 cylinder at compression top

dead center (TDC) by aligning the pointer
on the gear cover with the TDC line on the
crankshaft pulley.
14900073
Remove the distributor head bolt and copper washer

from the injection pump.
Discard the copper washer.
14900074
Install the dial gauge, Part No. 3377259, into the

distributor head.
NOTE: Check that the stylus end of the dial gauge
contacts the plunger head.
14900075

Rotate the crankshaft opposite normal engine rotation
(counterclockwise) slightly, until the dial gauge does
not move any longer.
Set the dial gauge pointer to 0.
14900076
Rotate the crankshaft in the normal direction until the

dial gauge reads 1.0 ± 0.3 mm [0.04 ± 0.01 in].
14900077
Look at the pointer on the crankshaft. It should point

to the timing mark in degrees as stamped on the
dataplate. The timing marks on the crank pulley range
from 6 to 14 degrees in two degree increments.
NOTE: Check the values on the data plate. Values
may change as new ratings are developed.
NOTE: The gauge reading ±0.03 mm [0.001 in] is
equivalent to ±0.5 degrees fuel injection
timing.
NOTE: The crankshaft must be rotated in the
normal direction (clockwise looking from
14900070 the front of the engine) without stopping.
If the dial readings are not within the standard value,

loosen nut. Adjust the fuel injection timing to within
standard value by rotating the injection pump body.
Tighten the nut.
14900078

Remove the dial gauge.
Install the distributor head bolt and new copper
washer into the injection pump.
Tighten the bolt.
14900074
Stamp a match mark on the injection pump and the

timing gear case.
14900080
Adjusting the Idle
Move the governor control lever to the desired idling

speed by using the idling adjustment screw.
14900082
Injector
Testing
WARNING
Keep your body clear of test spray. Fluid can be
injected into the bloodstream causing blood
poisoning and possible death.
NOTE: All nozzles must be tested for opening

pressure, chatter and spray pattern.
fi900sa

Check the opening pressure.
a. Open valve.
b. Operate lever at one stroke per second.
c. Read pressure indicated when spray begins.
fi900de
If the opening pressure is out of specification,

disassemble the injector and change the shims in
order to change the opening pressure.
NOTE: .01 mm [0.0039 in] shim thickness equals
41 bar [595 psi].
fi900oa
Leakage Test
a. Open the valve.

b. Operate the lever to hold pressure 20 bar [290
psi] below opening pressure.
c. No drops should fall from the tip within 10
seconds.
fi900df
Chatter Test
The chatter test indicates the ability of the needle

valve to move freely and correctly atomize the fuel.
An audible sound should be heard as the valve
rapidly opens and closes. A well optimized spray
pattern should be seen.
Used nozzles should not be evaluated for chatter at
lower speeds. A used nozzle can generally be used if
it passes the leakage test.
fi900dd

Disassembly
Remove the copper sealing washer and discard.
filsema
Clamp the nozzle holder in a soft jawed vise and

remove the nozzle nut.
fi900fb
Remove the nozzle needle valve and intermediate

plate.
NOTE: To avoid damage, place the injector nozzle
and needle valve in a suitable bath of clean
test oil.
fi900fc
Remove the nozzle holder from the vise; then remove

the pressure spindle, pressure spring, and shims.
fi900fd

Assembly
NOTE: Make sure all mating surfaces and pressure

faces are clean and lubricated with fuel oil
before assembly.
fi900ab
WARNING
Install the same thickness of shims that were
removed in disassembly. Use the pressure spring
to make sure the shims are installed flat.
Install the shims.
fi900ha
Clamp the nozzle holder in a soft jawed vise and

install the spindle.
fi900ce
Install the intermediate plate.
fi900ad

Install the needle valve and nozzle assembly.
fi900ce
Install the nozzle nut.
fi900ob

Lubricating System
Measuring Oil Pressure
WARNING
When measuring the oil pressure, be careful not
to get caught in rotating parts. always remove or
install plug or oil pressure gauges with the engine
stopped.
Remove the oil pressure sensor, and install the

pressure gauge.
14900086
NOTE: Measure the oil pressure while the engine is

warm (oil temperature minimum: 82° C
[180° F]).
Start the engine, and measure the oil pressure.
Lubricating Oil Pressure

kPa ft-lb
210 MIN 30
700 MAX 102
14900087

Specifications
Valves, Valve Guides, and Springs
18900014
Ref Inspection Item Standard Remarks

VALVES
Tolerance:
-0.035 mm
Intake [-0.0014 in]
-0.050 mm
Nominal: [-0.0020 in]
Stem Diameter 8 mm
[0.3130 in] Tolerance:
3 -0.050 mm
Exhaust [-0.0020 in]
-0.065 mm
[-0.0026 in]
0.035 to 0.065 mm
Intake Clearance Limit:
[0.0014 to 0.0026 in]
Clearance Between Guide and Stem 0.20 mm
0.050 to 0.080 mm [0.0079 in]
Exhaust
[0.0020 to 0.0031 in]
Intake Repair Limit:
1.40 to 1.60 mm
2 Head Thickness 1.00 mm
Exhaust [0.0551 to 0.0630 in]
[0.039 in]
0.35 mm
Intake Tolerance:
Valve Clearance [0.0138 in]
1 ±0.02 mm
(at Cold and Warm) 0.50 mm
Exhaust [±0.0008 in]
[0.0197 in]
VALVE GUIDE
Intake Tolerance:
Protrusion Above Cylinder Head 14.5 mm
5 ±0.2 mm
Surface Exhaust [0.571 in]
[±0.0079 in]
VALVE SPRING
Repair Limit:
49.2 mm
Free-Length 48.5 mm
[1.94 in]
[1.90 in]
40.5 mm
Installed Length —
[1.59 in]
4
Repair Limit:
18.5 ±0.9 kg
Installed Load 16.5 kg
[40.8±2.0 lb]
[36.4 lb]
Repair Limit:
Squareness —
1.85
Diesel Engine 101 Specifications
Rocker Arm Shaft, Push Rod and Tappets
18900016

VALVE ROCKER ARM SHAFT
Tolerance:
19 mm
Diameter of Shaft -0.020 mm
[0.75 in]
[-0.0008 in]
Tolerance:
Nominal: 0.030 mm
Diameter of Rocker Arm Shaft Hole 19 mm [0.0012 in]
1 [0.75 in] 0.010 mm
[0.0004 in]
Clearance Limit:
0.010 to 0.050 mm
Clearance Between Rocker Arm and Shaft 0.12 mm
[0.0004 to 0.0020 in]
[0.0047 in]
Repair Limit:
Bend of Shaft — 0.20 mm
[0.0079 in]
PUSH ROD
Repair Limit:
2 Bend of Push Rod — 0.30 mm
[0.012 in]
TAPPET
Clearance Limit:
0.012 to 0.048 mm
3 Clearance Between Tappet and Tappet Hole 0.12 mm
[0.0005 to 0.0020 in]
[0.0047 in]

Cylinder Head
18900011

CYLINDER HEAD
Repair Limit:
0.00 to 0.05 mm
1 Surface Flatness (Warpage Limit) 0.30 mm
[0.00 to 0.002 in]
[0.012 in]
Repair Limit:
1.00 ±0.100 mm
Intake 2.00 mm
[0.039 ±0.004 in]
[0.079 in]
2 Valve Seat
Repair Limit:
0.90 ±0.100 mm
Exhaust 1.90 mm
[0.035 ±0.004 in]
[0.075 in]
Tolerance:
3.12 ±0.28 mm
3 Nozzle (Protrusion) 2.700 to 3.500 mm
[0.123 ±0.011 in]
[0.106 to 0.138 in]
Repair Limit: Judge
Tolerance:
4 Valve Seat Angle 45° condition of contact
±0°15'
surface by vacuum test.

Cylinder Block
18900012

CYLINDER BLOCK
Repair Limit:
0.00 to 0.08 mm
1 Surface Flatness (Warpage Limit) 0.15 mm
[0.00 to 0.003 in]
[0.006 in]
Repair Limit:
70.000 mm
STD 70.200 mm
[2.756 in]
[2.764 in]
Repair Limit:
69.750 mm
U/S 0.25 69.950 mm
[2.746 in]
[2.754 in]
Repair Limit:
Inner Diameter of 69.500 mm
2 U/S 0.50 69.700 mm
Main Bearing [2.736 in]
[2.744 in]
Repair Limit:
69.250 mm
U/S 0.75 69.450 mm
[2.726 in]
[2.734 in]
Repair Limit:
69.000 mm
U/S 1.00 69.200 mm
[2.717 in]
[2.724 in]
Repair Limit:
50.500 mm
3 Inner Diameter of Cam Bushing 50.600 mm
[1.988 in]
[1.992 in]

Camshaft and Camshaft Bushing
18900015

CAMSHAFT
Naturally Aspirated Naturally Aspirated
0.03 mm
1 Bend of Shaft —
[0.0012 in]
Repair Limit:
42.69 mm
Intake 42.20 mm
[1.681 in]
Cam [1.661 in]
2
Height Repair Limit:
43.04 mm
Exhaust 42.50 mm
[1.694 in]
[1.673 in]
Repair Limit:
Thrust 0.150 to 0.350 mm
3 0.50 mm
Clearance [0.0059 to 0.0138 in]
[0.0197 in]
CAMSHAFT BUSHING
Clearance No. 1 Repair Limit:
0.040 to 0.140 mm
4 to No. 2 0.25 mm
[0.0016 to 0.0055 in]
Cam No. 3 [0.0098 in]

Crankshaft
18900019

CRANKSHAFT
0.131 to 0.351 mm Repair Limit: 0.40 mm
1 Thrust Clearance
[0.0052 to 0.0138 in] [0.016 in]
70.000 mm Repair Limit: 69.86 mm
STD
[2.756 in] [2.750 in]
U/S 0.25
[2.746 in] [2.741 in]
Main Journal U/S 0.50
[2.736 in] [2.731 in]
2 U/S 0.75
[2.726 in] [2.721 in]
U/S 1.00
[2.717 in] [2.711 in]
Repair Limit: 0.020 mm
Roundness —
[0.0008 in]
0.043 to 0.103 mm Clearance Limit: 0.25 mm
Clearance
[0.0017 to 0.0041 in] [0.0098 in]
STD
[2.244 in] [2.241 in]
U/S 0.25
[2.234 in] [2.231 in]
Crank Pin Journal U/S 0.50
[2.224 in] [2.221 in]
3 U/S 0.75
[2.215 in] [2.211 in]
U/S 1.00
[2.205 in] [2.201 in]
Roundness —
[0.0008 in]
0.029 to 0.089 mm Clearance Limit: 0.22 mm
Clearance of Crank Pin Journal
[0.0011 to 0.0035 in] [0.0087 in]
4 Bend of Crankshaft —
[0.0035 in]

Timing Gear
18900018

TIMING GEAR
Naturally Aspirated and
Turbocharged
Crankshaft gear 0.08 mm to 0.19 mm

A
and idler gear [0.0031 in to 0.007 in]

B
and idler gear [0.0031 in to 0.007 in] Replacement
Limit:
Injection pump 0.07 mm to 0.29 mm 0.40 mm
1 Bend of Shaft C
gear and idler gear [0.003 in to 0.011 in] [0.0157 in]

a
and oil pump gear [0.003 in to 0.011 in]

b
and PTO gear [0.006 in to 0.012 in]
Replacement
2 Clearance Between Bushing and Shaft
[0.0006 in to 0.002 in] 0.10 mm
[0.0039 in]
Replacement
3 End Play of Idler Gear
[0.0012 in to 0.0035 in] 0.20 mm
[0.0079 in]

Flywheel
18900013

FLYWHEEL
Repair Limit:
1 Face Runout of Flywheel Housing — 0.30 mm
[0.012 in]
Repair Limit:
2 Radial Runout of Flywheel Housing — 0.35 mm
[0.014 in]
Repair Limit:
3 Face Runout of Flywheel — 0.15 mm
[0.0059 in]
Repair Limit:
4 Radial Runout of Flywheel — 0.20 mm
[0.079 in]

Cylinder
18900020

CYLINDER
Repair Limit:
ID: Tolerance:
ID:
Bore STD 95.00 mm 0.022 mm
95.15 mm
[3.740 in] [0.0008 in]
[3.746 in]
1
Roundness of Cylinder —
Repair Limit:
0.02 mm
[0.0008 in]
Cylindricity of Cylinder —

Piston
18900020

PISTON
Repair Limit:
ID:
ID:
1 Diameter STD 95.00 mm
94.85 mm
[3.740 in]
[3.734 in]
Repair Limit:
0.06 to 0.10 mm 2.0 mm
2 Top 0.15 mm
[0.0024 to 0.0039 in] [0.079 in]*
Clearance [0.0059 in]
Between Repair Limit:
2.0 mm
3 Piston Ring Second 0.20 mm
[0.079 in]*
Groove and 0.03 to 0.07 mm [0.0079 in]
Piston Ring [0.0012 to 0.0028 in] Repair Limit:
4.0 mm
4 Oil 0.15 mm
[0.158 in]*
[0.0059 in]
*Width of Groove (Nominal)

Connecting Rod, Piston Ring and Piston Pin
18900022

PISTON PIN
Nominal OD:
Outer Diameter 30.00 mm —
[1.181 in]
1
Clearance Limit:
0.004 to 0.018 mm
Clearance 0.05 mm
[0.0002 to 0.0007 in]
[0.002 in]
PISTON RING
Clearance Limit:
0.30 to 0.45 mm
A Top 2.00 mm
[0.012 to 0.018 in]
[0.079 in]
Clearance Limit:
0.30 to 0.45 mm
B Piston Ring Gap Second 2.00 mm
[0.012 to 0.018 in]
[0.079 in]
Clearance Limit:
0.25 to 0.45 mm
C Oil 1.50 mm
[0.0098 to 0.018 in]
[0.059 in]
CONNECTING ROD
Maximum: Repair Limit:
2 Bend (B)/Torsion (T) 0.20/0.30 mm 0.25/0.35 mm
[0.0078/0.0118 in] [0.0098/0.0138 in]
Tolerance:
33.00 mm
3 Inner Diameter of Bushing Hole 0.025 mm
[1.299 in]
[0.001 in]
CONNECTING ROD BUSHING
Nominal OD: Clearance Limit:
Clearance Between Bushing and 0.020 to 0.039 mm
1 30.00 mm 0.100 mm
Piston Ring (Small End) [0.0008 to 0.0015 in]
[1.18 in] [0.0039 in]
CONNECTING ROD BEARING
Repair Limit:
57.00 mm
4 Inner Diameter STD 57.20 mm
[2.244 in]
[2.252 in]

Oil Pump
18900017

Clearance Limit:
0.030 to 0.085 mm
1 Axial 0.10 mm
[0.0012 to 0.0033 in]
[0.0039 in]
Clearance of Pump Gear
Clearance Limit:
0.045 to 0.090 mm
2 Radial 0.13 mm
[0.0018 to 0.0035 in]
[0.0051 in]

Regulator Valve
18900023

Standard Tolerance Standard Clearance
Size Clearance Limit
Shaft Hole
Clearance
1 Between -0.050mm 0.020 mm 0.030 to
Valve and Body -0.077mm -0.020mm 0.097 mm
11 mm
[0.43 in]
[0.002 in] [0.0008 in] [0.001 to
[0.003 in] [0.0008 in] 0.004 in]
Standard Repair Limit
Free- Installed Installed Free- Installed
Length Length Load Length Load Replace
Regulator Valve
SprIng 33.1 mm 27.8 mm 2.44 kg 2.30 kg
—
Naturally [1.30 in] [1.09 in] [5.38 lb] [5.07 lb]
2 Aspirated
Regulator Valve
30.1 mm 27.8 mm 2.02 kg 1.92 kg
SprIng —
[1.18 in] [1.09 in] [4.45 lb] [4.23 lb]
Turbocharged
Repair or
Regulator Valve
3 Standard: 5.0 ±0.5 kg/cm Replace
Set Pressure
Spring

Thermostat
18900024

THERMOSTAT
Cracking Temperature:
82° C ±2° C [180° F ±2° F]
(Fully Open: Shall open fully
Fully Open Temperature:
when immersed in hot water
95° C [203° F]
1 Thermostat bath at a temperature between Replace
77° C [171° F] and 95° C
Fully Open Lift:
[203° F] for 4 to 5 minutes)
Minimum: 8 mm [0.315 in] (when
immersed in a hot water bath at
95° C [203° F] for 4 to 5 minutes)

Capscrew Markings and Torque Values
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:
17800016 17800017
NOTE: :
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.
4. When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values - Metric
Body
Size Torque Torque Torque
Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m 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 49 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 Body Size Cast Iron Aluminum Cast Iron Aluminum

N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
- 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
- 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
- 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
- 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
- 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
- 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
- 14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
- 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 9/16 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 5/8 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 11/16 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 3/4 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 7/8 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 Conversion Chart
N•m ft-lb N•m ft-lb N•m ft-lb

1 8.850756 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
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 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 N•m ft-lb N•m 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

Tap-Drill Chart - U.S. Customary and Metric
NOTE ON SELECTING TAP-DRILL SIZE: The tap drill size shown on this card give the theoretical tap drill size for
approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the
60% range as these sizes will provide about 90% of the potential holding power. Drill sizes in the 75% range are
recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.
17800013

Weight and Measures - Conversion Factors
From U.S. From Metric

Customary To U.S.
Quantity U.S. Customary Metric
To Metric Customary
Multiply By Multiply By
Unit Name Abbreviation Unit Name Abbr.
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 g/kW-
lb/hp-hr 608.277 0.001645
Consumption horsepower hour kilowatt hour hr
kilometers per
miles per gallon mpg km/l 0.4251 2.352
Fuel liter
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 H2 O kilopascal kPa 0.2488 4.019299
millimeters of mm
inches of mercury in Hg 25.40 0.039370
Pressure mercury Hg
Millimeters of mm H2
inches of water in H2 O 25.40 0.039370
water O
bars bars kilopascals kPa 100.001 0.00999
millimeters of mm
bars bars 750.06 0.001333
mercury Hg
Temperature fahrenheit °F centigrade °C (°F-32) 1.8 (1.8x°C) +32
pound force per
ft-lb Newton-meter N•m 1.35582 0.737562
foot
Torque
pound force per
in-lb Newton-meter N•m 0.113 8.850756
inch
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 cubic inch in3 liter l 0.01639 61.02545
displacement cubic
cubic inch in3 cm3 16.387 0.06102
centimeter
Weight
pounds (avoir.) lb kilograms kg 0.4536 2.204623
(mass)
British Thermal
BTU joules J 1054.5 0.000948
Unit
British Thermal
Work BTU kilowatt-hour kW-hr 0.000293 3414
Unit
horsepower
hp-hr kilowatt-hour kW-hr 0.746 1.341
hours

SPECIAL TOOLS
Style Tool No. Tool name
ST 434 Vacuum Gauge
ST 537 Dial Depth Gauge
ST 1111-3 Seal Leakage Tester
ST 1273 Pressure Gauge
3162745 Injector/Connector Removal tool
Diesel Engine 121 Special Tools

3163054 Camshaft Gear R&I 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
3397773 Piston Ring Compressor

3822476 Blow By tool, use with ST111-3
3822666 Digital Thermometer (Dual Input)
3823137 Pistion ring expander
3164438 Depth Gauge Assembly
3823956 Fuel Pump Mounting Kit

3824078 Oil Seal/Sleeve Installation Tool (rear)
3824498 Oil Seal Installation Tool
3824500 Wear Sleeve Installation Tool
3824591 Engine Barring Tool
3375193 Engine Rebuild Stand

3375194 Engine Rebuild Stand (Portable)
3163625 Bracket
3397890 Flange Puller

SB4136E00
Jun. 2004
Service Manual
G420E/G424E Tier LP Engine
Lift Trucks
G15S-2, G18S-2, G20SC-2
GC15S-2, GC18S-2, GC20SC-2
With G420E Tier LP Engine
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
with G424E Tier LP Engine
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
WARNING
in injury or death.
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. DAEWOO dealers have the most current information available.
1
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before installing,
operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow
instructions can cause personal injury and/or property damage.
The engine or other type of prime mover should be equipped with an over speed (over temperature, or
overpressure, where applicable) shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine or other type of prime mover with possible
personal injury or loss of life should the mechanical-hydraulic governor(s) or electric control(s), the actuator(s), fuel
control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging
device is turned off before disconnecting the battery from the system. Electronic controls contain static-sensitive
parts. Observe the following precautions to prevent damage to these parts.
z Discharge body static before handling the control (with power to the control turned off, contact a grounded
surface and maintain contact while handling the control).
z Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.
z Do not touch the components or conductors on a printed circuit board with your hands or with conductive
devices.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation, which, if not avoided, could result in death or
serious injury.
CAUTION—indicates a potentially hazardous situation, which, if not avoided, could result in damage to
equipment.
NOTE—provides other helpful information that does not fall under the warning or caution categories.
* This manual shows just LP fuel and engine control system for TIER- LP engine, so regarding
other ares(basic engine), please refer to the separate manual of SB4008E for G420 and SB2215E for
G424.
G420E/G424E Tier LP Engine 3 Table of Contents

Index CHAPTER 3 MI- 04 MAINTENANCE
SCHEDULE
WORKING WITH LPG EQUIPMENT RECOMMENDED MAINTENANCE SCHEDULE.....30

Test Fuel System for Leaks ......................................30
Inspect Engine for Fluid Leaks .................................30
CHAPTER 0 LPG AND LPG FUEL TANKS
Inspect Vacuum Lines and Fittings...........................30
Inspect Electrical System .........................................30
LPG Fuel Supply........................................................8
Inspect Acceleration Pedal Operation ......................31
LPG Fuel Tanks..........................................................9
Check Coolant Level ................................................31
Installing LPG Fuel Tanks ..........................................9
Inspect Coolant Hoses .............................................31
LPG Fuel Tank Components ....................................10
Inspect Battery System ............................................31
Fuel Gauge ..............................................................10
Inspect Ignition System ............................................31
Service Valve ...........................................................10
Replace Spark Plugs ................................................31
Quick Disconnect Coupling...................................... 11
Replace LP Fuel Filter Element................................32
Filler Valve................................................................ 11
Testing Fuel Lock-off Operation................................33
Pressure Regulator/Converter Testing and
nspection ..................................................................33
CHAPTER 1 ENGINE SPECIFICATION Fuel Trim Valve Inspection (FTV) .............................33
Inspect Air/Fuel Valve Mixer Assembly.....................33
Indication of Engine Serial Number..........................12 Inspect for Intake Leaks ...........................................34
Specifications(G420E) .............................................13 Inspect Throttle Assembly ........................................34
Specifications(G424E) .............................................14 Checking the TMAP Sensor .....................................34
Inspect Engine for Exhaust Leaks............................34
Replace Oxygen Sensor ..........................................34
CHAPTER 2 MI-04 LPG SYSTEM Maintenance Schedule.............................................35
OPERATIONAL OVERVIEW
MI-04 General Description .......................................15 CHAPTER 4 MI-04 LP BASIC

MI-04 LP Fuel Filter..................................................17 TROUBLESHOOTING
MI-04 Fuel Lock-Off (Electric) ..................................17
MI-04 N-2001 Regulator/Converter..........................18 Basic Troubleshooting ..............................................37
N-2001 Theory of Operation ....................................19
MI-04 N-CA55-500TR Mixer ....................................20
N-CA55-500-TR Air/Fuel Mixer Theory of
CHAPTER 5 MI-04 LP ADVANCED
Operation .................................................................20
MI-04 Electronic Throttle..........................................22 DIAGNOSTICS
MI-04 Fuel Trim Valve ..............................................23
Heated Exhaust Gas Oxygen Sensor (HEGO) ........24 Advanced Diagnostics..............................................44
MI-04 SECM (General Description) .........................25 Reading Diagnostic Fault Codes..............................44
MI-04 SECM (Fuel Management) ............................25 Displaying Fault Codes (DFC) From SECM
MI-04 SECM (Load/Speed Management)................27 Memory ....................................................................45
MI-04 Ignition management .....................................29 Clearing Fault (DFC) Codes.....................................45
Fault Action Descriptions..........................................45
Fault List Definitions .................................................46
Table a. MI-04 Diagnostic Fault Codes (Flash
Codes)......................................................................48
CHAPTER 6 MI-04 ELECTRICAL

CONNECTIONS
Resistance Checks...................................................62
Voltage Checks.........................................................63

CHAPTER 7 N2001 PRESSURE
REGULATOR /CONVERTER
Removal and Installation of N2001 LP

Regulator/Converter.................................................64
Hose Connections....................................................65
N2001 Removal Steps: ............................................66
N2001 Regulator Disassembly Steps:......................67
N2001 Disassembled Service..................................69
CHAPTER 8 N-CA55-500TR AIR/FUEL

MIXER
Removal and Installation of the N-CA55-500TR

Mixer ........................................................................70
N-CA55-500TR Mixer Removal Steps: ....................71
N-CA55-500TR Disassembly and Service...............72
N-CA55-500TR Disassembled Service....................74
Installing the Mixer/Throttle Assembly......................75
CHAPTER 9 TEST AND ADJUSTMENTS
N2001 Service Testing .............................................78

Primary Stage Test Hardware ..................................79
Primary Stage Pressure Test....................................79
N-CA55-500TR Service AVV (Air Valve Vacuum)
Testing......................................................................81
Ignition Timing Adjustment .......................................82
Idle Mixture Adjustment............................................85
CHAPTER 10 SERVICE TOOL KIT
Service Tool Kit ........................................................87

WORKING WITH LPG NOTE
EQUIPMENT
NFPA (National Fire Protection Agency) 58 covers the
procedures for storage and garaging for repair
purposes, on propane powered equipment.
WARNING
Propane Vapor is heavier than air and can collect in CAUTION

low areas when adequate ventilation or air movement
is not present to disperse it. Never check for leaks Safety is an important consideration for any repair
with a flame or match. Use a leak detector solution or facility, and repairing LPG fueled machinery is no
an electronic detector. Make sure the container exception. Refer to the NFPA (National Fire
service valve is closed when connecting or Protection Agency) for the appropriate fire
disconnecting. If the container service valve does not extinguisher specifications and fluorescent lighting
operate properly, discontinue use and contact your requirements.
propane supplier. Never insert any object into the
pressure relief valve. Propane has a heavier than air vapor density and will
fall if a leak occurs, while natural gas, by comparison,
will rise in the event of a leak (Figure 1).
WARNING This is an important property that technicians need to
be aware of when performing maintenance. When
LP gas is highly flammable. To prevent personal injury, repairing propane machinery, the work should be
keep fire and flammable materials away from the lift performed in the lowest point of the facility where
truck when work is done on the fuel system. possible. The tank supply should be shut off, except
Gas vapor may reduce oxygen available for breathing, when required for running equipment.
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.
Diesel
CAUTION CNG
The regulator/converter and mixer are part of a Figure 1 LPG

certified system complying with EPA and CARB 2004
requirements. Only trained certified technicians
should perform disassemble, service or replacement
of the regulator/converter or mixer.
CAUTION
LPG fueled machinery may be garaged anywhere

gasoline powered vehicles are garaged. When
machines are stored for a long period, it is advisable
to shut off the tank supply valve and run the machine
until the fuel trapped down stream of the valve is
depleted.
G420E/G424E Tier LP Engine 7 Working with LPG Equipment

The same principle is applied to LPG in a container,
LPG Fuel Supply commonly referred to as an LPG tank or cylinder.
Typically an LPG tank is not filled over 80% capacity
Liquefied petroleum gas (LPG) consists mainly of allowing for a 20% vapor expansion space. Outside
propane, propylene, butane, and butylenes in various air temperature effect’s an LPG tank and must be
mixtures. LPG is produced as a by-product of natural considered when using an LPG system. (Figure 2)
gas processing or it can be obtained from crude oil as shows the relationship between pressure and
part of the oil refining process. LPG, like gasoline, is a temperature in a LPG tank at a steady state condition.
compound of hydrogen and carbon, commonly called
hydrocarbons.
LPG Tank Pressure VS Temperature
In its natural state, propane is colorless and odorless; 300
an odorant (ethyl mercaptan) is added to the fuel so 250

its presence can be detected. There are currently
three grades of propane available in the United States. 200
Pressure, psig
A propane grade designation of HD5 (not exceeding 150
5% propylene), is used for internal combustion
100
engines while much higher levels of propylene
(HD10) are used as commercial grade propane along 50
with a commercial propane /butane mixture. 0

-20 0 20 40 60 80 100 120 140
Figure 2 Temperature, deg F
APPROXIMATE COMPOSITION OF HD5

With 128 PSIG vapor pressure acting against the
PROPANE BY VOLUME
liquid propane the boiling point has been raised to
slightly more than 80 deg. F / 27 deg. C.
Propane Propy Butane Iso- Methane
TOTAL
(C3H8) lene (C4H10) Butane (CH4)
90.0%
5% max. 2.0% 1.5% 1.5% 100%
min. Compressed
Vapor
An advantage of LPG is the ability to safely store and 128 PSIG Liquid
transport the product in the liquid state. In the liquid Propane
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 propane LPG Tank
in liquid form. The point at which the liquid becomes a
Figure 3
gas (boiling point) depends on the amount of
pressure applied to the container.
NOTE
This process operates similarly to an engine coolant Vapor pressure inside an LPG tank
system where water is kept from boiling by depends on the ambient air temperature
pressurizing the system and adding a mixture of outside the tank, not the amount of liquid
glycol. For example water at normal atmospheric inside the tank. A tank that is ¾ full of
pressure will boil at 212 deg. F / 100 deg. C. If an liquid propane at 80 deg. F will contain
engines operating temperature is approximately 230 the same vapor pressure as a tank that is
deg. F / 110 deg. C, then the water in an open un- only ¼ full of liquid propane.
pressurized cooling system would simply boil off into
steam, eventually leaving the cooling system empty LPG’s relative ease of vaporization makes it an
and over heating the engine. If we install a 10 PSIG excellent fuel for low-rpm engines on start-and-stop
cap on the radiator, pressurizing the cooling system operations. The more readily a fuel vaporizes the
to 10 PSIG, the boiling point of the water increases to more complete combustion will be.
242 deg. F / 117 deg. C, which will cause the water to Because propane has a low boiling point (-44F), and
remain in liquid state at the engines operating is a low carbon fuel, engine life can be extended due
temperature. to less cylinder wall wash down and little, if any,
carbon build up.
G420E/G424E Tier LP Engine 8 LPG and LPG Fuel Tanks

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 be
for industrial use and lift truck applications are within the outline of the vehicle to prevent damage to
portable universal cylinders and permanently the valves when maneuvering in tight spaces.
mounted tanks. Portable universal cylinders are used Horizontal tanks must be installed on the saddle that
primarily for off-highway vehicles and are constructed contains an alignment pin, which matches the hole in
in accordance with the DOT-TC (United States the collar of the tank. When the pin is in the hole, the
Department of Transport – Transport Canada). The liquid withdrawal tube is positioned to the bottom of
cylinders are referred to as universal because they the tank. A common problem is that often these
can be mounted in either a vertical or horizontal guide-pins are broken off, allowing the tank to be
position (Figure 4). 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, safety glasses and
gloves should be worn.
Figure 4
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 thereafter.
The tank must be discarded if the collar is damaged

to the point that it can no longer protect the valves. It
must also be replaced if the foot ring is bent to the
point where the tank will not stand or is easily
knocked over.

LPG Fuel Tank Components Service Valve
The service valve is a manually operated valve using
a small hand wheel to open and close the fuel supply
2 3 7 8 to the service line (fuel supply line). The service valve
9 installs directly into the tank and has two main
1 categories, liquid and vapor service valves. Liquid
service valves used on portable LPG tanks use a 3/8”
(3/8” NPT) male pipe thread on the service valve
outlet for attachment of a quick disconnect coupler.
4 An excess flow valve is built into the inlet side of the

6 12 10
11 service valve as a safety device in case of an
5
Figure 5 accidental opening of the service line or damage to
the service valve itself. The excess flow valve shuts
(1) Fuel Gauge (2) 80% Stop Bleeder off the flow of liquid propane if the flow rate of the
(3) Pressure Relief Valve liquid propane exceeds the maximum flow rate
(4) Service Valve (Tank end male coupling) (5) Filler Valve
(6) Alignment Pin
specified by the manufacturer.
(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
Outlet
In figure 5 a visual fuel gauge is used to show the fuel
level in the tank. A mechanical float mechanism
detects the liquid propane level. A magnet on the end
of the float shaft moves a magnetic pointer in the fuel Excess Flow
gauge. Some units have an electronic sending unit Valve
using a variable resistor, installed in place of a gauge Figure 6
for remote monitoring of the fuel level. The gauge
may be changed with fuel in the tank. DO NOT
REMOVE THE FOUR LARGE FLANGE BOLTS CAUTION
THAT RETAIN THE FLOAT ASSEMBLY, WITH When the tank is in use the service valve
FUEL IN THE TANK! should be completely open. If the valve is
partly open, the vehicle may not be
WARNING getting enough fuel to operate efficiently.
It is not a legal practice to fill the tank
through the liquid contents gauge. In addition to possibly starving the engine for fuel,
a partly open valve may restrict the flow enough
In some applications a fixed tube fuel indicator is
to prevent the excess flow valve from closing in
used in place of a float mechanism. A fixed tube
the event of a ruptured fuel line.
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 Most liquid service valves have an internal hydrostatic
opened during refueling by the fueling attendant. relief valve and are usually labeled “LIQUID WITH
When opened during refueling and the tanks LPG INTERNAL RELIEF”. The hydrostatic relief valve
level is below 80%, a small amount of vapor will exit protects the fuel service line between the tank and
the valve. When the LPG tank level reaches 80% the lock off from over pressurization. The internal
liquid propane will begin exiting the valve in the form hydrostatic relief valve has a minimum opening
of a white mist (Always wear the appropriate pressure of 375 PSIG and a maximum pressure of
protective apparel when refueling LPG cylinders). In 500 PSIG. These type of relief valves have an
order for this type of gauge to be accurate, the tank advantage over external relief valves because the
must be positioned properly. When full (80% LPG) propane is returned to the tank in the event of an over
the valve is closed by turning the knurled knob pressurization instead of venting the propane to
clockwise. Typically a warning label surrounds the atmosphere.
fixed tube gauge which reads STOP FILLING WHEN
LIQUID APPEARS.

Quick Disconnect Coupling Filler Valve
The liquid withdrawal or service valve on a DOT tank The liquid filler valve (Figure 9) has a male thread to
has male threads and accepts the female portion of a receive a fuel nozzle and typically has a plastic or
quick disconnect coupling (Figure 8). The female brass screw on cap that is retained with a small chain
portion is adapted to the liquid hose going to the fuel or plastic band to keep debris out of the filler valve.
system. Both halves are equipped with 100% shutoffs, The filler valve is a one-way flow device that uses two
which open when coupled together to allow fuel flow. check valves to allow fuel to enter the tank but
The coupler has two seals. One is an o-ring and the prevent it from exiting. Both check valves are
other is a flat washer. The o-ring prevents leakage backpressure type check valves, designed so that
from the shaft on the other coupling and the flat backpressure from the tank assists the check valves
washer seals when the coupler is fully connected. own spring pressure to close the valve. The first valve
uses a neoprene on metal seal and the second valve
NOTE uses a metal on metal seal.
The flat seal and/or the o-ring will
sometimes pop off when disconnecting A weakness ring is machined into the filler valve just
and slide up the shaft of the mating above the check valves and will allow the filler valve
connector, causing the valve not to open to shear off in case of an accident. The valve will
when fully mated. The extra washer or o- break or shear off above the check valves so that the
ring must be removed from the shaft and tank will be sealed and no liquid propane can escape.
the coupling reconnected.
Weakness
Ring
Figure 9
Figure 8
G420E/G424E Tier LP Engine 11 MI-04 System Overview

CHAPTER 1 ENGINE SPECIFICATION
Indication of Engine Serial Number
G420E/G424E Tier LP Engine 12 Engine Specification

Specifications(G420E)
GENERAL DESCRIPTION
ENGINE TYPE: Water-cooled, Inline 4-Cycle, 4-Cylinders
Naturally Aspirated 1-Venturi Intake Manifold
COMBUSTION SYSTEM:
Semi-spherical Combustion chamber
EXHAUST SYSTEM: Cast Iron, Dry
VALVE CONFIGURATION: OHC, 2 Valves per Cylinder
DISPLACEMENT: 1,997 cc (122 CID)
BORE: 85 mm (3.35 in.)
STROKE: 88 mm (3.46 in.)
COMPRESSION RATIO: 8.5:1
COMPRESSION PRESSURE: 1,128 kPa (163.5 psi)
Intake Valve: 12° BTDC(Open)/ 40° ABDC(Close)
VALVE TIMING:
Exhaust Valve: 54° BBDC(Open)/ 6° ATDC(Close)
FIRING ORDER: 1-3-4-2
SPARK PLUGS: BPR5ES: 0.7-0.8 mm (0.028-0.031 in.) Air Gap
WEIGHT: 139 Kg (306 lbs.), Dry
ROTATION: Counter-Clockwise (CCW) when viewed from Flywheel End
FUELTYPE: LPG
GOVERNED SPEED: 2400 +/- 25 RPM
IDLE RPM: 700 +/- 25 RPM
IGNITIOIN TIMING: Electronic controlled by ECM
LP FUEL SYSTEM
MIXER: Piston Type Air Valve Assembly inside, Downdraft
REGULATOR: Two-Stage Negative Pressure Regulator
FUEL FILTRATION: 40 Microns Maximum
COOLING SYSTEM
WATER PUMP ROTATION: V-Belt Drive - Clockwise (CW) when viewed from engine front
Opening Temperature: 82°C (180°F)
THERMOSTAT:
Fully Open Temperature: 95°C (203°F)
COOLING WATER CAPACITY 3.1 L (block only)
LUBRICATION SYSTEM
450 kPa (65 psi) @ Hi Idle
OIL PRESSURE:
50 kPa (7 psi) @ Low Idle
Upper Limit: 125°C (257°F)
OIL TEMPERATURE: Recommended: 99 - 110°C (210 - 230°F)
Lower Limit: 80°C (176°F)
CRANKCASE CAPACITY: 3.7 L
OIL FILTER: 0.3 L
ENGINE OIL SPECIFICATION: API - SJ, SAE 10W30 or SAE 5W30
ENGINE ELECTRICAL
IGNITION TYPE: Electronic Advanced by ECM
IGNITION COIL: 12 V operation volt, Ignition driver circuitry inside
DISTRIBUTOR: Mitsubishi Distributor
STARTER MOTOR: 12 Volt, 1.2 kW, Reduction drive
ALTERNATOR: 12 Volt, 61 Amp
ENGINE OIL PR. S/W: 24.5 kPa (3.6 psi)
ENGINE CONTROL MODULE(ECM): 12 V operation volt, 24 pins of I/O
VR SENSOR: Magnetic pick up sensor
TMAP: Intake Air Temp. & Manifold Absolute Press. Sensor
PEDAL ANGLE SENSOR: Two-Output Signals (Installed on Accelerator Pedal)
Heated Exhaust Gas Oxygen Sensor (HEGO)
OXYGEN SENSOR:
12 V operation volt
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
FUEL TRIM VALVE (FTV): 12 V operation volt
LP FUEL LOCK-OFF: 12 V operation volt, ON/OFF Control by ECM
EXHAUST SYSTEM
CATALYTIC MUFFLER: Three-way Catalyst included

Specifications(G424E)
GENERAL DESCRIPTION
Naturally Aspirated 1-Venturi Intake Manifold
COMBUSTION SYSTEM:
Semi-spherical Combustion chamber
VALVE CONFIGURATION: OHC, 2 Valves per Cylinder
DISPLACEMENT: 2,350 cc (143 CID)
BORE: 86.5 mm (3.41 in.)
STROKE: 100 mm (3.94 in.)
COMPRESSION PRESSURE: 1,128 kPa (163.5 psi)
Intake Valve: 12° BTDC(Open)/ 40° ABDC(Close)
VALVE TIMING:
Exhaust Valve: 54° BBDC(Open)/ 6° ATDC(Close)
SPARK PLUGS: BPR5ES: 0.7-0.8 mm (0.028-0.031 in.) Air Gap
FUELTYPE: LPG
LP FUEL SYSTEM
COOLING SYSTEM
THERMOSTAT:
COOLING WATER CAPACITY: 3.1 L (block only)
LUBRICATION SYSTEM
OIL PRESSURE: 50 kPa (7 psi) @ Low Idle 450 kPa (65 psi) @ Hi Idle
CRANKCASE CAPACITY: 3.7 L
OIL FILTER: 0.3 L
ENGINE OIL SPECIFICATION: API - SJ, SAE 10W30 or SAE 5W30
ENGINE ELECTRICAL
IGNITION COIL: 12 V operation volt, Ignition driver circuitry inside
DISTRIBUTOR: Mitsubishi Distributor
STARTER MOTOR: 12 Volt, 1.2 kW, Reduction drive
VR SENSOR: Magnetic pick up sensor
PEDAL ANGLE SENSOR: Two-Output Signals (Installed on Accelerator Pedal)
OXYGEN SENSOR: Heated Exhaust Gas Oxygen Sensor (HEGO) 12 V operation volt
EXHAUST SYSTEM

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL
OVERVIEW
MI-04 General Description

MI-04 control system is designed to provide a complete, fully integrated solution that will meet or exceed TIER-2
Large Spark Ignited Engines emission standards established by the California Air Research Board (CARB) and the
Environmental Protection Agency (EPA) for 2004. The MI-04 is a closed loop system utilizing a catalytic muffler to
reduce the emission level in the exhaust gas. In order to obtain maximum effect from the catalyst, an accurate
control of the air fuel ratio is required. A small engine control module (SECM) uses a heated exhaust gas oxygen
sensor (HEGO) in the exhaust system to monitor exhaust gas content.
MI-04 System with the N-CA55-500 Mixer
Fuel Filter
Fault Light
LP Fuel Line
Key switch
Fuel Lock
Main
Accel Pedal PWR
APP
Relay Converter
Vacuum Line
Air Cleaner Coolant Line Fuel Trim Valve
Mixer
DBW Throttle TPS
TMAP SECM
Oxygen
Engine Distributor
Catalytic
Muffler
VR Sensor
Coolant Temp Sensor
Figure 10
G420E/G424E Tier LP Engine 15 System Operational Overview

The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air/fuel
mixer by modulating the fuel trim valve (FTV) connected to the regulator. Reducing the fuel pressure leans the
air/fuel mixture and increasing the fuel pressure enriches the air/fuel mixture. To calculate any necessary
corrections to the air fuel ratio, the SECM uses a number of different sensors to gain information about the engines
performance. Engine speed is monitored by the SECM through a variable reluctance (VR) sensor. Intake manifold
air temperature and absolute pressure is monitored with a (TMAP) sensor. The MI-04 is a drive by wire (DBW)
system connecting the accelerator pedal to the electronic throttle through the electrical harness, mechanical
cables are not used. A throttle position sensor (TPS) monitors throttle position in relation to the accelerator pedal
position sensor (APP) feedback. Even engine coolant temperature is monitored by the SECM. The SECM
controller has full adaptive learning capabilities, allowing it to adapt control function as operating conditions change.
Factors such as ambient temperature, fuel variations, ignition component wear, clogged air filter, and other
operating variables are compensated.
Open Loop LP Fuel System
Fuel LP LP Engine
Governor Muffler
Lock-Off Converter Mixer
G420/G424 Open Loop LP Fuel System
MI-04 Closed Loop LP Fuel System
VR
Sensor
Coolant
Sensor Small
Engine
TMAP Control
Sensor Module
Acceleration (SECM)
pedal
Angle
Oxygen Fuel Trim
Sensor Smart Coil
Sensor Valve
Fuel LP LP Electronic Engine Catalytic

Lock-Off Converter Mixer Throttle Muffler
G420E/G424E Closed Loop LP Fuel System

MI-04 LP Fuel Filter MI-04 Fuel Lock-Off (Electric)
Figure 11 Figure 12
After exiting the fuel tank, liquid propane passes The fuel lock-off is a safety shutoff valve, normally
through a serviceable inline fuel filter to the electric held closed by spring pressure, which is operated by
fuel lock off. (Figure 11) shows a typical inline type LP an electric solenoid and prevents fuel flow to the
fuel filter manufactured by Century. The primary regulator/converter when the engine is not in
operation. This is the first of three safety locks in the
function of the fuel filter is to remove particles and
MI-04 system. (Figure 12) shows the electric fuel lock
sediments that have found their way into the tank.
assembly.
The LP fuel filter will not remove heavy end solids
and paraffin’s that build up in LPG fuel systems as a In the MI-04 design, power is supplied to the fuel
result of vaporization. lock-off with the SECM controlling the lock-off ground
(earth) connection. The lock-off remains in a normally
closed (NC) position until the key switch is activated,
this supplies power to the lock-off and the SECM but
will not open the lock-off until the SECM provides the
lock-off ground connection. This design gives the
SECM full control of the lock-off while providing
additional safety by closing the fuel lock-off in the
unlikely event of a power failure, wiring failure or
module failure.
When the liquid service valve in the fuel container is

opened liquid propane flows through the LP filter and
through the service line to the fuel lock-off. Liquid
propane enters the lock-off through the ¼” 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
VR sensor detects any engine revolutions. Stall, when
the key is in the ON position but the VR 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-off is
opened but if the operator fails to crank the engine,
the SECM will close the lock-off after 5 seconds.

MI-04 N-2001 N-2001
Regulator/Converter Heat Transfer
Chamber
Coolant
Passage
Figure 14
(Figure 14) shows the heat chamber and the coolant

passage in the N-2001.
Figure 13
After passing through the electric fuel lock-off, liquid

propane enters the N-2001 regulator/converter
(Figure 13). The N-2001 functions as a fuel vaporizer,
converting liquid propane to vapor propane and as a
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-04 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 stage) valve closes.
Unlike most other regulator/converters, the N-2001
primary valve closes with fuel pressure rather than
against pressure, extending primary seat life and
adding additional safety.
Liquid propane must be converted into a gaseous

form in order to be used as a fuel for the engine.
When the regulator receives the desired vacuum
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.

N-2001 Theory of Operation
N-2001
Cutaway View
7 8
6 5
9
4
1 3
2
Figure 15
Liquid propane, at tank pressure, enters the N-2001 signal (vacuum) travels through the vapor fuel outlet
through the fuel inlet port (1). Propane liquid then connection of the regulator (9), which is the regulator
flows through the primary valve (2). The primary valve secondary chamber, and the vapor fuel inlet of the
located at the inlet of the expansion chamber (3), is mixer. The negative pressure in the secondary
controlled by the primary diaphragm (4), which reacts chamber causes a pressure/force imbalance on the
to vapor pressure inside the expansion chamber. Two secondary diaphragm, which overcomes the
springs are used to apply force on the primary secondary spring force, opening the secondary valve
diaphragm in the primary diaphragm chamber (5), and allowing vapor propane to flow out of the
keeping the primary valve open when no fuel expansion chamber, through the secondary chamber
pressure is present. to the mixer.
A small port connects the expansion chamber to the
primary diaphragm chamber. At the outlet of the Because vapor propane has now left the expansion
expansion chamber is the secondary valve (6). The chamber, the pressure in the chamber will drop,
secondary valve is held close by the secondary causing the primary diaphragm spring force to re-
spring on the secondary valve lever (7). The open the primary valve allowing liquid propane to
secondary diaphragm controls the secondary lever. enter the regulator, and the entire process starts
When the pressure in the expansion chamber again. This creates a balanced condition between the
reaches 1.5 psi it causes a pressure/force imbalance primary and secondary chambers allowing for a
across the primary diaphragm (8). This force is constant flow of fuel to the mixer as long as the
greater than the primary diaphragm spring pressure demand from the engine is present. The fuel flow is
and will cause the diaphragm to close the primary maintained at a constant output pressure, due to the
valve. calibrated secondary spring. The amount of fuel
flowing will vary depending on how far the secondary
Since the fuel pressure has been reduced from tank valve opens in response to the negative pressure
pressure to 1.5 psi the liquid propane vaporizes. As signal generated by the air/fuel mixer. The strength of
the propane vaporizes it takes on heat from the that negative pressure signal developed by the mixer
expansion chamber. This heat is replaced by engine is directly related to the amount of air flowing through
coolant, which is pumped through the coolant the mixer into the engine. With this process, the
passage of the regulator. At this point vapor propane larger the quantity of air flowing into the engine, the
will not flow past the expansion chamber of the larger the amount of fuel flowing to the mixer.
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

MI-04 N-CA55-500TR Mixer N-CA55-500-TR Air/Fuel Mixer
Vapor propane fuel is supplied to the N-CA55-500TR
Theory of Operation
mixer by the N-2001 pressure regulator/converter.
The N-CA55-500TR mixer uses a piston type air
valve assembly to operate a gas-metering valve 1
inside the mixer. The gas-metering valve is normally
closed, requiring a negative pressure (vacuum) signal 4
from a cranking or running engine to open. This is the 2
3
third of the three safety locks in the MI-04 system. If 6 5
the engine stops or is turned off, the air valve
assembly closes the gas-metering valve, stopping
fuel flow past the mixer. The gas-metering valve
7
controls the amount of fuel to be mixed with the
incoming air at the proper ratio. The air/fuel mixture
then travels past the throttle, through the intake Figure 17
manifold and into the engine cylinders where it is
compressed, ignited and burned.
View of Venturi Air
Valve Piston Air Intake
Gas-Metering
Valve open
Figure 18
Figure 16 The air/fuel mixer is mounted in the intake air stream

between the air cleaner and the throttle. The design
of the main body incorporates a cylindrical bore or
(Figure 16) shows the N-CA55-500TR mixer installed
mixer bore, fuel inlet (1) and a gas discharge jet (2).
with the electronic throttle.
In the center of the main body is the air valve
assembly, which is made up of the piston air valve (3),
the gas-metering valve (4), and air valve sealing ring
(5), air valve spring (6) and the check valve plate (7).
The gas-metering valve is permanently mounted to
the piston air valve with a face seal mounted between
the two parts.
When the engine is not running this face seal creates

a seal against the gas discharge jet, preventing fuel
flow with the aid (upward force) of the air valve spring.
The outer surface of the piston air valve forms the
venturi section of the mixer while the inner portion of
the piston is hollow and forms the air valve vacuum
chamber. The check valve plate seals off the bottom
of the air valve vacuum (AVV) chamber and the air
valve sealing ring seals the top portion of the AVV
chamber as the piston moves against the air valve
spring.

When the engine is cranked over it begins to draw in
N-CA55-500TR
air, creating a negative pressure signal. This negative
pressure signal is transmitted through a port in the Air
Intake
check valve plate to the AVV chamber. A
pressure/force imbalance begins to build across the Idle Mixture
air valve piston between the AVV chamber (below the Adjustment
piston) and atmospheric pressure above the piston. Screw
Approximately 6” W.C. (Water Column) of negative
pressure is required to overcome the air valve spring
force and push the air valve assembly (piston) Electronic
downward off the valve seat. Approximately 24” W.C. Throttle
pushes the valve assembly to the bottom of its travel Figure 19

in the full open position.
A main mixture adjustment valve on the fuel inlet of
The amount of negative pressure generated is a the N-CA55-500TR is not used in the MI-04 system,
direct result of throttle position and the amount of air however an idle mixture adjustment is incorporated
flowing through the mixer to the engine. At low engine into the mixer (Figure 19).The idle mixture adjustment
speeds, low AVV causes the piston air valve to move is an air bypass port, adjusting the screw all the way
downward a small amount, creating a small venturi. in, blocks off the port and enriches the idle mixture.
At high engine speeds, high AVV causes the air valve Backing out the idle adjustment screw opens the port
piston to move much farther creating a large venturi. and leans the idle mixture. The idle mixture screw is a
The variable venturi air/fuel mixer constantly matches nylon type screw that is factory set with a tamper
venturi size to engine demand. To prevent engine resistant cap installed after adjustment. Accurate
reversion pulses, commonly encountered in small adjustment of the idle mixture can only be
displacement engines, from having an effect on the accomplished by adjusting for a specific fuel trim
piston AVV chamber, a check valve is incorporated on valve (FTV) duty cycle with the service tool software,
the check valve plate control port to the AVV chamber. and should be only be adjusted by trained service
The check valve is held open with gravity and technicians.
remains open with any negative pressure signal from
the engine. If a reverse pressure pulse, caused by
engine reversion, travels up the intake manifold
toward the mixer it will close the check valve for the
duration of the pulse, preventing the pulse from
entering the AVV chamber.

The SECM calculates the correct throttle valve
MI-04 Electronic Throttle opening that corresponds to the driver’s demand,
makes any adjustments needed for adaptation to the
Conventional throttle systems rely on mechanical
engine’s current operating conditions and then
linkage to control the throttle valve. To meet
generates a corresponding electrical (driver) signal to
fluctuating engine demands a conventional system
the throttle-valve actuator.
will typically include throttle valve actuators designed
to readjust the throttle valve opening in response to
There are multiple limp-home modes available with
engine demand, together with idle control actuators or
ETC. 1. If the throttle itself is suspected of being
idle air bypass valves.
inoperable, the SECM will remove the power to the
throttle motor. When the power is removed, the
throttle blade returns to its “default” position,
approximately 7% open. 2. If the SECM can still
control the throttle but some other part of the system
is suspected of failure, the SECM will enter a
“Reduced Power” mode. In this mode, the power
output of the engine is limited by reducing the
maximum throttle position allowed. 3. In some cases,
the SECM will shut the engine down. This is
accomplished by stopping ignition, turning off the fuel,
and disabling the throttle.
Figure 20 In place of a dual TPS design (TPS1 and TPS2), the

SECM calculates correct throttle position (Predicted
TPS) based on RPM and MAP and compares this to
In contrast, the MI-04 system uses electronic throttle
the actual throttle position, based on TPS1. The
control (ETC). The SECM controls the throttle valve
SECM continuously checks and monitors all sensors
based on engine RPM, engine load, and information
and calculations that effect throttle valve position
received from the Acceleration Pedal. Two mutually
whenever the engine is running. If any malfunctions
opposed potentiometers on the Acceleration Pedal
are encountered, the SECM’s initial response is to
assembly monitor accelerator pedal travel. The
revert to redundant sensors and calculated data. If no
electronic throttle used in the MI-04 system is a
redundant signal is available or calculated data
Bosch 32mm Electronic Throttle Body DV-E5 (Figure
cannot solve the malfunction, the SECM will drive the
20). The DV-E5 is a single unit assembly, which
system into one of it’s limp-home modes or shut the
includes the throttle valve, throttle-valve actuator (DC
engine down, storing the appropriate fault information
motor) and the throttle position sensor (TPS) (Figure
in the SECM.
21).
Throttle Plate
Gear Drive
DC Drive Motor
Bosch 32mm Electronic Throttle Body DV-E5

Figure 21 Picture courtesy of Robert Bosch GmbH

A branch-tee fitting is installed in the atmospheric
MI-04 Fuel Trim Valve vent port of the N2001 with one side of the branch-tee
connected to the intake side of the mixer forming 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 FTV is open AVV is sent to the
atmospheric side of the N2001 secondary diaphragm,
which lowers the reference pressure, closing the
N2001 secondary valve and leaning the air/fuel
mixture. The MI-04 system is calibrated to run rich
without the FTV. By modulating (pulsing) the FTV the
Fuel Trim Valve SECM can control the amount of AVV applied to the
N2001 secondary diaphragm. Increasing the amount
of times the FTV opens (modulation or duty cycle)
causes the air/fuel mixture to become leaner;
The Fuel Trim Valve (FTV) is a two-way electric
decreasing the modulation (duty cycle) enriches the
solenoid valve and is controlled by a pulse width
mixture.
modulated (PWM) signal provided by the SECM. The
FTV is used to bias the output fuel pressure on the
LPG regulator/converter (N-2001), by metering air
valve vacuum (AVV) into the atmospheric side of the
N-2001 secondary regulator diaphragm. An orifice
balance line connected to the air inlet side of the
mixer provides atmospheric reference to the N-2001 Balance Line
when the FTV is closed. The SECM uses feedback
FTV
voltage from the O2 sensor to determine the amount
of bias needed to the regulator/converter.
In normal operation the N2001 maintains fuel flow at

a constant output pressure, due to the calibrated
secondary spring. The amount of fuel flowing from the Figure 22
N2001 will vary depending on how far the secondary
diaphragm opens the secondary valve in response to
(Figure 22) shows the Fuel Trim Valve connected in
the negative pressure signal generated by the air/fuel
the MI-04 system.
mixer. One side of the N2001 secondary diaphragm is
referenced to atmospheric pressure while the other
side of the diaphragm reacts to the negative pressure
signal from the mixer. If the pressure on the
atmospheric side of the N2001 secondary diaphragm
is reduced, the diaphragm will close the secondary
valve until a balance condition exists across the
diaphragm, reducing fuel flow and leaning the air/fuel
mixture.

The HEGO stoichiometric air/fuel ratio voltage target
Heated Exhaust Gas Oxygen is approximately 500mV and changes slightly as a
Sensor (HEGO) function of speed and load. When the HEGO sensor
sends a voltage signal less than 500mV the SECM
interprets the air/fuel mixture to be lean. The SECM
then decreases the duty cycle of the FTV lowering the
amount of air valve vacuum (AVV) acting on the
increasing the regulator vapor propane output to
richen the air/fuel mixture. The opposite is true if the
SECM receives a voltage signal above 500mV 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 FTV.
Figure 24 CAUTION
The HEGO sensor used is calibrated to
work with the MI-04 system. Using
The HEGO sensor (Figure 24) installed in the exhaust alternate sensors may impact drivability
manifold before the catalytic muffler is a basic and the ability of the system to diagnose
zirconium type oxygen sensor comprised of a hollow rich and lean conditions.
cone-shaped internal element made of zirconium
dioxide (ZrO2, a ceramic material), which is coated
with a thin layer of micro-porous platinum. The outer
layer is exposed to the exhaust stream, while the
inner layer is vented to the atmosphere and attached
to a wire that runs to the SECM. It operates like a
galvanic cell with the zirconium dioxide acting as the
electrolyte and the platinum layers serving as
electrodes. Once the ZrO2 reaches approximately
600 deg. F., it becomes electrically conductive and
attracts negatively charged ions of oxygen. These
ions collect on the inner and outer platinum surfaces.
Naturally, there's more oxygen in plain air than in
exhaust, so the inner electrode will always collect
more ions than the outer electrode, and this causes a
voltage potential for electrons to flow. The
concentration of oxygen in the exhaust stream
determines the number of ions on the outer electrode,
hence the amount of voltage produced. If the engine
is running rich, little oxygen will be present in the
exhaust, few ions will attach to the outer electrode,
and voltage output will be relatively high. In a lean
situation, more oxygen will be present, and that
translates into more ions on the outer electrode, a
smaller electrical potential, and less voltage. In order
for the sensor to conduct and create an electrical
signal below 600 deg. F., a heated element is added
to the sensor housing. Two wires provide the
necessary 12VDC and ground signal for the heater
element. A fourth wire provides an independent
ground for the sensor.

MI-04 SECM MI-04 SECM
(General Description) (Fuel Management)
The Woodward Small Engine Control Module (SECM) During engine cranking at startup, the SECM
controller has full authority over spark, fuel and air. provides a low side driver signal to the fuel lock-off,
Utilizing Motorola’s HCS12 micro controller, the which opens the lock-off allowing liquid propane to
SECM has 24 pins of I/O and is fully waterproof and flow to the N2001 regulator. A stall safety shutoff
shock hardened (Figure 23). To optimize engine feature is built into the SECM to close the lock-off in
performance and drivability, the SECM uses several case of a stall condition. The SECM monitors three
sensors for closed loop feedback information. engine states. Crank, when the VR sensor detects
These sensors are used by the SECM for closed loop any engine revolutions. Stall, when the key is in the
control in three main categories: ON position but the VR sensor detects no engine
z Fuel Management revolutions, and the Run state, when the engine
z Load/Speed Management reaches pre-idle RPM. When an operator turns on the
z Ignition Management 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
SECM (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. Intake manifold air
temperature and absolute pressure is monitored with
a (TMAP) sensor. The HEGO voltage is converted to
an air fuel ratio value. This value is then compared to
Figure 23 a target value in the SECM. The target value is based
on optimizing catalyst efficiency for a given load and
speed. The SECM then calculates any corrections
The SECM monitors system parameters and stores that need to be made to the air fuel ratio.
any out of range conditions or malfunctions as faults
in SECM memory. Engine run hours are also stored The system operates in open loop fuel control until
in memory. Stored fault codes can be displayed on the engine has done a certain amount of work. This
the Malfunction Indicator Light (MIL) as flash codes or ensures that the engine and HEGO are sufficiently
read by the MI-04 Service Tool software through a warmed up to stay in control. In open loop control, the
CAN (Controller Area Network) communication link. FTV duty cycle is based on engine speed and load.
Once the HEGO reaches operating temperature the
Battery power (12 VDC) is supplied through the fuse fuel management is in closed loop control for all
block to the main power relay. The ignition key switch steady state conditions, from idle through full throttle.
is used to energize the main power relay. A main In closed loop mode, the FTV duty cycle is based on
power relay supplies 12 VDC power to the SECM, the feedback from the HEGO sensor. In order to handle
heated element of the oxygen sensor, Fuel Lock-Off, transient loads, engine RPM and load is compared to
Fuel Trim Valve (FTV) and the Smart Coil. The SECM a threshold used by the SECM. When this threshold
supplies positive voltage to the electronic throttle is exceeded, the FTV duty cycle will be set to a Feed
actuator, oil pressure switch and the coolant Forward Adaptive value.
temperature sensor. Transducer or sensor power (+5
VDC) is regulated by the SECM and supplied to the The SECM then makes any necessary corrections to
Temperature/Manifold Air Pressure Sensor (TMAP), the air fuel ratio by controlling the inlet fuel pressure
Throttle Position Sensor (TPS), and the Accelerator to the air/fuel mixer Reducing the fuel pressure leans
Pedal Position Sensors (APP1 & APP2). The SECM the air/fuel mixture and increasing the fuel pressure
provides a constant voltage (VCC) to the Smart Coil enriches the air/fuel mixture. Control is achieved by
Driver, transducer ground for the all sensors, and a modulating the fuel trim
low side driver signal controlling the fuel lock-off, MIL
and FTV.

Catalytic Muffler As exhaust and catalyst temperatures rise the
following reaction occurs:
All exhaust gases pass through a catalyst that is z Oxides of nitrogen (NOx) are reduced into simple
mounted in the catalytic muffler. It filters the harmful nitrogen (N2) and carbon dioxide (CO2).
gases through a dense honeycomb structure coated z Hydrocarbons (HC) and carbon monoxide (CO)
with precious metals such as platinum, palladium, are oxidized to create water (H2O) and carbon
and rhodium. Chemical reactions occur on these dioxide (CO2).
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 gas, a harmless Catalyst
Efficiency
emission. On the rich cycle, the primary pollutant is
carbon monoxide. By adding the oxygen that was
stored on the lean cycle to the carbon monoxide, Operational
carbon dioxide is produced. Range of
Converter
Inside the catalytic muffler is a three-way catalyst as Richer Air Fuel Ratio Leaner
well as sound dampening and spark arresting
features. The three-way catalyst section consists of a
honeycomb coated with a mixture of platinum, The third stage is the MI-04 control system that
palladium and rhodium. As engine exhaust gases monitors the exhaust stream, and uses this
flow through the converter passageways, they contact information to control the air/fuel mixture. By using
the coated surface, which initiate the catalytic process. the signal from the HEGO the SECM can increase or
The reduction catalyst is the first stage of the decrease the amount of oxygen in the exhaust by
catalytic converter. It uses platinum and rhodium to modulating the FTV and adjusting the air/fuel ratio.
help reduce the NOx emissions. The oxidation This control scheme allows the SECM to make sure
catalyst is the second stage of the catalytic converter. that the engine is running at close to the
It reduces the unburned hydrocarbons and carbon stoichiometric point, and also to make sure that there
monoxide by burning (oxidizing) them over a platinum is enough oxygen in the exhaust to allow the
and palladium catalyst. Cerium is also used to oxidization catalyst to burn the unburned
promote oxygen storage and improve oxidation hydrocarbons and CO.
efficiency.
Oxidation and Reduction Process
Reduction:
NOx, CO > N2 + CO2
Oxidation:
HC, CO, O2 > H2O + CO2
3-Way Catalytic
Muffler
Figure 25

NOTE
MI-04 SECM The DV-E5 is not a serviceable assembly.
(Load/Speed Management) If the TPS sensor fails, the assembly
should be replaced.
Drive by wire refers to the fact that the MI-04 control
system has no throttle cable from the Acceleration
Pedal (Figure 26) to the throttle body. Instead, the
SECM is electronically connected both to the
Acceleration Pedal assembly and the throttle body.
The SECM monitors the Acceleration Pedal position
and controls the throttle plate by driving a dc motor
connected to the throttle. The dc motor actuates the
throttle plate to correspond to the Acceleration Pedal
position when the operator depresses the pedal.
The use of electronic throttle control (ETC) ensures
that the engine only receives the correct amount of
throttle opening for any given situation, greatly Figure 27
improving idle quality and drivability.
Figure 26 Figure 28
SECM self-calibration and “cross checking” of the

TPS is accomplished by comparing the TPS signal to
a calculated throttle position in the SECM software
(Predicted TPS). In addition to the throttle position
sensor, a Temperature/Manifold Air Pressure Sensor
(TMAP) is used to monitor intake manifold
temperature and pressure (Figure 28). This enables
the SECM full control capabilities monitoring actual
airflow in relationship to desired airflow. The TMAP
sensor is a single unit incorporating both intake
manifold temperature and manifold pressure
measurement.
A Throttle Position Sensor (TPS), (Figure 27) which is

integral to the Drive By Wire (DBW) throttle assembly,
provides feedback for position control by monitoring
the exact position of the throttle valve.

The MI-04 system also performs minimum (min) and
Acceleration
maximum (max) governing through the SECM and
Pedal
DBW throttle. For min governing, or idle speed control,
the idle speed is fixed by the SECM. Unlike a
mechanical system, the idle speed is not adjustable
by the end user. The idle speed is adjusted by the
SECM based on engine coolant temperature. At
these low engine speeds, the SECM uses spark and
throttle to maintain a constant speed regardless of APP2
load.
The MI-04 system eliminates the need for air velocity APP1
governors. This substantially increases the peak
torque and power available for a given system as
shown in (Figure 29). 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 speed exceeds this max governing point,
spark is interrupted to attempt to bring the speed APP 0-100%
•Self Calibration
back to a point that can be controlled by throttle alone.
SECM 5msec • Cross Check of
If over speed is detected multiple times, the engine is Update APP1 & APP2
shutdown. Rate
System Power Comparison
60.0 TPS TPSd

(Demand)
Power, hp (corrected)
40.0 DBW
Throttle
20.0
MI-4 System
Baseline system PID
0.0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
RPM
Figure 30
(Figure 30) describes the signal flow process of the

MI-04 DBW section. The Acceleration Pedal
assembly uses two potentiometers to detect pedal
System Torque Comparison
position. These two signals, accelerator pedal
140.0 position 1 (APP1) and accelerator pedal position 2
(APP2) are sent directly to the SECM. The SECM
Torque, ft-lb (corrected)
120.0
100.0
uses a series of algorithms to self calibrate and cross
80.0
check the signals from the pedal assembly. A demand
60.0
position for the throttle will then be derived and sent
40.0
to the throttle as a throttle position sensor demand
20.0 MI-4 System
Baseline system (TPSd). The signal will be processed through a PID
0.0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 (Proportional, Integral, Derivative) controller in the
RPM
SECM to achieve the appropriate motor-current
response then passed to the throttle. The throttle
moves to the commanded position and provides a
feedback signal from the throttle position sensor
(TPS) to the SECM.

MI-04 Ignition management “SmartCoil”
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, idle speed control.
VR Sensor
The MI-04 system uses a single coil, which
incorporates the ignition driver circuitry inside the coil
itself. The SECM signals the “smart coil” when to
1
begin its dwell cycle then the coil waits for the trigger
2 signal from the SECM.
The “smart coil” eliminates the need for a driver circuit

inside the SECM or externally from the coil. Using a
single VR sensor and “smart coil” eliminates multiple
sensors and coil packs used in more complex ignition
systems.
Figure 31
Distributor
(1) Timing Wheel (2) VR Sensor
The distributor of G420/G424 engine has the
A Variable Reluctance sensor (Figure 31) is an mechanical advance system internally. But the new
electromagnetic device consisting of a permanent distributor of G420E/G424E engine has no internal
magnet surrounded by a winding of wire. The sensor
advance mechanisms.
is used in conjunction with a ferrous timing wheel
located on the crankshaft pulley. The timing wheel is
A333011: Distributor assy for G420E/G424E engines
referred to as 30-5 ignition because the wheel has 30
A218350: Distributor assy for G420/G424 engines
gear teeth with 5 removed at precise locations, giving
the SECM a very accurate speed reference signal.
Rotation of the timing wheel near the tip of the sensor
changes the magnetic flux, creating an analog
voltage signal in the sensor coil.
Ignition Coil (Smart Coil)

The MI-04 system is capable of operating with either
a distributor based ignition system or a distributor less
ignition system. The current application uses a
distributor based ignition system. The distributor will
have no internal advance mechanisms giving the
SECM consistent authority over ignition timing. The
spark is sent to the appropriate cylinder in the
conventional way via the rotor arm and spark plug
wires. The SECM uses the signal from the VR
(Variable Reluctance) sensor mounted near the
crankshaft pulley to determine the engine position
and RPM at any time. It uses this information together
with the information from the TPS sensor and TMAP
to calculate the appropriate ignition timing settings for
the “smart coil”.

CHAPTER 3 MI- 04 MAINTENANCE SCHEDULE
RECOMMENDED Inspect Engine for Fluid
MAINTENANCE SCHEDULE Leaks
Suggested maintenance requirements for an engine z Start the engine and allow it to reach operating
equipped with an MI-04 fuel system are contained in temperatures.
this section. The owner should, however, develop his z Turn the engine off.
own maintenance schedule using the requirements z Inspect the entire engine for oil and/or coolant
listed in this section and any other requirements listed leaks.
by the engine manufacturer. z Repair as necessary before continuing.
Test Fuel System for Leaks Inspect Vacuum Lines and

Fittings
z Visually inspect vacuum lines and fittings for
physical damage such as brittleness, cracks and
kinks. Repair/replace as required.
z Solvent or oil damage may cause vacuum lines
to become soft resulting in a collapsed line while
the engine is running.
z If abnormally soft lines are detected, replace as
necessary.
Check
Points
Vacuum
z Obtain a leak check squirt bottle or pump spray Lines
bottle.
z Fill the bottle with an approved leak check
solution.
z Spray a generous amount of the solution on the
fuel system fuel lines and connections, starting at
the storage container.
z Wait approximately 15-60 seconds then perform
a visual inspection of the fuel system. Leaks will
cause the solution to bubble.
z Repair any leaks before continuing.
z Crank the engine through several revolutions. Inspect Electrical System
This will energize the fuel lock-off and allow fuel
to flow to the pressure regulator/converter. z Check for loose, dirty or damaged connectors
Apply additional leak check solution to the and wires on the harness including: Fuel lock-off,
regulator/converter fuel connections and housing. TMAP sensor, O2 sensor, Electronic throttle,
Repeat leak inspection as listed above. Control Relays, Fuel Trim Valve, Acceleration
z Repair any fuel leaks before continuing. Pedal, and Distributor sensor.
z Repair and/or replace as necessary.
G420E/G424E Tier LP Engine 30 Maintenance Schedule

Inspect Acceleration Pedal Inspect Ignition System
Operation z Disconnect Battery Cables.
z Remove and inspect the spark plugs. Replace as
z Verify Acceleration Pedal travel is smooth
required.
without sticking.
z Test secondary cables with an Ohmmeter. If
maximum resistance is higher than 25 kOhms,
repair and/or replace.
Check Coolant Level z Remove distributor cap and perform visual
inspection. Replace cap and rotor if corrosion is
z The items below are a general guideline for found on the contacts.
system checks. Refer to the engine z Inspect the ignition coil for cracks and heat
manufacturers specific recommendations for deterioration. Visually inspect the coil heat sink
proper procedures. fins. If any fins are broken replace as required.
z Engine must be off and cold.
WARNING
1
NEVER REMOVE THE PRESSURE CAP
ON A HOT ENGINE.
z The coolant level should be equal to the “COLD”

mark on the coolant recovery tank. 2
z Add approve coolant to the specified level if the
system is low.
Inspect Coolant Hoses Figure 31
(1) Spark Plug Cables (2) Distributor Cap

z Visually inspect coolant hoses and clamps.
Remember to check the two coolant lines that
connect to the pressure regulator/converter.
z Replace any hose that shows signs of swelling, Replace Spark Plugs
cracking, abrasion or deterioration.
z Disconnect Battery Cables.
z Using a gentle twisting motion remove the high
voltage cables from the spark plugs. Replace
Inspect Battery System any damaged cables.
z Remove the spark plugs.
z Clean battery outer surfaces with a mixture of z Gap the new spark plugs to the proper
baking soda and water. specifications.
z Inspect battery outer surfaces for damage and
replace as necessary. Spark plug air gap : 0.7 - 0.8 mm
z Remove battery cable and clean, repair and/or
replace as necessary. z Apply anti-seize compound to the spark plug
threads and install.
Spark plug tightening torque : 25 N•m (18 lb•ft)
CAUTION
DO NOT OVERTIGHTEN THE SPARK
PLUGS.
z Re-install the high voltage cables.

Replace LP Fuel Filter Fuel Filter Disassembly
Element
2
Park the lift truck in an authorized refueling area with
the forks lowered, parking brake applied and the 4 1
transmission in Neutral.
1. Close the fuel shutoff valve on the LP-Fuel tank. 5

Run the engine until the fuel in the system runs
out and the engine stops. 3
2. Turn off the ignition switch.

6 7
3. Scribe a line across the filter housing covers,
which will be used for alignment purposes when
re-installing the filter cover. 5. Remove top cover (2), magnet (3), spring (4), and
filter element (7) from bottom cover (5).
Filter 6. Replace the filter element (7).

Housing 1
Scribe 7. Check bottom cover O-ring seal (6) for damage.
Point Replace if necessary.
8. Re-assemble the filter assembly aligning the

scribe lines on the top and bottom covers.
9. Install the cover retaining screws, tightening the

screws in an opposite sequence across the cover.
10. Open the fuel valve by slowly turning the valve

counterclockwise.
4. Remove the cover retaining screws (1).
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.

Testing Fuel Lock-off Fuel Trim Valve Inspection
Operation (FTV)
z Start engine. z Visually inspect the Fuel trim valve (C) for
z Locate the electrical connector for the fuel lock abrasions or cracking. Replace as necessary.
(A). z To ensure the valve is not leaking a blow-by test
z Disconnect the electrical connector. can be performed.
z The engine should run out of fuel and stop within
a short period of time. 1. With the engine off, disconnect the electrical
z Turn the ignition key switch off and re-connect connector to the FTV.
the fuel lock-off connector.
2. Disconnect the vacuum line from the FTV to the
pressure regulator/converter, at the converter’s
tee connection.
A B C 3. 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 the FTV.
Inspect Air/Fuel Valve Mixer

Assembly
(A) LP fuel lock-off (B) LP regulator/converter Refer to the LP mixer (G) section of the service
(C) Fuel Trim Valve manual for procedures.
NOTE
The length of time the engine runs on
trapped fuel vapor increases with any
increase in distance between the fuel
lock-off and the pressure
regulator/converter.
G
Pressure
Regulator/Converter Testing
and Inspection
z Visually inspect the pressure regulator/converter (G) LP mixer
(B) housing for coolant leaks. Refer to the
pressure regulator/converter section of the
service manual if maintenance is required.
NOTE
For pressure testing and internal
inspection of the pressure
regulator/converter, refer to the pressure
regulator/converter section of the service
manual.

Inspect for Intake Leaks Inspect Engine for Exhaust
z Visually inspect the intake manifold, throttle
Leaks
assembly (D), and manifold adapters (E), for
z Start the engine and allow it to reach operating
looseness and leaks. Repair as necessary.
temperatures.
z Perform visual inspection of exhaust system.
z Repair any/all leaks found.
D
Replace Oxygen Sensor
E
F
(D) Throttle Assembly (E) Manifold Adapter

(F) TMAP Sensor
Inspect Throttle Assembly

z Visually inspect the throttle assembly motor
housing for coking, cracks and missing cover- 1. Stop engine and wait until the exhaust pipe and
retaining clips. Repair and/or replace as exhaust pipe is cooled.
necessary.
2. Disconnect the electrical connector of oxygen
NOTE sensor.
Refer to the LP mixer and throttle section
of the service manual for procedures on 3. Remove oxygen sensor.
removing the mixer and inspecting the
throttle plate. 4. Assemble new oxygen sensor.
Tightening torque : 45 N•m (32.5 lb•ft)

Checking the TMAP Sensor 5. Connect the electrical connector of oxygen sensor.
z Verify that the TMAP sensor (F) is mounted

tightly into the manifold adapter (E), with no
leakage.
z If the TMAP is found to be loose, remove the
TMAP retaining screw and the TMAP sensor
from the manifold adapter.
z Visually inspect the TMAP O-ring seal for
damage. Replace as necessary.
z Apply a thin coat of an approved silicon lubricant
to the TMAP o-ring seal.
z Re-install the TMAP sensor into the manifold
adapter and securely tighten the retaining screw.

Maintenance Schedule
Interval Hours
Every Every Every Every Every

CHECK POINT Every
500 1000 1500 2600 4500
Daily 250hrs or
Hours or Hours or Hours or Hours or Hours or
a month
3 months 6 months 9 months 15 months 2 years
General Maintenance Section

Test Fuel System for Leaks Prior to any service or maintenance activity
Inspect engine for fluid leaks X
Inspect all vacuum lines and
X
fittings
Inspect electrical system- check
for loose, dirty, or damaged wires X
and connections
Inspect all fuel fittings and hoses X
Inspect Acceleration Pedal travel
X
and operation
Engine Coolant Section
Check Coolant Level X
Inspect coolant hoses and fittings
for leaks, cracks, swelling, or X
deterioration
Engine Ignition Section
Inspect battery for damage and
X
corroded cables
Inspect ignition system X
Replace spark plugs X
Fuel Lock-Off/Filter Section
Replace LP fuel filter element X
Inspect lock-off and fuel filter for
X
leaks
Ensure lock-off stops fuel flow
X
when engine is off
Pressure Regulator/Converter Section
Test regulator pressures X
Inspect pressure regulator vapor
X
hose for deposit build-up
Inspect regulator assembly for
X
fuel/coolant leaks
Fuel Trim Valve Section
Inspect valve housing for wear,
X
cracks or deterioration
Ensure valve seals in the closed
X
position when the engine is off

Maintenance Schedule Continued
Interval Hours
Every Every Every Every

Every Every
CHECK POINT 1000 1500 2600 4500
Daily 250hrs or 500hrs or
Hours or Hours or Hours or Hours or
a month 3 months
6 months 9 months 15 months 2 years
Carburetor Section
Check air filter indicator X
Check for air leaks in the filter
X
system
Inspect air/fuel valve mixer
X
assembly
Inspect air/fuel mixer assembly
X
throat
Check for vacuum leaks in the
intake system including manifold
X
adapter and mixer to throttle
adapter
Inspect throttle assembly X
Inspect air filter X
Replace air filter element X
Check TMAP sensor for tightness
X
and leaks
Exhaust & Emission Section
Inspect engine for exhaust leaks X
Replace Oxygen Sensor X
Replace PCV Valve and breather
X
element

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING
Basic Troubleshooting
The MI-04 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the
Malfunction Indicator Lamp (MIL) and are covered in the Advanced Diagnostics section. Items such as fuel level,
plugged fuel lines, clogged fuel filters and malfunctioning pressure regulators may not set a fault code by the Small
Engine Control Module (SECM). Below are basic checks that should be made before referring to the Advanced
Diagnostics section, if engine or drivability problems are encountered.
Locating a problem in a propane engine is done exactly the same way as with a gasoline engine. Consider all
parts of the ignition and mechanical systems as well as the fuel system.
Problem Probable Cause Corrective Action

Engine Cranking Fuel container empty Fill fuel container
but Will Not Start z Do not exceed 80% of liquid 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 of Operation &
Maintenance Manual, Fuses replacement
Clogged fuel filter Repair/replace as required
z See Chapter 3 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 Chapter 3 Fuel Lock-off
Pressure regulator/converter Test pressure regulator/converter operation

malfunction z See Chapter 9 Tests and Adjustments
Incorrect air/fuel or ignition/spark See Chapter 5 Advanced Diagnostics

control
G420E/G424E Tier LP Engine 37 Basic Troubleshooting

Engine Cranking No VR Sensor Signal Verify the VR signal is present
but Will Not Start z See Chapter 5 Advanced Diagnostics
Difficult to Start Fuel container almost empty LPG Vapor from liquid outlet
z Fill fuel container
z Do not exceed 80% of liquid capacity

Slowly open liquid valve

z Leak test

collapsed hose
Fuel container almost empty LPG Vapor from liquid outlet

Air filter clogged Check air filter

z Clean/replace as required
Incorrect air/fuel or ignition control See Chapter 5 Advanced Diagnostics

Engine Mechanical See Engine Manufacturers Service Manual

Will Not Run Fuel container almost empty LPG Vapor from liquid outlet
Continuously z Fill fuel container


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
z 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 Chapter 5 Advanced Diagnostics

problem
Will Not Fuel container almost empty LPG Vapor from liquid outlet
Accelerate/Hesita z Fill fuel container
tion During
Acceleration Excess flow valve closed Reset excess flow valve

Will Not Clogged fuel filter Repair/replace as required
Accelerate/Hesita z See Chapter 3 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 Chapter 5 Advanced Diagnostics
or sticking
Acceleration Pedal signal incorrect
or intermittent
Incorrect air/fuel or ignition control
Engine Stalls Fuel container almost empty LPG Vapor from liquid outlet



Engine Stalls Fuel Lock-off malfunction Repair/replace Fuel Lock-off
z See Chapter 3 Fuel Lock-Off

collapsed hose
z -35F minimum
z Verify one pressure hose and one return
hose
Pressure regulator malfunction Test pressure regulator operation
z See Chapter 9 Tests and Adjustments
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
z See Chapter 8 Air/Fuel mixer section
Rough Idle Faulty vapor connection between Check connection

collapsed hose

manifold
head

Rough Idle Incorrect Idle speed control See Chapter 5 Advanced Diagnostics &
Incorrect timing or spark control Chapter 9 Tests and Adjustments
High Idle Speed Incorrect Idle speed control See Chapter 5 Advanced Diagnostics &
Throttle sticking Chapter 9 Tests and Adjustments
Acceleration Pedal sticking or Check pedal return spring travel for binding
incorrect pedal signal z See Chapter 5 Advanced Diagnostics
Poor High Speed Clogged fuel filter Repair/replace as required

Performance z See Chapter 3 Fuel Filter replacement



collapsed hose

Restricted exhaust system Check exhaust system

z Measure exhaust back pressure
Incorrect ignition control See Chapter 5 Advanced Diagnostics &

Incorrect air/fuel control Chapter 9 Tests and Adjustments
Incorrect throttle position

Excessive Fuel Air/Fuel Mixer malfunction Check mixer
Consumption/LP z See Chapter 8 Air/Fuel mixer section
G Exhaust Smell Air filter clogged Check air filter

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 Chapter 9 Tests and Adjustments
Faulty FTV Check FTV for housing cracks or obstructions

z See Chapter 5 Advanced Diagnostics
FTV operation
z Repair and/or replace as necessary
Weak ignition and/or spark control See Chapter 5 Advanced Diagnostics

Incorrect air/fuel control See Chapter 5 Advanced Diagnostics
Exhaust system leaks Repair exhaust system
Oxygen sensor failure Replace as necessary

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS
Advanced Diagnostics Reading Diagnostic Fault
The MI-04 systems are equipped with built-in fault
Codes
diagnostics. Detected system faults can be displayed
All MI-04 fault codes are two digit codes. When the
by the Malfunction Indicator Lamp (MIL) as
fault codes are retrieved (displayed) the MIL will flash
Diagnostic Fault Codes (DFC) or flash codes, and
for each digit with a short pause (.5 seconds)
viewed in detail with the use of service tool software.
between digits and a long pause (1.2 seconds)
When the ignition key is turned ON the MIL will
between fault codes. A code 12 is displayed at the
perform a self-test, illuminate once and then go OFF.
beginning of the code list.
If a detected fault condition exists, the fault or faults
will be stored in the memory of the small engine
EXAMPLE: A code 26 has been detected
control module (SECM). Once a fault occurs the MIL
(ETCSticking) and the engine has shutdown and the
will illuminate and remain ON. This signals the
MIL has remained ON. When the codes are displayed
operator that a fault has been detected by the SECM.
the MIL will flash one time (1), pause, then flash two
times (2). This identifies a twelve (12), which is the
beginning of the fault list. It will then pause for 1.2
seconds (long pause) and flash two times (2), pause,
then flash six times (6). This identifies a twenty-six
(26), 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 meaning the fault
list will begin again.
1
IB1O003L
(1) Malfunction Indicator Lamp (MIL) for Engine control system
G420E/G424E Tier LP Engine 44 Advanced Diagnostics

Displaying Fault Codes (DFC) Clearing Fault (DFC) Codes
From SECM Memory To clear the stored fault codes from SECM memory
you must complete the reset fault pedal maneuver.
To enter code display mode you must turn OFF the
ignition key. Now turn ON the key but do not start the
CAUTION
engine. As soon as you turn the key to the ON
Once the fault list is cleared it cannot be
position you must cycle the Acceleration Pedal by
restored.
depressing it to the floor and then fully releasing the
pedal (pedal maneuver). You must fully cycle the
First turn OFF the ignition key. Now turn ON the key
Acceleration Pedal three (3) times within five (5)
but do not start the engine. As soon as you turn the
seconds to enable the display codes feature of the
key to the ON position you must cycle the
SECM. Simply turn the key OFF to exit display mode.
Acceleration Pedal by depressing it to the floor and
The code list will continue to repeat until the key is
then fully releasing the pedal (pedal maneuver). You
turned OFF. An automatic code display feature is
must fully cycle the Acceleration Pedal ten (10) times
activated if a Acceleration Pedal fault condition exists.
within five (5) seconds to clear the fault code list of
This feature enables the service technician to view
the SECM. Simply turn the key OFF to exit the reset
the fault codes by turning the key to the ON position,
mode. The code list is now clear and the SECM will
if a Acceleration Pedal malfunction is preventing the
begin storing new fault codes as they occur.
retrieval of the stored fault codes from the SECM.
Malfunction Indicator Light (MIL) Fault Action Descriptions

Each fault detected by the SECM is stored in memory
= CODE 12 (FIFO) and has a specific action or result that takes
place. Listed below are the descriptions of each fault
ON OFF ON ON OFF
action.
Engine Shutdown: The most severe action is an

Engine Shutdown. The MIL will light and the engine
will immediately shutdown, stopping spark with the
fuel lock-off closing.
Delayed Engine Shutdown: Some faults such as

low oil pressure will cause the MIL to illuminate for 30
seconds and then shutdown the engine.
Disable Throttle: The throttle moves to its default

position. The engine will run at idle but will not
accelerate.
Limp Home Mode: A “limp home” mode reduces

the lift truck power, and is provided to enable the
operator to drive the lift truck in an unsafe situation
but not use the truck for normal operation.
MIL ONLY: The MIL will light by an active low signal

provided by the SECM, indicating a fault condition but
no further action will take place.

ThrottleSensorRangeHi: (Throttle Position Sensor
Fault List Definitions (TPS1) Range has measured High) the TPS1
potentiometer has malfunctioned. An improper TPS
Several sensors in the MI-04 system have input
reading may be due to dirt or oxidation on the sensor
low/high faults and a sensor range fault. These are
traces. NOTE: The TPS is not a serviceable item and
the coolant temperature sensor, the throttle position
can only be repaired by replacing the DV-EV throttle
sensor and the pedal position sensors. Signals to
assembly.
these sensors are converted into digital counts by the
SECM. A low/high sensor fault is normal set when
ETCSticking: (Electronic Throttle Control is Sticking)
the converted digital counts reach the minimum of 0
is normally set if either of the ETC driver signals have
or the maximum of 1024 (1024=5.0 VDC with ~204
opened or become disconnected. This can also occur
counts per volt). A sensor range fault is set if the
if the throttle plate (butterfly valve) inside the throttle
parameter measured by the sensor is outside the
bore is sticking. The plate sticking can be due to
normal operating range.
some type of obstruction; a loose throttle plate or
worn components shaft bearings. Certified
technicians using the service tool software can
1024 Counts (Input High) perform a throttle motion test to confirm sticking
problems. NOTE: The throttle assembly is not a
serviceable item and can only be repaired by
replacing the DV-EV throttle assembly.
Sensor Range
PredictedTPSDifference: (Predicted Throttle
Position Sensor Difference) measured TPS1 is
different than SECM Calculated throttle position.
0 Counts (Input Low) Normally caused by intake leaks between the throttle
assembly and the engine.
Figure F1
ETCSpringTestFailed: (Electronic Throttle Control
ECTSensorInputLow: (Engine Coolant Temperature Spring Return Test has Failed) upon the initial startup
Sensor Input is Low) normally set if the coolant of the engine the SECM will perform a safety test of
sensor wire has shorted to chassis ground or the the throttle return spring. If this spring has become
sensor has failed. weak the throttle will fail the test and set the fault.
NOTE: The throttle assembly is not a serviceable
ECTSensorInputHigh: (Engine Coolant Temperature item and can only be repaired by replacing the DV-EV
Sensor Input is High) normally set if the coolant throttle assembly.
sensor wire has been disconnected or the circuit has
opened to the SECM. ETCDriverFault: (Electronic Throttle Control Driver
has Failed) an over current condition has occurred on
ECTRangeHigh: (Engine Coolant Temperature
either ETC+ or ETC- driver signals.
Range is High) the sensor has measured an
excessive coolant temperature typically due to the
engine overheating. MapSensorInputLow: (Manifold Air Pressure Sensor
Input is Low) is normally set if the TMAP pressure
ThrottleSensorInputLo: (Throttle Position Sensor signal wire has been disconnected or the circuit has
(TPS1) Input is Low) is normally set if the TPS1 opened to the SECM.
signal wire has been disconnected or the circuit has
opened to the SECM. MapSensorInputHigh: (Manifold Air Pressure
Sensor Input is High) is normally set if the TMAP
ThrottleSensorInputHi: (Throttle Position Sensor pressure signal wire has become shorted to power,
(TPS1) Input is High) is normally set if the TPS1
shorted to the IAT signal, the TMAP has failed or the
signal wire has become shorted to power, the TPS1
SECM has failed.
has failed or the SECM has failed.
ThrottleSensorRangeLo: (Throttle Position Sensor IATSensorInputLow: (Intake Air Temperature Sensor

(TPS1) Range has measured Low) the TPS1 Input is Low) is normally set if the TMAP temperature
potentiometer has malfunctioned. An improper TPS signal wire has become shorted to ground, shorted to
reading may be due to dirt or oxidation on the sensor the MAP signal, the TMAP has failed or the SECM
traces. NOTE: The TPS is not a serviceable item and has failed.
assembly.

IATSensorInputHigh: (Intake Air Temperature Pedal1SensorRangeHi: (Accelerator Pedal Position
Sensor Input is High) normally set if the TMAP 1 Sensor Range is High) the APP1 potentiometer has
temperature signal wire has become disconnected or malfunctioned. An improper APP1 reading may be
the circuit is open to the SECM. due to dirt or oxidation on the sensor traces.
Pedal2SensorInputLo: (Accelerator Pedal Position 2
EST1Low: (Electronic Spark Trigger) is a current Sensor Input is Low) normally set if the APP2 signal
driver signal and normally set if the signal from the wire has become shorted to APP power, APP2 has
SECM is shorted to ground. failed or the SECM has failed.
EST1High: (Electronic Spark Trigger) is a current Pedal2SensorInputHi: (Accelerator Pedal Position 2

driver signal and normally set if the signal from the Sensor Input is High) normally set if the APP2 signal
SECM is open or lost. wire has become disconnected or the circuit is open
to the SECM.
LowOilPressure: (Low Oil Pressure) the oil pressure
switch has opened or become disconnected, normally Pedal2SensorRangeLo: (Accelerator Pedal Position
indicating a low oil condition in the engine. 2 Sensor Range is Low) the APP2 potentiometer has
malfunctioned. An improper APP2 reading may be
BatterySensorInputLow: (Battery Voltage Sensor due to dirt or oxidation on the sensor traces.
Input is Low) normally set if the power to the SECM
drops below 8.5 VDC. Pedal2SensorRangeHigh: (Accelerator Pedal
Position 2 Sensor Range is Low) the APP2
BatterySensorInputHigh: (Battery Voltage Sensor potentiometer has malfunctioned. An improper APP2
Input is High) normally set if the power to the SECM reading may be due to dirt or oxidation on the sensor
increases above 15.9 VDC. traces.
XDRPSensorInputLow: (Transducer Voltage Sensor Pedal1ToPedal2Difference: (Accelerator Pedal

Input is Low) normally set if the sensor power from Position Sensor 1 and Accelerator Pedal Position
the SECM drops below 4.8 VDC. Sensor 2 are Different) normally set when APP1
measured pedal position is different from APP2
XDRPSensorInputHigh: (Transducer Voltage Sensor measured pedal position.
Input is High) normally set if the sensor power from
the SECM increases above 5.9 VDC. AFRTrimValveOutput: (Air Fuel Ratio Trim Valve
(FTV) Driver) is normally set when the FTV driver
EngineOverspeed: (Engine Over speed) is set when signal is open due to the connector becoming
the engine RPM increases above the SECM disconnected.
maximum governing RPM. Typically this is in
association with one or more throttle faults. This AFRTrimValveLowerDC: (Air Fuel Ratio Trim Valve
fault can be set without additional throttle faults if the (FTV) Lower Duty Cycle) normally set when the duty
operator motors the lift truck down a steep grade (hill). cycle of the FTV reaches the minimum limit (running
too lean).
Pedal1SensorInputLo: (Accelerator Pedal Position 1
Sensor Input is Low) normally set if the APP1 signal AFRTrimValveUpperDC: (Air Fuel Ratio Trim Valve
wire has become disconnected or the circuit is open (FTV) Upper Duty Cycle) normally set when the duty
to the SECM. cycle of the FTV reaches the maximum limit (running
too rich).
Pedal1SensorInputHi: (Accelerator Pedal Position 1
Sensor Input is High) normally set if the APP1 signal O2SensorSwitching: (Oxygen Sensor Switching)
wire has become shorted to APP power, APP1 has is set when the O2 sensor can no longer switch or be
failed or the SECM has failed. driven above and below 500mv by the SECM.
Pedal1SensorRangeLo: (Accelerator Pedal Position OxygenSensorInputHigh: (Oxygen Sensor Input is

1 Sensor Range is Low) the APP1 potentiometer has High)
malfunctioned. An improper APP1 reading may be
due to dirt or oxidation on the sensor traces. OxygenSensorInputLow: (Oxygen Sensor Input is
Low)

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)
DFC Probable Fault Action Corrective Action, First Check
12 NONE NONE None, used as a beginning and end
Signifies the end of one pass through of the fault list identification
the fault list
14 ECTSensorInputLow Stored Fault Code Check ECT sensor connector and
Coolant sensor failure or shorted to (MIL Only) wiring for a short to GND
GND
SECM (SIGNAL) PIN 16 to
ECT PIN A
SECM (GND) PIN 1 to

ECT PIN B
15 ECTSensorInputHigh Stored Fault Code Check if ECT sensor connector is
Coolant sensor disconnected or open (MIL Only) disconnected or for an open ECT
circuit circuit

ECT PIN A
SECM (GND) PIN 1 to

ECT PIN B
16 ECTRangeHigh Delayed Engine Check coolant system for radiator

Engine Overheating Shutdown blockage, proper coolant level and for
leaks in the system. Possible ECT
short to GND, check ECT signal
wiring

ECT PIN A
SECM (GND) PIN 1 to

ECT PIN B
z Check regulator for coolant leaks

*See Chapter 7.0
22 ThrottleSensorInputLo Disable Throttle Check throttle connector connection
TPS1 signal disconnected or open and TPS1 sensor for an open circuit
circuit
(Expected faults when ETC ETC PIN 6 to SECM PIN 17
connector is unplugged (SIGNAL)
CODES: 22 & 24)
ETC PIN 2 to SECM PIN 1 (GND)

23 ThrottleSensorInputHi Disable Throttle Check throttle connector and TPS1
TPS1 sensor failure or shorted circuit sensor wiring for a shorted circuit
ETC PIN 6 to SECM PIN 17

(SIGNAL)
24 ThrottleSensorRangeLo Stored Fault Code Check the throttle connector and pins
TPS1 potentiometer malfunction. (MIL Only) for corrosion.
Improper TPS reading may be due to Perform Throttle test with the Service
dirt or oxidation on the sensor traces. Tool several times to clean sensor
To check the TPS disconnect the

throttle connector and measure the
resistance (1.25KΩ +/-30%) from
TPS PIN 2 (GND) to

PIN 6 (TPS1 SIGNAL)
TPS PIN 3 (PWR) to PIN 6 (TPS1

SIGNAL)
*See Chapter 6.0 for sensor checks
25 ThrottleSensorRangeHi Stored Fault Code Check the throttle connector and pins
Improper TPS reading may be due to z Perform Throttle test with the
dirt or oxidation on the sensor traces. Service Tool several times to
clean sensor

TPS PIN 2 (GND) to PIN 6 (TPS1

SIGNAL)

SIGNAL)

26 ETCSticking Engine Shutdown Check for debris or obstructions
Throttle plate sticking inside the inside the throttle body
throttle body or the ETC driver signal Perform the Throttle test using the
is open Service Tool and re-check for fault
Check throttle-plate shaft for bearing
wear
Check the ETC driver wiring for an

open circuit
ETC+ PIN 1 to SECM PIN 22
ETC-PIN 4 to SECM PIN 24
Check the ETC internal motor drive

by disconnecting the throttle
connector and measuring the motor
drive resistance at the throttle
TPS PIN 1 (+DRIVER) to PIN 4 (-

DRIVER) ~3.0Ω +/-30%
27 PredictedTPSDifference Engine Shutdown Check for manifold leaks between the

Measured TPS1 is different than throttle and the engine
SECM Calculated throttle position Note: Fault Code 27 is predicted
TPS. This fault means that the throttle
and our calculated prediction for
throttle do not agree. This code often
comes up as suspected during
transient manuevers. It is not system
trouble. If the fault really sets, then
the engine will shut down.
28 ETCSpringTestFailed Power Limit Perform throttle spring test by cycling

Upon initial key-up the internal the ignition key and re-check for fault
throttle return spring has become
weak

29 ETCDriverFault Disable Throttle Check ETC driver wiring for a shorted
Throttle driver over-current or driver circuit
signals shorted ETC+ PIN1 to SECM PIN 22
ETC- PIN 4 to SECM PIN 24
z Perform Throttle test and with

the Service Tool and re-check for
fault


DRIVER) ~3.0Ω +/-30%
33 MapSensorInputLow Disable Throttle Check TMAP connector and MAP

MAP signal disconnected, open signal wiring for an open circuit
circuit or sensor malfunction TMAP PIN 4 to SECM PIN 5
(Expected faults when TMAP (SIGNAL)
connector is unplugged TMAP PIN 1 to SECM PIN 1 (GND)
CODES: 33 & 38) TMAP PIN 3 to SECM PIN 18
(XDCR +5VDC)
Check the MAP sensor by

disconnecting the TMAP connector
and measuring at the sensor
TMAP PIN 1(GND) to PIN 4
(PRESSURE SIGNAL KPA) (2.4kΩ -
8.2kΩ)
TMAP PIN 3(PWR) to PIN 4

8.2kΩ)

34 MapSensorInputHigh Disable Throttle Check TMAP connector and MAP
TMAP sensor failure or shorted circuit signal wiring for a shorted circuit
TMAP PIN 4 to SECM PIN 5
(SIGNAL)
TMAP PIN 1 to SECM PIN 1 (GND)
(XDCR +5VDC)

8.2kΩ)

8.2kΩ)
37 IATSensorInputLow Stored Fault Code Check TMAP connector and IAT

TMAP sensor failure or shorted circuit (MIL Only) signal wiring for a shorted circuit
(SIGNAL)
TMAP PIN 3 to SECM PIN 18 (XDCR
+5VDC)
To check the IAT sensor of the TMAP

disconnect the TMAP connector and
measure the IAT resistance
*See the IAT table in Chapter 6.0

38 IATSensorInputHigh Stored Fault Code Check TMAP connector and IAT
IAT signal disconnected, open circuit (MIL Only) signal wiring for an open circuit
or sensor malfunction TMAP PIN 2 to SECM PIN 4
(SIGNAL)
TMAP PIN 3 to SECM PIN 18 (XDCR
+5VDC)
To check the IAT sensor of the TMAP

disconnect the TMAP connector and
measure the IAT resistance
42 EST1Low Stored Fault Code Check coil driver wiring and

Coil driver signal low or under-current (MIL Only) connector for shorts
SECM PIN 7(EST1) to COIL PIN A
Verify GND on COIL PIN B

Verify GND on COIL PIN C
Verify GND on COIL PIN D
Verify +12vdc on COIL PIN E
To check the Smart Coil internal

circuit disconnect the coil connector
and measure the resistance from pin
to pin
*See Smart Coil resistance check

in Chapter 6.0

43 EST1High Stored Fault Code Check coil driver wiring for an open
Coil driver signal high or over-current (MIL Only) circuit or disconnected connector


and measure the resistance from pin
to pin

in Chapter 6.0
53 BatterySensorInputLow Stored Fault Code Check battery voltage

Battery voltage measured below (MIL Only) z Perform maintenance check on
+8.0 VDC electrical connections to the
battery and chassis ground
z Check battery voltage during
starting and with the engine
running to verify charging system
and alternator function
Measure battery power at the SECM

with a multimeter
SECM PIN 13 (BATT +) to SECM

PIN 14 (BATT -)

54 BatterySensorInputHigh Stored Fault Code Check battery and charging system
Battery voltage measured above (MIL Only) voltage
+15.9 VDC z Check battery voltage during
running
z Check voltage regulator,
alternator and charging system
z Check battery and wiring for
overheating and damage
z Measure battery power at the
SECM with a multimeter
SECM PIN 13 (BATT +) to
SECM PIN 14 (BATT -)
55 XDRPSensorInputLow Engine Shutdown Measure transducer power at the

+5VDC Transducer power supplied TMAP connector with a multimeter
by the SECM to the sensors is below TMAP PIN 3 +5VDC to TMAP PIN 1
+4.60VDC XDCR GND
(Expected faults when Transducer
power is lost Verify transducer power at the SECM
CODES: 22, 24, 33, 62, 64, 66, 68 & with a multimeter
69) SECM PIN 18 +5VDC to SECM PIN
1 XDCR GND
Verify transducer power at ETC with

a multimeter
ETC PIN 3 XDCR PWR to ETC PIN
2 XDCR GND
Verify transducer power to the

Acceleration Pedal with a multimeter

56 XDRPSensorInputHigh Engine Shutdown Measure transducer power at the
by the SECM to the sensors is above TMAP PIN 3 +5VDC to TMAP PIN 1
+5.20VDC XDCR GND
Verify transducer power at the SECM

with a multimeter
SECM PIN 18 +5VDC to SECM PIN
1 XDCR GND

a multimeter
2 XDCR GND

Acceleration Pedal with a multimeter
57 Engine OverSpeed Engine Shutdown Usually associated with additional

Engine RPM increased beyond ETC faults
maximum RPM set point z Check for ETC Sticking or other
ETC faults
z Verify if the lift truck was motored
down a steep grade
61 Pedal1SensorInputLo MIN Power Limit Check Acceleration Pedal connector

APP1 signal disconnected, open z Check APP1 signal at SECM
circuit or sensor malfunction PIN 15
(Expected faults when APP connector
is unplugged
CODES: 61 & 66)
62 Pedal1SensorInputHi MIN Power limit Check Acceleration Pedal connector

APP1 sensor failure or shorted circuit z Check APP1 signal at SECM
PIN 15
63 Pedal1SensorRangeLo Stored Fault Code Check Acceleration Pedal connector

APP1 potentiometer malfunction. (MIL Only) z Cycle the pedal several times
Improper APP1 reading may be due and check APP1 signal at SECM
to dirt or oxidation on the sensor PIN 15
traces.
64 Pedal1SensorRangeHi Stored Fault Code Check Acceleration Pedal connector

traces

65 Pedal2SensorInputLo MIN power Limit Check Acceleration Pedal connector
APP2 sensor failure or shorted circuit z Cycle the pedal several times
and check APP2 signal at SECM
PIN 2
66 Pedal2SensorInputHi MIN power Limit Check Acceleration Pedal connector

APP2 signal disconnected, open z Check APP2 signal at SECM
circuit or sensor malfunction PIN 2
(Expected faults when APP connector
is unplugged
CODES: 61 & 66)
67 Pedal2SensorRangeLo Stored Fault Code Check Acceleration Pedal connector

traces.
68 Pedal2SensorRangeHi Stored Fault Code Check Acceleration Pedal connector

traces.
69 Pedal1ToPedal2Difference MIN power Limit Check Acceleration Pedal connector

Measured APP2 pedal position signal z Cycle the pedal several times
is different than APP1 signal and check APP1 signal at SECM
PIN 15
z Check APP2 signal at SECM
PIN 2
71 AFRTrimValveOutput Stored Fault Code Check FTV for an open wire or FTV
FTV modulation driver signal fault (MIL, Disable Adaptive connector being disconnected
learns) FTV PIN A (SIGNAL) TO PIN B
(PWR)
Check FTV for an open coil by

disconnecting the FTV connector and
measuring the resistance (~26Ω +/-
2Ω)
FTV PIN A (SIGNAL) TO PIN B

(PWR)

72 AFRTrimValveLowerDC Stored Fault Code Engine measured Air/Fuel ratio at the
FTV duty cycle at lower (lean) limit (MIL, Disable Adaptive O2 sensor is excessively lean
learns) z Check for intake manifold leaks
z Check balance line (vacuum
hose) connection at the regulator
z Check N-CA55-500-TR mixer for
heavy end build-up and
operation (see mixer section)
z Check N2001 secondary for
operation or low primary
pressure (see N2001 Regulator
section)
Note: If LP-Gas fuel in LP tank is not
enough, this fault code can be set. If
LP tank is frozen, this fault code can
be set, too. It is not system trouble.
73 AFRTrimValveUpperDC Stored Fault Code Engine measured Air/Fuel ratio at the

FTV duty cycle at high (rich) limit (MIL, Disable Adaptive O2 sensor is excessively rich
(Expected fault when FTV connector learns)
is unplugged) Check FTV connector wiring for an
open circuit
(PWR)

measuring the resistance (~26Ω +/-
2Ω)
(PWR)
z Check N-CA55-500-TR mixer for

heavy end build-up and
operation (see N2001 Regulator
section)

74 O2SensorSwitching Stored Fault Code Check the FTV for proper operation
O2 sensor is not switching across the (MIL, Disable Adaptive z Check FTV Hose Connections
reference AFR voltage learns)
measuring the resistance
(~26Ω +/-2Ω)

(PWR)
Note: If LP-Gas fuel in LP tank is not

77 OxygenSensorInputHigh Stored Fault Code Check if O2 sensor is shorted to

O2 sensor SECM driver signal is (MIL, Disable Adapts) +5VDC or Battery.
shorted to power O2 (SIGNAL) PIN B to SECM PIN 3
(AFRTrimValveLowerDC fault should

also occur)
Verify O2 sensor heater circuit is

operating by measuring circuit
resistance (2.1Ω +/-0.4Ω)
O2 PIN C (HEATER GND) to PIN D

(HEATER PWR)

CHAPTER 6 MI-04 ELECTRICAL CONNECTIONS
Figure E1
G420E/G424E Tier LP Engine 60 Electrical Connections

CAN BUS
CONNECTOR
CAN1+
CAN1-
(FEMALE)
A B C D E F G J K
H
SECM CONNECTOR SECM CONNECTOR

(MALE)
SECM PWR +12vdc
XDCR PWR +5vdc

R01
Coil Drive Signal
120 OHM
Lock-Off GND
ETC Driver +
VR Sensor +
ETC Driver -
VR Sensor -
SECM GND
XDCR GND
O2 Sensor
CAN1+
CAN1-
APP2
APP1
TPS1
FTV -
MIL -
MAP
ECT
IAT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
APP
GND
APP
PWR
APP2
APP1
+12VDC
FUEL LOCK-OFF
VR SENSOR
A
2
B
1
+12VDC
MIL -
FUEL TRIM VALVE

A
COOLANT SENSOR
B
B
A
+12VDC
+12VDC
+12VDC
A B C D 1 2 3 4 A B C D E 1 2 3 4 5 6
OXYGEN SENSOR TMAP SENSOR SMART COIL ELECTRONIC THROTTLE
Figure E2

Resistance Checks
NOTE
All resistive checks are made with the sensor or device disconnected from the harness.
SENSOR POINT TO POINT EXPECTED RANGE

TMAP TMAP PIN 1 (GND) TO PIN 4 2.4kΩ - 8.2kΩ
(PRESSURE SIGNAL KPA)
TMAP PIN 3 (PWR) TO PIN 4 3.4kΩ - 8.2kΩ
TMAP PIN 1 (GND) TO PIN 2 *SEE TMAP IAT TABLE FOR
(TEMPERATURE SIGNAL) PROPER RANGE
TMAP SENSOR IAT TABLE
Temperature in F Temperature in C Resistance in Ω (OHMS)

+/-1 +/-1 MINIMUM NOMINAL MAXIMUM
-4 -20 14.0K 15.6K 17.3K
32 0 5.4K 5.9K 6.5K
68 20 2.3K 3.0K 3.3K
104 40 1.1K 1.2K 1.3K
140 60 572 612 655
176 80 309 329 351
212 100 176 186 197
248 120 103 110 116

TPS TPS PIN 2 (GND) TO PIN 6 (TPS1 1.25KΩ +/-30%
(ELECTRONIC THROTTLE) SIGNAL)
TPS PIN 3 (PWR) TO PIN 6 (TPS1 1.25KΩ +/-30%
SIGNAL)
TPS PIN 1 (+DRIVER) TO PIN 4 (- ~3.0Ω +/-30%
DRIVER)

ECT ECT PIN A (SIGNAL) TO PIN B 2.8KΩ AT 25 C (77 F)
(COOLANT TEMPERATURE) (GND) +/- 8 C

O2 O2 PIN C (HEATER GND) TO PIN 2.1 +/- 0.4 ohms
(OXYGEN SENSOR) D (HEATER PWR)
G420E/G424E Tier LP Engine 62 N2001 Regulator/Converter

VR SENSOR VR PIN 1 (+) TO PIN 2 (-) ~320Ω
SMART COIL COIL PIN A (SIGNAL) TO PIN B ~10KΩ

COIL PIN A (SIGNAL) TO PIN D ~34KΩ
COIL PIN A (SIGNAL) TO PIN E ~15KΩ
(PWR)
COIL PIN B TO PIN D ~44KΩ
COIL PIN B TO PIN E (PWR) ~26KΩ
COIL PIN D TO PIN E (PWR) ~17KΩ
CONNECTOR POINT TO POINT EXPECTED RANGE

FTV FTV PIN A (SIGNAL) TO PIN B (~26Ω +/-2Ω)
(FUEL TRIM VALVE) (PWR)

FUEL LOCK-OFF LOCK-OFF PIN A (PWR) TO PIN B ~20-25Ω
(GND SIGNAL)
Voltage Checks

ACCELERATION PEDAL ANGLE APP1: PIN B (SIGNAL A) TO PIN C 0.4 +/- 0.1V AT LOW IDLE
SENSOR (GND) 3.6 +/- 0.15V AT FULL ACCEL
APP2: PIN E (SIGNAL B) TO PIN 4.5 +/- 0.1V AT LOW IDLE
D (GND) 1.4 +/- 0.15V AT FULL ACCEL
Note: When you check the output voltage of acceleration pedal angle sensor, it must be connected to SECM so
that SECM can supply 5V to the angle sensor.

CHAPTER 7 N2001 PRESSURE REGULATOR
/CONVERTER
Propane is a by-product of crude oil and natural gas. Removal and Installation of
In the extraction process various hydrocarbons such
as gasoline, kerosene, propane and butane are N2001 LP
separated. Each of these carry a certain amount of Regulator/Converter
by-product residue, commonly called heavy ends.
Under normal circumstances these residues remain
WARNING
suspended in liquid and pass through the system
undetected.
z LP gas is highly flammable. To prevent
personal injury, keep fire and flammable
Engine coolant flows through the regulator/converter
materials away from the lift truck when work
assisting in the propane vaporization process. As the
is done on the fuel system.
coolant temperature rises, the regulator/converter
z Gas vapor may reduce oxygen available for
temperature also rises. The gas becomes hot and
breathing, cause headache, nausea,
expands to the point where it cannot carry the heavier
dizziness and unconsciousness and lead to
hydrocarbons or heavy-ends through the system.
injury or death. Always operate the forklift in
Because of this, the heavy-ends are deposited
a well ventilated area
(dropped out) into the regulator/converter, the vapor
z Liquid propane may cause freezing of tissue
line from the regulator to the mixer and even in the
or frostbite. Avoid direct contact with skin or
mixer itself. When these heavy-ends cool they form
tissue; always wear appropriate safety
a wax-like deposit or sludge. HD5 grade propane is
protection including gloves and safety
recommended for motor fuel use, however HD5
glasses when working with liquid propane.
propane will carry a certain amount of heavy-ends.
A fuel filter cannot remove this because it is not dirt or
debris but part of the liquid propane. As these
CAUTION
deposits build up over time regulator fuel ports and
The regulator/converter and mixer are
valve seats can be affected, reducing the
part of a certified system complying with
performance of the regulator. All propane systems
EPA and CARB 2004 requirements. Only
incorporating a regulator/converter are subject to
trained certified technicians should
heavy-end fouling over time. Because of this it may
perform disassemble, service or
be necessary for the certified technician to
replacement of the regulator/converter or
disassemble, clean and service the
mixer.
regulator/converter after long periods of operation.

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 diagram (Figure R1) for proper routing and maximum hose lengths when
reinstalling system components.
A
Liquid Propane From
Fuel Tank
Balance Line From

Mixer Air Intake To
Regulator Vent Fitting
C C
Coolant Inlet Coolant Return
B From Engine
Breather
Vapor Fuel Line From D
Regulator Outlet To
Mixer Inlet
Control Line From

Regulator Vent Fitting F Control Line From
To Fuel Trim Valve FTV To Air Valve
(FTV) Vacuum (AVV)
Figure R1
Hose Type
A. High-pressure fuel line.
B. 5/8” I.D. Vapor Hose-Wire Reinforced (15 inch maximum length)
C. 3/8” I.D. Hose-Coolant
D. 1/2” I.D. Hose -Breather
E. 7/32” I.D. Vacuum Hose (10 inch recommended maximum length)
F. 7/32” I.D. Vacuum Hose (11.5 inch recommended maximum length)
G. 7/32” I.D. Vacuum Hose (18 inch recommended maximum length)

N2001 Removal Steps:
1. Close the liquid outlet valve in the fuel storage
container.
2. Purge the system of fuel by starting the engine

and running until all trapped fuel in the system is
exhausted and the engine shuts down.
3. Remove the fuel inlet line (1) from the lock-off, the
two vacuum lines (2) from the branch-tee fitting in
the regulator vent and disconnect the lock-off
connector (3).
4. Remove the two rear-mounting bolts that hold the

regulator to the support bracket. This will allow
you 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.
7. If it is necessary to fully disassemble the N2001

regulator, you will need to remove the fuel lock-off
at this time.
3 2
5
4
Figure 24
(1) Fuel inlet line (2) Vacuum line (3) Fuel Lock-off
(4) Cooling line (5) Fuel vapor outlet hose
NOTE
For installation of the N2001 reverse the
removal steps.

N2001 Regulator
Disassembly Steps:
Figure R5
1
Figure R3
3
Figure R5
3. Remove the six primary diaphragm cover screws

(4) and the primary cover assembly (5).
Figure R4
1. Remove the six secondary cover screws (1), the

secondary cover (2) and the secondary
diaphragm (3).

Figure R6
4. Remove the primary diaphragm by sliding the

diaphragm to one side, releasing the primary
valve pin (Figure R6).

10
3
11
Figure R7 Figure R8
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
regulator before installing in the vehicle.
9 Torque primary cover screws to (40-50
inch lbs.), secondary cover screws to (15-
Figure R8
18 inch lbs.).
Figure R9
5. 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
Figure R11
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.
Replace components as necessary.
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.
5. Make sure all parts (Figure R11) are completely

dry before re-assembly.

CHAPTER 8 N-CA55-500TR AIR/FUEL MIXER
as gasoline, kerosene, propane and butane are the N-CA55-500TR Mixer
separated. Each of these carry a certain amount of
Under normal circumstances these residues remain WARNING
undetected. z LP gas is highly flammable. To prevent
Engine coolant flows through the regulator/converter materials away from the lift truck when work
assisting in the propane vaporization process. As the is done on the fuel system.
coolant temperature rises, the regulator/converter z Gas vapor may reduce oxygen available for
temperature also rises. The gas becomes hot and breathing, cause headache, nausea,
expands to the point where it cannot carry the heavier dizziness and unconsciousness and lead to
hydrocarbons or heavy-ends through the system. injury or death. Always operate the forklift in
Because of this, the heavy-ends are deposited a well ventilated area
(dropped out) into the regulator/converter, the vapor z Liquid propane may cause freezing of tissue
line from the regulator to the mixer and even in the or frostbite. Avoid direct contact with skin or
mixer itself. When these heavy-ends cool they form a tissue; always wear appropriate safety
wax-like deposit or sludge. HD5 grade propane is protection including gloves and safety
recommended for motor fuel use, however HD5 glasses when working with liquid propane.
A fuel filter cannot remove this because it is not dirt or CAUTION
debris but part of the liquid propane. As these The regulator/converter and mixer are
deposits build up over time regulator fuel ports and part of a certified system complying with
valve seats can be affected, reducing the EPA and CARB 2004 requirements. Only
performance of the regulator. All propane systems trained certified technicians should
incorporating a regulator/converter are subject to perform disassemble, service or
heavy-end fouling over time. Because of this it may replacement of the regulator/converter or
be necessary for the certified technician to mixer.
G420E/G424E Tier LP Engine 70 N-CA55-500TR Mixer

N-CA55-500TR Mixer
Removal Steps: O-Ring
Spacer
1
4
3
2 Figure M3
NOTE
There will be a plastic o-ring spacer and
Figure M3
an o-ring inside this adapter, be careful
not to lose these items when removing
1. Close the liquid outlet valve in the forklift cylinder the mixer/adapter assembly from the
or fuel storage container. throttle (Figure M3).

3. Remove the air horn air inlet adapter and hose

(Figure M1-1).
4. Mark the two vacuum lines to the mixer and

throttle adapter for identification; they must be
installed correctly for proper operation. Remove
the two vacuum lines (Figure M1-2).
Figure M2
5. Remove the vapor fuel inlet line (Figure M1-3).
6. Remove the electronic throttle connector (Figure

M1-4).
7. Remove the four bolts that mount the throttle

adapter to the electronic throttle body (Figure M2-
5).
8. Remove the mixer/adapter assembly from the

throttle by gently pulling upwards.

N-CA55-500TR Disassembly
and Service
14
Figure M4
1
7 1. With the mixer/adapter assembly removed, and
the Air Horn removed from the mixer, remove the
12 four adapter retaining screws from the bottom of
the mixer (Figure M4).
11
13
3
5 Figure M5
6
2. Gently remove the throttle adapter from the

bottom of the mixer (Figure M5).
9
10
(1) BODY (2) SCREW (3) VALVE (4) SPRING

(5) ASSEMBLY (6) GASKET (7) GASKET (8) SCREW
(9) WASHER (10) SCREW (11) ORIFICE FITTING
(12) LABEL (13) LABEL (14) CAP
Figure M6
3. Components of the N-CA55-500TR and the mixer

body are shown in (Figure M6).

Figure M7 Figure M10
4. Replace the air-valve sealing ring as shown 7. After the air valve spring install the check valve
(Figure M7). The ring is similar to a piston ring plate (Figure M10).
and forms a seal from the air valve assembly to
the mixer main body. Small raised circular
formations can be found on one side of this ring.
Place the ring so that these circular markings face
upward toward the fuel-metering pin for proper
sealing.
Figure M11
8. Place the mixer to throttle body gasket over the

check valve plate (Figure M11). To properly install
the gasket the hole for the idle port in the throttle
adapter must be aligned with the idle port in the
Figure M8
gasket.
5. Insert the air valve assembly into the main body

(Figure M8).
Figure M12
9. Align the check valve notch in the throttle adapter

Figure M9
with the mixer check valve and the adapter idle
port with the mixer idle port. Install the throttle
6. Next, install the air valve spring (Figure M9). adapter tamper-resistant screws to the mixer
(Figure M12).

N-CA55-500TR Disassembled
Service
1. Clean the air valve assembly with soap and warm
water to remove heavy-end deposits. Inspect the
fuel metering valve and sealing ring for wear.
Replace worn components as necessary.
2. Clean the check valve plate with soap and warm

water. Inspect for wear, tears or pinholes in the
Figure M13
check valve and deformations that may cause
leaks or poor performance. Replace components
10. Check for binding of the air valve assembly by as necessary.
pressing down with two fingers on opposite sides
of the air valve assembly (Figure M13). The air 3. Replace all gaskets before assembly.
valve assembly should move freely without
binding and have full travel. If the air valve is 4. Clean the mixer body (casting) with a parts
binding, loosen the four adapter retaining screws, cleaning solvent. Be sure to remove all seals and
re-check the air valve for binding and re-tighten gaskets before cleaning the casting with solvent.
the adapter retaining screws. Make sure all parts are completely dry before re-
assembly.
11. Clean and check the orifice fitting (Mixer hose
barb) for obstruction. NOTE
For re-assembly of the N-CA55-500TR
reverse the disassembly steps.
CAUTION
The 1/8” NPT X ¼” hose barb fitting that
is installed in the mixer housing uses a WARNING
specific machined orifice size through the DO NOT spray carburetor cleaner or
fitting. This orifice fitting is part of the solvent into the mixer while installed on
mixer assembly and an integral part of the engine. These chemicals may damage
the MI-04 control. DO NOT replace this the oxygen sensor and cause pre-mature
fitting with a standard hose barb fitting or failure of the catalytic muffler.
use a drill bit to clean out the fitting
passage way. If this fitting is damaged the
mixer will need to be replaced.

Installing the
Mixer/Throttle Assembly
22(2.2 N•m)
21
23
Figure M15
20
19
1. Align the Mixer-Throttle Adapter gasket between
the mixer and the throttle adapter (Figure M15),
and then attach the mixer to the adapter using the
18 four tamper-resistant retaining screws.
13
(2.2 N•m) 15
12
(8.6 N•m) 17 14
16 11 24
10
4
7 3 (41.6
(4.2 8 6
N•m)
N•m)
9
CHECK VALVE IDLE PORT
2
1 Figure M16
CAUTION
The mixer must be installed with the idle
5 (0.8 N•m) INTAKE
port aligned with the idle port in the
MANIFOLD
adapter, and the mixer check valve
aligned with the valve recess in the
adapter to operate properly (Figure M16).
(1) GASKET-INTAKE MANIFOLD
(2) ADAPTER-INTAKE MANIFOLD (3) BOLT-ADAPTER
(4) BRACKET-TMAP (5) BOLT-TMAP BRACKET
(6) TMAP SENSOR (7) WASHER-TMAP MTG
(8) BOLT-TMAP MTG (9) GASKET-ITB(32MM)
(10) ITB(32MM) (11) O-RING (12) APOLLO ADAPTER-ITB
(13) FITTING (14) PLUG (15) BOLT-APOLLO ADAPTER
(16) WASHER-ITB (17) BOLT-ITB
(18) MIXER(CA55) (19) FITTING (20) AIR HORN ADAPTER,
(21) WASHER-AIR HORN (22) BOLT-AIR HORN,
(23) FITTING-VENTILATION (24) O-RING SPACER
The mixer/throttle assembly consists of a manifold

adapter, electronic throttle, mixer-throttle adapter and
air horn adapter. The manifold adapter is designed to Figure M17
mount the mixer/throttle assembly to a two-bolt intake
manifold. The air horn adapter allows the intake hose
2. Tighten the four tamper-proof retaining screws to
from the air cleaner to be attached to the mixer air
the specified torque (Figure M17).
intake, along with the vent line from the engine PCV
valve.
G420E/G424E Tier LP Engine 75 Test And Adjustments

O-Ring
Spacer
3. Check for free travel of the mixer’s piston 6. Place the O-ring Spacer over the outside throat of
diaphragm assembly by pushing the piston the throttle. This spacer is necessary to assure
diaphragm downward (Figure M18). If you detect that the O-ring, which seals the throttle to the
any binding, loosen the retaining screws, re-align adapter, properly seats against the throttle adapter.
the gasket and re-tighten the retaining screws.
Check for binding again, if the piston assembly 7. Place the throttle adapter O-ring over the outside
moves freely, re-torque the fasteners and continue. throat of the throttle, below the throttle bore
retaining lip and on top of the O-ring Spacer
4. Install the manifold adapter by placing the (Figure M19). Apply a generous amount of
manifold gasket between the manifold and the lubricating grease (vacuum grease) to the O-ring
manifold adapter. The manifold adapter should be and fully seat it against the machined surface.
mounted with the TMAP sensor ports facing the
thermostat housing. Tighten the two internal 8. Carefully slide the pre-assembled mixer/throttle
socket bolts to specified torque values. adapter assembly over the throat of the throttle
using a rocking motion, aligning the mounting
5. Place the throttle bottom gasket between the holes of the adapter with the mounting holes of
electronic throttle assembly and the manifold the throttle Face the fuel inlet of the mixer toward
adapter. Place the throttle assembly on top of the the plastic motor assembly cover of the electronic
gasket aligning the four mounting holes with the throttle assembly.
threaded holes in the manifold adapter. The
plastic motor assembly cover, of the electronic NOTE
throttle assembly should be facing opposite of the Avoid pinching the O-ring in the cutaway
TMAP sensor mounting holes. of the throttle adapter. This will damage
the O-ring and cause a manifold leak in
the system.

9. Tighten the four mounting bolts hand tight using a
crossing pattern from one side of the adapter to
the other. This prevents the adapter O-ring from
misaligning against the throttle, which may cut the
O-ring and cause an intake leak. Finally, tighten
the four throttle adapter fasteners to the specified
torque values.
Figure M20
10. Install the TMAP sensor mounting-bracket to the

manifold adapter. Apply a small amount of
vacuum grease to the TMAP sensor O-ring and
install the sensor into the manifold adapter, tighten
the fasteners to specified torque values.
NOTE
Be careful not to over tighten the sensor
retaining screw or damage to the sensor
housing may result.
11. Place mixer intake gasket on top of the mixer

(Figure M20), then place the air horn adapter on
top of the mixer with the intake tube facing the
valve cover (air cleaner side of the engine).
Tighten the air horn retaining bolts to specified
torque values.

WARNING
N2001 Service Testing
After overhaul or for simply checking the N2001
regulator/converter operation, the following tests can
be performed (See Chapter 7 for removal/installation
of the N2001). 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. You will
need the following hardware:
z Liquid propane may cause freezing of tissue Secondary Stage Test Hardware
tissue; always wear appropriate safety 1. Hand vacuum pump.
glasses when working with liquid propane. 2. Regulator vapor outlet test fitting ¾” NPT X ¼”
hose barb.
CAUTION
The regulator/converter and mixer are 3. Union Tee ¼” NPT with three ¼” NPT X ¼” hose
part of a certified system complying with barb.
trained certified technicians should 4. Vacuum hose.
replacement of the regulator/converter or 5. 0-3 in W.C. Magnehelic Gauge (inches of water
mixer. column).
Secondary Stage (Break-Off) Test
1. Connect the vacuum pump, the Magnahelic

gauge and the regulator vapor outlet to the Union
Tee fitting (Figure R11). Make sure there is no
leakage at any of the fittings.
2. Using the vacuum pump slowly apply enough

vacuum to measure above -2 in WC on the gauge.
This vacuum signal opens the secondary valve in
the N2001 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 in 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, repair
as necessary (See Chapter 7 for disassembly of
the N2001).

Secondary Stage Test Connection Primary Stage Test Hardware
1. Hand vacuum pump.
Magnahelic
Gauge 2. Regulator Fuel Inlet test fitting (¼” NPT standard
air coupling).
3. Test Gauge fitting (1/4” NPT X 1/4” Hose Barb).
Vacuum
4. Vacuum hose or vinyl tubing.
Hand Pump
Union Tee
5. 0-60 in W.C. Magnehelic Gauge (inches of water
Vapor Outlet
Test Fitting column).
Figure R11
Primary Stage Pressure Test

1. Remove the primary test port plug from the side of
the regulator and install the ¼” NPT hose barb
fitting.
2. Connect a compressed air line (shop air ~100psi)

to the liquid propane fuel inlet of the N2001
Regulator (Figure R12).
Test Port
Fule Inlet
Figure R12

NOTE
The N2001 Primary stage pressure can
also be tested at idle on a running engine.
The N-2001 primary pressure should be
between 40" and 55" water column at 700
RPM, idle.
WARNING

Figure R13
3. Apply compressed air, wait for air to exit the hose is done on the fuel system.
barb in the test port, and then connect the
Magnahelic gauge (Figure R13) to the hose barb z Gas vapor may reduce oxygen available for
using the vacuum hose or vinyl tubing. This breathing, cause headache, nausea,
prevents the gauge from reading maximum dizziness and unconsciousness and lead to
pressure due to the large velocity of compressed injury or death. Always operate the forklift in
air entering the primary chamber. a well ventilated area
4. Make sure there is no leakage at any of the z Liquid propane may cause freezing of tissue
fittings. The static pressure should read between or frostbite. Avoid direct contact with skin or
40-60 inches of water column on the Magnahelic tissue; always wear appropriate safety
gauge and maintain a constant pressure for 60 protection including gloves and safety
seconds. glasses when working with liquid propane
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 you will need to disassemble the
primary side of the regulator, repair the cause of
the leak, re-assemble the regulator and test the
primary stage again (See Chapter 7 for
disassembly of the N2001).
6. If the pressure begins to decrease, the secondary

seat is probably not making an adequate seal and
is leaking. If a leak is present you will need to
disassemble the secondary cover of the regulator,
repair the cause of the leak, re-assemble the
regulator and test the primary and secondary
stage again (See Chapter 7 for disassembly of the
N2001).
7. Once the test is successful, re-install the primary

test port plug and check the fittings for leaks (See
Chapter 7 for installation of the N2001).

NOTE
N-CA55-500TR Service AVV If the measured water column is
(Air Valve Vacuum) Testing excessively high, check for a sticking or
binding piston diaphragm assembly
AVV Test Hardware inside the mixer. (See Chapter 8 for
removal, installation and disassembly of
1. Mixer AVV test fitting ¼” NPT X ¼” hose barb. the N-CA55-500TR mixer).
2. Union Tee ¼” NPT with three ¼” NPT X ¼” hose

barb. WARNING
DO NOT spray carburetor cleaner or
3. Vacuum hose. solvent into the mixer while installed on
the engine. These chemicals may damage
4. 0-20 in W.C. Magnehelic Gauge (inches of water the oxygen sensor and cause pre-mature
column). failure of the catalytic muffler.
AVV Test
1. Install the Union Tee fitting between the FTV and

the AVV fitting.
2. Connect the vacuum hose from the Union Tee

fitting to the Magnahelic gauge (Figure T1). You
should now have the gauge inline between the
FTV and the mixer to throttle adapter.
3. With the engine running at idle (700 RPM) the

AVV should be between 5" and 10" water column.
Gauge
Fitting
AVV Fitting
Figure T1

Ignition Timing Adjustment Distributor with Rotor Cap Removed
With the MI-04 system both mechanical and vacuum

advance are no longer inside the distributor. All
ignition timing advance is controlled by the SECM.
The only timing adjustment that can be made by a
technician is the mechanical alignment of the
distributor. The SECM uses a 40-degree timing
window from –5 degrees BTDC to 35 degrees BTDC.
Because of this an accurate adjustment cannot be
made with a standard timing light since the SECM will
maintain the correct timing even if the distributor is
moved (as long as the distributor setting remains
within the 40-degree window). Therefore the ignition
timing setting of the distributor becomes very
important and is described in the following steps. Firing Order
1-3-4-2
Timing Wheel at 0
degrees TDC
Figure G2
2. Remove the distributor rotor cap and verify that

the distributor rotor is lined up with number 1
cylinder on the distributor cap (Figure G2).
View of Distributor Rotor Cap

Distributor View of Internal VR Sensor
Internal
#1 Cylinder
VR Sensor
Signal
Rotor
3. Remove the distributor rotor and dust cover so

that the internal VR sensor and signal rotor gear
are visible (Figure G3). The internal VR sensor
inside the distributor is not used by the SECM for
a speed reference with the G420E/G424E engine
and it’s wiring harness does not connect to the
system. The distributors internal VR sensor is only
used as an alignment reference point for setting
the correct distributor position.
Figure G1
1. Using the timing indicator on the crankshaft pulley,

set the engine on 0 degrees Top Dead Center
(TDC) of number 1 cylinder (Figure G1).

Incorrect
Alignments
#1 Tooth
Flat Side
of Shaft
Figure G4
4. Loosen the distributor hold down nut and rotate

the distributor so that the signal rotor gear tooth of Correct Alignment
the #1 cylinder (tooth opposite the flat side of the
distributor shaft) lines up with the sensor pickup.
(Figure G4). 1
Figure G5
5. To correctly set the distributor, align the center of

the #1 cylinder tooth with the leading edge of the
VR sensor pickup (Figure G5). Keep in mind that
the distributor rotates in a clockwise direction.
6. Once the proper alignment is obtained, lock the

distributor in place by tightening the hold down nut
to the specified torque value and re-install the
rotor, dust cover and rotor cap.
WARNING
Improper alignment of the distributor may
cause system ignition problems resulting
in ignition misfires or backfires.

Figure G6 Figure G8
7. After you have completed setting the distributor 9. Using a feeler gauge (Figure G8), loosen the
alignment you will need to adjust the VR sensor sensor retaining bolts and adjust the gap between
used by the SECM for speed reference. This the sensor and the gear tooth from 1.25mm to
sensor is mounted near the crankshaft pulley 1.5mm. Re-tighten the sensor retaining bolts
wheel (Figure G6). when complete.
10. Rotate the crankshaft pulley 180 degrees and

align a timing gear tooth in the center of the VR
sensor pickup as you did in step 8. Verify that the
sensor gap is still within 1.25mm to 1.5mm. This
step is to check timing gear run out and insures
proper speed signal amplitude.
11. If the VR sensor gap is not within the specification

repeat steps 9 & 10 and continue adjusting the
sensor gap until you are within tolerance. This
completes setting ignition timing and sets the
center of the SECM ignition control range at 15
Figure G7 degrees BTDC.
8. Rotate the crankshaft pulley so that one of the

gear teeth on the timing wheel aligns in the center
of the VR sensor (Figure G7).

Idle Mixture Adjustment
Figure G9
Figure G7 5. Launch the MotoView program on your computer

and open the Service Tool display.
The method for making the idle mixture adjustment to
6. Start the engine; you should now see the idle
a running engine is to use the Service Tool software
RPM on your Service Tool display Run Screen
by connecting a laptop computer to the SECM. If you
(Figure G9).
do not have the Service Tool proceed to (step 12). A
USB (Universal Serial Bus) to CAN (Controller Area
NOTE
Network) communication adapter by Kavaser will be
Service Tool software (MotoTuneViewer)
required along with a Crypt Token (Figure G7). The
and the security Crypt Token is
Crypt Token acts as a security key allowing the laptop
obtainable by certified technicians
to retrieve the necessary data from the SECM.
through authorized dealers.
Crypt
Token
Figure G8
1. Install the Crypt Token in an available USB port in

the computer (Figure G8).
2. With the ignition key in the OFF position, connect

the Kavaser communication cable from a second
USB port on the computer to the CAN
communications cable on the engine. (*If your
laptop computer does not have a second USB
port an appropriate USB Hub will need to be
used).
3. Connect a timing light to the engine.
4. Turn the ignition key to the ON position (Do Not

Start the Engine).

Idle Mixture
Screw
Tamper Proof
Cap
Figure 10 Figure 11
7. While on the Run Screen adjust the idle mixture 13. Install the tamper proof cap on the idle mixture
screw on the mixer until a reading of 25-50% is screw adjustment port so that no further
reached for the FTV Duty Cycle (Figure G10). adjustments can be made (Figure G11).
8. To make this adjustment you will need to adjust NOTE

the nylon screw all the way inward and then back If the FTV Duty Cycle reading is cannot
out the screw ¼ turn. be adjusted between 25-50%, check for
possible vacuum leaks, manifold leaks or
9. Use the accelerator pedal to increase RPM above a faulty mixer.
idle momentarily (Rev the engine) then release
the pedal to return to idle RPM. The duty cycle
setting should remain within the adjustment range
(25-50%).
10. To obtain an accurate FTV Duty Cycle reading

when the tamper proof is not installed, place your
thumb over the idle screw port so that no air will
leak past the screw threads.
11. If the FTV Duty Cycle reading is above 50% back

the idle adjustment screw out again and re-check
your duty cycle reading. Continue to do this until
the FTV Duty Cycle reading is within the proper
range (25-50%)
12. Turn the ignition key to the OFF position to shut

down the engine.

A343079
USB (Universal Serial Bus) to CAN (Controller Area
Network) Converter Assembly
A343080
Service Tool Software (includes CD and Crypt Token
(License Dongle))
Crypt
Token
A334071
Extension Cable
G420E/G424E Tier LP Engine 87 Service Tool Kit

SB4137E00
May. 2004
Service Manual
G430E/G643E Tier LP Engine
Lift Trucks
G20P-3, G25P-3, G30P-3, G32P-3, G33P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
With G430E Tier LP Engine
G35S-2, G40S-2, G45S-2, G50C-2
G50S-2, G60S-2, G70S-2
with G643E Tier LP Engine
WARNING
in injury or death.
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. DAEWOO dealers have the most current information available.
1
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before installing,
operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow
instructions can cause personal injury and/or property damage.
The engine or other type of prime mover should be equipped with an over speed (over temperature, or
overpressure, where applicable) shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine or other type of prime mover with possible
personal injury or loss of life should the mechanical-hydraulic governor(s) or electric control(s), the actuator(s), fuel
control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging
device is turned off before disconnecting the battery from the system. Electronic controls contain static-sensitive
parts. Observe the following precautions to prevent damage to these parts.
z Discharge body static before handling the control (with power to the control turned off, contact a grounded
surface and maintain contact while handling the control).
z Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.
z Do not touch the components or conductors on a printed circuit board with your hands or with conductive
devices.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation, which, if not avoided, could result in death or
serious injury.
CAUTION—indicates a potentially hazardous situation, which, if not avoided, could result in damage to
equipment.
NOTE—provides other helpful information that does not fall under the warning or caution categories.
* This manual shows just LP fuel and engine control system for TIER- LP engine, so regarding
other ares(basic engine), please refer to the separate manual of SB4005E for G430 and SB2110E &
SB2111E for G643.
G430E/G643E Tier LP Engine 3 Table of contents

Index CHAPTER 3 MI- 4 MAINTENANCE
SCHEDULE
WORKING WITH LPG EQUIPMENT RECOMMENDED MAINTENANCE SCHEDULE.....33

Test Fuel System for Leaks ......................................33
Inspect Engine for Fluid Leaks .................................33
Inspect Vacuum Lines and Fittings...........................33
Inspect Electrical System .........................................33
Inspect Acceleration Pedal Operation ......................34
LPG Fuel Supply........................................................8
Check Coolant Level ................................................34
LPG Fuel Tanks..........................................................9
Inspect Coolant Hoses .............................................35
Installing LPG Fuel Tanks ..........................................9
Inspect Battery System ............................................35
LPG Fuel Tank Components......................................9
Inspect Ignition System ............................................35
Fuel Gauge ..............................................................10
Replace Spark Plugs ................................................36
Pressure Relief Valve...............................................10
Replace LP Fuel Filter Element................................36
Service Valve ...........................................................10
Testing Fuel Lock-off Operation................................37
Quick Disconnect Coupling...................................... 11
Pressure Regulator/Converter Testing and
Filler Valve................................................................ 11
Inspection .................................................................38
Fuel Trim Valve Inspection (FTV) .............................38
Inspect Air/Fuel Valve Mixer Assembly.....................38
CHAPTER 1 G430E & G643E ENGINE Inspect for Intake Leaks ...........................................38
SPECIFICATION Inspect Throttle Assembly ........................................39
Checking the TMAP Sensor .....................................39
Indication of Engine Serial Number .........................12 Inspect Engine for Exhaust Leaks............................39
Specifications (G430E) ............................................13 Replace Oxygen Sensor ..........................................39
Specifications (G643E) ............................................14 Maintenance Schedule.............................................40
CHAPTER 2 MI-04 LPG SYSTEM CHAPTER 4 MI-04 LP BASIC

OPERATIONAL OVERVIEW G430E & TROUBLESHOOTING
G643E
Basic Troubleshooting ..............................................42
MI-04 General Description .......................................15
MI-04 LP Fuel Filter..................................................18
MI-04 Fuel Lock-Off (Electric) ..................................18 CHAPTER 5 MI-04 LP ADVANCED
MI-04 N-2001 Regulator/Converter..........................19 DIAGNOSTICS
N-2001 Theory of Operation ....................................20
MI-04 N-CA55-500TR Mixer ....................................21 Advanced Diagnostics..............................................49
N-CA55-500-TR Air/Fuel Mixer Theory of Reading Diagnostic Fault Codes..............................49
Operation .................................................................21 Displaying Fault Codes (DFC) From SECM
MI-04 (N-CA100TR Mixer) .......................................23 Memory ....................................................................50
N-CA100TR Air/Fuel Mixer Theory of Operation......24 Clearing Fault (DFC) Codes.....................................50
MI-04 Electronic Throttle..........................................25 Fault Action Descriptions..........................................50
MI-04 Fuel Trim Valve ..............................................26 Fault List Definitions .................................................51
Heated Exhaust Gas Oxygen Sensor (HEGO) ........27 Table a. MI-04 Diagnostic Fault Codes
MI-04 SECM (General Description) .........................28 (Flash Codes)...........................................................53
MI-04 SECM (Fuel Management) ............................28
MI-04 SECM (Load/Speed Management)................30
MI-04 Ignition management .....................................32
CHAPTER 6 MI-04 ELECTRICAL
CONNECTIONS
Resistance Checks...................................................67
Voltage Checks.........................................................68

REGULATOR/CONVERTER
Removal and Installation of N2001 LP

Regulator/Converter.................................................69
Hose Connections....................................................70
N2001 Removal Steps: ............................................72
N2001 Regulator Disassembly Steps:......................73
N2001 Disassembled Service..................................75
CHAPTER 8 N-CA55-500TR AIR/FUEL

MIXER
Removal and Installation of the N-CA55-500TR

Mixer ........................................................................76
N-CA55-500TR Mixer Removal Steps: ....................77
N-CA55-500TR Disassembly and Service...............78
N-CA55-500TR Disassembled Service....................80
CHAPTER 9 N-CA100TR AIR/FUEL MIXER
Removal and Installation of the N-CA100TR Mixer .84

N-CA100TR Mixer Removal Steps:..........................85
N-CA100TR Disassembly and Service ....................86
N-CA100TR Disassembly and Service ....................86
N-CA100TR Disassembled Service.........................87
N2001 Service Testing .............................................90

Primary Stage Test Hardware ..................................91
Primary Stage Pressure Test....................................92
N-CA55-500TR Service AVV (Air Valve Vacuum)
Testing......................................................................93
N-CA100TR Service AVV (Air Valve Vacuum)
Testing......................................................................93
Ignition Timing Adjustment .......................................94
Final Timing and Idle Mixture Adjustment ................95
Idle Mixture Adjustment............................................97
Service Tool Kit ........................................................98

WORKING WITH LPG NOTE
EQUIPMENT
NFPA (National Fire Protection Agency) 58 covers the
procedures for storage and garaging for repair
WARNING purposes, on propane powered equipment.
Propane Vapor is heavier than air and can collect in

low areas when adequate ventilation or air movement CAUTION
is not present to disperse it. Never check for leaks
with a flame or match. Use a leak detector solution or Safety is an important consideration for any repair
an electronic detector. Make sure the container facility, and repairing LPG fueled machinery is no
service valve is closed when connecting or exception. Refer to the NFPA (National Fire
disconnecting. If the container service valve does not Protection Agency) for the appropriate fire
operate properly, discontinue use and contact your extinguisher specifications and fluorescent lighting
propane supplier. Never insert any object into the requirements.
pressure relief valve.
Propane has a heavier than air vapor density and will
fall if a leak occurs, while natural gas, by comparison,
WARNING will rise in the event of a leak (Figure 1).
This is an important property that technicians need to
z LP gas is highly flammable. To prevent personal be aware of when performing maintenance. When
injury, keep fire and flammable materials away repairing propane machinery, the work should be
from the lift truck when work is done on the fuel performed in the lowest point of the facility where
system. possible. The tank supply should be shut off, except
z Gas vapor may reduce oxygen available for when required for running equipment.
breathing, cause headache, nausea, dizziness
and unconsciousness and lead to injury or death.
Always operate the forklift in a well ventilated
area.
z 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 Diesel
working with liquid propane.
CNG
CAUTION
Figure 1 LPG
The regulator/converter and mixer are part of a
certified system complying with EPA and CARB 2004
requirements. Only trained certified technicians
should perform disassemble, service or replacement
of the regulator/converter or mixer.
CAUTION
LPG fueled machinery may be garaged anywhere

gasoline powered vehicles are garaged. When
machines are stored for a long period, it is advisable
to shut off the tank supply valve and run the machine
until the fuel trapped down stream of the valve is
depleted.

The same principle is applied to LPG in a container,
LPG Fuel Supply commonly referred to as an LPG tank or cylinder.
Typically an LPG tank is not filled over 80% capacity
Liquefied petroleum gas (LPG) consists mainly of allowing for a 20% vapor expansion space. Outside
propane, propylene, butane, and butylenes in various air temperature effect’s an LPG tank and must be
mixtures. LPG is produced as a by-product of natural considered when using an LPG system. (Figure 2)
gas processing or it can be obtained from crude oil as shows the relationship between pressure and
part of the oil refining process. LPG, like gasoline, is a temperature in a LPG tank at a steady state condition.
compound of hydrogen and carbon, commonly called
hydrocarbons.
LPG Tank Pressure VS Temperature
300
In its natural state, propane is colorless and odorless;
an odorant (ethyl mercaptan) is added to the fuel so 250
its presence can be detected. There are currently 200
Pressure, psig
three grades of propane available in the United States.
A propane grade designation of HD5 (not exceeding 150
5% propylene), is used for internal combustion 100

engines while much higher levels of propylene
50
(HD10) are used as commercial grade propane along
with a commercial propane /butane mixture. 0
-20 0 20 40 60 80 100 120 140
Figure 2 Temperature, deg F
APPROXIMATE COMPOSITION OF HD5
PROPANE BY VOLUME With 128 PSIG vapor pressure acting against the
liquid propane the boiling point has been raised to
slightly more than 80 deg. F / 27 deg. C.
Propane Propy Butane Iso- Methane
TOTAL
(C3H8) lene (C4H10) Butane (CH4)
90.0%
5% max. 2.0% 1.5% 1.5% 100%
min.
Compressed
An advantage of LPG is the ability to safely store and
Vapor
transport the product in the liquid state. In the liquid
128 PSIG Liquid
state propane is approximately 270 times as dense
as it is in a gaseous form. By pressurizing a container Propane
of LPG we can effectively raise the boiling point
above –44 deg. C / -42 deg. C, keeping the propane
in liquid form. The point at which the liquid becomes a
gas (boiling point) depends on the amount of LPG Tank
pressure applied to the container. Figure 3
This process operates similarly to an engine coolant

system where water is kept from boiling by NOTE
Vapor pressure inside an LPG tank
pressurizing the system and adding a mixture of
depends on the ambient air temperature
glycol. For example water at normal atmospheric
outside the tank, not the amount of liquid
pressure will boil at 212 deg. F / 100 deg. C. If an
inside the tank. A tank that is ¾ full of
engines operating temperature is approximately 230 liquid propane at 80 deg. F will contain
deg. F / 110 deg. C, then the water in an open un- the same vapor pressure as a tank that is
pressurized cooling system would simply boil off into only ¼ full of liquid propane.
steam, eventually leaving the cooling system empty
and over heating the engine. If we install a 10 PSIG LPG’s relative ease of vaporization makes it an
cap on the radiator, pressurizing the cooling system excellent fuel for low-rpm engines on start-and-stop
to 10 PSIG, the boiling point of the water increases to operations. The more readily a fuel vaporizes the
242 deg. F / 117 deg. C, which will cause the water to more complete combustion will be.
remain in liquid state at the engines operating Because propane has a low boiling point (-44F), and
temperature. is a low carbon fuel, engine life can be extended due
to less cylinder wall wash down and little, if any,
carbon build up.

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 be
for industrial use and lift truck applications are within the outline of the vehicle to prevent damage to
portable universal cylinders and permanently the valves when maneuvering in tight spaces.
mounted tanks. Portable universal cylinders are used Horizontal tanks must be installed on the saddle that
primarily for off-highway vehicles and are constructed contains an alignment pin, which matches the hole in
in accordance with the DOT-TC (United States the collar of the tank. When the pin is in the hole, the
Department of Transport – Transport Canada). The liquid withdrawal tube is positioned to the bottom of
cylinders are referred to as universal because they the tank. A common problem is that often these
can be mounted in either a vertical or horizontal guide-pins are broken off, allowing the tank to be
position (Figure 4). 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, safety glasses and
gloves should be worn.
Figure 4
NOTE
LPG Fuel Tank Components
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 2 3 7 8
years and every 10 years thereafter. 9
1
The tank must be discarded if the collar is damaged
to the point that it can no longer protect the valves.
It must also be replaced if the foot ring is bent to the
point where the tank will not stand or is easily
knocked over.
6 4
12 11 10
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 fuel The service valve is a manually operated valve using
level in the tank. A mechanical float mechanism a small hand wheel to open and close the fuel supply
detects the liquid propane level. A magnet on the end to the service line (fuel supply line). The service valve
of the float shaft moves a magnetic pointer in the fuel installs directly into the tank and has two main
gauge. Some units have an electronic sending unit categories, liquid and vapor service valves. Liquid
using a variable resistor, installed in place of a gauge service valves used on portable LPG tanks use a 3/8”
for remote monitoring of the fuel level. The gauge (3/8” NPT) male pipe thread on the service valve
may be changed with fuel in the tank. DO NOT outlet for attachment of a quick disconnect coupler.
REMOVE THE FOUR LARGE FLANGE BOLTS
THAT RETAIN THE FLOAT ASSEMBLY, WITH An excess flow valve is built into the inlet side of the
FUEL IN THE TANK! service valve as a safety device in case of an
accidental opening of the service line or damage to
WARNING the service valve itself. The excess flow valve shuts
It is not a legal practice to fill the tank off the flow of liquid propane if the flow rate of the
through 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.
When opened during refueling and the tanks LPG
level is below 80%, a small amount of vapor will exit Outlet
the valve. When the LPG tank level reaches 80%
liquid propane will begin exiting the valve in the form
of a white mist (Always wear the appropriate
Excess Flow
protective apparel when refueling LPG cylinders). In
Valve
order for this type of gauge to be accurate, the tank Figure 6
must be positioned properly. When full (80% LPG) the
valve is closed by turning the knurled knob clockwise.
Typically a warning label surrounds the fixed tube CAUTION
gauge which reads STOP FILLING WHEN LIQUID When the tank is in use the service valve
APPEARS. should be completely open. If the valve is
partly open, the vehicle may not be
getting enough fuel to operate efficiently.
Pressure Relief Valve
In addition to possibly starving the engine for fuel, a
A pressure relief valve is installed for safety purposes partly open valve may restrict the flow enough to
on all LPG tanks. Portable fuel tank safety pressure prevent the excess flow valve from closing in the
relief valves are a normally closed spring-loaded event of a ruptured fuel line.
valve and are calibrated to open at 375 PSIG tank
pressure. This will allow propane vapor to escape to Most liquid service valves have an internal hydrostatic
the atmosphere. When tank pressure drops below the relief valve and are usually labeled “LIQUID WITH
preset value the valve closes. INTERNAL RELIEF”. The hydrostatic relief valve
protects the fuel service line between the tank and
the lock off from over pressurization. The internal
hydrostatic relief valve has a minimum opening
pressure of 375 PSIG and a maximum pressure of
500 PSIG. These type of relief valves have an
advantage over external relief valves because the
propane is returned to the tank in the event of an over
pressurization instead of venting the propane to
atmosphere.

Quick Disconnect Coupling Filler Valve
The liquid withdrawal or service valve on a DOT tank The liquid filler valve (Figure 9) has a male thread to
has male threads and accepts the female portion of a receive a fuel nozzle and typically has a plastic or
quick disconnect coupling (Figure 8). The female brass screw on cap that is retained with a small chain
portion is adapted to the liquid hose going to the fuel or plastic band to keep debris out of the filler valve.
system. Both halves are equipped with 100% shutoffs, The filler valve is a one-way flow device that uses two
which open when coupled together to allow fuel flow. check valves to allow fuel to enter the tank but
The coupler has two seals. One is an o-ring and the prevent it from exiting. Both check valves are
other is a flat washer. The o-ring prevents leakage backpressure type check valves, designed so that
from the shaft on the other coupling and the flat backpressure from the tank assists the check valves
washer seals when the coupler is fully connected. own spring pressure to close the valve. The first valve
uses a neoprene on metal seal and the second valve
NOTE uses a metal on metal seal.
The flat seal and/or the o-ring will
sometimes pop off when disconnecting A weakness ring is machined into the filler valve just
and slide up the shaft of the mating above the check valves and will allow the filler valve
connector, causing the valve not to open to shear off in case of an accident. The valve will
when fully mated. The extra washer or o- break or shear off above the check valves so that the
ring must be removed from the shaft and tank will be sealed and no liquid propane can escape.
the coupling reconnected.
Weakness
Ring
Figure 9
Figure 8

CHAPTER 1 G430E & G643E ENGINE SPECIFICATION
Indication of Engine Serial
Number
G430E Engine
G643E Engine

Specifications (G430E)
GENERAL DESCRIPTION
COMBUSTION SYSTEM: Naturally Aspirated 1-Venturi Intake Manifold
VALVE CONFIGURATION: Pushrod Actuated Overhead Valves - 2 Per Cylinder
DISPLACEMENT: 2.967 cc (181 CID)
BORE: 101.60 mm (4.00 in.)
STROKE: 91.44 mm (3.60 in.)
COMPRESSION PRESSURE: 690 kPa (100 psi) Minimum
SPARK PLUGS: AC R46TS - 0.9 mm (0.035 in.) Air Gap
FUELTYPE: LPG
LP FUEL SYSTEM
COOLING SYSTEM
THERMOSTAT:
LUBRICATION SYSTEM
28 kPa (4 psi) @ 700 RPM
OIL PRESSURE (MIN. HOT):
124 kPa (18 psi) @ 2000 RPM
CRANKCASE CAPACITY: 3.8 L (4.0 qts.)
OIL FILTER: 0.95 L (1 qt.)
ENGINE OIL SPECIFICATION: API - SJ, SAE 10W30
ENGINE ELECTRICAL
IGNITION COIL: 12 V operation volt
DISTRIBUTOR: Delco EST Distributor with ignition module
STARTER MOTOR: 12 Volt, 2.0 kW
CRANK SENSOR: Built in Distributor
PEDAL ANGLE SENSOR: Installed on Accelerator Pedal
OXYGEN SENSOR:
12 V operation volt
EXHAUST SYSTEM

Specifications (G643E)
GENERAL DESCRIPTION
ENGINE TYPE: 90°4-Cycle V6
COMBUSTION SYSTEM: Naturally Aspirated
Pushrod Actuated Overhead Valves - 2 Per Cylinder
VALVE CONFIGURATION:
Auto Lash adjustment by hydraulic valve lifter
CAMSHAFT DRIVING: Timing Chain System
BALANCE SHAFT: One Balance Shaft System
DISPLACEMENT: 4294 cc (262 CID)
BORE: 101.60 mm (4.00 in.)
STROKE: 88.39 mm (3.48 in.)
COMPRESSION PRESSURE: 690 kPa (100 psi) Minimum
FIRING ORDER: 1-6-5-4-3-2
SPARK PLUGS: AC MR43LTS or R42LTS, 0.9 mm (0.035 in.) Air Gap
WEIGHT: 296 Kg (653 lbs.), Wet
FUELTYPE: LPG
LP FUEL SYSTEM
MIXER: Diaphragm Type Air Valve Assembly inside, Downdraft
COOLING SYSTEM
Serpentine Belt Drive - Clockwise (CW) when viewed from
WATER PUMP ROTATION:
engine front
THERMOSTAT:
LUBRICATION SYSTEM
28 kPa (4 psi) @ 700 RPM
OIL PRESSURE (MIN. HOT):
124 kPa (18 psi) @ 2000 RPM
CRANKCASE CAPACITY: 4.3 L (4.5 qts.)
OIL FILTER: 0.47 L (0.5 qt.)
ENGINE OIL SPECIFICATION: API - SJ, SAE 10W30
ENGINE ELECTRICAL
IGNITION COIL: 12 V operation volt
DISTRIBUTOR: Delco EST Distributor with ignition module
STARTER MOTOR: 12 Volt, 1.6 kW
CRANK SENSOR: Built in Distributor
PEDAL ANGLE SENSOR: Installed on Accelerator Pedal
OXYGEN SENSOR:
12 V operation volt
EXHAUST SYSTEM

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL
OVERVIEW G430E & G643E
MI-04 General Description

MI-04 control system is designed to provide a complete, fully integrated solution that will meet or exceed TIER-2
Large Spark Ignited Engines emission standards established by the California Air Research Board (CARB) and the
Environmental Protection Agency (EPA) for 2004. The MI-04 is a closed loop system utilizing a catalytic muffler to
reduce the emission level in the exhaust gas. In order to obtain maximum effect from the catalyst, an accurate
control of the air fuel ratio is required. A small engine control module (SECM) uses a heated exhaust gas oxygen
sensor (HEGO) in the exhaust system to monitor exhaust gas content.
MI-04 System: G430E Engine
Fault Light Fuel Filter
Key switch LP Fuel Line
Accel Pedal Main Fuel Lock

PWR
Relay
Vacuum Line
Converter
APP
Air Cleaner Coolant Line Fuel Trim Valve
Mixer
DBW Throttle TPS
TMAP SECM
Oxygen Sensor
Engine Distributor Coil

Catalytic
Muffler
Crank Sensor
Coolant Temp Sensor
Figure 10

MI-04 System: G643E Engine
LP Fuel Line
Fault Light Key switch
Fuel Filter Fuel Lock
Main
Accel Pedal PWR
Relay Converter Vacuum Line
APP
Coolant Line
Air Cleaner Fuel Trim Valve
Mixer
DBW Throttle TPS

Ignition Coil TMAP
Oxygen Sensor
SECM
Coolant Temperature Sensor
Catalytic
Muffler
Figure 10
The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air/fuel
mixer by modulating the fuel trim valve (FTV) connected to the regulator. Reducing the fuel pressure leans the
air/fuel mixture and increasing the fuel pressure enriches the air/fuel mixture. To calculate any necessary
corrections to the air fuel ratio, the SECM uses a number of different sensors to gain information about the engines
performance. Engine speed is monitored by the SECM through a variable reluctance (VR) sensor. Intake manifold
air temperature and absolute pressure is monitored with a (TMAP) sensor. The MI-04 is a drive by wire (DBW)
system connecting the accelerator pedal to the electronic throttle through the electrical harness, mechanical
cables are not used. A throttle position sensor (TPS) monitors throttle position in relation to the accelerator pedal
position sensor (APP) feedback. Even engine coolant temperature is monitored by the SECM. The SECM
controller has full adaptive learning capabilities, allowing it to adapt control function as operating conditions change.
Factors such as ambient temperature, fuel variations, ignition component wear, clogged air filter, and other
operating variables are compensated.

Open Loop LP Fuel System
Fuel LP LP Governor Engine Muffler

Lock-Off Converter Mixer
G430/G643 Open Loop LP Fuel System
MI-04 Closed Loop LP Fuel System
VR
Sensor
Coolant
Sensor Small
Engine
TMAP Control
Sensor Module
Acceleration (SECM)
Pedal
Angle Sensor
Oxygen Fuel Trim
Sensor Valve Coil
Fuel LP LP Electronic Engine Catalytic

Lock-Off Converter Mixer Throttle Muffler
G430E/G643E Closed Loop LP Fuel System

MI-04 LP Fuel Filter MI-04 Fuel Lock-Off (Electric)
Figure 11 Figure 12
After exiting the fuel tank, liquid propane passes The fuel lock-off is a safety shutoff valve, normally
through a serviceable inline fuel filter to the electric held closed by spring pressure, which is operated by
fuel lock off. (Figure 11) shows a typical inline type LP an electric solenoid and prevents fuel flow to the
fuel filter manufactured by Century. The primary regulator/converter when the engine is not in
function of the fuel filter is to remove particles and operation. This is the first of three safety locks in the
sediments that have found their way into the tank. MI-04 system. (Figure 12) shows the electric fuel lock
The LP fuel filter will not remove heavy end solids assembly.
and paraffin’s that build up in LPG fuel systems as a
result of vaporization. In the MI-04 design, power is supplied to the fuel
lock-off with the SECM controlling the lock-off ground
(earth) connection. The lock-off remains in a normally
closed (NC) position until the key switch is activated,
this supplies power to the lock-off and the SECM but
will not open the lock-off until the SECM provides the
lock-off ground connection. This design gives the
SECM full control of the lock-off while providing
additional safety by closing the fuel lock-off in the
unlikely event of a power failure, wiring failure or
module failure.
When the liquid service valve in the fuel container is

opened liquid propane flows through the LP filter and
through the service line to the fuel lock-off. Liquid
propane enters the lock-off through the ¼” 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
VR sensor detects any engine revolutions. Stall, when
the key is in the ON position but the VR 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-off is
opened but if the operator fails to crank the engine,
the SECM will close the lock-off after 5 seconds.

MI-04 N-2001 N-2001
Heat Transfer
Regulator/Converter Chamber
Coolant
Passage
Figure 14
(Figure 14) shows the heat chamber and the coolant

passage in the N-2001.
Figure 13
After passing through the electric fuel lock-off, liquid

propane enters the N-2001 regulator/converter
(Figure 13). The N-2001 functions as a fuel vaporizer,
converting liquid propane to vapor propane and as a
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-04
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
stage) valve closes. Unlike most other
regulator/converters, the N-2001 primary valve closes
with fuel pressure rather than against pressure,
extending primary seat life and adding additional
safety.
Liquid propane must be converted into a gaseous

form in order to be used as a fuel for the engine.
When the regulator receives the desired vacuum
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.

N-2001 Theory of Operation
N-2001
Cutaway View
7 8
6 5
9
4
1 3
2
Figure 15
Liquid propane, at tank pressure, enters the N-2001 When the engine is cranking or running a negative
through the fuel inlet port (1). Propane liquid then pressure signal (vacuum) travels through the vapor
flows through the primary valve (2). The primary valve fuel outlet connection of the regulator (9), which is the
located at the inlet of the expansion chamber (3), is regulator secondary chamber, and the vapor fuel inlet
controlled by the primary diaphragm (4), which reacts of the mixer. The negative pressure in the secondary
to vapor pressure inside the expansion chamber. Two chamber causes a pressure/force imbalance on the
springs are used to apply force on the primary secondary diaphragm, which overcomes the
diaphragm in the primary diaphragm chamber (5), secondary spring force, opening the secondary valve
keeping the primary valve open when no fuel and allowing vapor propane to flow out of the
pressure is present. expansion chamber, through the secondary chamber
A small port connects the expansion chamber to the to the mixer.
primary diaphragm chamber. At the outlet of the
expansion chamber is the secondary valve (6). The Because vapor propane has now left the expansion
secondary valve is held close by the secondary chamber, the pressure in the chamber will drop,
spring on the secondary valve lever (7). The causing the primary diaphragm spring force to re-
secondary diaphragm controls the secondary lever. open the primary valve allowing liquid propane to
When the pressure in the expansion chamber enter the regulator, and the entire process starts
reaches 1.5 psi it causes a pressure/force imbalance again. This creates a balanced condition between the
across the primary diaphragm (8). This force is primary and secondary chambers allowing for a
greater than the primary diaphragm spring pressure constant flow of fuel to the mixer as long as the
and will cause the diaphragm to close the primary demand from the engine is present. The fuel flow is
valve. maintained at a constant output pressure, due to the
calibrated secondary spring. The amount of fuel
Since the fuel pressure has been reduced from tank flowing will vary depending on how far the secondary
pressure to 1.5 psi the liquid propane vaporizes. As valve opens in response to the negative pressure
the propane vaporizes it takes on heat from the signal generated by the air/fuel mixer. The strength of
expansion chamber. This heat is replaced by engine that negative pressure signal developed by the mixer
coolant, which is pumped through the coolant is directly related to the amount of air flowing through
passage of the regulator. At this point vapor propane the mixer into the engine. With this process, the
will not flow past the expansion chamber of the larger the quantity of air flowing into the engine, the
regulator until the secondary valve is opened. To larger the amount of fuel flowing to the mixer.
open the secondary valve a negative pressure signal
must be received from the air/fuel mixer.

MI-04 N-CA55-500TR Mixer N-CA55-500-TR Air/Fuel Mixer
Vapor propane fuel is supplied to the N-CA55-500TR
Theory of Operation
The N-CA55-500TR mixer uses a piston type air
valve assembly to operate a gas-metering valve 1
closed, requiring a negative pressure (vacuum) signal 4
from a cranking or running engine to open. This is the 2
3
third of the three safety locks in the MI-04 system. If 6
5
7
then travels past the throttle, through the intake Figure 17
View of Venturi Air
Valve Piston Air Intake
Gas-Metering
Valve open
Figure 18
Figure 16 The air/fuel mixer is mounted in the intake air stream

(Figure 16) shows the N-CA55-500TR mixer installed
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 piston air valve (3),
the gas-metering valve (4), and air valve sealing ring
(5), air valve spring (6) and the check valve plate (7).
The gas-metering valve is permanently mounted to
the piston air valve with a face seal mounted between
the two parts.
When the engine is not running this face seal creates

a seal against the gas discharge jet, preventing fuel
flow with the aid (upward force) of the air valve spring.
The outer surface of the piston air valve forms the
venturi section of the mixer while the inner portion of
the piston is hollow and forms the air valve vacuum
chamber. The check valve plate seals off the bottom
of the air valve vacuum (AVV) chamber and the air
valve sealing ring seals the top portion of the AVV
chamber as the piston moves against 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 a port in the Air
Intake
check valve plate to the AVV chamber. A
pressure/force imbalance begins to build across the Idle Mixture
air valve piston between the AVV chamber (below the Adjustment
piston) and atmospheric pressure above the piston. Screw
Approximately 6” W.C. (Water Column) of negative
pressure is required to overcome the air valve spring
force and push the air valve assembly (piston) Electronic
downward off the valve seat. Approximately 24” W.C. Throttle
pushes the valve assembly to the bottom of its travel Figure 19

in the full open position.
A main mixture adjustment valve on the fuel inlet of
The amount of negative pressure generated is a the N-CA55-500TR is not used in the MI-04 system,
direct result of throttle position and the amount of air however an idle mixture adjustment is incorporated
flowing through the mixer to the engine. At low engine into the mixer (Figure 19). The idle mixture
speeds, low AVV causes the piston air valve to move adjustment is an air bypass port, adjusting the screw
downward a small amount, creating a small venturi. all the way in, blocks off the port and enriches the idle
At high engine speeds, high AVV causes the air valve mixture. Backing out the idle adjustment screw opens
piston to move much farther creating a large venturi. the port and leans the idle mixture. The idle mixture
The variable venturi air/fuel mixer constantly matches screw is a nylon type screw that is factory set with a
venturi size to engine demand. To prevent engine tamper resistant cap installed after adjustment.
reversion pulses, commonly encountered in small Accurate adjustment of the idle mixture can only be
displacement engines, from having an effect on the accomplished by adjusting for a specific fuel trim
piston AVV chamber, a check valve is incorporated on valve (FTV) duty cycle with the service tool software,
the check valve plate control port to the AVV chamber. and should be only be adjusted by trained service
The check valve is held open with gravity and technicians.
remains open with any negative pressure signal from
the engine. If a reverse pressure pulse, caused by
engine reversion, travels up the intake manifold
toward the mixer it will close the check valve for the
duration of the pulse, preventing the pulse from
entering the AVV chamber.

MI-04 (N-CA100TR Mixer)
Figure 15
Vapor propane fuel is supplied to the N-CA100TR

The N-CA100TR mixer uses a diaphragm type air
valve assembly to operate a gas-metering valve
closed, requiring a negative pressure (vacuum) signal
from a cranking or running engine to open. This is the
third of the three safety locks in the MI-04 system. If
then travels past the throttle, through the intake
Figure 16
(Figure 16) shows the N-CA100TR mixer installed


A pressure/force imbalance begins to build across the
N-CA100TR Air/Fuel Mixer air valve diaphragm between the AVV chamber
Theory of Operation (above the diaphragm) and atmospheric pressure
below the diaphragm. Approximately 6” W.C. (Water
Column) of negative pressure is required to overcome
the air valve spring force and push the air valve
6
5 assembly upward off the valve seat. Approximately
3 24” W.C. pushes the valve assembly to the top of its
travel in the full open position.
1
The amount of negative pressure generated is a
direct result of throttle position and the amount of air
2 flowing through the mixer to the engine. At low engine
4 speeds, low AVV causes the air valve diaphragm
assembly to move upward a small amount, creating a
Figure 17 small venturi. At high engine speeds, high AVV
causes the air valve diaphragm assembly to move
much farther creating a large venturi. The variable
venturi air/fuel mixer constantly matches venturi size
Bottom View of the to engine demand.
Air Valve Assembly
Vacuum Ports Gas- N-CA100TR
Metering
Valve
Main Idle Mixture
Mixture Adjustment
Orifice Port Screw
Air Intake
Figure 18
Electronic
Throttle
The air/fuel mixer is mounted in the intake air stream Figure 19
mixer bore, fuel inlet (1) and a gas discharge jet (2). A main mixture adjustment valve on the fuel inlet of
In the center of the main body is the air valve the N-CA100TR is not used in the MI-04 system,
assembly, which is made up of the air valve (3), the however an idle mixture adjustment is incorporated
gas-metering valve (4), and air valve diaphragm (5) into the mixer (Figure 19). The idle mixture
and air valve spring (6). The gas-metering valve is adjustment is an air bypass port, adjusting the screw
permanently mounted to the air valve diaphragm all the way in, blocks off the port and enriches the idle
assembly with a face seal mounted between the two mixture. Backing out the idle adjustment screw opens
parts. the port and leans the idle mixture. The idle mixture
screw is a nylon type screw that is factory set with a
When the engine is not running this face seal creates tamper resistant cap installed after adjustment.
a seal against the gas discharge jet, preventing fuel Accurate adjustment of the idle mixture can only be
flow with the aid (downward force) of the air valve accomplished by adjusting for a specific fuel trim
spring. When the engine is cranked over it begins to valve (FTV) duty cycle with the service tool software,
draw in air, creating a negative pressure signal. This and should be only be adjusted by trained service
negative pressure signal is transmitted through four technicians.
vacuum ports in the air valve.

The SECM calculates the correct throttle valve
MI-04 Electronic Throttle opening that corresponds to the driver’s demand,
makes any adjustments needed for adaptation to the
Conventional throttle systems rely on mechanical
engine’s current operating conditions and then
linkage to control the throttle valve. To meet
generates a corresponding electrical (driver) signal to
fluctuating engine demands a conventional system
the throttle-valve actuator.
will typically include throttle valve actuators designed
to readjust the throttle valve opening in response to
In place of a dual TPS design (TPS1 and TPS2), the
engine demand, together with idle control actuators or
SECM calculates correct throttle position (Predicted
idle air bypass valves.
TPS) based on RPM and MAP and compares this to
the actual throttle position, based on TPS1. 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 SECM’s 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 it’s limp-home modes or shut the
engine down, storing the appropriate fault information
in the SECM.
Figure 20 There are multiple limp-home modes available with

ETC. 1. If the throttle itself is suspected of being
inoperable, the SECM will remove the power to the
In contrast, the MI-04 system uses electronic throttle
throttle motor. When the power is removed, the
control (ETC). The SECM controls the throttle valve
throttle blade returns to its “default” position,
based on engine RPM, engine load, and information
approximately 7% open. 2. If the SECM can still
received from the Acceleration Pedal. Two mutually
control the throttle but some other part of the system
opposed potentiometers on the Acceleration Pedal
is suspected of failure, the SECM will enter a
assembly monitor accelerator pedal travel. The
“Reduced Power” mode. In this mode, the power
electronic throttle used in the MI-04 system for
output of the engine is limited by reducing the
G430E Engine is a Bosch 32mm Electronic Throttle
maximum throttle position allowed. 3. In some cases,
Body DV-E5 (Figure 20). The electronic throttle used
the SECM will shut the engine down. This is
in the MI-04 system for G643E Engine is a Bosch
accomplished by stopping ignition, turning off the fuel,
40mm Electronic Throttle Body DV-E5. The DV-E5 is
and disabling the throttle.
a single unit assembly, which includes the throttle
valve, throttle-valve actuator (DC motor) and the
throttle position sensor (TPS) (Figure 21).
Throttle Plate
Gear Drive
DC Drive Motor
Bosch Electronic Throttle Body DV-E5

Figure 21 Picture courtesy of Robert Bosch GmbH

A branch-tee fitting is installed in the atmospheric
MI-04 Fuel Trim Valve vent port of the N2001 with one side of the branch-tee
connected to the intake side of the mixer forming 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 FTV is open AVV is sent to the
which lowers the reference pressure, closing the
N2001 secondary valve and leaning the air/fuel
mixture. The MI-04 system is calibrated to run rich
without the FTV. By modulating (pulsing) the FTV the
Fuel Trim Valve SECM can control the amount of AVV applied to the
N2001 secondary diaphragm. Increasing the amount
of times the FTV opens (modulation or duty cycle)
causes the air/fuel mixture to become leaner;
The Fuel Trim Valve (FTV) is a two-way electric
decreasing the modulation (duty cycle) enriches the
solenoid valve and is controlled by a pulse width
mixture.
modulated (PWM) signal provided by the SECM. The
FTV is used to bias the output fuel pressure on the
LPG regulator/converter (N-2001), by metering air G430E Engine
valve vacuum (AVV) into the atmospheric side of the
N-2001 secondary regulator diaphragm. An orifice
balance line connected to the air inlet side of the
mixer provides atmospheric reference to the N-2001
when the FTV is closed. The SECM uses feedback
Balance
voltage from the O2 sensor to determine the amount
Line FTV
of bias needed to the regulator/converter.
In normal operation the N2001 maintains fuel flow at

a constant output pressure, due to the calibrated
secondary spring. The amount of fuel flowing from the
N2001 will vary depending on how far the secondary Figure 22
diaphragm opens the secondary valve in response to
the negative pressure signal generated by the air/fuel
mixer. One side of the N2001 secondary diaphragm is G643E Engine
referenced to atmospheric pressure while the other
side of the diaphragm reacts to the negative pressure
signal from the mixer. If the pressure on the
atmospheric side of the N2001 secondary diaphragm
is reduced, the diaphragm will close the secondary
valve until a balance condition exists across the Balance FTV
diaphragm, reducing fuel flow and leaning the air/fuel Line
mixture.
Figure 22
(Figure 22) shows the Fuel Trim Valve connected in

the MI-04 system.

The HEGO stoichiometric air/fuel ratio voltage target
Heated Exhaust Gas Oxygen is approximately 500mV and changes slightly as a
Sensor (HEGO) function of speed and load. When the HEGO sensor
sends a voltage signal less than 500mV the SECM
interprets the air/fuel mixture to be lean. The SECM
then decreases the duty cycle of the FTV lowering the
amount of air valve vacuum (AVV) acting on the
increasing the regulator vapor propane output to
richen the air/fuel mixture. The opposite is true if the
SECM receives a voltage signal above 500mV 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 FTV.
Figure 24 CAUTION
The HEGO sensor used is calibrated to
work with the MI-04 system. Using
The HEGO sensor (Figure 24) installed in the exhaust alternate sensors may impact drivability
manifold before the catalytic muffler is a basic and the ability of the system to diagnose
zirconium type oxygen sensor comprised of a hollow rich and lean conditions.
cone-shaped internal element made of zirconium
dioxide (ZrO2, a ceramic material), which is coated
with a thin layer of micro-porous platinum. The outer
layer is exposed to the exhaust stream, while the
inner layer is vented to the atmosphere and attached
to a wire that runs to the SECM. It operates like a
galvanic cell with the zirconium dioxide acting as the
electrolyte and the platinum layers serving as
electrodes. Once the ZrO2 reaches approximately
600 deg. F., it becomes electrically conductive and
attracts negatively charged ions of oxygen. These
ions collect on the inner and outer platinum surfaces.
Naturally, there's more oxygen in plain air than in
exhaust, so the inner electrode will always collect
more ions than the outer electrode, and this causes a
voltage potential for electrons to flow. The
concentration of oxygen in the exhaust stream
determines the number of ions on the outer electrode,
hence the amount of voltage produced. If the engine
is running rich, little oxygen will be present in the
exhaust, few ions will attach to the outer electrode,
and voltage output will be relatively high. In a lean
situation, more oxygen will be present, and that
translates into more ions on the outer electrode, a
smaller electrical potential, and less voltage. In order
for the sensor to conduct and create an electrical
signal below 600 deg. F., a heated element is added
to the sensor housing. Two wires provide the
necessary 12VDC and ground signal for the heater
element. A fourth wire provides an independent
ground for the sensor.

MI-04 SECM (General MI-04 SECM
Description) (Fuel Management)
During engine cranking at startup, the SECM
provides a low side driver signal to the fuel lock-off,
which opens the lock-off allowing liquid propane to
flow to the N2001 regulator. A stall safety shutoff
feature is built into the SECM to close the lock-off in
SECM case of a stall condition. The SECM monitors three
engine states. Crank, when the VR sensor detects
any engine revolutions. Stall, when the key is in the
ON position but the VR sensor detects no engine
revolutions, and the Run state, when the engine
reaches pre-idle RPM. When an operator turns on
Figure 23 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.
The Woodward Small Engine Control Module (SECM)
controller has full authority over spark, fuel and air. To maintain proper exhaust emission levels, the
Utilizing Motorola’s HCS12 micro controller, the SECM uses a heated exhaust gas oxygen sensor
SECM has 24 pins of I/O and is fully waterproof and (HEGO) mounted before the catalyst, to measure
shock hardened (Figure 23). To optimize engine exhaust gas content in the LP gas system. Engine
performance and drivability, the SECM uses several speed is monitored by the SECM through a variable
sensors for closed loop feedback information. reluctance (VR) sensor. Intake manifold air
These sensors are used by the SECM for closed loop temperature and absolute pressure is monitored with
control in three main categories: a (TMAP) sensor. The HEGO voltage is converted to
z Fuel Management an air fuel ratio value. This value is then compared to
z Load/Speed Management a target value in the SECM. The target value is based
z Ignition Management on optimizing catalyst efficiency for a given load and
speed. The SECM then calculates any corrections
The SECM monitors system parameters and stores that need to be made to the air fuel ratio.
any out of range conditions or malfunctions as faults
in SECM memory. Engine run hours are also stored The system operates in open loop fuel control until
in memory. Stored fault codes can be displayed on the engine has done a certain amount of work. This
the Malfunction Indicator Light (MIL) as flash codes or ensures that the engine and HEGO are sufficiently
read by the MI-04 Service Tool software through a warmed up to stay in control. In open loop control, the
CAN (Controller Area Network) communication link. FTV duty cycle is based on engine speed and load.
Once the HEGO reaches operating temperature the
Battery power (12 VDC) is supplied through the fuse fuel management is in closed loop control for all
block to the main power relay. The ignition key switch steady state conditions, from idle through full throttle.
is used to energize the main power relay. A main In closed loop mode, the FTV duty cycle is based on
power relay supplies 12 VDC power to the SECM, the feedback from the HEGO sensor. In order to handle
heated element of the oxygen sensor, Fuel Lock-Off, transient loads, engine RPM and load is compared to
Fuel Trim Valve (FTV) and the Smart Coil. The SECM a threshold used by the SECM. When this threshold
supplies positive voltage to the electronic throttle is exceeded, the FTV duty cycle will be set to a Feed
actuator, oil pressure switch and the coolant Forward Adaptive value.
temperature sensor. Transducer or sensor power (+5
VDC) is regulated by the SECM and supplied to the The SECM then makes any necessary corrections to
Temperature/Manifold Air Pressure Sensor (TMAP), the air fuel ratio by controlling the inlet fuel pressure
Throttle Position Sensor (TPS), and the Accelerator to the air/fuel mixer Reducing the fuel pressure leans
Pedal Position Sensors (APP1 & APP2). The SECM the air/fuel mixture and increasing the fuel pressure
provides a constant voltage (VCC) to the Smart Coil enriches the air/fuel mixture. Control is achieved by
Driver, transducer ground for the all sensors, and a modulating the fuel trim
low side driver signal controlling the fuel lock-off, MIL
and FTV.

Catalytic Muffler As exhaust and catalyst temperatures rise the
following reaction occurs:
All exhaust gases pass through a catalyst that is z Oxides of nitrogen (NOx) are reduced into simple
mounted in the catalytic muffler. It filters the harmful nitrogen (N2) and carbon dioxide (CO2).
gases through a dense honeycomb structure coated z Hydrocarbons (HC) and carbon monoxide (CO)
with precious metals such as platinum, palladium, are oxidized to create water (H2O) and carbon
and rhodium. Chemical reactions occur on these dioxide (CO2).
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 gas, a harmless Catalyst
Efficiency
emission. On the rich cycle, the primary pollutant is
carbon monoxide. By adding the oxygen that was
stored on the lean cycle to the carbon monoxide, Operational
carbon dioxide is produced. Range of
Converter
Inside the catalytic muffler is a three-way catalyst as Richer Air Fuel Ratio Leaner
well as sound dampening and spark arresting
features. The three-way catalyst section consists of a
honeycomb coated with a mixture of platinum, The third stage is the MI-04 control system that
palladium and rhodium. As engine exhaust gases flow monitors the exhaust stream, and uses this
through the converter passageways, they contact the information to control the air/fuel mixture. By using
coated surface, which initiate the catalytic process. the signal from the HEGO the SECM can increase or
The reduction catalyst is the first stage of the decrease the amount of oxygen in the exhaust by
catalytic converter. It uses platinum and rhodium to modulating the FTV and adjusting the air/fuel ratio.
help reduce the NOx emissions. The oxidation This control scheme allows the SECM to make sure
catalyst is the second stage of the catalytic converter. that the engine is running at close to the
It reduces the unburned hydrocarbons and carbon stoichiometric point, and also to make sure that there
monoxide by burning (oxidizing) them over a platinum is enough oxygen in the exhaust to allow the
and palladium catalyst. Cerium is also used to oxidization catalyst to burn the unburned
promote oxygen storage and improve oxidation hydrocarbons and CO.
efficiency.
Oxidation and Reduction Process
Reduction:
NOx, CO > N2 + CO2
Oxidation:
HC, CO, O2 > H2O + CO2
3-Way Catalytic
Muffler
Figure 25

NOTE
MI-04 SECM (Load/Speed The DV-E5 is not a serviceable assembly.
Management) If the TPS sensor fails, the assembly
should be replaced.
Drive by wire refers to the fact that the MI-04 control
system has no throttle cable from the Acceleration
Pedal (Figure 26) to the throttle body. Instead, the
SECM is electronically connected both to the
Acceleration Pedal assembly and the throttle body.
The SECM monitors the Acceleration Pedal position
and controls the throttle plate by driving a dc motor
connected to the throttle. The dc motor actuates the
throttle plate to correspond to the Acceleration Pedal
position when the operator depresses the pedal.
The use of electronic throttle control (ETC) ensures
that the engine only receives the correct amount of
throttle opening for any given situation, greatly Figure 27
improving idle quality and drivability.
Figure 26 Figure 28
SECM self-calibration and “cross checking” of the

TPS is accomplished by comparing the TPS signal to
a calculated throttle position in the SECM software
(Predicted TPS). In addition to the throttle position
sensor, a Temperature/Manifold Air Pressure Sensor
(TMAP) is used to monitor intake manifold
temperature and pressure (Figure 28). This enables
the SECM full control capabilities monitoring actual
airflow in relationship to desired airflow. The TMAP
sensor is a single unit incorporating both intake
manifold temperature and manifold pressure
measurement.
A Throttle Position Sensor (TPS), (Figure 27) which is

integral to the Drive By Wire (DBW) throttle assembly,
provides feedback for position control by monitoring
the exact position of the throttle valve.

The MI-04 system also performs minimum (min) and
maximum (max) governing through the SECM and Acceleration
DBW throttle. For min governing, or idle speed control, Pedal
the idle speed is fixed by the SECM. Unlike a
mechanical system, the idle speed is not adjustable
by the end user. The idle speed is adjusted by the
SECM based on engine coolant temperature. At
these low engine speeds, the SECM uses spark and
throttle to maintain a constant speed regardless of
APP2
load.
The MI-04 system eliminates the need for air velocity APP1
governors. This substantially increases the peak
torque and power available for a given system as
shown in (Figure 29). 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 speed exceeds this max governing point,
spark is interrupted to attempt to bring the speed APP 0-100%
•Self Calibration
back to a point that can be controlled by throttle alone.
SECM 5msec • Cross Check of
If over speed is detected multiple times, the engine is Update APP1 & APP2
shutdown. Rate
System Power Comparison
TPS TPSd
(Demand)
Power, hp (corrected)
DBW
Throttle
MI-4 system
Baseline system PID
RPM Figure 30
Figure 29
(Figure 30) describes the signal flow process of the

MI-04 DBW section. The Acceleration Pedal
assembly uses two potentiometers to detect pedal
System Torque Comparison
position. These two signals, accelerator pedal
position 1 (APP1) and accelerator pedal position 2
(APP2) are sent directly to the SECM. The SECM
Torque, ft-lb (corrected)
uses a series of algorithms to self calibrate and cross

check the signals from the pedal assembly. A demand
position for the throttle will then be derived and sent
MI-4 system
to the throttle as a throttle position sensor demand
Baseline system
(TPSd). The signal will be processed through a PID
(Proportional, Integral, Derivative) controller in the
RPM
Figure 29 SECM to achieve the appropriate motor-current
response then passed to the throttle. The throttle
moves to the commanded position and provides a
feedback signal from the throttle position sensor
(TPS) to the SECM.

MI-04 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 Coil
the SECM may need to vary the ignition timing,
including low engine coolant temperature, air
temperature, start-up, idle speed control. Ignition
Module
Figure 32
GM Delco EST Ignition System G430E Engine
The MI-04 system is capable of operating with either

a distributor based ignition system or a distributor less Coil
ignition system. The current application uses a
distributor based ignition system. The distributor will
have no internal advance mechanisms giving the
SECM consistent authority over ignition timing. The
spark is sent to the appropriate cylinder in the
conventional way via the rotor arm and spark plug Ignition
wires. The SECM uses the signal from the GM Module
(General Motors) Delco Ignition Module to determine
the engine position and RPM at any time. It uses this Figure 32
information together with the information from the
G643E Engine
TPS sensor and TMAP to calculate the appropriate
ignition timing settings.
The General Motors (GM) distributor (Figure 31) used
in the Delco EST ignition system, incorporates a
Variable Reluctance (VR) sensor, which transmits a
reference signal to the GM ignition module (Figure
32) located on the distributor. A Variable Reluctance
sensor is an electromagnetic device consisting of a
permanent magnet surrounded by a winding of wire.
The sensor is used in conjunction with a ferrous
signal rotor on the distributor shaft. The signal rotor
has four lobes, one for each cylinder. Rotation of the
signal rotor near the tip of the sensor changes the
magnetic flux, creating an analog voltage signal in the
sensor coil.
Figure 31
The rising edge of the VR signal is converted to a

rising 5-volt signal by the ignition module. As the VR
signal passes back through zero volts, a falling edge
is created producing a square wave or digital signal,
similar to the signal produced by a Hall effect sensor.
This falling edge signal provides a stable engine
position reference at all engine speeds for the SECM.

CHAPTER 3 MI- 4 MAINTENANCE SCHEDULE
RECOMMENDED Inspect Engine for Fluid
MAINTENANCE SCHEDULE Leaks
Suggested maintenance requirements for an engine z Start the engine and allow it to reach operating
equipped with an MI-04 fuel system are contained in temperatures.
this section. The owner should, however, develop his z Turn the engine off.
own maintenance schedule using the requirements z Inspect the entire engine for oil and/or coolant
listed in this section and any other requirements listed leaks.
by the engine manufacturer. z Repair as necessary before continuing.
Test Fuel System for Leaks Inspect Vacuum Lines and

Fittings
z Visually inspect vacuum lines and fittings for
physical damage such as brittleness, cracks and
kinks. Repair/replace as required.
z Solvent or oil damage may cause vacuum lines
to become soft resulting in a collapsed line while
the engine is running.
z If abnormally soft lines are detected, replace as
necessary.
Check
Points
Vacuum
z Obtain a leak check squirt bottle or pump spray Line
bottle.
z Fill the bottle with an approved leak check
solution.
z Spray a generous amount of the solution on the
fuel system fuel lines and connections, starting at
the storage container.
z Wait approximately 15 - 60 seconds then
perform a visual inspection of the fuel system.
Leaks will cause the solution to bubble.
z Repair any leaks before continuing.
z Crank the engine through several revolutions.
This will energize the fuel lock-off and allow fuel Inspect Electrical System
to flow to the pressure regulator/converter. Apply
additional leak check solution to the z Check for loose, dirty or damaged connectors
regulator/converter fuel connections and housing. and wires on the harness including: Fuel lock-off,
Repeat leak inspection as listed above. TMAP sensor, O2 sensor, Electronic throttle,
z Repair any fuel leaks before continuing. Control Relays, Fuel Trim Valve, Acceleration
Pedal, and Distributor sensor.
z Repair and/or replace as necessary.

Inspect Acceleration Pedal
Operation
z Verify Acceleration Pedal travel is smooth
without sticking.
Check Coolant Level

z The items below are a general guideline for
system checks. Refer to the engine
manufacturers specific recommendations for
proper procedures.
z Engine must be off and cold.
WARNING
NEVER REMOVE THE PRESSURE CAP
ON A HOT ENGINE.
z The coolant level should be equal to the “COLD”

mark on the coolant recovery tank.
z Add approve coolant to the specified level if the
system is low.

Inspect Coolant Hoses
z Visually inspect coolant hoses and clamps.
Remember to check the two coolant lines that
1
z Replace any hose that shows signs of swelling, 2
cracking, abrasion or deterioration.
Inspect Battery System

z Clean battery outer surfaces with a mixture of G430E Engine
baking soda and water. (1) Spark Plug Cables
(2) Distributor Cap
z Inspect battery outer surfaces for damage and
replace as necessary.
z Remove battery cable and clean, repair and/or
Inspect Ignition System 1

z Remove and inspect the spark plugs. Replace as 2
required.
z Test secondary cables with an Ohmmeter. If
maximum resistance is higher than 25 kOhms,
z Remove distributor cap and perform visual G643E Engine
inspection. Replace cap and rotor if corrosion is (1) Spark Plug Cables
(2) Distributor Cap
found on the contacts.
z Inspect the ignition coil for cracks and heat
deterioration. Visually inspect the coil heat sink
fins. If any fins are broken replace as required.

Replace Spark Plugs Replace LP Fuel Filter
Element
z Using a gentle twisting motion remove the high
Park the lift truck in an authorized refueling area with
voltage cables from the spark plugs. Replace
the forks lowered, parking brake applied and the
any damaged cables.
transmission in Neutral.
z Remove the spark plugs.
z Gap the new spark plugs to the proper
1. Close the fuel shutoff valve on the LP-Fuel tank.
specifications.
out and the engine stops.
G430E Engine : 0.9 mm
G643E Engine : 0.9 mm
z Apply anti-seize compound to the spark plug
3. Scribe a line across the filter housing covers,
threads and install.
which will be used for alignment purposes when
re-installing the filter cover.
G430E Engine : 30 N•m (22 lb•ft)
G643E Engine : 30 N•m (22 lb•ft)
CAUTION Filter
DO NOT OVERTIGHTEN THE SPARK Housing 1
PLUGS. Scribe
Point
z Re-install the high voltage cables.
Spark Plug Wire Routing (G643E)

Fuel Filter 2 Testing Fuel Lock-off
Disassembly
4 1
Operation
z Start engine.
5 z Locate the electrical connector for the fuel lock
(A).
3 z Disconnect the electrical connector.
z The engine should run out of fuel and stop within
a short period of time.
7 z Turn the ignition key switch off and re-connect
6
5. Remove top cover (2), magnet (3), spring (4), and

filter element (7) from bottom cover (5).
6. Replace the filter element (7). A

G
7. Check bottom cover O-ring seal (6) for damage.
Replace if necessary. D
C
8. Re-assemble the filter assembly aligning the F
scribe lines on the top and bottom covers. B
9. Install the cover retaining screws, tightening the

screws in an opposite sequence across the cover.
G430E Engine
10. Open the fuel valve by slowly turning the valve

counterclockwise.
G
A
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. B
12. Check the filter housing, fuel lines and fittings for
leaks. Repair as necessary. C
D F D
G643E Engine
(A) LP fuel lock-off (B) LP regulator/converter
(C) Fuel Trim Valve (FTV) (D) Throttle body
(E) TMAP sensor (F) Adapter-Manifold (G) LP mixer
NOTE
The length of time the engine runs on
trapped fuel vapor increases with any
regulator/converter.

Pressure Inspect for Intake Leaks
Regulator/Converter Testing z Visually inspect the intake manifold, throttle
and Inspection assembly (D), and manifold adapters (F), for
looseness and leaks. Repair as necessary.
z Visually inspect the pressure regulator/converter
(B) housing for coolant leaks. Refer to the
pressure regulator/converter section of the
service manual if maintenance is required.
E
NOTE
For pressure testing and internal
inspection of the pressure D
regulator/converter, refer to the pressure
regulator/converter section of the service
manual. F
Fuel Trim Valve Inspection G430E Engine

(FTV)
z Visually inspect the Fuel trim valve (C) for
abrasions or cracking. Replace as necessary.
z To ensure the valve is not leaking a blow-by test
can be performed.
F
1. With the engine off, disconnect the electrical
connector to the FTV.
2. Disconnect the vacuum line from the FTV to the

pressure regulator/converter, at the converter’s E
D
tee connection.
G643E Engine
3. Lightly blow through the vacuum line connected to (D) Throttle body (E) TMAP sensor (F) Adapter-Manifold
the FTV. Air should not pass through the FTV
when de-energized. If air leaks past the FTV when
de-energized replace the FTV.
Inspect Air/Fuel Valve Mixer

Assembly
Refer to the LP mixer (G) section of the service
manual for procedures.

Inspect Throttle Assembly Replace Oxygen Sensor
z Visually inspect the throttle assembly motor
housing for coking, cracks and missing cover-
retaining clips. Repair and/or replace as
necessary.
NOTE
Refer to the LP mixer and throttle section
of the service manual for procedures on
removing the mixer and inspecting the
throttle plate.
Checking the TMAP Sensor G430E Engine
z Verify that the TMAP sensor (E) is mounted

tightly into the manifold adapter (F), with no
leakage.
z If the TMAP is found to be loose, remove the
TMAP retaining screw and the TMAP sensor
z Visually inspect the TMAP O-ring seal for
z Apply a thin coat of an approved silicon lubricant
to the TMAP o-ring seal.
z Re-install the TMAP sensor into the manifold
adapter and securely tighten the retaining screw.
G643E Engine
Inspect Engine for Exhaust 1. Stop engine and wait until the exhaust pipe and
Leaks exhaust pipe is cooled.
z Start the engine and allow it to reach operating 2. Disconnect the electrical connector of oxygen
temperatures. sensor.
z Perform visual inspection of exhaust system.
Repair any/all leaks found. 3. Remove oxygen sensor.
4. Assemble new oxygen sensor.
5. Connect the electrical connector of oxygen sensor.

Maintenance Schedule
Interval Hours
Daily Every Every Every Every Every Every
250hrs or 500 1000 1500 2600 4500
CHECK POINT a month Hours or Hours or Hours or Hours or Hours or
General Maintenance Section

Test Fuel System for Leaks Prior to any service or maintenance activity
Inspect engine for fluid leaks X
Inspect all vacuum lines and
X
fittings
Inspect electrical system- check
for loose, dirty, or damaged wires X
and connections
Inspect all fuel fittings and hoses X
Inspect Acceleration Pedal travel
X
and operation
Engine Coolant Section
Check Coolant Level X
Inspect coolant hoses and fittings
for leaks, cracks, swelling, or X
deterioration
Engine Ignition Section
Inspect battery for damage and
X
corroded cables
Inspect ignition system X
Replace spark plugs X
Fuel Lock-Off/Filter Section
Replace LP fuel filter element X
Inspect lock-off and fuel filter for
X
leaks
Ensure lock-off stops fuel flow
X
when engine is off
Pressure Regulator/Converter Section
Test regulator pressures X
Inspect pressure regulator vapor
X
hose for deposit build-up
Inspect regulator assembly for
X
fuel/coolant leaks
Fuel Trim Valve Section
Inspect valve housing for wear,
X
cracks or deterioration
Ensure valve seals in the closed
X
position when the engine is off

Interval Hours
Daily Every Every Every Every Every Every
250hrs or 500 1000 1500 2600 4500
CHECK POINT a month Hours or Hours or Hours or Hours or Hours or
Carburetor Section
Check air filter indicator X
Check for air leaks in the filter
X
system
Inspect air/fuel valve mixer
X
assembly
Inspect air/fuel mixer assembly
X
throat
Check for vacuum leaks in the
intake system including manifold
X
adapter and mixer to throttle
adapter
Inspect throttle assembly X
Inspect air filter X
Replace air filter element X
Check TMAP sensor for tightness
X
and leaks
Exhaust & Emission Section
Inspect engine for exhaust leaks X
Replace Oxygen Sensor X
Replace PCV Valve and breather
X
element

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING
Basic Troubleshooting
The MI-04 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the
Malfunction Indicator Lamp (MIL) and are covered in the Advanced Diagnostics section. Items such as fuel level,
plugged fuel lines, clogged fuel filters and malfunctioning pressure regulators may not set a fault code by the Small
Engine Control Module (SECM). Below are basic checks that should be made before referring to the Advanced
Diagnostics section, if engine or drivability problems are encountered.
Locating a problem in a propane engine is done exactly the same way as with a gasoline engine. Consider all
parts of the ignition and mechanical systems as well as the fuel system.

Engine Cranking but Fuel container empty Fill fuel container
Will Not Start z Do not exceed 80% of liquid capacity


z Leak test

z See Maintenance Section of Operation
& Maintenance Manual, Fuses
replacement
Faulty vapor connection Check connection

between the pressure z Verify no holes in hose
regulator/converter and the z Clamps must be tight
mixer z Look for kinked, pinched and/or
collapsed hose

Incorrect air/fuel or ignition/spark See Chapter 5 Advanced Diagnostics

control

Engine Cranking but No VR Sensor Signal Verify the VR signal is present
Will Not Start z See Chapter 5 Advanced Diagnostics


z Leak test

collapsed hose


Incorrect air/fuel or ignition See Chapter 5 Advanced Diagnostics

control

Continuously z Fill fuel container


z Slowly open liquid fuel valve & Leak
test
z -35F minimum
z Verify one pressure hose and one
return hose
Incorrect idle speed or ignition See Chapter 5 Advanced Diagnostics

problem
Accelerate/Hesitation z Fill fuel container
During Acceleration

Accelerate/Hesitation z See Chapter 3 Fuel Filter replacement
During Acceleration Faulty vapor connection Check connection

collapsed hose
Throttle butterfly valve not See Chapter 5 Advanced Diagnostics
opening or sticking
Acceleration Pedal signal
incorrect or intermittent
Incorrect air/fuel or ignition
control


test

z See Chapter 3 Fuel Lock-Off

collapsed hose
z -35F minimum
return hose

manifold
head

Rough Idle Faulty vapor connection Check connection
collapsed hose

manifold
head

Rough Idle Incorrect Idle speed control See Chapter 5 Advanced Diagnostics &
Incorrect timing or spark control Chapter 9 Tests and Adjustments
High Idle Speed Incorrect Idle speed control See Chapter 5 Advanced Diagnostics &
Throttle sticking Chapter 9 Tests and Adjustments
Acceleration Pedal sticking or Check pedal return spring travel for binding
incorrect pedal signal z See Chapter 5 Advanced Diagnostics

Performance z See Chapter 3 Fuel Filter replacement

test

collapsed hose


Incorrect ignition control See Chapter 5 Advanced Diagnostics &

Incorrect air/fuel control Chapter 9 Tests and Adjustments

Consumption/LPG z See Chapter 8 Air/Fuel mixer section
Exhaust Smell Air filter clogged Check air filter

Vacuum leak Check system vacuum hoses from regulator

to FTV and mixer
Pressure regulator Test pressure regulator operation

malfunction/fuel pressure too z See Chapter 9 Tests and Adjustments
high
Faulty FTV Check FTV for housing cracks or
obstructions
FTV operation
Weak ignition and/or spark See Chapter 5 Advanced Diagnostics

control
Incorrect air/fuel control See Chapter 5 Advanced Diagnostics

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS
Advanced Diagnostics Reading Diagnostic Fault
The MI-04 systems are equipped with built-in fault
Codes
diagnostics. Detected system faults can be displayed
by the Malfunction Indicator Lamp (MIL) as
fault codes are retrieved (displayed) the MIL will flash
Diagnostic Fault Codes (DFC) or flash codes, and
for each digit with a short pause (.5 seconds)
viewed in detail with the use of service tool software.
between digits and a long pause (1.2 seconds)
When the ignition key is turned ON the MIL will
between fault codes. A code 12 is displayed at the
perform a self-test, illuminate once and then go OFF.
beginning of the code list.
If a detected fault condition exists, the fault or faults
will be stored in the memory of the small engine
EXAMPLE: A code 26 has been detected
control module (SECM). Once a fault occurs the MIL
(ETCSticking) and the engine has shutdown and the
will illuminate and remain ON. This signals the
MIL has remained ON. When the codes are displayed
operator that a fault has been detected by the SECM.
the MIL will flash one time (1), pause, then flash two
times (2). This identifies a twelve (12), which is the
beginning of the fault list. It will then pause for 1.2
seconds (long pause) and flash two times (2), pause,
then flash six times (6). This identifies a twenty-six
(26), 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
flashes (2). This identifies a twelve meaning the fault
list will begin again.
1
IIB1O003L
(1) Malfunction Indicator Lamp (MIL) : G(C)20/25/30P-3 and

G35/40/45S-2
(1) Malfunction Indicator Lamp (MIL) : G50/60/70S-2

Displaying Fault Codes (DFC) Fault Action Descriptions
From SECM Memory Each fault detected by the SECM is stored in memory
(FIFO) and has a specific action or result that takes
place. Listed below are the descriptions of each fault
ignition key. Now turn ON the key but do not start the
action.
engine. As soon as you turn the key to the ON
position you must cycle the Acceleration Pedal by
Engine Shutdown: The most severe action is an
Engine Shutdown. The MIL will light and the engine
will immediately shutdown, stopping spark with the
Acceleration Pedal three (3) times within five (5)
fuel lock-off closing.
seconds to enable the display codes feature of the
SECM. Simply turn the key OFF to exit display mode.
Delayed Engine Shutdown: Some faults such as
The code list will continue to repeat until the key is
low oil pressure will cause the MIL to illuminate for 30
seconds and then shutdown the engine.
activated if a Acceleration Pedal fault condition exists.
This feature enables the service technician to view
Disable Throttle: The throttle moves to its default
the fault codes by turning the key to the ON position,
position. The engine will run at idle but will not
if a Acceleration Pedal malfunction is preventing the
accelerate.
retrieval of the stored fault codes from the SECM.
Limp Home Mode: A “limp home” mode reduces the
Malfunction Indicator Light (MIL) lift truck power, and is provided to enable the operator
to drive the lift truck in an unsafe situation but not use
= CODE 12 the truck for normal operation.
ON OFF ON ON OFF
MIL ONLY: The MIL will light by an active low signal
provided by the SECM, indicating a fault condition but
no further action will take place.
Clearing Fault (DFC) Codes
To clear the stored fault codes from SECM memory
you must complete the reset fault pedal maneuver.
CAUTION
Once the fault list is cleared it cannot be
restored.
First 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
Acceleration Pedal by depressing it to the floor and
then fully releasing the pedal (pedal maneuver). You
must fully cycle the Acceleration Pedal ten (10) times
within five (5) seconds to clear the fault code list of
the SECM. Simply turn the key OFF to exit the reset
mode. The code list is now clear and the SECM will
begin storing new fault codes as they occur.

Fault List Definitions ThrottleSensorRangeLo: (Throttle Position Sensor
(TPS1) Range has measured Low) the TPS1
Several sensors in the MI-04 system have input
low/high faults and a sensor range fault. These are
the coolant temperature sensor, the throttle position
sensor and the pedal position sensors. Signals to
assembly.
these sensors are converted into digital counts by the
SECM. A low/high sensor fault is normal set when the
ThrottleSensorRangeHi: (Throttle Position Sensor
converted digital counts reach the minimum of 0 or
(TPS1) Range has measured High) the TPS1
the maximum of 1024 (1024=5.0 VDC with ~204
counts per volt). A sensor range fault is set if the
parameter measured by the sensor is outside the
normal operating range.
assembly.
1024 Counts (Input High) ETCSticking: (Electronic Throttle Control is Sticking)

is normally set if either of the ETC driver signals have
opened or become disconnected. This can also occur
if the throttle plate (butterfly valve) inside the throttle
bore is sticking. The plate sticking can be due to
Sensor Range
some type of obstruction; a loose throttle plate or
worn components shaft bearings. Certified
technicians using the service tool software can
0 Counts (Input Low) perform a throttle motion test to confirm sticking
problems. NOTE: The throttle assembly is not a
Figure F1 serviceable item and can only be repaired by
replacing the DV-EV throttle assembly.
ECTSensorInputLow: (Engine Coolant Temperature
PredictedTPSDifference: (Predicted Throttle
Sensor Input is Low) normally set if the coolant
Position Sensor Difference) measured TPS1 is
sensor wire has shorted to chassis ground or the
different than SECM Calculated throttle position.
sensor has failed.
Normally caused by intake leaks between the throttle
assembly and the engine.
ECTSensorInputHigh: (Engine Coolant Temperature
Sensor Input is High) normally set if the coolant
ETCSpringTestFailed: (Electronic Throttle Control
sensor wire has been disconnected or the circuit has
Spring Return Test has Failed) upon the initial startup
opened to the SECM.
of the engine the SECM will perform a safety test of
the throttle return spring. If this spring has become
ECTRangeHigh: (Engine Coolant Temperature
weak the throttle will fail the test and set the fault.
Range is High) the sensor has measured an
NOTE: The throttle assembly is not a serviceable
excessive coolant temperature typically due to the
item and can only be repaired by replacing the DV-EV
engine overheating.
throttle assembly.
ThrottleSensorInputLo: (Throttle Position Sensor
ETCDriverFault: (Electronic Throttle Control Driver
(TPS1) Input is Low) is normally set if the TPS1
has Failed) an over current condition has occurred on
either ETC+ or ETC- driver signals.
opened to the SECM.
MapSensorInputLow: (Manifold Air Pressure Sensor
ThrottleSensorInputHi: (Throttle Position Sensor
Input is Low) is normally set if the TMAP pressure
(TPS1) Input is High) is normally set if the TPS1
signal wire has become shorted to power, the TPS1
opened to the SECM.
has failed or the SECM has failed.

MapSensorInputHigh: (Manifold Air Pressure Pedal1SensorRangeLo: (Accelerator Pedal Position
Sensor Input is High) is normally set if the TMAP 1 Sensor Range is Low) the APP1 potentiometer has
pressure signal wire has become shorted to power, malfunctioned. An improper APP1 reading may be
shorted to the IAT signal, the TMAP has failed or the due to dirt or oxidation on the sensor traces.
SECM has failed.
Pedal1SensorRangeHi: (Accelerator Pedal Position
IATSensorInputLow: (Intake Air Temperature Sensor 1 Sensor Range is High) the APP1 potentiometer has
Input is Low) is normally set if the TMAP temperature malfunctioned. An improper APP1 reading may be
signal wire has become shorted to ground, shorted to due to dirt or oxidation on the sensor traces.
the MAP signal, the TMAP has failed or the SECM
has failed. Pedal2SensorInputLo: (Accelerator Pedal Position 2
Sensor Input is Low) normally set if the APP2 signal
IATSensorInputHigh: (Intake Air Temperature wire has become shorted to APP power, APP2 has
Sensor Input is High) normally set if the TMAP failed or the SECM has failed.
temperature signal wire has become disconnected or
the circuit is open to the SECM. Pedal2SensorInputHi: (Accelerator Pedal Position 2
Sensor Input is High) normally set if the APP2 signal
EST1Low: (Electronic Spark Trigger) is a current wire has become disconnected or the circuit is open
driver signal and normally set if the signal from the to the SECM.
SECM is shorted to ground.
Pedal2SensorRangeLo: (Accelerator Pedal Position
EST1High: (Electronic Spark Trigger) is a current 2 Sensor Range is Low) the APP2 potentiometer has
driver signal and normally set if the signal from the malfunctioned. An improper APP2 reading may be
SECM is open or lost. due to dirt or oxidation on the sensor traces.
LowOilPressure: (Low Oil Pressure) the oil pressure Pedal2SensorRangeHigh: (Accelerator Pedal
switch has opened or become disconnected, normally Position 2 Sensor Range is Low) the APP2
indicating a low oil condition in the engine. potentiometer has malfunctioned. An improper APP2
BatterySensorInputLow: (Battery Voltage Sensor traces.
Input is Low) normally set if the power to the SECM
drops below 8.5 VDC. Pedal1ToPedal2Difference: (Accelerator Pedal
Position Sensor 1 and Accelerator Pedal Position
BatterySensorInputHigh: (Battery Voltage Sensor Sensor 2 are Different) normally set when APP1
Input is High) normally set if the power to the SECM measured pedal position is different from APP2
increases above 15.9 VDC. measured pedal position.
XDRPSensorInputLow: (Transducer Voltage Sensor AFRTrimValveOutput: (Air Fuel Ratio Trim Valve
Input is Low) normally set if the sensor power from (FTV) Driver) is normally set when the FTV driver
the SECM drops below 4.8 VDC. signal is open due to the connector becoming
disconnected.
XDRPSensorInputHigh: (Transducer Voltage Sensor
Input is High) normally set if the sensor power from AFRTrimValveLowerDC: (Air Fuel Ratio Trim Valve
the SECM increases above 5.9 VDC. (FTV) Lower Duty Cycle) normally set when the duty
cycle of the FTV reaches the minimum limit (running
EngineOverspeed: (Engine Over speed) is set when too lean).
the engine RPM increases above the SECM
maximum governing RPM. Typically this is in AFRTrimValveUpperDC: (Air Fuel Ratio Trim Valve
association with one or more throttle faults. This fault (FTV) Upper Duty Cycle) normally set when the duty
can be set without additional throttle faults if the cycle of the FTV reaches the maximum limit (running
operator motors the lift truck down a steep grade (hill). too rich).
Pedal1SensorInputLo: (Accelerator Pedal Position 1 O2SensorSwitching: (Oxygen Sensor Switching) is

Sensor Input is Low) normally set if the APP1 signal set when the O2 sensor can no longer switch or be
wire has become disconnected or the circuit is open driven above and below 500mv by the SECM.
to the SECM.
OxygenSensorInputHigh: (Oxygen Sensor Input is
Pedal1SensorInputHi: (Accelerator Pedal Position 1 High)
Sensor Input is High) normally set if the APP1 signal
wire has become shorted to APP power, APP1 has OxygenSensorInputLow: (Oxygen Sensor Input is
failed or the SECM has failed. Low)

12 NONE NONE None, used as a beginning and end
the fault list
14 ECTSensorInputLow Stored Fault Code Check ECT sensor connector and

GND
SECM (SIGNAL) PIN 16 to ECT
PIN A
SECM (GND) PIN 1 to

ECT PIN B
15 ECTSensorInputHigh Stored Fault Code Check if ECT sensor connector is

circuit circuit

PIN A
SECM (GND) PIN 1 to

ECT PIN B
16 ECTRangeHigh Delayed Engine Check coolant system for radiator

Engine Overheating Shutdown blockage, proper coolant level and
for leaks in the system. Possible
ECT short to GND, check ECT
signal wiring

PIN A
SECM (GND) PIN 1 to

ECT PIN B
z Check regulator for coolant

leaks *See Chapter 7.0
22 ThrottleSensorInputLo Disable Throttle Check throttle connector connection

circuit
(Expected faults when ETC ETC PIN 6 to SECM PIN 17
connector is unplugged (SIGNAL)
CODES: 22 & 24)

23 ThrottleSensorInputHi Disable Throttle Check throttle connector and TPS1
TPS1 sensor failure or shorted circuit sensor wiring for a shorted circuit
ETC PIN 6 to SECM PIN 17

(SIGNAL)
24 ThrottleSensorRangeLo Stored Fault Code Check the throttle connector and

TPS1 potentiometer malfunction. (MIL Only) pins for corrosion.
clean sensor

TPS PIN 2 (GND) to

PIN 6 (TPS1 SIGNAL)

SIGNAL)
25 ThrottleSensorRangeHi Stored Fault Code Check the throttle connector and

TPS1 potentiometer malfunction. (MIL Only) pins for corrosion.
clean sensor

TPS PIN 2 (GND) to PIN 6 (TPS1

SIGNAL)

SIGNAL)

throttle body or the ETC driver signal z Perform the Throttle test using
is open the Service Tool and re-check
for fault
z Check throttle-plate shaft for
bearing wear

open circuit
ETC+ PIN 1 to SECM PIN 22
ETC-PIN 4 to SECM PIN 24


DRIVER) ~3.0Ω +/-30%
27 PredictedTPSDifference Engine Shutdown Check for manifold leaks between

Measured TPS1 is different than the throttle and the engine
TPS. This fault means that the
throttle and our calculated
prediction for throttle do not agree.
This code often comes up as
suspected during transient
manuevers. It is not system trouble.
If the fault really sets, then the
engine will shut down.
28 ETCSpringTestFailed Power Limit Perform throttle spring test by

Upon initial key-up the internal cycling the ignition key and re-
throttle return spring has become check for fault
weak

29 ETCDriverFault Disable Throttle Check ETC driver wiring for a
Throttle driver over-current or driver shorted circuit
signals shorted ETC+ PIN1 to SECM PIN 22
ETC- PIN 4 to SECM PIN 24
z Perform Throttle test and with

the Service Tool and re-check
for fault


DRIVER) ~3.0Ω +/-30%

circuit or sensor malfunction TMAP PIN 4 to SECM PIN 5
(Expected faults when TMAP (SIGNAL)
connector is unplugged TMAP PIN 1 to SECM PIN 1 (GND)
CODES: 33 & 38) TMAP PIN 3 to SECM PIN 18
(XDCR +5VDC)

(PRESSURE SIGNAL KPA) (2.4kΩ
- 8.2kΩ)

- 8.2kΩ)

TMAP sensor failure or shorted circuit signal wiring for a shorted circuit
(SIGNAL)
(XDCR +5VDC)

- 8.2kΩ)

- 8.2kΩ)

TMAP sensor failure or shorted circuit (MIL Only) signal wiring for a shorted circuit
(SIGNAL)
(XDCR +5VDC)
To check the IAT sensor of the

TMAP disconnect the TMAP
connector and measure the IAT
resistance

or sensor malfunction TMAP PIN 2 to SECM PIN 4
(SIGNAL)
(XDCR +5VDC)
To check the IAT sensor of the

TMAP disconnect the TMAP
connector and measure the IAT
resistance

Coil driver signal low or under-current (MIL Only) connector for shorts


and measure the resistance from
pin to pin

in Chapter 6.0

Coil driver signal high or over-current (MIL Only) circuit or disconnected connector


and measure the resistance from
pin to pin

in Chapter 6.0

Battery voltage measured below (MIL Only) z Perform maintenance check on
+8.0 VDC electrical connections to the
battery and chassis ground
running to verify charging
system and alternator function
Measure battery power at the



+15.9 VDC z Check battery voltage during
running
z Check voltage regulator,
alternator and charging system
z Check battery and wiring for
z Measure battery power at the

by the SECM to the sensors is below TMAP PIN 3 +5VDC to TMAP PIN
+4.60VDC 1 XDCR GND
(Expected faults when Transducer
power is lost Verify transducer power at the
CODES: 22, 24, 33, 62, 64, 66, 68 & SECM with a multimeter
69) SECM PIN 18 +5VDC to SECM
PIN 1 XDCR GND

a multimeter
2 XDCR GND

Acceleration Pedal with a
multimeter

by the SECM to the sensors is above TMAP PIN 3 +5VDC to TMAP PIN
+5.20VDC 1 XDCR GND
Verify transducer power at the

SECM PIN 18 +5VDC to SECM
PIN 1 XDCR GND

a multimeter
2 XDCR GND

Acceleration Pedal with a
multimeter
maximum RPM set point z Check for ETC Sticking or
other ETC faults
z Verify if the lift truck was
motored down a steep grade
61 Pedal1SensorInputLo MIN Power Limit Check Acceleration Pedal

APP1 signal disconnected, open connector
circuit or sensor malfunction z Check APP1 signal at SECM
(Expected faults when APP connector PIN 15
is unplugged
CODES: 61 & 66)
62 Pedal1SensorInputHi MIN Power limit Check Acceleration Pedal

APP1 sensor failure or shorted circuit connector
PIN 15
63 Pedal1SensorRangeLo Stored Fault Code Check Acceleration Pedal

APP1 potentiometer malfunction. (MIL Only) connector
Improper APP1 reading may be due z Cycle the pedal several times
to dirt or oxidation on the sensor and check APP1 signal at
traces. SECM PIN 15
64 Pedal1SensorRangeHi Stored Fault Code Check Acceleration Pedal

traces SECM PIN 15

65 Pedal2SensorInputLo MIN power Limit Check Acceleration Pedal
APP2 sensor failure or shorted circuit connector
z Cycle the pedal several times
and check APP2 signal at
SECM PIN 2
66 Pedal2SensorInputHi MIN power Limit Check Acceleration Pedal

APP2 signal disconnected, open connector
circuit or sensor malfunction z Check APP2 signal at SECM
(Expected faults when APP connector PIN 2
is unplugged
CODES: 61 & 66)
67 Pedal2SensorRangeLo Stored Fault Code Check Acceleration Pedal

traces. SECM PIN 2
68 Pedal2SensorRangeHi Stored Fault Code Check Acceleration Pedal

traces. SECM PIN 2
69 Pedal1ToPedal2Difference MIN power Limit Check Acceleration Pedal

Measured APP2 pedal position signal connector
is different than APP1 signal z Cycle the pedal several times
and check APP1 signal at
SECM PIN 15
PIN 2
FTV modulation driver signal fault (MIL, Disable Adaptive connector being disconnected
learns) FTV PIN A (SIGNAL) TO PIN B
(PWR)

disconnecting the FTV connector
and measuring the resistance
(~26Ω +/-2Ω)

(PWR)

72 AFRTrimValveLowerDC Stored Fault Code Engine measured Air/Fuel ratio at
FTV duty cycle at lower (lean) limit (MIL, Disable Adaptive the O2 sensor is excessively lean
learns) z Check for intake manifold leaks
hose) connection at the
regulator
z Check N-CA55-500-TR mixer
for heavy end build-up and
pressure (see N2001
Regulator section)
Note: If LP-Gas fuel in LP tank is
not enough, this fault code can be
set. If LP tank is frozen, this fault
code can be set, too. It is not
system trouble.
73 AFRTrimValveUpperDC Stored Fault Code Engine measured Air/Fuel ratio at

FTV duty cycle at high (rich) limit (MIL, Disable Adaptive the O2 sensor is excessively rich
(Expected fault when FTV connector learns)
open circuit
(PWR)

(~26Ω +/-2Ω)
(PWR)

operation (see N2001
Regulator section)

74 O2SensorSwitching Stored Fault Code Check the FTV for proper operation
O2 sensor is not switching across the (MIL, Disable Adaptive z Check FTV Hose Connections
reference AFR voltage learns)
(~26Ω +/-2Ω)

(PWR)
Note: If LP-Gas fuel in LP tank is

not enough, this fault code can be
set. If LP tank is frozen, this fault
code can be set, too. It is not
system trouble.

O2 sensor SECM driver signal is (MIL, Disable Adapts) +5VDC or Battery.
shorted to power O2 (SIGNAL) PIN B to SECM PIN
3
(AFRTrimValveLowerDC fault
should also occur)
Verify O2 sensor heater circuit is

operating by measuring circuit
resistance (2.1Ω +/-0.4Ω)
O2 PIN C (HEATER GND) to PIN D

(HEATER PWR)

CHAPTER 6 MI-04 ELECTRICAL CONNECTIONS
Figure E1

CAN BUS
CONNECTOR
CAN1+
CAN1-
(FEMALE)
A B C D E F G J K
H
SECM CONNECTOR SECM CONNECTOR

(MALE)
SECM PWR +12vdc
XDCR PWR +5vdc

R01
Coil Drive Signal
CRNK Signal +
120 OHM
Lock-Off GND
ETC Driver +
ETC Driver -
SECM GND
XDCR GND
O2 Sensor
CAN1+
CAN1-
APP2
APP1
TPS1
FTV -
MIL -
MAP
ECT
IAT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
APP
GND
APP
PWR
APP2
APP1
+12VDC
FUEL LOCK-OFF
A
B
+12VDC
MIL -
FUEL TRIM VALVE

A
COOLANT SENSOR
B
B
A
+12VDC
+12VDC
+12VDC
A B C D 1 2 3 4 A B C D A B 1 2 3 4 5 6
OXYGEN SENSOR TMAP SENSOR IGNITION COIL ELECTRONIC THROTTLE
MODULE POWER
Figure E2

Resistance Checks
NOTE
All resistive checks are made with the sensor or device disconnected from the harness.

TMAP TMAP PIN 1 (GND) TO PIN 4 2.4kΩ - 8.2kΩ
TMAP PIN 3 (PWR) TO PIN 4 3.4kΩ - 8.2kΩ
TMAP PIN 1 (GND) TO PIN 2 *SEE TMAP IAT TABLE FOR PROPER
(TEMPERATURE SIGNAL) RANGE
TMAP SENSOR IAT TABLE
Temperature in F +/- Temperature in C Resistance in Ω (OHMS)

1 +/-1 MINIMUM NOMINAL MAXIMUM
-4 -20 14.0K 15.6K 17.3K
32 0 5.4K 5.9K 6.5K
68 20 2.3K 3.0K 3.3K
104 40 1.1K 1.2K 1.3K
140 60 572 612 655
176 80 309 329 351
212 100 176 186 197
248 120 103 110 116

TPS TPS PIN 2 (GND) TO PIN 6 (TPS1 1.25KΩ +/-30%
(ELECTRONIC THROTTLE) SIGNAL)
TPS PIN 3 (PWR) TO PIN 6 (TPS1 1.25KΩ +/-30%
SIGNAL)
TPS PIN 1 (+DRIVER) TO PIN 4 (- ~3.0Ω +/-30%
DRIVER)

ECT ECT PIN A (SIGNAL) TO PIN B 2.8KΩ AT 25 C (77 F)
(COOLANT TEMPERATURE) (GND) +/- 8 C

O2 O2 PIN C (HEATER GND) TO PIN 2.1 +/- 0.4 ohms
(OXYGEN SENSOR) D (HEATER PWR)

IGNITION MODULE COIL PIN A TO PIN B (PWR) ~1.24MEGΩ
(2-PIN CONNECTOR)

IGNITION MODULE COIL PIN A (GND) TO PIN B ~5.5KΩ
(4-PIN CONNECTOR) (PWR)
COIL PIN A (GND) TO PIN C ~4MEGΩ
(CRANK SIGNAL)
COIL PIN A (GND) TO PIN D ~5.2KΩ
(DRIVER SIGNAL)
COIL PIN B (PWR) TO PIN C ~4MEGΩ
COIL PIN B (PWR) TO PIN D ~10.5KΩ
COIL PIN C TO PIN D ~5MEGΩ

FTV FTV PIN A (SIGNAL) TO PIN B (~26Ω +/-2Ω)
(FUEL TRIM VALVE) (PWR)

FUEL LOCK-OFF LOCK-OFF PIN A (PWR) TO PIN B ~20-25Ω
(GND SIGNAL)
Voltage Checks
ACCELERATION PEDAL APP1: PIN B (SIGNAL A) TO PIN C 0.4 +/- 0.1V AT LOW IDLE
ANGLE SENSOR (GND) 3.6 +/- 0.15V AT FULL ACCEL
APP2: PIN E (SIGNAL B) TO PIN D 4.5 +/- 0.1V AT LOW IDLE
(GND) 1.4 +/- 0.15V AT FULL ACCEL
Note: When you check the output voltage of acceleration pedal angle sensor, it must be connected to SECM so
that SECM can supply 5V to the angle sensor.

REGULATOR/CONVERTER
as gasoline, kerosene, propane and butane are N2001 LP
separated. Each of these carry a certain amount of Regulator/Converter
WARNING
undetected.
Engine coolant flows through the regulator/converter
assisting in the propane vaporization process. As the
coolant temperature rises, the regulator/converter
temperature also rises. The gas becomes hot and
expands to the point where it cannot carry the heavier
hydrocarbons or heavy-ends through the system.
Because of this, the heavy-ends are deposited
(dropped out) into the regulator/converter, the vapor
line from the regulator to the mixer and even in the
mixer itself. When these heavy-ends cool they form a
wax-like deposit or sludge. HD5 grade propane is
glasses when working with liquid propane.
CAUTION
debris but part of the liquid propane. As these
The regulator/converter and mixer are
deposits build up over time regulator fuel ports and
part of a certified system complying with
valve seats can be affected, reducing the
performance of the regulator. All propane systems
trained certified technicians should
incorporating a regulator/converter are subject to
heavy-end fouling over time. Because of this it may
replacement of the regulator/converter or
be necessary for the certified technician to
mixer.

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 diagram (Figure R1) for proper routing and maximum hose lengths when
reinstalling system components.
G430E
Figure R1
Hose Type
G.7/32” I.D. Vacuum Hose (18 inch recommended maximum length)

G643E
A
Liquid Propane
From Fuel Tank
C C
Coolant inlet Coolant outlet
B
Vapor Fuel Line From
Regulator Outlet To
Mixer Inlet
Control Line From

G Regulator Vent Fitting To
Fuel Trim Valve (FTV)
Control Line From

E
FTV To Air Valve
Vacuum (AVV)
From
Engine PCV
D
Figure R1
Hose Type
D. 3/8” I.D. Hose -Breather
G.7/32” I.D. Vacuum Hose (18 inch recommended maximum length)

1. Close the liquid outlet valve in the forklift cylinder
N2001 Removal Steps: or fuel storage container.

1 exhausted and the engine shuts down.
3
5
2 3. Remove the fuel inlet line (1) from the lock-off, the
two vacuum lines (2) from the branch-tee fitting in
the regulator vent and disconnect the lock-off
connector (3).
4 4. Remove the two rear-mounting bolts that hold the

regulator to the support bracket. This will allow
Figure 24 you easier access to the remaining hose clamps.
G430E Engine
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
4 1 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.
5
3 7. If it is necessary to fully disassemble the N2001
2 regulator, you will need to remove the fuel lock-off
at this time.
Figure 24 NOTE
G643E Engine For installation of the N2001 reverse the
removal steps.

N2001 Regulator
Disassembly Steps:
Figure R5
1
Figure R3
3
Figure R5

Figure R4
1. Remove the six secondary cover screws (1), the

secondary cover (2) and the secondary
diaphragm (3).

Figure R6
4. Remove the primary diaphragm by sliding the

diaphragm to one side, releasing the primary
valve pin (Figure R6).

10
3
11
Figure R7 Figure R10
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
disassembly. Tighten all fasteners to
8
recommended torque values and test the
regulator before installing in the vehicle.
9 Torque primary cover screws to (40-50
inch lbs.), secondary cover screws to (15-
Figure R8
18 inch lbs.).
Figure R9
5. 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.
Replace components as necessary.
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

Figure R11
5. Make sure all parts (Figure R11) are completely

dry before re-assembly.

CHAPTER 8 N-CA55-500TR AIR/FUEL MIXER
as gasoline, kerosene, propane and butane are the N-CA55-500TR Mixer
Under normal circumstances these residues remain WARNING
undetected. z LP gas is highly flammable. To prevent
Engine coolant flows through the regulator/converter materials away from the lift truck when work
assisting in the propane vaporization process. As the is done on the fuel system.
coolant temperature rises, the regulator/converter z Gas vapor may reduce oxygen available for
temperature also rises. The gas becomes hot and breathing, cause headache, nausea,
expands to the point where it cannot carry the heavier dizziness and unconsciousness and lead to
hydrocarbons or heavy-ends through the system. injury or death. Always operate the forklift in
Because of this, the heavy-ends are deposited a well ventilated area
(dropped out) into the regulator/converter, the vapor z Liquid propane may cause freezing of tissue
line from the regulator to the mixer and even in the or frostbite. Avoid direct contact with skin or
mixer itself. When these heavy-ends cool they form a tissue; always wear appropriate safety
wax-like deposit or sludge. HD5 grade propane is protection including gloves and safety
recommended for motor fuel use, however HD5 glasses when working with liquid propane.
debris but part of the liquid propane. As these CAUTION
deposits build up over time regulator fuel ports and The regulator/converter and mixer are
valve seats can be affected, reducing the part of a certified system complying with
performance of the regulator. All propane systems EPA and CARB 2004 requirements. Only
incorporating a regulator/converter are subject to trained certified technicians should
heavy-end fouling over time. Because of this it may perform disassemble, service or
be necessary for the certified technician to replacement of the regulator/converter or
disassemble, clean and service the mixer.
G430E/G643E Tier LP Engine 76 N-CA100TR Mixer

N-CA55-500TR Mixer
Removal Steps:
1
5
Figure M2
3 2
4
Figure M1 O-Ring
1. Close the liquid outlet valve in the forklift cylinder Spacer

or fuel storage container.

Figure M3
3. Remove the air horn air inlet adapter and hose
(Figure M1-1).
NOTE
4. Mark the two vacuum lines to the mixer and There will be a plastic o-ring spacer and
throttle adapter for identification; they must be an o-ring inside this adapter, be careful
installed correctly for proper operation. Remove not to lose these items when removing
the two vacuum lines (Figure M1-2). the mixer/adapter assembly from the
throttle (Figure M3).

M1-4).

5).


N-CA55-500TR Disassembly
and Service
14
Figure M4
1
7 1. With the mixer/adapter assembly removed, and
the Air Horn removed from the mixer, remove the
12 four adapter retaining screws from the bottom of
the mixer (Figure M4).
11
13
3
5 Figure M5
6
2. Gently remove the throttle adapter from the

bottom of the mixer (Figure M5).
9
10
(1) BODY (2) SCREW (3) VALVE (4)SPRING,

(5) ASSEMBLY (6) GASKET (7) GASKET (8) VSCREW
(9) WASHER (10) SCREW (11) ORIFICE FITTING,
(12) LABEL (13) LABEL (14) CAP Figure M6
3. Components of the N-CA55-500TR and the mixer

body are shown in (Figure M6).

4. Replace the air-valve sealing ring as shown 7. After the air valve spring install the check valve
(Figure M7). The ring is similar to a piston ring plate (Figure M10).
and forms a seal from the air valve assembly to
the mixer main body.
Figure M11
Figure M8
8. Place the mixer to throttle body gasket over the
check valve plate (Figure M11). To properly install
5. Insert the air valve assembly into the main body the gasket the hole for the idle port in the throttle
(Figure M8). adapter must be aligned with the idle port in the
gasket.
Figure M9
Figure M12
6. Next, install the air valve spring (Figure M9).

9. Align the check valve notch in the throttle adapter
with the mixer check valve and the adapter idle
port with the mixer idle port. Install the throttle
adapter tamper-resistant screws to the mixer
(Figure M12).

N-CA55-500TR Disassembled
Service
1. Clean the air valve assembly with soap and warm
2. Clean the check valve plate with soap and warm

water. Inspect for wear, tears or pinholes in the
Figure M13 check valve and deformations that may cause
leaks or poor performance. Replace components
10. Check for binding of the air valve assembly by as necessary.
pressing down with two fingers on opposite sides
of the air valve assembly (Figure M13). The air 3. Replace all gaskets before assembly.
valve assembly should move freely without
binding and have full travel. If the air valve is 4. Clean the mixer body (casting) with a parts
binding, loosen the four adapter retaining screws, cleaning solvent. Be sure to remove all seals and
re-check the air valve for binding and re-tighten gaskets before cleaning the casting with solvent.
the adapter retaining screws. Make sure all parts are completely dry before re-
assembly.
11. Clean and check the orifice fitting (Mixer hose
barb) for obstruction. NOTE
For re-assembly of the N-CA55-500TR
CAUTION reverse the disassembly steps.
is installed in the mixer housing uses a WARNING
specific machined orifice size through the DO NOT spray carburetor cleaner or
fitting. This orifice fitting is part of the solvent the mixer while installed on the
mixer assembly and an integral part of engine. These chemicals may damage the
the MI-04 control. DO NOT replace this oxygen sensor and cause pre-mature
fitting with a standard hose barb fitting or failure of the catalytic muffler.

Installing the Mixer/Throttle adapter, electronic throttle, mixer-throttle adapter and
Assembly air horn adapter. The manifold adapter is designed to
mount the mixer/throttle assembly to a two-bolt intake
manifold. The air horn adapter allows the intake hose
from the air cleaner to be attached to the mixer air
intake, along with the vent line from the engine PCV
24 (2.2 N•m)
valve.
25
23
22
21
20
17
19 16 (2.2 N•m)
15 (8.6 N•m)
14
18
26 Figure M15
13
12
(0.8 N•m) 9 10
3 11 (5.2 N•m) the mixer and the throttle adapter (Figure M15),
4 2
5 four tamper-resistant retaining screws.
6
(4.2 N•m) 7
8
(1) GASKET-MANIFOLD (2) ADAPTER-MANIFOLD CHECK VALVE IDLE PORT

(3) BRACKET-TMAP (4) FITTING-OUTLET (5) TMAP
Figure M16
(6) WASHER-TMAP MTG (7) BOLT-TMAP MTG
(8) FITTING-INLET (9) BOLT-TMAP BRACKET
(10) GASKET-ITB(32MM) (11) BOLT-ADAPTER CAUTION
(12) TROTTLE BODY(32MM) (13) O-RING The mixer must be installed with the idle
(14) WASHER-ITB (15) BOLT-ITB port aligned with the idle port in the
(16) BOLT-APOLLO ADAPTER (17) APOLLO ADAPTER-ITB adapter, and the mixer check valve
(18) BOLT-END PLUG (19) FITTING-TO TRIM V/V aligned with the valve recess in the
(20) MIXER(N-CA55) (21) FITTING-TO REG adapter to operate properly (Figure M16).
(22) AIR HORN-ADAPTER (23) WASHER-AIR HORN
(24) BOLT-AIR HORN (25) PLUG (26) O-RING SPACER

6. Place the O-ring Spacer over the outside throat of
the throttle. This spacer is necessary to assure
that the O-ring, which seals the throttle to the
adapter, properly seats against the throttle adapter.
O-Ring
Spacer
Figure M17
2. Tighten the four tamper-proof retaining screws to

the specified torque (Figure M17).
Figure M19
7. Place the throttle adapter O-ring over the outside

throat of the throttle, below the throttle bore
(Figure M19). Apply a generous amount of
lubricating grease (vacuum grease) to the O-ring
and fully seat it against the machined surface.
8. Carefully slide the pre-assembled mixer/throttle

adapter assembly over the throat of the throttle
Figure M18
using a rocking motion, aligning the mounting
holes of the adapter with the mounting holes of
3. Check for free travel of the mixer’s piston the throttle (Figure M20). Face the fuel inlet of the
diaphragm assembly by pushing the piston mixer toward the plastic motor assembly cover of
diaphragm downward (Figure M18). If you detect the electronic throttle assembly.
any binding, loosen the retaining screws, re-align
the gasket and re-tighten the retaining screws. NOTE
Check for binding again, if the piston assembly Avoid pinching the O-ring in the cutaway
moves freely, re-torque the fasteners and continue. of the throttle adapter. This will damage
the O-ring and cause a manifold leak in
4. Install the manifold adapter by placing the the system.
manifold gasket between the manifold and the
manifold adapter. The manifold adapter should be
mounted with the TMAP sensor ports facing the
thermostat housing. Tighten the two internal
socket bolts to specified torque values.
5. Place the throttle bottom gasket between the

electronic throttle assembly and the manifold
adapter. Place the throttle assembly on top of the
gasket aligning the four mounting holes with the
threaded holes in the manifold adapter. The
plastic motor assembly cover, of the electronic
throttle assembly should be facing opposite of the
TMAP sensor mounting holes.

9. Tighten the four mounting bolts hand tight using a
the other. This prevents the adapter O-ring from
misaligning against the throttle, which may cut the
O-ring and cause an intake leak. Finally, tighten
the four throttle adapter fasteners to the specified
torque values.
10. Install the TMAP sensor mounting-bracket to the

manifold adapter. Apply a small amount of
vacuum grease to the TMAP sensor O-ring and
install the sensor into the manifold adapter, tighten
the fasteners to specified torque values.
NOTE
retaining screw or damage to the sensor
housing may result.
Figure M20
11. Place mixer intake gasket on top of the mixer

(Figure M20), then place the air horn adapter on
top of the mixer with the intake tube facing the
valve cover (air cleaner side of the engine).
Tighten the air horn retaining bolts to specified
torque values.

CHAPTER 9 N-CA100TR AIR/FUEL MIXER
as gasoline, kerosene, propane and butane are the N-CA100TR Mixer
by-product residue, commonly called heavy ends. WARNING
suspended in liquid and pass through the system z LP gas is highly flammable. To prevent
undetected. personal injury, keep fire and flammable
Engine coolant flows through the regulator/converter is done on the fuel system.
assisting in the propane vaporization process. As the z Gas vapor may reduce oxygen available for
coolant temperature rises, the regulator/converter breathing, cause headache, nausea,
temperature also rises. The gas becomes hot and dizziness and unconsciousness and lead to
expands to the point where it cannot carry the heavier injury or death. Always operate the forklift in
hydrocarbons or heavy-ends through the system. a well ventilated area
Because of this, the heavy-ends are deposited z Liquid propane may cause freezing of tissue
(dropped out) into the regulator/converter, the vapor or frostbite. Avoid direct contact with skin or
line from the regulator to the mixer and even in the tissue; always wear appropriate safety
mixer itself. When these heavy-ends cool they form a protection including gloves and safety
wax-like deposit or sludge. HD5 grade propane is glasses when working with liquid propane.
A fuel filter cannot remove this because it is not dirt or CAUTION
debris but part of the liquid propane. As these The regulator/converter and mixer are
deposits build up over time regulator fuel ports and part of a certified system complying with
valve seats can be affected, reducing the EPA and CARB 2004 requirements. Only
performance of the regulator. All propane systems trained certified technicians should
incorporating a regulator/converter are subject to perform disassemble, service or
heavy-end fouling over time. Because of this it may replacement of the regulator/converter or
be necessary for the certified technician to mixer.
G430E/G643E Tier LP Engine 84 Test and Adjustments

N-CA100TR Mixer Removal
Steps:
4
1. Close the liquid outlet valve in the forklift cylinder
or fuel storage container.

and running until all trapped fuel in the system is 5
Figure M2
O-Ring
1 2 Spacer
3
Figure M1
Figure M3
3. Remove the air horn air inlet hose (Figure M1-1).

NOTE
4. Mark the two vacuum lines to the mixer and for There will be a plastic o-ring spacer and
identification; they must be installed correctly for an o-ring inside this adapter, be careful
proper operation. Remove the two vacuum lines not to lose these items when removing
(Figure M1-2). the mixer/adapter assembly from the
throttle (Figure M3).

M2-4).

5).


N-CA100TR Disassembly and N-CA100TR Disassembly and
Service Service
4
Figure M4
9
14 1. With the mixer/adapter assembly removed from
3 the engine, and the throttle adapter removed from
2
the mixer, remove the four cover retaining screws
from the top of the mixer (Figure M4).
1 15
10
Figure M5
11
2. Gently remove the diaphragm cover from the top
of the mixer. Take care not to loose the air-valve
spring shown in (Figure M5).
(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
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
Figure M7
4. Clean the heavy end deposits from the mixer body

with solvent. Be sure the mixer body is completely
N-CA100TR Disassembled
dry before installing the new air-valve assembly. Service
Replace the air-valve assembly as shown (Figure
M7). 1. Clean the air valve assembly with soap and warm
2. Replace all gaskets before assembly.
3. Clean the mixer body (casting) with a parts

Make sure all parts are completely dry before re-
assembly.
NOTE
Figure M8
For re-assembly of the N-CA100TR
reverse the disassembly steps.
5. Place the alignment mark on top of the air valve
assembly toward the fuel inlet of the mixer; this WARNING
places the small notches in the fuel metering DO NOT spray car carburetor cleaner or
valve (fuel cone) inline with the fuel inlet and the solvent into the mixer while installed on
large notches of the fuel metering valve “cone”, the engine. These chemicals may damage
perpendicular to the fuel inlet of the mixer. Now the oxygen sensor and cause pre-mature
reinstall the air-valve spring and diaphragm cover failure of the catalytic muffler.
(Figure M8).
Figure M9
6. Tighten the cover fastners and reinstall the mixer

on the engine (Figure M9).

Installing the Mixer/Throttle adapter, electronic throttle and mixer-throttle adapter.
Assembly The manifold adapter is designed to mount the
mixer/throttle assembly to a two-bolt intake manifold.
Tamper-Resistant
Screws Orifice Balance
Line Fitting
Fuel Inlet
Fitting
Tamper
Resistant
Screws
Mixer-Throttle
Adapter Gasket Figure M15
FTV Fitting
the mixer and the throttle adapter (Figure M15),
four tamper-resistant retaining screws. Tighten the
four tamper-proof retaining screws to the specified
O-Ring torque.
O-Ring
Spacer
TMAP
Retaining
Bolt Electronic
Throttle
Throttle-Manifold
Gasket
Manifold
Adapter
Figure M16
TMAP
Sensor 2. Install the manifold adapter by placing the
manifold gasket between the manifold and the
manifold adapter. The manifold adapter should be
Mixer/Throttle Assembly mounted with the TMAP sensor ports facing the
thermostat housing (Figure M16). Tighten the two
internal socket bolts to specified torque values.

3. Place the throttle bottom gasket between the NOTE
electronic throttle assembly and the manifold Avoid pinching the O-ring in the cutaway
adapter. Place the throttle assembly on top of the of the throttle adapter. This will damage
gasket aligning the four mounting holes with the the O-ring and cause a manifold leak in
threaded holes in the manifold adapter. The the system.
plastic motor assembly cover, of the electronic
throttle assembly should be facing the SECM. 7. Tighten the four mounting bolts hand tight using a
4. Place the O-ring Spacer over the outside throat of the other. This prevents the adapter O-ring from
the throttle. This spacer is necessary to assure misaligning against the throttle, which may cut the
that the O-ring, which seals the throttle to the O-ring and cause an intake leak. Finally, tighten
adapter, properly seats against the throttle adapter. the four throttle adapter fasteners to the specified
torque values.
8. Install the TMAP sensor to the manifold adapter.

Apply a small amount of vacuum grease to the
O-Ring
TMAP sensor O-ring and install the sensor into
the manifold adapter, tighten the fasteners to
Spacer specified torque values.
9. Connect the air inlet hose from the air cleaner
10. Connect the balance line to the orifice barb and

the FTV vacuum line.
Figure M17
NOTE
5. Place the throttle adapter O-ring over the outside retaining screw or damage to the sensor
throat of the throttle, below the throttle bore housing may result.
(Figure M17). Apply a generous amount of
lubricating grease (vacuum grease) to the O-ring
and fully seat it against the machined surface.
Figure M18
6. Slide the pre-assembled mixer/throttle adapter

assembly over the throat of the throttle, aligning
the mounting holes of the adapter with the
mounting holes of the throttle (Figure M18).
Face the fuel inlet of the mixer toward the plastic
motor assembly cover of the electronic throttle
assembly.

WARNING
N2001 Service Testing
After overhaul or for simply checking the N2001
regulator/converter operation, the following tests can
be performed (See Chapter 7 for
removal/installation of the N2001). 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. You will need the following hardware:
z Liquid propane may cause freezing of tissue Secondary Stage Test Hardware
tissue; always wear appropriate safety 1. Hand vacuum pump.
glasses when working with liquid propane. 2. Regulator vapor outlet test fitting ¾” NPT X ¼”
hose barb.
CAUTION
The regulator/converter and mixer are 3. Union Tee ¼” NPT with three ¼” NPT X ¼” hose
part of a certified system complying with barb.
trained certified technicians should 4. Vacuum hose.
replacement of the regulator/converter or 5. 0-3 in W.C. Magnehelic Gauge (inches of water
mixer. column).

Secondary Stage (Break-Off) Test Primary Stage Test Hardware
1. Connect the vacuum pump, the Magnahelic 1. Hand vacuum pump.
gauge and the regulator vapor outlet to the Union
Tee fitting (Figure R11). Make sure there is no 2. Regulator Fuel Inlet test fitting (¼” NPT standard
leakage at any of the fittings. air coupling).
2. Using the vacuum pump slowly apply enough 3. Test Gauge fitting (1/4” NPT X 1/4” Hose Barb).
vacuum to measure above -2 in WC on the gauge.
This vacuum signal opens the secondary valve in 4. Vacuum hose or vinyl tubing.
the N2001 regulator/converter.
5. 0-60 in W.C. Magnehelic Gauge (inches of water
3. Release the vacuum pump lever and you will see column).
the gauge needle start falling back toward zero.
When the pressure drops just below the specified
break-off pressure (-1.2 in WC) of the secondary
spring, the needle should stop moving.
Secondary Stage Test Connection
Magnahelic
Gauge
Vacuum
Union Tee Hand Pump
Vapor Outlet
Figure R11 Test Fitting
1. 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, repair
as necessary (See Chapter 7 for disassembly of
the N2001).

4. Make sure there is no leakage at any of the
Primary Stage Pressure Test fittings. The static pressure should read between
40-60 inches of water column on the Magnahelic
1. Remove the primary test port plug from the side of
gauge and maintain a constant pressure for 60
the regulator and install the ¼” NPT hose barb
seconds.
fitting.
5. If the pressure reading begins to increase, a leak
is most likely present at the primary valve, either
Test Port the primary valve o-ring or the valve itself. If a leak
is present you will need to disassemble the
primary side of the regulator, repair the cause of
the leak, re-assemble the regulator and test the
primary stage again (See Chapter 7 for
disassembly of the N2001).
6. If the pressure begins to decrease, the secondary

seat is probably not making an adequate seal and
Fuel Inlet is leaking. If a leak is present you will need to
Figure R12 disassemble the secondary cover of the regulator,
repair the cause of the leak, re-assemble the
regulator and test the primary and secondary
2. Connect a compressed air line (shop air ~100psi)
stage again (See Chapter 7 for disassembly of
to the liquid propane fuel inlet of the N2001
the N2001).
Regulator (Figure R12).
7. Once the test is successful, re-install the primary
test port plug and check the fittings for leaks (See
Chapter 7 for installation of the N2001).
NOTE
The N2001 Primary stage pressure can
also be tested at idle on a running engine.
The N-2001 primary pressure should be
between 40" and 55" water column at 700
RPM, idle.
Figure R13 WARNING

3. Apply compressed air, wait for air to exit the hose
barb in the test port, and then connect the
Magnahelic gauge (Figure R13) to the hose barb
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.

glasses when working with liquid propane

N-CA55-500TR Service AVV N-CA100TR Service AVV (Air
(Air Valve Vacuum) Testing Valve Vacuum) Testing
AVV Test Hardware AVV Test Hardware
1. Mixer AVV test fitting ¼” NPT X ¼” hose barb. 1. Mixer AVV test fitting ¼” NPT X ¼” hose barb.
2. Union Tee ¼” NPT with three ¼” NPT X ¼” hose 2. Union Tee ¼” NPT with three ¼” NPT X ¼” hose
barb. barb.
3. Vacuum hose. 3. Vacuum hose.
4. 0-20 in W.C. Magnehelic Gauge (inches of water 4. 0-20 in W.C. Magnehelic Gauge (inches of water
column). column).
AVV Test AVV Test
1. Install the Union Tee fitting between the FTV and 1. Install the Union Tee fitting between the FTV and
the AVV fitting. the AVV fitting.

3. With the engine running at idle (700 RPM) the

Gauge
Fitting
AVV Fitting
Figure T1 Gauge Fitting

3. With the engine running at idle (700 RPM) the AVV Fitting
Figure T1
NOTE NOTE
If the measured water column is If the measured water column is
excessively high, check for a sticking or excessively high, check for a sticking or
binding piston diaphragm assembly binding piston diaphragm assembly
inside the mixer. (See Chapter 8 for inside the mixer. (See Chapter 9 for
removal, installation and disassembly of removal, installation and disassembly of
the N-CA55-500TR mixer). the N-CA100TR mixer).
WARNING WARNING
DO NOT spray carburetor cleaner or DO NOT spray carburetor cleaner or
solvent into the mixer while installed on solvent into the mixer while installed on
the engine. These chemicals may damage the engine. These chemicals may damage
the oxygen sensor and cause pre-mature the oxygen sensor and cause pre-mature
failure of the catalytic muffler. failure of the catalytic muffler.

Ignition Timing Adjustment
DISTRIBUTOR
With the MI-04 system ignition timing advance is
controlled by the SECM. The initial ignition timing
setting of the distributor is described in the following
steps. It will be necessary to mechanically adjust the
distributor to an initial setting for startup, and then
adjust the final timing using the service tool. Ignition
Module
Figure G3
4. Disconnect the 4-PIN connector (Figure G3) to the

ignition module. This eliminates the +12VDC
power on PIN D and puts the ignition to a default
value not controlled by the SECM.
Figure G1
1. Using the timing indicator on the crankshaft pulley,

set the engine on 0 degrees Top Dead Center
(TDC) of number 1 cylinder (Figure G1).
G430E
Figure G4
5. Using a standard inductive timing light (Figure G4)

with no offset adjustment set the initial timing to 4
degrees BTDC (advanced), by rotating the
distributor while cranking the engine with the
ignition key.
Figure G2
2. Verify that the distributor rotor is lined up with

number 1 cylinder on the distributor cap (Figure
G2).
3. Disconnect the fuel lock-off connector at the lock-

off so that fuel cannot flow during cranking.

6. Turn the ignition key to the OFF position.
Final Timing and Idle Mixture
7. Tighten the distributor hold-down bolt to the Adjustment
specified torque value and re-connect the 4-PIN
ignition module connector and the fuel lock-off
connector.
Figure G7
To make the final timing adjustment to a running

Figure G5
engine with the Service Tool software you will need to
connect a laptop computer to the SECM. A USB
NOTE (Universal Serial Bus) to CAN (Controller Area
This completes the initial ignition timing. Network) communication adapter by Kavaser will be
The final ignition adjustment can be made required along with a Crypt Token (Figure G7). The
at engine start-up using the software Crypt Token acts as a security key allowing the laptop
service tool. to retrieve the necessary data from the SECM.
Crypt
Token
Figure G8
1. Install the Crypt Token in an available USB port in

the computer (Figure G8).
2. With the ignition key in the OFF position, connect

the Kavaser communication cable from a second
USB port on the computer to the CAN
communications cable on the engine. (*If your
laptop computer does not have a second USB
port an appropriate USB Hub will need to be
used).
3. Connect a timing light to the engine.
4. Turn the ignition key to the ON position (Do Not

Start the Engine).

Figure G9 Figure G11
5. Launch the MotoView program on your computer 8. Start the engine. Use the timing light to check the
and open the Service Tool display. engine timing. The timing should be at 10 degrees
BTDC. If it is not, loosen the distributor-retaining
6. Start the engine; you should now see the idle nut and rotate the distributor (Figure G11) until the
RPM on your Service Tool display screen (Figure timing light shows an engine timing of 10 degrees
G9). BTDC.
NOTE 9. Tighten the distributor-retaining nut and verify the

Service Tool software (MotoTuneViewer) timing is still 10 degrees BTDC.
and the security Crypt Token is
obtainable by certified technicians 10. Unlock the Spark Control Lock bit, the field should
through authorized dealers. now read unlocked.
11. Use the accelerator pedal to increase RPM above

the pedal to return to idle RPM.
Figure G10
7. Select the Run Screen, you will see an option to

lock the ignition bit (Spark Control Lock), select
the check box to lock the timing (Figure G10).
This locks the SECM programmed spark advance
at 10 degrees BTDC.

Idle Mixture Adjustment
Idle Mixture
Screw
Tamper Proof
Cap
Figure G13
Figure G28 7. Install the tamper proof cap on the idle mixture
screw adjustment port so that no further
adjustments can be made (Figure G13).
1. While on the Run Screen adjust the idle mixture
screw on the mixer until a reading of the proper
NOTE
range is reached for the FTV Duty Cycle (Figure
If the FTV Duty Cycle reading is cannot
G12).
be adjusted between within proper range,
- Proper range
check for possible vacuum leaks,
G430E : 25 - 50%
manifold leaks or a faulty mixer.
G643E : 40 - 60%
2. To make this adjustment you will need to adjust

the nylon screw all the way inward and then back
out the screw ¼ turn.
3. Use the accelerator pedal to increase RPM above

the pedal to return to idle RPM. The duty cycle
setting should remain within the adjustment range.
G430E : 25 - 50%
G643E : 40 - 60%
4. To obtain an accurate FTV Duty Cycle reading

when the tamper proof is not installed, place your
thumb over the idle screw port so that no air will
leak past the screw threads.
5. If the FTV Duty Cycle reading is above 40% back

the idle adjustment screw out again and re-check
your duty cycle reading. Continue to do this until
the FTV Duty Cycle reading is within the proper
range.
G430E : 25 - 50%
G643E : 40 - 60%
6. Turn the ignition key to the OFF position to shut

down the engine.

A343079
USB (Universal Serial Bus) to CAN (Controller
Area Network) Converter Assembly
A343080
Service Tool Software (includes CD and Crypt
Token (License Dongle))
Crypt
Token
A334071
Extension Cable
G430E/G643E Tier LP Engine 98 Service Tool Kit

SB2007E02
Jan.2004
Service Manual
DAC CS-121
Series Alternators
accident occurs. A person must be alert to potential hazards. This person should also have the necessary train-
ing, skills and tools to perform these functions properly.
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
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 publica-
tion.
technique not specifically recommended by DAEWOO 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, lubri-
cation, maintenance or repair procedures you choose.
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. DAEWOO dealers have the most current information avail-
able.
1
Index
Specifications
Alternator................................................................. 5
Systems Operation
Alternator................................................................. 6
CS-121 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
DAC Alternators 3 Index

Specifications
Alternator
DAC ALTERNATOR COVERAGE CHART

DAEWOO
Part No. Series Voltage BAT
D167411 CS-121 12V
IDAS012B
CS-121 Alternator End View
ALTERNATOR SPECIFICATIONS
DAEWOO Part No. D167411
DAC Series CS-121
Voltage Rating 12V
Polarity Neg. Gnd.
Rotation CW
2 Test Speed 6500 rpm
Rated Output (Cold) 61A
IDAS011B
Output Voltage 14.0L0.5V
CS-121 Alternator Cross-Sectional View Rotor Field Winding
Resistance [At 27C(80°F)] -
Field Current [At 14.0V or -
27.5V and 27C(80°F)]
Stator Winding -
Resistance
Turn On Speed (Max.) -
Slip Rings (3) : -
Maximum Runout (TIR)
Minimum Diameter -
Brush Length (Measured
On Longest Side) : -
New
Minimum
Pulley Nut (2) Torque 100 L 7 N I m
(75 L lb I ft)
Thru Bolt (1) Torque -
Terminal Torques :
Bat 3.6 L 0.8 N I m
(32 L 7 lb I in)
Gnd -
DAC Alternators 5 Specifications

Systems Operation
The alternator converts mechanical and magnetic
Alternator energy to alternating current (AC) and voltage. This
process is done by rotating a direct current (DC)
electromagnetic field (rotor) inside a three phase
Introduction 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
The CS-121 DAC Alternators have three phase, full-
rectifier diodes. This alternator does not have a diode
wave, rectified output.
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.
The alternator is connected to the battery through

terminal “L” and the ignition or key start switch for
alternator turn-on. Therefore, alternator excitation
occurs when the switch is turned on.
IDAS001C
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
2 9
3 5 6
1 2 4
10
IDAS002C
Alternator Components-Inside View of Rear Frame

(2) Rear frame. (7) Brush holder. (9) Regulator.
(10) Rectifier.
7
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
8 feature a high ampere output per pound of weight,
IDAS013B with a totally new and different regulator. A diode trio
is not used. A delta wound stator, rectifier bridge,
Alternator Components-Cross-Sectional View rotor with slip rings and brushes are electrically
(1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive similar to the SI series. alternators. The CS stands
end frame. (6) External fan. (7) Brush holder. (8) Internal for Charging System. The 121 denotes the outside
fan. diameter in millimeters of the stator laminations. This
series of alternators has two fans for cooling the
alternator.
IDAS014B
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).

1 10
3
IDAS003C 8
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) pro-
vide the surfaces for brush contact. Internal fan (8) IDAS016B
pulls air through the rear frame to cool the rectifier
bridge and regulator.
Rectifier
(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.
11
7
IDAS015B
Brush Holder
(7) Brush holder. (11) Brushes.
Brush holder (7) contains two brushes (11). They

contact the two rotating slip rings on the rotor. IDAS017B
Current flows to the rotor coil through the brushes
and slip rings. There is one positive (+) and one neg- Regulator
ative (-) brush. The brush material is copper graphite. (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 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
BATTERY
SWITCH 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.
INDICATOR
RESISTOR
LAMP The regulator switches the field voltage on and off at
a fixed frequency of about 400 cycles per second.
BAT 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
P L I S 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

TR1 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
regulator may be on only 10 percent of the time and
off 90 percent of the time. This duty cycle will change
FIELD as operating factors change to provide just the right
RECTIFIER
amount of voltage.
BRIDGE Most regulators are temperature compensated to
STATOR
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
IDAS018B
for charging under these conditions.
The regulator circuitry is designed to perform a

CS-121 Integral Charging System Schematic
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.

Problem 2: Alternator Charge Rate Is Low Or Not
Testing And Adjusting Regular
Probable Cause:
Troubleshooting
1. Loose Drive Belt For Alternator:
Adjust the alternator drive belt.
Troubleshooting can be difficult. On the page that 2. Loose Alternator Drive Pulley:
follows is a list of possible problems. To make a repair Check the pulley for wear. If it is worn, install a
to a problem, make reference to the probable cause. new pulley. Tighten the pulley nut to the correct
torque shown in Specifications.
This list of problems and probable causes will only
give an indication of where a possible problem can 3. Charging Or Ground Return Circuit Or Battery
be and what repairs are needed. Sometimes more or Connections Defective:
other repair work is needed beyond the Inspect all cables and connections. Clean and
recommendations in the list. Remember that a tighten all connections. Replace defective parts.
problem is not normally caused by one part, but by
4. Regulator Is Defective:
the relation of one part with other parts. This list
Replace the regulator.
cannot give all possible problems and probable
causes. The serviceman must find the problem and 5. Rectifier Is Defective:
its source, then make the necessary repairs. Replace the rectifier.
6. Brushes Are Worn Or Dirty:

Troubleshooting Problem List Install a new brush holder.
1. Alternator Does Not Charge. Problem 3: Alternator Charges Too Much

2. Alternator Charge Rate Is Low Or Not Regular. Probable Cause:
3. Alternator Charges Too Much. 1. Alternator Or Regulator Has Loose Connections:
4. Alternator Is Noisy. Tighten all connections to alternator or regulator.
2. Regulator Is Defective:
Install a new regulator.
Troubleshooting Problems
Problem 4: Alternator Is Noisy
Problem 1: Alternator Does Not Charge
Probable Cause:
Probable Cause:
1. Drive Belt For Alternator Is Worn Or Defective:
1. Loose Drive Belt For Alternator : 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. Drive Belt And Drive Pulley For Alternator Are Not
3. Charging Or Ground Return Circuit Or Battery In Alignment:
Connection Are Defective: Make an adjustment to put the drive belt and drive
Inspect all cables and connections. Clean and pulley in correct alignment.
tighten all connections. Replace defective parts. 4. Alternator Bearings Are Worn:
4. Rotor Field Winding Or Regulator Is Defective: Install new bearings in the alternator.
Install a new rotor or regulator.
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 ................................. 14.0L0.5V
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 phase, If voltage drops below spec., -
Below Specification. and/or rectifier). Check ignition repair alternator (open rectifier
or key start switch circuit.* and/or stator phase).
Reached Alternator and battery in spec. Repair alternator
Repair alternator Turn on all accessories to verify.
Specification (defective regulator). (shorted regulator).
and then tapered off. Voltage must stay in spec.
Exceeds Specification Check battery. Alternator in spec. Repair alternator
and stays high. Check battery. (shorted regulator).
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.

SB2008E01
M a y. 1 9 9 8
Service Manual
Bosch K1 Series
Alternators
accident occurs. A person must be alert to potential hazards. This person should also have the necessary train-
ing, skills and tools to perform these functions properly.
this publication and on the product labels are identified by the following symbol.
WARNING
in injury or death.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publica-
tion.
technique not specifically recommended by DAEWOO 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, lubri-
cation, maintenance or repair procedures you choose.
and most current information before starting any job. DAEWOO dealers have the most current information avail-
able.
1
Index
Specifications
Alternator................................................................. 5
Systems Operation
Alternator................................................................. 7
Alternator Operation ........................................ 7
Alternator Components ............................ 7
Alternator Operation Schematic ............... 9
Regulator Operation............................... 13
Introduction ...................................................... 7

Alternator Component Tests.................................. 17
Brush Tests .................................................... 21
Capacitor Test................................................ 18
Rectifier Tests ................................................ 20
Regulator Test................................................ 17
Rotor Field Winding Tests.............................. 19
Stator Tests.................................................... 19
Alternator Output Test ........................................... 16
Bench Test ............................................. 17
Machine Test .......................................... 16
Troubleshooting..................................................... 15
Troubleshooting Problem List ................ 15
Troubleshooting Problems ..................... 15
Disassembly And Assembly

Alternator............................................................... 22
Assemble Alternator....................................... 24
Disassemble Alternator.................................. 22
Bosch Alternators 3 Index

Specifications
Alternator
Bosch Alternator Coverage Chart

DAEWOO Part Model Voltage Amperage
Number Number B+
8C5535 K1 12 32
D+
2 3
1
W
B-
IDAS020B
Alternator End View
D- D+
IDAS019B
Alternator Sectional View
B+
DF
IDAS021B
Alternator Enclosed End View
Bosch Alternators 5 Specifications

ALTERNATOR SPECIFICATIONS ALTERNATOR TIGHTENING SPECIFICATIONS
DAEWOO P/NO. 8C5535 DAEWOO P/NO. 8C5535
Model Number K1 Pulley Nut (1) Torque 35 L 10 N • m
(25 L 7 lb • ft)
Voltage Rating 12V
Thru Bolts (2) Torque 4.1 to 5.5 N • m
Polarity Neg. Grd. (36 to 49 lb • in)
Rotation CW Terminal Torques: 3.6 L 0.8 N • m
Test Speed B+ (32 L 7 lb • in)
5000 rpm
Rated Output (Cold) B- -
29A
Output Voltage 2.25 L 0.25 N • m
14.0 L 0.5V D+ (20.0 L 2.2 lb • in)
Rotor Field Winding 3.4 to 3.7 Ω 2.25 L 0.25 N • m
Resistance D- (20.0 L 2.2 lb • in)
Field Current(@ 2.25 L 0.25 N • m
28.0V or 14.0V) 3.8 to 4.1A
DF (20.0 L 2.2 lb • in)
Stator Winding
Resistance .14 to .15 Ω W -
Turn On Speed
(Max.)
Slip Rings (3):
Maximum Runout (TIR) 0.03 mm
(.001 in)
27.00 mm
Minimum Diameter (1.06 in)
Brush (4) Length: 17.00 mm
New (.67 in)
Brush (4) Length: 11.5 mm
Minimum (.45 in)
Brush Spring Force 2.0 to 3.8 N
(.45 to .86 lb)
Bosch Alternators 6 Specifications

These alternators are self-exciting at high speed.
Systems Operation That means they have residual magnetism in the
rotor. The excitation circuit cannot start the charging
process until the pre-excitation circuit produces the
Alternator required breakdown voltage. The alternator is
connected to the battery through the ignition or key
start switch. This connection supplies the necessary
Introduction current to the pre-excitation circuit. This current is
available every time the ignition switch is turned on.
The K1 Series Bosch Alternator has three phase, full

Alternator Components
wave, rectified output. It is the brush-type. See the
Bosch Alternator Coverage Chart in Specifications for
the list of alternators covered in this module.
2 3 4 5
1
Alternator Operation
IDAS004C
Bosch Alternator
9
IDAS022B
The alternator is an electrical and mechanical Alternator Components

component driven by belt rotation from the engine. It (1) Fan. (2) Front frame assembly. (3) Stator. (4) Rotor.
is used to charge the storage battery during engine (5) Rectifier. (6) Slip ring. (7) Brushes. (8) Regulator.
operation. The alternator is cooled by a fan that is (9) Rear frame assembly.
part of the alternator. The fan pulls air through the
back of the alternator. The air exits the front of the
alternator, cooling it in the process. The major components of the alternator are stator
The alternator converts mechanical and magnetic energy (3), rotor (4), rectifier (5), regulator assembly (8),
to alternating current (AC) and voltage. This process is brushes (7) and a capacitor (if equipped).
done by rotating a direct current (DC) electromagnetic
field (rotor) inside a three phase stator assembly. The
alternating current and voltage (generated by the stator)
are changed to direct current (DC) by a three phase, full
wave rectifier system. The rectifier system has six silicon
rectifier diodes. DC current flows to the alternator output
terminal. The rectifier also has three exciter diodes. They
rectify the current needed to start the charging process.
A solid state regulator is installed on the back of the

alternator. Two brushes conduct current, through two
slip rings, to the rotor field. A capacitor, installed on
some alternators, smooths alternator DC voltage.
Bosch Alternators 7 Systems Operation

3
7
IDAS005C IDAS007C
Stator Brushes
(3) Stator. (7) Brushes.
Stator (3) consists of a stator core and coils. As the rotor There are two brushes (7). They contact the two
turns, its varying magnetic field causes the stator coil to rotating slip rings on the rotor. Current flows to the
produce three phase alternating current (AC). rotor coil through the brushes and slip rings. There is
one positive (+) and one negative (-) brush. The
brush material is copper graphite.
4
10
11
6
IDAS006C
Rotor IDAS008C
(4) Rotor. (6) Slip ring.
Rectifier
(5) Rectifier. (10) Positive (+) diodes. (11) Negative (-) diodes.
Rotor (4) consists of a core, coils and slip ring (6).
The rotor provides the magnetic field between the
rotor field winding and the stator. Slip ring (6) Rectifier (5) contains three positive diodes (10) and
provides the surfaces for brush contact. three negative (-) diodes (11). They form the full
wave rectifier which is connected to the stator.
Rectifier (5) changes or rectifies three phase AC to
DC. The rectifier also provides excitation current
through three exciter diodes (not shown).

Alternator Operation Schematics
8 The electrical schematics that follow indicate terminals

and basic circuitry for the K1 series alternators.
EXCITER DIODES
IDAS009C D+
CAPACITOR
Regulator
(8) Regulator.
B- B+
Regulator (8) controls alternator output. It is mounted
on the alternator rear frame assembly.
V +
DIODES
DIODES
U W
W
8 EXCITATION
WINDING
REGULATOR
D-
D+ DF
IDAS010C
IDAS023B
Capacitor
(12) Capacitor.
K1 Series Alternator Schematic (12V)
Capacitor (12) smooths alternator DC voltage. The

capacitor is mounted on the back of the alternator.

EXCITER DIODES
D+
B+
- +
DIODES V DIODES
STATOR U W
WINDINGS
D-
TO
REGULATOR
EXCITATION WINDING
DF
IDAS024B
K1 Series Fully Enclosed Alternator Schematic (12V)

Charging Circuit
Current for battery charging and for the electrical

accessories is taken from the B+ terminal of the D- -DIODES+ B+
alternator. The flow of current for battery charging U
and electrical accessories at an instant of time (120°
W
phase angle) is shown in illustration Phase
Relationships (120°)
U (+) LOAD
B-
W(-) V(O) BATTERY

D- -DIODES+ B+ STATOR
U WINDINGS
W U V W U = POS
V = POS
W = NEG
U (+) LOAD
150° IDAS026B
B-
W(-) V(O) BATTERY Phase Relationships

Charging circuit with phase angle of phase U=150°
STATOR
WINDINGS
U V W U = POS If another time instant is chosen (150° phase angle)
V =O
W = NEG
where none of the voltages are zero, the current
would flow as shown in illustration Phase
Relationships (150°).
120°
IDAS025B
Equal currents flow from windings U and V to the

Phase Relationships respective positive diodes. They return to the neutral
Charging circuit with phase angle of phase U=120°
point through W winding negative diode and winding
W. Note that not all the diodes belonging to the
Voltage at the output of winding U is positive, while it various phases are used at the instant of time
is negative at W and zero at V (no voltage). The examined in this example. This remains true of all
current path is as follows: the other instants of time which could be examined.
Individual phase currents change in magnitude and
polarity, while the output current to the battery or
Output from winding U through positive diode U, electrical accessories remains uniform.
alternator terminal B+, battery ground, alternator
terminal D-, negative diode W, output of winding W
to the neutral point.

Excitation Circuit Pre-excitation CiRcuit
The exciting current for generation of the magnetic When in operation at high speed, the alternator is
field is taken from the stator winding. It is rectified by self-excited. Excitation current for the magnetic field
three exciter diodes and the three negative power is obtained from the main current. However, when
diodes. The exciting current follows the path shown in initially starting, the alternator depends on residual
the illustration. magnetism. When the current of an electromagnet is
disconnected, the magnetic field does not disappear
completely. The iron core remains slightly magnetic.
REGULATOR This is called residual magnetism. There is enough
residual magnetism in the core to induce a small
EXCITER D+ DF
voltage in the stator windings. This small voltage
DIODES
causes a weak current to flow through the closed
-DIODES circuit of the excitation winding. This current
B+ produces a weak magnetic field of its own. This is
D-
added to the residual magnetism of the core and
W U
slightly boosts the intensity of the exciter field. A
+DIODES boosted exciter field results in a higher voltage. The
U (+)
effect is cumulative, and the process repeats itself
STATOR WINDINGS until the desired voltage, corresponding to the
W(-)
V(O)
alternator speed, is reached.
DF The exciter circuit in the alternator contains three positive

EXCITATION diodes, three negative diodes and three exciter diodes.
WINDINGS
Alternator self-excitation cannot start until the pre-

U V W excitation circuit produces the breakdown voltage
required by two of the diodes (one negative diode and
U = POS
V =O one positive diode per phase) connected in series.
W = NEG
120°
IDAS027B
EXCITER DIODES REGULATOR

Phase Relationships D+ D+ D-
Excitation circuit with phase angle of phase U=120°
DIODES B+
Current flows from the output of winding U (positive at
W LIMITING
this instant of time), through its corresponding exciter
RESISTOR
diode and the alternator D+ terminal to the regulator
D+ terminal. When the regulator is turned on, current IGNITION OR
then flows to the regulator DF terminal to the KEY START SWITCH
excitation winding by the way of terminal DF of the
alternator. Current then flows to the alternator B+
terminal D- and the negative power diode to winding
W (negative at this instant of time) completing its
circuit at the neutral point. POSITIVE DIODES BATTERY ROTOR EXCITATION
WINDING
IDAS028B
Pre-excitation Circuit (Typical)
The existing residual magnetic field of the rotor generates

this breakdown voltage only at high speed.

Therefore, the alternator has to be pre-excited during Regulator Switched ON
start-up. This is done by taking current from the
battery through the ignition or key start switch,
limiting resistor and on some alternators a diode
assembly. When the ignition or key start switch is
turned on, pre-excitation current flows from the
positive (+) terminal of the battery through the ignition (+)
or key start switch, limiting resistor and diode D+ B+
assembly (if equipped) to the D+ terminal of the 3

R1 D+
regulator. The current flows through the regulator to R6 D3
the excitation winding where it is grounded. It is then R2 DF
returned to the negative (-) side of the battery. R R7
3
1
As current flows through the excitation winding, it 4
2 T2
produces a magnetic field strong enough ZD T3
to start self-excitation of the alternator. C G
R4 R5
D-
Regulator Operation (-) TWZ TWT B-
The transistor regulator is the Bosch type EE. It is

used on all K1 alternators except the K1 enclosed
alternator. The EE will be used in describing the IDAS029B
construction and operating of the regulator.
Regulator Circuit Diagram (Switched On)
(1) Output stage. (2) Control stage. (3) Voltage divider.
The most important part of the regulator is formed by (4) Temperature compensation diodes. (C) Capacitor.
two integrated assemblies:
1. TWZ which includes transistor T1, resistor R4 and As long as the actual voltage is below the set
uni-directional breakdown diode ZD. This is the alternator voltage, the breakdown voltage of diode
control stage. ZD is not yet reached. No current flows through the
2. TWT which includes transistor T2, resistor R5 and branch of the circuit containing diode ZD. No current
transistor T3. This is the output stage. flows to the base of transistor T1. Transistor T1 is in
a non-conducting state.
The following circuit diagrams show what happens in
the regulator when the excitation current is switched With transistor T1 in the non-conducting state, control
ON and OFF. The actual value of the alternator current can flow from the exciter diodes and terminal
voltage between terminals D+ and D- is detected by a D+ through resistor R6 to the base of transistor T2.
voltage divider which is formed by resistors R1, R2 This current switches transistor T2 on. Transistor T2
and R3. Connected in parallel with R3 is a now makes the connection between terminal DF and
unidirectional breakdown diode ZD. This diode the base of transistor T3. Therefore, if transistor T2
determines the system charging voltage at the conducts, so does transistor T3. The excitation
regulator. A partial voltage is constantly applied to current now flows through transistor T3. Current also
this diode. This voltage is proportional to the flows through the excitation winding and increases
alternator voltage. during on time, causing the alternator voltage to rise.
At the same time, there is a voltage rise across the
voltage divider and diode ZD.

Regulator Switched OFF Capacitor (C) smooths the DC voltage. Resistor R7
insures the fast, precise switching of transistor T2
and T3. Resistor R7 also reduces switching losses.
Temperature compensation diodes (4) adjust system

voltage according to ambient temperature. The charg-
ing voltage must be higher in cold weather than in hot
(+)
B+
weather.
D+
3
R1 D+
R6 D3
R2 DF
R R7
3
1
4
2 T2
ZD T3
C G
R4 R5
D-
(-) TWZ TWT B-
IDAS030B
Regulator Circuit Diagram (Switched OFF)

(1) Output stage. (2) Control stage. (3) Voltage divider.
(4) Temperature compensation diodes. (C) Capacitor.
When the system voltage finally exceeds the

regulator set value, diode ZD starts to conduct when
the breakdown voltage is reached. Current now flows
from D+ through resistors R1, R2 and diode ZD to the
base of transistor T1 which now conducts. Now the
voltage across the base of transistor T2 drops and
the base current stops flowing. Transistors T2 and T3
are turned off. The excitation circuit is now
interrupted. The alternator excitation is suppressed
and the output voltage drops again. The interruption
of the excitation current now generates a turn-off
voltage spike as a result of the induction in the
excitation winding (stored magnetic energy) which
could destroy transistors T2 and T3.
To prevent this, the decaying excitation current is

discharged through free wheeling diode D3, which is
connected in parallel with the excitation winding. As
soon as the alternator voltage has dropped below the
set value and diode ZD has returned to the non-
conducting state, the excitation winding is switched
on again. This cycle (in which the excitation winding
is alternately supplied with voltage or is short-
circuited through diode D3) is repeated in periodic
sequence. The on/off ratio depends on the rotational
speed of the alternator and the load current
requirements of the system.

Problem 2: Alternator Charge Rate Is Low Or Not
Testing And Adjusting Regular.
Probable Cause:
Troubleshooting
Troubleshooting can be difficult. Following is a list of
possible problems. To make a repair to a problem, 2. Loose Alternator Drive Pulley:
make reference to the probable cause. Check the key groove in the pulley for wear. If the
groove is worn, install a new pulley. Tighten the
This list of problems and probable causes will only pulley nut to the correct torque. See Specifications.
give an indication of where a possible problem can
be and what repairs are needed. Sometimes more or 3. Charging Or Ground Return Circuit Or Battery
other repair work is needed beyond the Connections Defective:
recommendations in the list. Remember that a Inspect all cables and connections. Clean and
problem is not normally caused by one part, but by tighten all connections. Replace defective parts.
the relation of one part with other parts. This list 4. Regulator Is Defective:
cannot give all possible problems and probable Install a new regulator assembly.
causes. The serviceman must find the problem and
its source, then make the necessary repairs. 5. Rectifier Is Defective:
Install a new rectifier.
Troubleshooting Problem List 6. Brushes Are Worn Or Dirty:

Install new brushes.
1. Alternator Does Not Charge.

Problem 3: Alternator Charges Too Much.
2. Alternator Charge Rate Is Low Or Not Regular.
Probable Cause:
3. Alternator Charges Too Much.
1. Alternator Or Regulator Has Loose Connections:
4. Alternator Is Noisy. Tighten all connections to the alternator or
regulator.
Troubleshooting Problems 2. Regulator Is Defective:

Install a new regulator assembly.
Problem 1: Alternator Does Not Charge.

Problem 4: Alternator Is Noisy.
Probable Cause:
Probable Cause:
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:
Check the key groove in the pulley for wear. If the 2. Loose Alternator Drive Pulley:
groove is worn, install a new pulley. Tighten the Check the key groove in the pulley for wear. If the
pulley nut to the correct torque. See Specifications. groove is worn, install a new pulley. Tighten the
pulley nut to the correct torque. See Specifications.
3. Charging Or Ground Return Circuit Or Battery
Connections Are Defective: 3. Drive Belt And Drive Pulley For Alternator Are Not
Inspect all cables and connections. Clean and In Alignment:
tighten all connections. Replace defective parts. Make an adjustment to put the drive belt and drive
pulley in correct alignment.
4. Rotor Field Winding Or Regulator Is Defective:
Install a new rotor or regulator assembly. 4. Alternator Bearings Are Worn:
Install new bearings in the alternator.
Bosch Alternators 15 Testing and Adjusting

Alternator Output Test
FAULT CONDITIONS AND POSSIBLE CAUSES

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 phase, If voltage drops below spec.,
Below Specification. and/or rectifier) repair alternator (open rectifier
and/or stator phase).
Alternator and battery in spec. Repair alternator
Reached Specification Repair alternator Turn on all accessories to verify.
and then tapered off. (defective regulator). (shorted regulator).
Voltage must stay in spec.
Exceeds Specification Check battery. Alternator in spec. Repair alternator
and stays high. Do alternator test again (shorted regulator).
if necessary Check battery. Also check battery
for possible damage.
NOTE: The proper drive pulley is required for the correct alternator output.
Tools Needed 5. The alternator output should stabilize within

Digital Multimeter or Equivalent 1 approximately 10 minutes at full throttle (possible
longer, depending upon battery size, condition and
AC/DC Clamp-On Ammeter 1
alternator rating). When operating correctly, the
alternator output voltage is:
12V System .......................................... 14.0 L 0.5V
Machine Test
If the alternator is NOT performing within specifications,
1. Put the multimeter positive (+) lead on the B+
see the Fault Condition and Possible Causes chart.
terminal of the alternator. Put the negative (-) lead
on the negative (-) terminal or frame of the 6. The charging current during this period should
alternator. Put the clamp-on ammeter around the taper off the less than approximately 10 amps,
positive output wire of the alternator. depending again upon battery and alternator
capacities. If the charging current does NOT
2. Turn off all electrical accessories. With the fuel off,
decrease as specified, see the Fault Conditions
crank the engine for 30 seconds. Wait two minutes
and Possible Causes chart.
to let the starting motor cool. If the system appears
to operate at the specifications, crank the engine 7. The K1 alternators are self-excited at high speeds.
again for 30 seconds. For this reason, they are turned on by the battery,
through the ignition or key start switch, to start the
NOTE: Cranking the engine for 30 seconds partially
charging process at low speed. They are turned on
discharges the batteries in order to do a
any time the ignition or key start switch is either in
charging test. If batteries are already low in
the ON or START position.
charge, skip this step. Jump-start engine or
charge batteries as required. 8. On lift trucks, check the alternator light to make
sure its working properly. Also, if a machine is
3. Start the engine and run at full throttle.
jump started because the battery is too low, the
NOTE: Full throttle approximates the required drive alternator may not have any output. This is
pulley speed of 5000 rpm. because the battery may be too low to send
current to the alternator. The alternator needs
4. Immediately check output current. When operating current to start the charging process.
correctly, this initial charging current is equal to or
greater than the full output current shown below:
8C5535.............................................................. 29A

Regulator Test Alternator Component Tests
If the alternator does not have the correct output, the
field can be grounded on the 8C5535 alternators.
Tools Needed
This can be done on the machine to determine if the
Digital Multimeter or Equivalent 1
regulator is bad. Do the procedure that follows:
Regulator Test
2
1 TEST EQUIPMENT CHART
Quantity Symbol Description
1 VPS 0 to 40V, 6A Variable Power Supply
2 V, A Digital Multimeter Or Equivalent
B+
D+ VPS
W
B
3
IDAS031B FRAME GROUND
(IF ALTERNATOR DOES
NOT HAVE B - TERMINAL)
Alternator
IDAS032B
(1) Jumper wire. (2) D+ terminal. (3) DF terminal.
Test circuit For Regulator Test (K1 Shown)
1. Repeat Steps 1-3 of Machine Test. Ground the

field by connecting jumper wire (1) from D+ terminal This test can be performed to determine an alternator
(2) to DF terminal (3) as shown. This calls for full or regulator malfunction. This test does not cover all
alternator output. of the failure possibilities, but verifies a few common
problems. See the Test Equipment Chart for the
2. If output is now within 10 amps of rated output, the equipment needed for this test.
regulator is bad and must be replaced.
Alternator output voltage is regulated by controlling
3. If output is not within 10 amps of rated output, the field coil current. The regulator senses output voltage.
alternator must be disassembled for component If the voltage is low, the regulator allows field current
testing. See Alternator Component Tests. flow and the voltage builds. When output voltage
exceeds the upper limit, field current is turned off. The
output voltage of a properly functioning alternator and
Bench Test
regulator is:
Put the alternator on an alternator test bench. The 12V System ........................................ 14.0 L 0.5V
maximum current output and regulated voltage
The voltage should not vary more than approximately
should be the same as shown in the machine test.
0.3V during this process. This test measures voltage
when the regulator turns field current on and off and
determines if there is an open or short in the diode
trio (exciter diodes), field coil or regulator.

1. Connect variable power source (VPS) positive (+) Capacitor Test
lead to the alternator B+ and D+ terminals as
shown. Connect VPS negative (-) lead to the
alternator B- terminal or frame ground.
1
2. Adjust the voltage of the VPS until ammeter (A)
first indicates current draw. Measure voltage (V)
and write this measurement down as turn-on
voltage. When correctly operating, the turn-on
voltage is:
12V System ...................................... 14.0 L 0.5V 2
3. Ammeter (A) reads field current. When correctly

IDAS011C
operating, the field current is: See Specifications
for the K1, 12V alternators.
8C5535, Alternators ............ 3.8 to 4.1A at 14.0V Discharging Capacitor
(1) Capacitor mounting screw. (2) Capacitor lead.
NOTE: Divide the voltage that first indicates field
current by rotor field winding resistance as
shown in specifications. This will give the 1. Disconnect capacitor lead (2) from its terminal on
correct field current that should be seen on the back of the alternator. Remove the plastic
ammeter (A). housing from lead (2) that surrounds the clip.
4. If ammeter (A) indication is zero amps, the rectifier 2. Touch lead (2) to the capacitor mounting screw (1).
or field coil or regulator are open. If ammeter (A) This discharges the capacitor.
indication is too high (see Step 2), the field coil
may be shorted. The regulator is also bad if the NOTE: Each time this test is done, the capacitor must
turn-on voltage is not: be discharged.
12V System ...................................... 14.0 L 0.5V
5. If the measurements in Steps 3 and 4 are correct,

go to Step 6. If they are not correct, the alternator
and/or regulator are bad.
6. Adjust VPS to the turn-on voltage as measured in

Step 2. Slowly increase the voltage until ammeter 2
(A) indicates zero amps. Write this voltage down
as turn-off voltage.
7. The difference between the turn-off and turn-on

voltages must be no more than 0.3V. A larger
IDAS012C
value indicates a regulator malfunction. Also,
ammeter (A) should drop sharply to zero amps.
Capacitor Test
If not, the regulator is faulty.
(1) Capacitor mounting screw. (2) Capacitor lead.
8. If the alternator and regulator meet all test
requirements and there is still a problem, do the 3. Put the multimeter on the 20M resistance (Ω)
additional component tests that follow. scale. Connect one multimeter lead to capacitor
lead (2). Touch the other lead to capacitor
mounting screw (1).
4. There should be a very low resistance for a short

period of time. Then resistance should stabilize
above 100,000 ohms (meter reading 0.10 or
greater).
5. If the reading is not correct, replace the capacitor.

Rotor Field Winding Tests 2. Both readings should be 100,000 ohms or greater
(meter reading 0.10 or greater).
Rotor Field Winding Continuity Test
3. If the meter reading is low, the rotor is grounded
and must be replaced.
3
Stator Tests
Stator Winding Continuity Test
5
6
4
IDAS013C
Rotor Field Winding Continuity Test

1. Put the multimeter on the 200 ohm resistance (Ω)

scale. Touch the meter leads to each slip ring (4)
IDAS015C
on rotor (3) as shown.
Stator Winding Continuity Test
2. The resistance values should be as follows. (5) Stator. (6) Stator leads.
See specifications for the K1, 12V alternators.
8C5535, Alternators ................... 3.4 to 3.7 ohms
Tools Needed
3. If the resistance is not correct, the rotor is open or Ohmmeter capable of measuring 1
shorted and must be replaced. less than 0.1 ohms.
Rotor Field Winding Ground Test 1. Put the multimeter on the 200 ohm resistance (Ω)
scale. Connect the meter leads between each pair
of stator leads (6) of stator (5) for a total of three
readings.
3
2. The resistance values should be as follows.
4 See Specifications for the K1, 12V alternators
8C5535 Alternators ......................... 14 to 15 ohms
3. If the resistance is not correct, the stator is open or

shorted and must be replaced.
IDAS014C
Rotor Field Winding Ground Test

1. Put the multimeter on the 20M resistance (Ω)

scale. Touch the meter leads between each slip
ring (4) and the rotor shaft.

Stator Winding Ground Test Negative Diode Check
3
6
IDAS016C IDAS018C
Stator Winding Ground Test Negative Diode Check

(5) Stator. (6) Stator leads. (8) Negative (-) diode.
1. Put the multimeter on the 20M resistance (Ω) 1. Put the multimeter on the diode scale. Connect the
scale. Connect one meter lead to each stator lead meter leads between each negative (-) diode (8)
(6) and touch the other meter lead to the stator and the surface of the rectifier that is not painted.
frame. The negative diodes are silver.
2. The resistance value should be 100 000 ohms or 2. Note the meter reading and reverse the meter
greater (meter reading 0.10 or greater). leads.
3. If the meter reading is low, the stator is grounded 3. One reading should be OL and the other .4 to .9
and must be replaced. volts. If both readings are OL or low (0 to .1 volts),
the diode is open or shorted and the rectifier must
be replaced.
Rectifier Tests
Positive Diode Check Exciter Diode Check
1
9
IDAS017C IDAS019C
Positive Diode Check Exciter Diode Check
(7) Positive (+) diode. (7) Positive (+) diode. (9) Exciter diodes connection.
1. Put the multimeter on the diode scale. Connect the 1. Put the multimeter on the diode scale. Connect the
meter leads between each positive (+) diode (7) meter leads between exciter diodes connection (9)
and the B+ stud. The positive diodes are black. and each positive (+) diode (7) (three of them).
2. Note the meter reading and reverse the meter leads. 2. Note the meter reading and reverse the meter leads.
3. One reading should be OL and the other .4 to .9 3. One reading should be OL and the other .4 to .9
volts. If both readings are OL or low (0 to .1 volts), volts. If both readings are OL or low (0 to .1 volts),
the diode is open or shorted and the rectifier must the exciter diode is open or shorted and the
be replaced. rectifier must be replaced.

Brush Tests Brush Length Check
Brush Continuity Test
11
10 X
10
IDAS020C
IDAS033B
Brush Continuity Test
(10) Positive (+) brush. (11) Terminal.
Brush Length Check
(10) Brush. (X) Brush length.
1. Put the multimeter on the 200 ohm resistance (Ω)
scale. Touch the meter leads between positive (+) 1. Measure the length of brushes (10) on the longest
brush (10) and terminal (11). side. Brush length (X) should be as follows.
2. The meter reading should be .1 to .3 ohms. If the New length:
resistance is not correct, the positive (+) brush is K1, 12V alternators ....17.0 mm (.67 in)
open or shorted and the brushes must be
replaced.
Minimum length:
K1, 12V alternators ......11.5 mm (.45 in)
Brush Ground Test
2. If the brushes are worn near or below the minimum

11
length, replace them.
12
IDAS021C
Brush Ground Test

(11) Terminal. (12) Negative (-) brush.
1. Put the multimeter on the 20M resistance (Ω)

scale. Touch the meter leads between negative (-)
brush (12) and terminal (11).
2. The meter reading should be 100,000 ohms or

greater (meter reading 0.10 or greater). If the
resistance is low, the brush is grounded and the
brushes must be replaced.
Bosch Alternators 21 Testing and Adjustinga

Disassembly and Assembly
6
Alternator
NOTE: The disassembly and assembly that follows is

of a K1, 12V alternator. The other alternators
are similar.
IDAS024C
Disassemble Alternator
Start By: 4. Mark the front and rear frame assemblies for
proper assembly. Remove four screws (6) (one
a. remove alternator
has a nut on it on the back of the alternator).
5. Separate the front frame and rotor assembly from

the rear frame and stator assembly. Watch for the
wave washer, at the back of the rear frame
assembly, to fall out.
1
7
2
IDAS022C
8
1. Remove the two screws and regulator (1).
2. Disconnect capacitor lead (2) from the back of the

IDAS025C
alternator. Remove the screw and capacitor (3).
6. Remove four screws (7) and rotor (8) from the front
frame.
IDAS023C
3. Remove the pulley nut, washer, pulley (4), fan (5)

and the key from the rotor shaft.
Bosch Alternators 22 Disassembly and Assembly

17
10
IDAS026C 11 IDAS029C
7. Remove spacer (10) and front bearing (11), with a 10. Remove three screws (17). Remove the stator and
suitable puller. Remove bearing cover (9) from the rectifier assembly from the rear frame. Remove the
rotor. remaining insulators from the terminal studs.
18
12
13
19
IDAS027C IDAS030C
8. Remove rear bearing (12) with a suitable puller. 11. Unsolder the three stator leads and separate
Unsolder both rotor winding leads from slip ring rectifier (18) from stator (19).
(13). Remove slip ring (13) with a suitable puller.
14
15
16
IDAS028C
9. Remove terminal nuts (14), (15) and (16). Remove

all of the washers and insulators.

18 19
5 6 8 19
4 18
20
11 12
13
IDAS032C
9 1
2. Position the insulators on the rectifier terminal studs.

Position rectifier (18) and stator (19) into the rear
frame, and install the three screws. Install the terminal
insulators, washers and nuts. Position wave washer
(20) into the bearing bore of the rear frame.
IDAS034B
K1 Alternator
(1) Regulator. (4) Pulley. (5) Fan. (6) Screws. (8) Rotor.
(9) Bearing cover. (11) Front bearing. (12) Rear bearing.
(13) Slip ring. (18) Rectifier. (19) Stator. 12
Assemble Alternator
13
18 IDAS033C
3. Install slip ring (13) on the rotor. Connect and

solder the rotor leads to the slip ring. Install rear
bearing (12).
19
IDAS031C
1. Connect and solder stator (19) leads to the positive

(+) diodes of rectifier (18). 9
10
11
IDAS034C
4. Install bearing cover (9), front bearing (11), and

spacer (10) on the rotor.

8 4
IDAS035C IDAS037C
5. Install rotor (8) and the four screws into the front 7. Install the key, fan (5), pulley (4), washer and
frame. pulley nut.
22
21
IDAS036C IDAS038C
6. Assemble front frame and rotor assembly (22) into 8. Install the capacitor and connect capacitor lead (2)
rear frame and stator assembly (21). Make sure to the back of the alternator.
the wave washer is in the rear frame bearing bore.
Align the front and rear frame marks made at 9. Install regulator (1).
disassembly for correct assembly.
End By:
Install the four screws.
a. install alternator

SB2102E01
Jan.2004
Specifications
Systems Operation
Testing & Adjusting
Lift Trucks Power Train
D20S-3, D25S-3, D30S-3, D32S-3
D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3),
D32S-3(B3.3), D33S-3(B3.3)
G20S-3, G25S-3, G30S-3
GC20S-3, GC25S-3, GC30S-3
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
G20P-3, G25P-3, G30P-3, G32P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
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.
this publication and on the product labels are identified by the following symbol .
WARNING
in injury or death.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
The information, specifications, and illustration in this publication are on the basis of information available at the
and most current information before starting any job. DAEWOO dealers have the most current information
available.
1
Index
Specifications
Drive Axle Mounting Group....................................... 14
Drive Tire Installation ................................................ 12
Drive Wheel Installation ............................................ 13
Final Drives And Wheels........................................... 11

Forward / Reverse Clutch Elements ...........................6
Forward And Reverse Control Group .........................5
Tightening Torques .....................................................9

Torque Converter ........................................................5
Transmission Solenoid ...............................................5
Valve Block Elements .................................................7

Valve Spring in Transmission Bearing Plate ...............8
Systems Operation
General Information .................................................. 15
Transmission and Drive Axle .................................... 16

Basic Control Scheme........................................... 34
Drive Axle .............................................................. 21
Hydraulic System .................................................. 24
Torque Converter .................................................. 16
Transmission ......................................................... 17
Transmission Hydraulic System ............................ 25

Troubleshooting ........................................................ 38
Check List During Operation ................................. 39
Check List From Operation Noises ....................... 40
Check List From Pressure Tests ........................... 41
Visual Checks ....................................................... 38
Transmission and Drive Axle Tests And Adjustments

.................................................................................. 44
Adjustment of Crown Wheel.................................. 58
Adjustment of Wheel Bearings.............................. 60
Adjustments on Drive Axle and Transmission ....... 55
Converter Stall Test ............................................... 46
Electric Control System Tests ............................... 50
Inching Pedal Adjustment...................................... 53
Installation of Pinion .............................................. 57
Maintenance Transmission and Drive Axle ........... 48
Transmission Pressure Tests ................................ 44
Power Train 3 Index

Forward And Reverse Control
Specifications Group
Torque Converter
(1) Torque for screws (four) that hold clamp to hand

control switch………..3.4 to 3.9 N·m (30 to 35 lb·in)
(2) Torque for bolts (two) that hold clamp to steering

column……………….2.8 to 3.4 N·m (25 to 30 lb·in)
Apply a bead of LOCTITE NO.242 Sealant to inner

radius of the clamp, prior to assembly.
(1) Torque for six bolts that hold torque converter drive
plate to the flywheel Transmission Solenoid
…………………………………...45 ± 7 N·m (33 ±5 lb·ft)
Valve block elements located on top of transmission

housing…………………………………9.7 to 10.3 ohms
For additional solenoid and valve group
specifications see section “Valve block elements”
Power Train 5 Specifications

Forward / Reverse Clutch
Elements
C
1.4 minimum
B
A
Snap ring
c) Piston return spring

Length under test force……………...29 mm (1.14 in)
a) Outer clutch Disc Test force………………..970.9 ±50 N (218.4 ± 11 lb)
Free length after test(nominal) ..…56.6 mm (2.23 in)
Outside diameter…………………..…95 mm (3.74 in)
d) Clearance between piston and pressure disc (disc

pack pushed against snap ring, piston fully
retracted in gear)………………..1.4 mm (0.0551 in)
b) Inner clutch Plate

Valve Block Elements
(On top of transmission)
Tighten to 50±7 N·m (37±5 Ib·ft)

Tighten to 0.6 N·m (0.44 Ib·ft) min
Tighten to 25±4 N·m (18.5±3 Ib·ft) SECTION A-A
Tighten to 5±1 N·m (3.7±1 Ib·ft)
Tighten to 5.5±1.5 N·m

(4±1 Ib·ft)
A C Tighten to 50±5 N·m (37±3.7 Ib·ft)

D,E
Tighten to 50±7 N·m B
(37±5 Ib·ft)
Tighten to 50±7 N·m (37±5 Ib·ft)
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)
E) Spring(Inner)
B) Spring(Inner)
Length under test force………..…20.0 mm (0.79 in)
Length under test force……….….26.6 mm (1.05 in)
Test force……………...3.34 ± 0.27 N (0.75±0.06 lb)
Test force……………….….37.8 ± 3.0 N (8.5±0.7 lb)
Free length after test(nominal)...55.93 mm (2.20 in)
Free length after test(nominal)….48.2 mm (1.90 in)
Outside diameter………………..7.75 mm (0.305 in)
Outside diameter………………….10.8 mm (0.43 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 N·m (33.2 Ib·ft)
Converter Inlet Valve
Tighten to 45 N·m (33.2 Ib·ft)
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 diameter…………………10.7 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)
Tightening Torques
Bearing Plate
Pump Housing
9
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
Power Train
Nut 150 N m (110.7 Ib ft)
Apply Loctite 242 to thread and face
Spacer and Shims
(See Instructions) Bolt 115 N m (84.9 Ib ft)
Apply Loctite 242 to thread
Tightening Torques
Nut 50 N m (36.9 Ib ft) Shims

(See Instructions) (See Instructions)
10
Bolt 80+_8 N m (59.0+
_5.9 Ib ft)
Adjust to (Slightly Oiled)
19.6 N m (14.5 Ib ft) drag
(See Instructions)
Grease Bearing Bolt 115 N m (84.9 Ib ft)
Bolt 285 N m (210.3 Ib ft) With Molycote BR2 Apply Loctite 242 to thread Bolt 28 N m (20.7 Ib ft)
Apply Loctite 242 to thread Apply Loctite 242 to thread
Specifications
Final Drives And Wheels D,G Model Trucks
Dual Drive wheels shown
GC Model Trucks
1 2
1 2
3
5 6
4 5
Oil Cooled Disc Brake Type
Oil Cooled Disc Brake Type (1) Apply LOCTITE NO.242 Thread Lock to threads of
spindle bolts.
Torque for bolts that hold spindle to drive axle
(1) Apply LOCTITE NO.242 Thread Lock to threads of housing………………..115 ± 14 N∙m (85 ± 10 lb∙ft)
spindle bolts.
Torque for bolts that hold spindle to drive axle (2) Use a crisscross procedure to tighten nuts.
housing……………..115 ± 14 N∙m (85 ± 10 lb∙ft)
(a) Torque for single drive wheel mounting.
(2) Torque for wheel mounting bolts…270 ± 25 N∙m nuts………...........644 ± 34 N∙m (470 ± 25 lb∙ft)
………………………………………(200 ± 20 lb∙ft) (b) Torque for inner and outer dual drive wheel
mounting nuts…………………….644 ± 34 N∙m
(3) Wheel bearing adjustment : (470 ± 25 lb∙ft)
(a) Tighten wheel bearing nut to 135 N∙m (100lb∙ft) (3) Torque for bolts that hold adapter assembly to
while the wheel is turned in both directions. hub………………...285 ± 13 N∙m (210 ± 10 lb∙ft)
(b) Loosen the nut completely. Tighten the nut
again to 50 ± 5 N∙m (37 ± 4 lb∙ft). (4) Wheel bearing adjustment :
(c) Bend a tab of the lockwasher into a groove of (a) Tighten wheel bearing nut to 135 N∙m(100 lb∙ft)
the wheel bearing nut. while the wheel is turned in both directions
(b) Loosen the nut completely. Tighten the nut
(4) Torque for bolts that hold cover to axle housing again to 50 ± 5 N∙m (37 ± 4 lb∙ft).
……………………………55 ± 10 N∙m (40 ± 7 lb∙ft) (c) Bend a tab of the lockwasher into a groove of
the wheel bearing nut.
(5) Apply Loctite No.515 Sealant to the axle flange and
cover on the contact area. (5) Torque for bolts that hold cover to axle housing
………………..…………..55 ± 10 N∙m (40 ± 7 lb∙ft).
(6) Apply Loctite No.515 Sealant to the axle flange or

spacer and cover on the contact area.

Drive Tire Installation
GC30, GC32 Models-Wide Axle
GC20, GC25 Models

WARNING
The drive tire must be installed as shown below.

Failure to do so will decrease the stability of the
truck, and can cause injury to the operator.
GC20, GC25 Models

Install the tire so that the edge of the tire is even with
the outside edge of the wheel.
GC30, GC32 Models

Narrow Axle :
GC30, GC32 Models-Narrow Axle
Install the tire so there is distance (X) between the
edge of the tire and the inside edge of the wheel.
Distance(X) is……………38.2 ± 0.8 mm (1.50 ± .03 in)
Wide Axle :
Install the tire so there is distance (Y) between the

edge of the tire and the outside edge of the wheel.
Distance(Y) is....................25.0 ± 0.8 mm (.98 ± .03 in)

.

Drive Wheel Installation
D,G Model Trucks
GC Model Trucks
(1) Tighten wheel mounting bolts to a torque of

……………………….270 ± 25 N∙m (200 ± 20 lb∙ft)
(1) Tighten wheel mounting bolts to a torque of
……………………….644 ± 34 N∙m (470 ± 25 lb∙ft)
Use a crisscross procedure to tighten nuts.

Drive Axle Mounting Group
1 Special shoulder Bolt
Chassis
Standard Bolt
Drive
Axle
Housing
2
(1) Torque for two nuts that hold the axle to the
chassis……………..…488 ± 27 N∙m (360 ± 20 lb∙ft)
(2) Torque for two nuts that hold the axle to the
chassis………...…..….488 ± 27 N∙m (360 ± 20 lb∙ft)

Systems Operation
General Information
2 3
4
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 the bevel gear set to the differential.
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 yoke of
drive axle(1).
The transmission has two hydraulically operated clutch
packs that are spring released.
The transmission has one speed in forward and one
speed in reverse.
Power Train 15 Systems Operation

Transmission and Drive Axle 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
Torque Converter 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
(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
4 stator.
The hub, which is part of impeller (3), fits into the

2 transission oil pump. The turning impeller (3) rotates
the pump to supply oil for the operation of the torque
converter and transmission
When the engine is turning, oil flows through the

converter to lubricate and cool it. With the
transmission in neutral, the impeller, turbine, stator
6
and oil are all turning together in a direct fluid coupling.
The turbine/impeller speed ratio is 1/1.
Once a direction is selected the direct fluid coupling no

longer exists, the turbine/impeller speed ratio changes
5 (the turbine will be turning slower than the impeller).
When this happens the impeller outlet pressure to
turbine inlet pressure changes. This causes the oil
flow in the torus (fluid path containing the impeller,
turbine and stator) to gain momentum.
1
As impeller (3) turns, it increases the energy state of
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
3 absorbed by turning the turbine. The pressure and
flow change in the torus becomes torque and speed at
the turbine and transmission input shaft.
Oil follows the turbine blades inward toward the center

Torque converter of the converter. When the turbine/impeller speed ratio
(1) Turbine. (2) Stator. (3) Impeller. (4) Housing. is less than .85/1, oil is directed against the concave
(5) Stator support. (6) Stator clutch. side of stator (2) with enough force to stop its one way
rotation and lock the freewheel clutch.
There is no direct mechanical connection between Most of the energy from the oil that strikes the turbine
engine and the transmission. Power from the engine is is used to turn the turbine, but some energy is left over.
transferred through the torque converter, which Torque multiplication comes about because the locked
hydraulically connects the engine to the transmission. stator (2) directs this left over oil back to impeller (3) in
Transmission drive train oil is used to turn the turbine the same direction as the impeller rotation. This
and transmission input shaft. energy force of the oil increases the torque on the
turbine and transmission input shaft. During operation,
When the lift truck works against a load, the torque this cycle is repeated over and over.
converter can multiply the torque from the engine and
send a higher torque to the transmission. Without the stator, oil leaving the turbine is travelling in
a direction that is against impeller rotation. Torque
multiplication is only possible because of the stator.

Transmission
11
9A 2
3 10
1 4
9
16
5A
6
14
5
15
14A
8 7 13
12
(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. (16) Axle Lubrication Pump.
The Transmission consists of 3 sections: which is in mesh and drives the output gear, when
the forward clutch (8) is closed.
a) TC housing (1) which contains torque converter (4)
and the oil pump (6) and its housing. Tangs on the The reverse shaft (9) carries the reverse shaft gear
TC neck engage in and drive the pump. (9A), the reverse clutch (10) and the reverse gear (11)
which is in mesh and drives the output gear (12) when
b) Bearing plate (2) which contains the rear bearings the reverse clutch (10) is selected.
of input, reverse shaft and output gear and the oil The quill shaft (14) is splined to the torque converter
supply channels. The oil channels are sealed by and therefore rotates with engine speed and direction.
the front TC housing wall. A coupling (14A) connects the PTO pump (15) to the
quill shaft (14).
c) Transmission housing (3) containing input shaft (5), The axle lubrication (16) pump engages in and is
forward clutch (8), forward gear (7), reverse shaft driven by the reverse shaft. It always operates when
(9), reverse clutch (10), reverse gear (11), output the engine rotates, but rotating speed varies with
gear (12) and parking brake. The input shaft torgue converter output.
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),

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 Cooler
TC
Relieve
Valve
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.
High temperatures can be caused during repeated
shifting of the lift truck.

Drive Axle
88
10
10
3 99
77
11
11 66 12
12
22 5,5A,5B,5C
5,5A,5B,5C
11
11
11
66 12
12
77
3
99
88
10
10
(1) Axle Housing. (2) Carrier (3) Brake Housing Left/Right. (4) Pinion. (5) Crown wheel/differential.
(6) Drive Shaft Left/right. (7) Ring Gear/Hub. left/right. (8) Pneumatic Tire Wheel Flange Left/right. (9) Multi-disc brake left/right.
(10) Spindle. (11) Axle Mounting Pads. (12) Mast Mounting Hooks.
The Axle Consists of 4 main sections c,d) Hub section left and right with ring gear (7), wheel
flange (8), spindle (10) and multi-disc brake (9).
a) The carrier housing (2), pinion (4) and crownwheel Wheel flange (8) used with pneumatic tire trucks only.
with differential assembly (5).
b) The axle housing with left and right drive shaft (6),
mounting pads (11) and mast mounting hooks (12).

Axle power flow
Power is transmitted by the transmission output shaft

to the pinion (4) which meshes with and drives the
crownwheel (5), which is mounted to the differential.
The differential is part of the drive axle. It is a single When the lift truck moves in a forward direction and
reduction unit with a differential drive gear fastened on there is the same traction under each wheel, torgue in
the differential case. each axle and pinion gears (5B) are balanced. Both
left and right axles roatate the same. During a turn, the
The differential is used to send the power from the force(traction) that is on the drive wheels is different.
transmission to the wheels. When one wheel turns These different forces are also felt on opposite sides
slower than the other, the differential lets the inside of the differential and cause pinion gears (5) to turn.
wheel stop or turn slower in relation to the outside The rotation of pinion gears (5) stops or slows the
wheel. inside wheel and lets the outside wheel go faster. This
moves the machine through a turn under full power.
Differential case (5A) has four differential pinion gears The differential gets lubrication from oil thrown about
(5B) on the differential pinion shaft. The pinion gears inside the housing.
are engaged with two side gears (5C). The side gears
are splined to the axle shafts.

Axle Lubrication Schematic
PUMP
PUMP 22
3
3 11 33
The axle is lubricated by means of the transmission-

mounted lubricant pump (2) which gets oil from the
axle suction port (1) and supplies it to the hub section
pressure parts (3) to lubricate and cool hub drive and
multi-disc brakes.
Oil returns to the sump through the drive shaft
bearings and axle housing.

Hydraulic System
(1) Transmission Oil Sump. (2) Oil Pump. (3) Primary Filter. (4) Main Valve. (5) Orifice. (6) Inching Valve. (7) Modulating Valve.
(7A) Load Piston. (7B) Modulating Valve Orifice. (8) Selector Valve. (9) Solenoid Valve Forward. (10) Solenoid Valve Reverse.
(11) Forward Clutch. (12) Reverse Clutch. (13) Relief Valve. (14) Torque Converter. (15) Relief Valve. (16) Converter Bypass.
(17) Oil Cooler. (18) Torque Converter Supply Bypass.

Transmission Hydraulic System
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.
4
Pump, Filter, Torque Converter And Oil Cooler
Systems
6 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.
7
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 .
8
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
10 9 thick, a bypass valve in the filter will open. The
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
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
The basic components of the hydraulic system for valve (13) protects the torque converter from oil
operating the transmission are transmission oil sump pressure higher than 670 kPa (97 psi), such as during
(1), oil pump (2), primary oil filter (3), valve block, cold oil start-ups. At this pressure, the oil is released
containing main valve (4), orifice (5), inching valve (6), back to the reservoir. Converter inlet passage has
modulating valve (7), selection valve (8), forward and converter bypass orifice (16). The purpose of this
reverse solenoid valves (9,10), forward clutch (11), orifice is to prevent too much of a pressure load on the
reverse clutch (12), torque converter (14) with relief torque converter by allowing some of the oil to bypass
valves (13,15), bypass (16) and oil cooler (17). the converter. In converter outlet passage, there is
cooler bypass valve (15). Cooler bypass valve (15) will
The pump is located in the torque converter housing, release oil back to the reservoir if the oil pressure
and valve block is located on top of transmission, the reaches 400 kPa (58 psi). This can happen if the oil
filter is located on the right hand of the transmission cooler has a restriction or if the oil is cold and thick.
housing.

Neutral Position When the transmission is in NEUTRAL position with
the engine running, oil is pulled from reservoir and the
Transmission Hydraulic System-Neutral 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
(1) Transmission Oil Sump.
lubricate the torque converter during hot, low speed
(2) Oil Pump. conditions.
(3) Primary Filter.
When the pump pressure reaches 895 kPa (130 psi),
(4) Main Valve. relief valve spool (4A) will move to the left side and
most of the pressure oil flows to the torque converter.
(5) Orifice.
(6) Inching Valve. Spool will move left and right to maintain 895 kPa (130
psi). Oil can also bypass the torque converter through
(7) Modulating Valve. converter bypass orifice (16). The purpose of orifice
(7A) Load Piston. (16) is to prevent too much of a pressure load being
put on the torque converter.
(7B) Modulating Valve Orifice.
Oil flows from the torque converter through a passage
(8) Selector Valve.
to oil cooler (17). Oil then flows back to transmission to
(9) Solenoid Valve Forward. cool and lubricate the clutches and shaft bearings.
(10) Solenoid Valve Reverse. In NEUTRAL position, the remaining pressure oil flows
(11) Forward Clutch. from main relief valve (4) to inching valve (6).
Without inching (inching pedal up and valve in), oil
(12) Reverse Clutch. flows around and through the center of spool (6A) to
(13) Relief Valve. the bottom of the spool. The oil, at the bottom, pushes
the spool to the position shown. Oil flows around the
(14) Torque Converter. lands of the spool and through a passage to
modulating valve (7).
(15) Relief Valve.
(16) Converter Bypass. In NEUTRAL position, forward solenoid (9) and
reverse solenoid (10) are OFF. Pump oil flow is
(17) Oil Cooler. blocked at the solenoids. Oil cannot flow through oil
(18) Torque Converter Supply Bypass. 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,
Transmission Hydraulic System-Forward 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
(2) Oil Pump. (6). Without inching (inching pedal up and valve in), oil
flows around and through the center of reducing spool
(3) Primary Filter.
(6A) to the bottom of the spool. The oil, at the bottom,
(4) Main Valve. pushes the spool up to the position shown. Oil flows
around the lands of the spool and through a passage
(5) Orifice. to modulating valve group (7).
(6) Inching Valve.
In FORWARD, forward solenoid (9) is ON, so pump oil
(7) Modulating Valve. is sent to the forward selector spool through oil
(7A) Load Piston. passage. Forward selector spool (8A) moves to the
right, causing reverse selector spool (8B) to move to
(7B) Modulating Valve Orifice. the right also.
(8) Selector Valve.
With the reverse spool in this position, reverse clutch
(9) Solenoid Valve Forward. (12) is open to drain, Forward selector spool (8A)
opens forward clutch (11) to pump oil. This also opens
(10) Solenoid Valve Reverse. reverse selector spool (8B) to drain through oil
(11) Forward Clutch. passage. Forward clutch (11) will fill with pump oil.
Once filled, oil pressure begins to build up. Pump oil
(12) Reverse Clutch. goes through orifice (7B) and moves load piston (7A)
(13) Relief Valve. to the left as pump pressure increases. Oil pressure
increases as the load piston moves further to the left.
(14) Torque Converter. The pressure increases to the control pressure of 895
kPa (130 psi). Forward clutch (11) will now be fully
(15) Relief Valve.
engaged. Modulating valve assembly (7) will now
(16) Converter Bypass. shuttle between pump oil and drain to maintain clutch
pressure. Clutch fill time takes 0.4 seconds and
(17) Oil Cooler. pressure increase takes 0.7 seconds. This
(18) Torque Converter Supply Bypass. approximate 1.1 second clutch fill and pressure rise
time, gives a cushion engagement of forward clutch
(11).

Reverse Direction When the transmission is in REVERSE, the oil flow
from the reservoir, through the pump, primary filter,
Transmission Hydraulic System-Reverse 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
(2) Oil Pump. (6). Without inching (inching pedal up and valve in), oil
flows around and through the center of reducing spool
(3) Primary Filter.
(6A) to the bottom of the spool. The oil, at the bottom,
(4) Main Valve. pushes the spool up to the position shown. Oil flows
around the lands of the spool and through a passage
(5) Orifice. to modulating valve group (7).
(6) Inching Valve.
In REVERSE, reverse solenoid (10) is ON, so the
(7) Modulating Valve. pump oil is sent to the reverse selector spool through
(7A) Load Piston. an oil passage. Reverse selector spool (8B) moves to
the left, causing forward selector spool (8A) to move to
(7B) Modulating Valve Orifice. the left also.
(8) Selector Valve.
With the forward selector spool in this position, forward
(9) Solenoid Valve Forward. clutch (11) is open to drain. Reverse selector spool
(8B) opens reverse clutch (12) to pump oil. This also
(10) Solenoid Valve Reverse. opens forward selector spool (8A) to drain through
(11) Forward Clutch. passages. Reverse clutch (12) will fill with pump oil.
Once filled, oil pressure begins to build up. Pump oil
(12) Reverse Clutch. goes through orifice (7A) and moves load piston (7A)
(13) Relief Valve. to the left as pump pressure increases. Oil pressure
increases as the load piston moves further to the left.
(14) Torque Converter. The pressure increases to the control pressure of 895
kPa (130 psi). Reverse clutch (12) will now be fully
(15) Relief Valve.
engaged. Modulating valve assembly (7) will now
(16) Converter Bypass. shuttle between pump oil and drain to maintain clutch
pressure. Clutch fill time takes 0.4 seconds and
(17) Oil Cooler. pressure increase takes 0.7 seconds. This
(18) Torque Converter Supply Bypass. approximate 1.1 second clutch fill and pressure rise
time, gives a cushion engagement of reverse clutch
(12).

Forward Direction During Inching When the transmission is in FORWARD (or
REVERSE) during INCHING, the oil flow from the
Transmission Hydraulic System-Forward Inching reservoir, through the pump, filter, torque converter
and oil cooler circuits will be the same as explained in
NEUTRAL position.
(2) Oil Pump. Oil will flow from the main relief valve through a
passage, to inching valve (6). Inching valve (6) lets the
(3) Primary Filter.
operator control the oil pressure to forward clutch (11)
(4) Main Valve. between 280 and 0 kPa (40 and 0 psi), which permits
a partial engagement of the clutch. Through the use of
(5) Orifice. the inching valve, the lift truck can move slowly while
(6) Inching Valve. the engine is at higher speeds. This lets the operator
move the lift truck slowly up to a load while the mast is
(7) Modulating Valve. raised rapidly.
(7A) Load Piston.
When the operator pushes the inching pedal part of
(7B) Modulating Valve Orifice. the way down, inching plunger (6B) moves out of the
inching valve. This takes away some of the spring
(8) Selector Valve.
force between plunger (6B) and reducing spool (6A). It
(9) Solenoid Valve Forward. also removes the balance condition between the pump
pressure, at the bottom of spool (6A), and the spring
(10) Solenoid Valve Reverse. force.
(11) Forward Clutch. Reducing spool (6A) moves to the right, which
causes a restriction for the pump oil flow. The
(12) Reverse Clutch. pressure drops from 895 kPa (130 psi) to 280 kPa (40
(13) Relief Valve. psi). The pressure can drop further depending on the
position of plunger (6A). Pressure reduces as plunger
(14) Torque Converter. (6A) is moved out (as the inching pedal is pushed
down).
(15) Relief Valve.
(16) Converter Bypass. This reduced pressure flows to selector valve group
(8). The oil will flow through the valve as explained in
(17) Oil Cooler. forward direction. The reduced (inching) pressure will
(18) Torque Converter Supply Bypass. 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).

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

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
Troubleshooting directions.
4. Remove and check the filter element for loose

Troubleshooting can be difficult. A list of possible particles. Check the strainer behind the
problems and corrections is on the pages that follow. transmission oil plug for foreign material.
This list of problems and probable causes will only a. Particles of friction material give an indication of
give an indication of where a problem can be and what a clutch failure.
repairs are needed. Normally, more or other repair b. Metallic (metal) particles in the filter give an
work is needed beyond the recommendations on the indication of wear or mechanical failure in the
list. Remember that a problem is not transmission and/or axle.
necessarily caused only by one part, but by the c. Rubber particles give an indication of seal or
relation of one part with other parts. This list cannot hose failure.
give all possible problems and probable causes. The
serviceman must find the problem and its source, then If metal or rubber particles are found, all components
make the necessary repairs. of the transmission hydraulic system must be flushed.
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
To prevent personal injury, when testing and transmission and axle oil level.
adjusting the power train, move the machine to an
area clear of obstructions. There must be
adequate ventilation for the exhaust. When drive
wheels are off the ground for testing, keep away Activate the controls for the FORWARD direction and
from wheels that are in rotation. then for the REVERSE direction. The modulation will
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
all noises that are not normal and find their source. If Operate the machine in each direction. Make note of
the operation is not correct, make reference to the noises that are not normal and find their source. If the
troubleshooting chart for "problems" and "probable operation is not correct, make reference to the check
causes". List During Operation for "problems" and "probable
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 38 Testing and Adjusting

Check List During Operation g. Leakage inside the transmission.
Worn or broken metal seal rings on input
Problem: Engine starts with directional control or 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 FORWARD.

Probable cause:
Probable cause:
1. Parking brake switch is defective.
1. Forward clutch is locked up.
Problem: Transmission will not stay in gear when
shifted. 2. Reverse solenoid valve does not actuate.
Probable cause: 3. Reverse clutch components have damage.
1. Parking brake switch mounting is loose. a. Leakage caused by worn or broken metal sea-
ling rings.
Problem: Transmission does not operate in either
direction or does not shift. b. Leakage caused by worn or broken clutch piston.
Probable cause: c. Failure of shaft seal ring.
1. Problems in the electrical circuit (directional con- Problem: Transmission operates only in REVERSE.
trol)
Probable cause:
a. Open circuit between ignition switch and direc-
tional control switch. 1. Reverse clutch is locked up.
b. Defective directional control switch.
2. Forward solenoid valve does not actuate.
c. Defective wiring harness between directional
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
sealing rings
2. Low oil pressure or no oil pressure caused by:
b. Leakage caused by worn or broken seal around
a. Iow oil, no oil or thick oil. clutch piston.
b. Inching control valve linkage loose, broken or c. Failure of shaft seal ring.
adjustment is not correct.
Problem: Transmission gets hot.
c. Inching valve reducing spool stuck open.
Probable cause:
d. Failure of the oil pump or a defect in the oil
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 3. Core of the oil cooler not completely open.
screen.
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

the pump.

7. Low oil flow through converter. Converter relief Check List From Operation Noises
valve stuck open (converter bypass orifice plugged)
Problem: Noise in NEUTRAL only.
8. Incorrect use of vehicle. Loads are too heavy for the
lift truck.
Probable cause:
9. Too much inching operation (slipping the clutch
1. Worn one-way clutch in torque converter.
plates and discs).
2. Low oil level (pump cavitation).
10. Too much stalling of torque converter.
3. Worn bearing next to pump.
11. Cooler relief valve stuck open, full oil flow does
not go through oil cooler.
Problem: Pump noise not normal
Problem: Clutch engagement is slow or loss of
Probable cause:
power during engagement.
1. A loud sound at short time periods gives an
Probable cause:
indication that foreign material is in the
transmission hydraulic system.
1. Low oil pressure
2. A constant loud noise is an indication of pump
2. Air mixed in the oil.
failure.
a. Air leaks on suction side of pump.
Problem: Noise in the Transmission that is not
normal.
b. Low oil level also causes aeration.
Probable cause:
3. Inching valve linkage adjustment is not correct.
1. Transmission components have wear or damage.
4. Modulating valve assembly leaks or partially stuck.
a. Damaged gears.
Problem: Clutch engagement makes a rough shift.
b. Worn teeth or clutch plates and/or clutch discs.
Probable cause:
c. Slipping clutch plates and disc noise.
1. Modulating valve assembly, load piston and/or
reducing valve stuck.
d. Other component parts have wear or damage.
Problem: Vehicle operates in one direction and
e. Failure of the thrust washers.
creeps in that direction in NEUTRAL. Engine stalls
when shifted to the other direction.
2. Modulating valve assembly makes noise.
Probable cause:
Problem: Constant noise in the Drive axle.
1. Failure of clutch in the direction the lift truck moves.
Probable cause:
Clutch discs or plates are warped (damaged) or
held together because of too much heat.
1. Lubricant not to the specific level.
2. Failure of the modulating valve assembly in the
2. Wrong type of lubricant.
direction the lift truck moves. The valve assembly
stuck in the engaged position possibly caused by
3. Wheel bearings out of adjustment or have a defect.
metal burrs (particles) or oil contamination.
4. Bevel gears not in adjustment for correct tooth
contact.
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
4. Thrust washers worn or have damage.
REVERSE clutches.
5. Too much clearance (backlash) between side gears
Probable cause:
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
Probable cause:
Pressure.
1. Loss through hub seals.
a. Lubricant above specification level.
7. Modulating valve assembly stuck.
b. Wrong kind of lubricant.
Problem: Clutch pressure and pump pressure are
high.
c. Restriction of axle housing breather.
Probable cause:
d. Hub oil seal installed wrong or has damage.
1. Main relief valve is stuck.
2. A restriction in the hydraulic circuit.
3. Main relief valve not adjusted properly.

Problem: Pressure to one clutch is low. Problem: High converter charge pressure.
Probable cause: Probable cause:
1. Clutch piston seal alignment is not correct, oil leaks 1. A plugged converter bypass orifice.
through.
2. A restriction inside the converter assembly.
2. Seal rings on shaft or clutch piston seals are broken
or worn. 3. A plugged oil flow passage.
3. Modulating valve assembly stuck. Problem: Low converter charge pressure.
Problem: Low pump pressure. Probable cause:
Probable cause: 1. Converter relief valve stuck open.
1. Low oil level. 2. Main relief valve movement is restricted.
2. Main relief valve movement is restricted. Problem: Low converter outlet pressure or cooler
inlet pressure.
3. Transmission oil pump is worn.
Probable cause:
4. Inner oil leakage.
1. Low oil pressure.
5. Main relief valve not adjusted properly.
2. Cooler relief valve stuck open.
Problem: Low lubrication pressure or no
lubrication pressure. Problem: High converter outlet pressure or cooler
inlet pressure.
Probable cause:
Probable cause:
1. Low oil pressure or no oil pressure caused by:
1. Restriction in oil cooler lines or a plugged oil
a. Failure of the oil pump or a defect in the oil cooler.
pump.
b. Restriction in the oil flow circuit such as a dirty Problem: Low stall speed.
oil screen.
Probable cause:
c. Inching valve reducing spool stuck open.
1. Engine performance is not correct.
d. Leakage inside of transmission caused by com-
ponent defects. 2. The one-way clutch of the torque converter does not
hold.
2. Oil cooler has restriction to oil flow.
Problem: High stall speed in both directions.
Problem: High lubrication pressure.
Probable cause:
Probable cause:
1. Low oil level.
1. Restricted external oil lines or internal passages.
2. Air in the oil.
3. Clutches slip (clutch plates slide in relation to one
another).
4. Torque converter failure.

Problem: High stall speed in one direction. Problem: Modulation spool problems.
Probable cause: 1. Slow or no modulation of both clutches
1. There is a leak in the clutch circuit. (If only 1 clutch does not modulate correctly then
the problem is either with the selector spool or it is
2. There is a failure in that clutch assembly (clutch a problem in the transmission).
slipping). Probable cause:
1. orifice plugged with debris

Problem: Selector spool problems.
2. Modulation valve stuck
1. Transmission stays in neutral, no shift.
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
a. O-rings leaking (cut) 2. Modulation time is too quick

b. O-rings missing Probable cause:
c. Ports not machined properly 1. The upstream orifice (in the oil supply) is not
d. Contamination in solenoid installed. (The orifice is located in the valve block)
e. Electrical problem 2. The load piston is only moving a small amount
3. orifice plugged before it sticks. Check the spool to see if it freely
a. With debris fits in the bore. This check must be made while the
b. Bad part aluminum body is still bolted down to the
4. Modulation valve stuck in "off" position transmission.
5. Modulation valve not correctly assembled. 3. The plastic orifice is not installed or the hole in the
plastic housing is too large.

2. Transmission will not shift into or out of 1 gear
4. The modulating valve is stuck in an open position.
Probable cause:
Check to see if the valve moves freely while the
1. Spools mechanically stuck(same as above)
aluminum body is still bolted down.
2. Solenoids not working(same as above)
5. The springs are not installed or the pin has jammed
3. Valve not correctly assembled(same as above)
the load piston
4. Holes not drilled into case properly
5. Excessive leakage internally in body
a. Porosity in body
b. Selector bore too large
c. Spool too small
d. Slug/spool fit not right.

Transmission and Drive Axle Most problems in the hydraulic circuit can normally be
found when the pump pressure is checked. If more
Tests And Adjustments information is necessary, gauges can be installed at
each pressure tap location. Locations of the pressure
taps and procedures for testing are given as follows. If
Transmission Pressure Tests any of the pressures are not correct, refer to
Troubleshooting For Problems and Probable Causes.
Tools Needed
1. Be sure the transmission control adjustments are
Pressure Gauge Group 1
correct before tests are made.
See Inching Pedal Adjustment in Testing And
Adjusting.
WARNING
2. Install a tachometer to the engine to show engine
To prevent personal injury, when the transmission speed during the test.
is tested, move the truck to a clear area, that is
level. Keep all other personnel away from the lift 3. Put a thermistor probe in place of the dipstick in the
truck. Use lifting equipment or a save method to transmission oil reservoir.
lift the front of the lift truck until the drive wheels
are off the floor. Put wood blocks or jack stands of 4. Remove each of the following pressure tap plugs in
the correct capacity under it to hold it in this the order shown and install the 0 to 2050 kPa (0 to
position while pressure tests are performed. 300 psi) pressure gauge. After the pressure check
is done, remove the gauge and install the plug
again.
When the transmission tests are made, the
transmission oil must be at the correct level. The 5. Check pump pressure with the transmission in
pressure given in the chart are taken with the neutral at pressure tap (6) on the valve body first. If
transmission oil temperature at 49 to 71°C (120 to it is not correct, then check pump pressure at
160°F). If the oil temperatue is lower than 49°C pressure tap (1) on the bearing plate.
(120°F) the oil pressure will be higher than that shown.
If the oil temperature is higher than 71°C (160°F), the a. If the pressure is low at pressure tap (6), but
pressure will be lower than that shown. correct at pressure tap (1), there could be an oil
line restriction or a defective inching valve.
Raise the front of the lift truck off the floor. Put wood
blocks or jack stands of the correct capacity under it to
hold it in this position while pressure tests are NOTE: Pump pressure should be checked at
performed. pressure tap (6) first because pressure tap (6) is
easier to get to than pump pressure tap (1) on the
bearing plate. If pump pressure is correct at
WARNING pressure tap (6), it will be correct at pressure tap
(1) also.
Before any pressure tap plugs or connections are
removed, the engine must be stopped with the b. If the pressure is low at both locations, see
transmission controls in NEUTRAL. This will Problem: Low pump pressure in Troubleshooting.
release hydraulic pressure in the transmission.
NOTE: Pump pressure is adjusted by adding or
removing shims in the D700296 Plug. The plug is
For more identification of transmission problems, the located in the main relief valve on the valve body.
pressures that follow can be checked.
6. Check clutch pressure as follows:
a. Pump pressure in neutral.
a. Check forward clutch pressure at pressure tap
b. Forward clutch pressure in forward. (4) with the transmission in forward. If the
pressure is not correct, see Problem: Low
c. Reverse clutch pressure in reverse. forward clutch pressure in Troubleshooting.
d. Converter charge pressure in neutral. b. Check reverse clutch pressure at pressure tap
(5) with the transmission in reverse. If the
e. Converter outlet or cooler inlet pressure in neutral. pressure is not correct, see Problem: Low
reverse clutch pressure in Troubleshooting.
f. Lubrication pressure in neutral.

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 Converter Stall Test
the transmission in neutral.
NOTE: Make sure that the transmission oil is at the
a. If lubrication pressure is low, see Problem: Low correct temperature for operation before tests are
lubrication pressure in Troubleshooting. made.
b. If lubrication pressure is high, see Problem: The converter stall test is a test to check engine power.
High lubrication pressure in Troubleshooting. It can also be used to locate a problem in the
transmission or torque converter when the condition of
8. Check converter charge (inlet) pressure at pressure the engine is known. An engine, which does not have
tap (3) with the transmission in neutral. correct performance, will give an indication of a stall
speed that is not correct. If the engine performance is
a. If converter charge pressure is low, see correct and the stall speed is not correct, the problem
Problem: in the converter or transmission can be found with this
Low converter charge pressure in test.
Troubleshooting.
NOTE: To check the engine performance, see the
b. If converter charge pressure is high, see respective engine module. This test checks the
Problem: maximum RPM that the engine, at full throttle, can turn
High converter charge pressure in the converter with the turbine held stationary. To hold
Troubleshooting. the converter turbine, engage the brakes with the
transmission in FORWARD or REVERSE.
9. Check converter outlet or cooler inlet pressure at
pressure tap (2) with the transmission in neutral. The drive wheels must not turn during the stall test.
Put a heavy load on the forks. Also put the truck in
a. If the pressure is low, see Problem: Low position against a solid object that will not move (such
converter outlet or cooler inlet pressure in as a loading dock). When the tests are made, the
Troubleshooting. wheel brakes must be engaged with the left foot. The
accelerator pedal can be operated with the right foot.
b. If the pressure is high, see Problem: High
converter outlet or cooler inlet pressure in
Troubleshooting. WARNING
NOTE: Do not activate the inching pedal when Make tests in a clear level area only. There must be
pressure checks are made. Check for the pressures one operator. Keep all other personnel away from
as shown in Transmission Pressure Chart in the order the lift truck. Check the operation of the brakes
that follows: before the tests are made.
Transmission Pressure Chart
Low idle 2000 rpm
Shift position - Neutral
Check the high idle setting before the stall test is made.
Set the high idle to the specification, as given in the
830 to 1030 kPa 895 to 1100kPa
Main Line respective engine module.
(120 to 150psi) (130 to 160psi)
0 kPa 0 kPa
Clutch NOTE: Make sure that the transmission oil is at the
(0 psi) (0 psi)
correct temperature for operation before tests are
14 to 70 kPa 240 to 345 kPa
Lubrication made.
(2 to 10 psi) (35 to 50 psi)
70 to 140 kPa 590 to 795 kPa
Converter Chage 1. Connect a tachometer to the engine. Start the
(10 to 20 psi) (85 to 115 psi)
engine. Engage the wheel brakes with the left foot.
Converter Outlet 25 to 55 kPa 250 to 400 kPa
or Cooler Inlet (4 to 8 psi) (36 to 58 psi)
2. Put the transmission control lever in FORWARD
Shift position – Forward or Reverse and push the accelerator pedal down completely
Main Line - - with the right foot. Read the RPM on the
725 to 860 kPa 725 to 965 kPa tachometer, then release the accelerator pedal.
Clutch
(105 to 125 psi) (105 to 140 psi)
Lubrication - -
Converter Chage - -
Converter Outlet - -
or Cooler Inlet - -

The stall speed must be the same in FORWARD and
REVERSE. If the stall speed is high in FORWARD and
NOTICE REVERSE, check the following:
To make sure that the transmission oil does not a. Check for air in the oil.
get hot, do not hold the transmission in a stall
condition for more than ten seconds. After the b. Check the torque converter and the clutch
transmission is stalled, put the controls in pressures according to transmission Pressure
NEUTRAL and run the engine at 1200 to 1500 RPM Tests in Testing And Adjusting.
to cool the oil.
c. If clutch pressure is correct, make an inspection of
the clutch assembly for that direction for possible
damage to clutch components.
3. Repeat the procedure above for the REVERSE
direction.
4. The stall speeds for the different trucks are listed

in the charts that follow:
Engine
LIFT TRUCK STALL SPEED
Max.RPM
RPM±100 RPM±100
Engine Without Power With Power -
Brakes Applied Brakes Applied
DB33A 1778 1678 2450±50
B3.3 1830 1730 2450±50
Hercules
1633 1533 2500±100
2.7 LP
Hercules
1633 1533 2500±100
2.7 Gas
Hercules
1520±75 1420±75 2500±100
2.7 Dual
MMC
1830 1730 2700±50
G424 LP
MMC
1890 1790 2700±50
G424 Gas
MMC
1740±75 1640±75 2700±50
G424 Dual
GM
1750 1650 2600 ± 50
G430 LP
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 and Drive Axle
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.

Drive Axle
Combined Oil Filler and

Dipstick
Brake Cooling Port
Pump Suction Port Brake Cooling Port

Oil Drain Plug Port
ATTENTION : Clean suction strainer when replacing oil.

Electric Control System Tests Power To 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 assembly.
Digital Multimeter 1
2. Disconnect harness connector (2) from directional
NOTE : Refer to Schematic. control switch connector(1).
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.
1
A beginning check of the direction control system
should be performed before testing the individual
2
components and wiring
harness. When the direction solenoids are energized
they become magnetized. By holding a metal
screwdriver next to the solenoids it can be
determined whether they are energized or not. Directional Control Switch Connector
(1) Directional Control Switch Connector.
Turn the ignition switch ON, DO NOT start the engine. (2) Harness Connector.
Release the parking brake. Place the
direction control switch in forward and check the
forward solenoid for magnetism. Do the same for the 3. Engage the parking brake and turn the ignition
reverse direction. switch ON, DO NOT start the engine. Put the
multimeter on the 20 volt range.
z If the solenoids didn’t energize begin testing the
control system with step 1.
z If the solenoids did energize, go to step 10.
Power To Directional Control Switch Check

(2) Harness Connector.
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.

Directional Control Switch Check
5. Turn the ignition switch OFF and put the

multimeter on the 200 ohm range.
6. Check continuity between pins 4 and 7 of

connector (1) with the switch in neutral. forward
and then reverse positions. There should be
continuity in neutral and no continuity in forward
and reverse.
a. If the above checks are correct, do Step 7.
b. If any of the above checks are not correct, replace

the directional control switch.
Directional Control Switch Continuity Check

(1) Directional control switch connector.
7. Check continuity between pins 1 and 2 of

connector (1) in forward and then neutral position.
There should be continuity in forward and no
continuity in neutral. While the continuity is
checked in forward position, move the lever back
and forth (but stay in forward position) to see if the
resistance goes up or down. The resistance should
be constant.
a. If the above checks are correct, do step 8.
b. If the above checks are not correct, replace the

directional control switch.
8. Check continuity between pins 1 and 3 of connector

(1) in reverse and then neutral positions. There
should be continuity in reverse and no continuity in
neutral. While the continuity is checked in reverse
position, move the lever back and forth (but stay in
reverse position) to see if the resistance goes up or
down. The resistance should be constant.
a. If the above checks are correct, do Step 9.
b. If any of the above checks are not correct, replace

the directional control switch.
2 1
3 4
Transmission Directional Control Schematic

(1) Directional Switch Connector. (2) Connector- Instrument Harness (3) Main Connector-Instrument Harness
(4) Main Connector-Engine Harness

Transmission Control Harness Check Inching Pedal Adjustment
3 To check the inching valve adjustment and operation,
do the procedure that follows :
WARNING
When this procedure is used, the lift truck must be
in an area clear of obstructions. There must be
one operator with all other personnel away from
the lift truck. Check the operation of the brakes
5 before the test is made.
Transmission Control Harness.

(3) Harness. (5) Connector
1. With the engine at idle speed, put the transmission
9. Disconnect the connector (5) of Engine harness in FORWARD.
from the connector of transmission harness.
Check continuity of socket 12, 13 of engine
harness (3) from one end to the other. Repair or
replace the wiring harness if there is no continuity.
Transmission Solenoids Visual Check
10. A visual check can be done to see if the solenoid

plungers are moving.
Remove the modulating valve assemblies from the
transmission 1
11. Turn the ignition switch ON, DO NOT start the

Inching Operation Test
engine. Release the parking brake.
(1) Inching pedal.
12. Put the directional control switch in neutral.

2. Slowly push down on inching pedal (1) until the
movement of the brake pedal causes the brake
z Both solenoid plungers should be flush with the
discs to make contact (small drag) with the brake
solenoid.
plates.
3. Increase the engine speed to high idle. The truck

13. Put the directional control switch in forward and
must not move.
then reverse.
If the operation of the inching valve is not correct, do

z The plunger of the solenoid that is activated should
the procedure that follows.
move in approximately 3.18mm(.125 in).
1. Adjust and bleed the wheel brakes as shown in the

14. If the solenoid plungers do not move as explained
Vehicle Systems module.
in Steps 12 and 13, replace the defective solenoid.
15. If the solenoid plungers are good, the modulating

valves could be stuck or there is mechanical failure
in the transmission.

WARNING
To prevent personal injury, when the inching pedal
is adjusted, move the truck to a clear area that is
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
off the floor. Put wood blocks or jack stands of the
correct capacity under it to hold it in this position
while the inching pedal is adjusted.
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.
Inching Pedal Adjustment

(1) Inching pedal. (2) Lug. (3) Bolt. (4) Nut.
3. Start the engine and put the transmission

FORWARD.
4. With the drive wheels turning, depress inching pedal

(1) until the drive wheels stop.
5. Now depress the brake pedal until disc contact is

felt.
6. Loosen nut (4) and adjust bolt (3) to contact lug (2)
that rotates the brake control cross shaft. Tighten
nut (4).
7. Check the inching valve operation again.

Adjustments on Drive axle and 4. Calaulate the shimpack thickness according to the
following formula.
Transmission Shimpack thickness = A-(127+B+C)
Example) if A=160.50, B=32.00, C=+0.05
Then, shimpack thickness
Axle, Pinion, crown gear =160.50-(127+32.00+0.55) = 1.45mm
* To minimize the measuring error, measure

three places at least and average them.
1. Measure the depth from center of diff. carrier to the

seat of pinion bearing cup. (Dimension A)
5. Shims of calculated thickness laid into bearing seat.
2. Measure the width of pinion bearing.(Dimension B)
6. Install bearing cup.
3. Check the etched value on the pinion face.

(Dimension c)
*unit : mm
7. Install crown gear, differential assy and lightly

torque bridge bilts.

8. Install bearing nuts for correct bridge position and
11. When drag is correct, mark position of nuts both on
lightly torque them to achieve bearing preload.
nuts and bridge.
9. Tap on differential on both sides to achieve correct

12. After marking of position remove differential assy.
bearing cone position, rotate differential (3-5 times).
10. Check drag 19.6 N.m (14.5 lb.ft) on rotating

differential.

Installation of Pinion
4. Tap bearing cone to correct position(Rotate pinion

3-5 times)
1. Install cup of rear pinion bearing
5. Assemble yoke and nut and tighten flange nut to

180 ±15 N∙m (133±11 lb∙ft)
2. Install spacer and shims on pinion (basic thickness
1.5mm (0.059 in)).
6. Measure the rolling torque. The value of rolling

torque should be 1.5~2.0 N∙m (1.1~1.5 lb∙ft)
3. Install bearing cone.
7. If the rolling torque exceeds 2 N∙m, add one shim
and if it is lower than 1.5 N∙m, subtract one shim
8. When the adjustment is correct, disassemble the

nut and the yoke.
Assemble the oil seal and yoke again and then
tighten the nut to 180 ±15 N·m (133±11 lb·ft)

Adjustment of Crown Wheel
3. Tap on both sides of the differential to achieve

correct position of bearing cups.
1. Torque crown wheel bolts to 80 N·m (59 lb·ft).
4. Check backlash between pinion and crown gear in 3

different positions. Backlash shall be 0.15-0.25mm
2. Install differential assy., to previously mounted (0.006-0.010 in)
position (rotate both nuts simultaneously to maintain
bearing preload).
5. Check contact face by rotating pinion in both

directions, hold back crown wheel.

6. Check contact area position and correct in
9. Position not correct.
accordance with specification if neccessary.
10. After correct adjustment of contact area secure

7. Position not correct differential nut with cotter pin.
8. Correct position.

Adjustment of Wheel Bearings
4. Remove wheel nut for lockwasher installation.
1. Assemble outer hub bearing without lockwasher.
5. Install lockwasher and nut.
2. Tighten wheel nut to 135 ± 14 N·m (100±10 lb·ft).
6. Tighten nut to 50 ±5 N·m (37±3 lb·ft).
3. Tap on and rotate hub 3-5 times to achieve correct

bearing position

SB2103E01
Jan.2004
Disassembly &
Assembly
Lift Trucks Power Train
D20S-3, D25S-3, D30S-3, D32S-3
D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3),
D32S-3(B3.3), D33S-3(B3.3)
G20S-3, G25S-3, G30S-3
GC20S-3, GC25S-3, GC30S-3
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
G20P-3, G25P-3, G30P-3, G32P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
WARNING
in injury or death.
publication.
available.
1
Index
Transmission
Assembly Input Shaft ...............................................16
Assembly Output Shaft ............................................19
Assembly Reverse Shaft..........................................11
Assembly Transmission Housing .............................20
Disassembly / Assembly Valve Body .......................26

Disassembly Input Shaft ..........................................14
Disassembly Output Shaft........................................19
Disassembly Reverse Shaft .......................................9
Disassembly Transmission Housing ..........................5
Drive Axle
Adjustment Bevel Pinion ..........................................37
Adjustment Disassembly /
Assembly of Bevel Pinion.........................................39
Assembly Bevel Pinion.............................................39
Assembly Carrier Diff ...............................................45
Assembly Crown wheel/Adjustment .........................42
Assembly Shaft As ...................................................31
Disassembly / Assembly Brake Parts.......................32

Disassembly / Assembly Differential ........................40
Disassembly / Assembly Hub Drive Axle..................33
Disassembly / Differential Assembly ........................34
Disassembly Axle .....................................................27
Disassembly Bevel Pinion ........................................35
Disassembly Shaft As...............................................31
Special Service Tools ...............................................51
WARNING
Disconnect batteries before performance of any
service work.
Power Train 3 Index

Disassembly
Transmission Housing
IDCD504P
4. To remove the torque converter housing,

loosen the upper housing screws.
(Hexagonal socket 17 mm)
IDCD501P
1. Mount the transmission on a suitable jig.
IDCD505P
5. Loosen the lower housing screws.

IDCD502P (Hexagonal socket 17 mm)
2. Disconnect valve body, loosen the screws (1) with 4

socket head wrench 8 mm.
ATTENTION: Loosen bolts from outside to inwards!
IDCD506P
3
6. Install 2 jackbolts (M10, 30mm (1.2in)) in locations
2 (4) until they stop against bearing plate,
alternately tighten bolts to separate the torque
converter housing from the transmission.
IDCD503P
3. Remove the Gasket (2) and oil dipstick (3).
Power Train 5 Disassembly & Assembly

IDCD507P IDCD510P
7. To remove strainer, loosen the screw with an allen 10. Remove the remaining screws between the T/M
head wrench. bearing plate and the torque converter housing.
(Hexagonal socket 17 mm).
IDCD508P
IDCD511P
8. Lift the torque converter housing from the T/M

bearing plate. 11. Secure the eyebolts M10 to remove the T/M
bearing plate.
IDCD509P
IDCD512P
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
IDCD513P IDCD516P
16. Remove the output shaft.

13. Turn the adjustment bolt until the strut (1) can be
removed from the brake band.
IDCD517P
IDCD514P
17. Remove the input shaft with forward clutch.
14. Remove the brake struts from the eccentric shaft.
IDCD518P
IDCD515P
18. Use the eyebolt M18 to lift the reverse shaft.
15. Lower the loosened brake band into the housing.

Remove after dismounting the shaft.

IDCD592P
19. Remove the lube pump. (Hexagonal socket 13

mm)
IDCD593P
20. Lift the lube pump with 2 screw drivers.

Disassembly
Reverse Shaft 1
IDCD524P
4. Remove the snap ring (1) from the support disk

with the circlip pliers.
IDCD521P
1. Disassemble the shaft with the 2-leg puller.
IDCD525P
5. Lift the multiple disk body.
IDCD522P
2
2. Remove the safety ball from the seat with a screw
driver.
IDCD526P
6. Remove the snap ring (2) while pressing the

return spring on the spring retainer with a
IDCD523P hydraulic press. Slowly relieve the tension of the
spring. (Tool Ref. No 1)
3. Remove the double needle bearing.

1
2
3
IDCD527P IDCD530P
7. Remove the parts - snap ring (1), spring 10. ATTENTION: Open the R-rings before lifting!
retainer(2) and return spring (3)
IDCD531P
IDCD528P
11. Remove the bearing from the shaft with a 2-leg

8. Lift the piston by using compressed air in the puller.
lower bore.
IDCD529P
9. Remove both R-rings before lifting the bearing (4).

Assembly
Reverse Shaft
IDCD535P
15. Inner and outer piston rings must be lubricated

IDCD532P
with transmission oil.
12. Heat bearing (1) to a temperature of 120°C

(248°F) and install it on the shaft.
IDCD536P
16. Insert the piston.

IDCD533P
ATTENTION: Canting the piston can cause damage.
13. After the bearing has cooled, the inner bearing

ring must be tapped into position.
4
2
IDCD537P
IDCD534P
17. Install return spring (3), spring retainer (4) and
snap ring (5).
14. Install both R-rings (2) in their grooves.

1
IDCD538P IDCD541P
18. Install snap ring (1) by pressing the return spring. 21. Align the teeth of the clutch disks.
(Tool Ref. No 1)
2
3
5
IDCD542P
IDCD539P 4
22. Install the needle bearing.

19. Elements of the multiple disk body: (2) pressure
disk, (3) inner separater disks, (4) outer clutch
disks, (5) support disk
IDCD543P
IDCD540P 23. Put the gear wheel on the shaft.
20. Put the multiple disk body on the gear and install
the snap ring.

4
IDCD544P IDCD547P
27. Heat bearing (4) to a temperature of 120°C

24. Lubricate the needle bearing before installing the
(248°F) and install it on the shaft.
washer.
IDCD548P
IDCD545P
28. After cooling the bearing, the inner bearing ring

25. After installing the washer (1), put the ball (2) in
must be tapped to set bearing.
the hole.
3 5
IDCD549P
IDCD546P
29. Install the R-ring (5).

26. Install the steel-washer (3).
ATTENTION: The ball must engage the notch!

Disassembly
Input Shaft
IDCD553P
4. Remove the ball from the seat with a magnet.
IDCD550P
4
1. Disassemble the shaft with a 2-leg puller.
Remove R-ring before lifting the bearing.
2
IDCD554P
3
5. Remove the double needle bearing (4) and the
brass washer (5).
1
6
IDCD551P
2. After lifting the gear wheel (1), remove bearing (2)

and washer (3).
IDCD555P
6. Remove the snap ring (6) from the support disk

with the circlip pliers and remove the disks.
IDCD552P
3. Lift the gear wheel.

1
IDCD556P IDCD530P
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)
IDCD559P
IDCD557P 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.
IDCD558P
9. Remove both R-rings before lifting the bearing.

Assembly
Input Shaft
IDCD563P
15. Insert the piston.

ATTENTION: Canting the piston can cause damage.
1
IDCD560P 2
12. Ring (1) and inner needle bearing (2).
IDCD564P
16. Install snap ring by pressing the return spring.

(Tool Ref. No 1)
IDCD561P
13. Drive the ring and bearing with an puncher

(Ø25mm, length 400 mm) (Ø 1.0 in X 15.75 in
length) into the shaft.
IDCD565P
17. Put the multiple disk body on the gear.
IDCD562P
14. Inner and outer piston rings must be lubricated

with the transmission oil.

1
IDCD566P IDCD569P
18. Mount the snap ring (1) on the support disk with 21. Align the teeth of the clutch disks and put gear
the circlip pliers. wheel on the shaft.
IDCD567P IDCD570P
19. Lubricate the support disk area. 22. Lubricate the washer.
IDCD571P
IDCD568P
23. Put the ball in the hole of the shaft and the notch
20. Install the washer and needle bearings. in the washer.
ATTENTION: The ball must engage the notch!

1
IDCD572P IDCD575P
24. Heat bearing (1) to a temperature of 120°C 27. Install the heated back bearing (120°C, 248°C) on
(248°F) and install it on the shaft. the shaft.
IDCD573P IDCD576P
25. Install the bearing on the shaft. 28. After mounting and cooling, the inner bearing ring
must be tapped into position.
IDCD574P
IDCD577P
26. After the bearing has cooled, the inner bearing

ring must be tapped into position. Install the R-ring. 29. Mount and hook the R-ring (2).

Disassembly Assembly
Output Shaft Output Shaft
IDCD578P
IDCD580P
1. ATTENTION: Set the puller on the inner bearing 3. Heat bearing (1) to a temperature of 120°C
ring! (248°F) and install it on the shaft.
IDCD579P
IDCD581P
2. Remove the shaft with suitable puller device.

This can be done from either end of shaft. 4. After cooling, the inner bearing ring must be
tapped into position.

Assembly
Transmission Housing
IDCD585P
4. Mount the brake band.
IDCD582P
1. Mount the parking brake adjustment bolt. 1
IDCD586P
5. Mount the snap ring of the park brake lever (1).
IDCD583P
2. Eccentric shaft for parking brake.

Check the free-movement. 2
IDCD587P
6. Oil Seal of output gear wheel (2) must be set flush

with the housing surface.
IDCD584P
3. Check the bearing parts for damages.

Be sure all surfaces are clean.

IDCD588P IDCD591P
7. Install the reverse shaft. 10. Assemble the struts for the parking brake band.
Adjust after assembly.
11. Install each bearing cup on the reverse shaft

assembly and the output shaft assembly.
Bearing Plate
B B’
Reverse Output
Shaft Shaft
A A’
IDCD589P
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 bearing of each
IDCD590P shaft, reverse and output (B or B’ dimension)
* For the output shaft, measurement should be

9. Install output shaft last.
done with the cover installed
Check for free rotation.
14. Caculate the required shimpack thickness (Z) with
the following formula.
Z = B-A+(0.05~0.08mm) or (0.002~0.003in)
For reverse shaft
= B’-A’+(0.05~0.08mm) or (0.002~0.003in)
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.

1
4
IDCD594P IDCD597P
16. Valves in the bearing plate consist of: ball(1), 19. Tap the bearing plate into position over dowel pins
spring(2), seal ring (3) and plug (4). and tighten all bearing plate mounting bolts.
Tighten the plug with allen head wrench 6 mm.
IDCD598P
IDCD595P
20. Using a punch, tap bearing cone down against
input shaft. Install bearing cup against cone in the
17. The housing areas must be cleaned and same manner.
degreased. Apply sealing compound (LOCTITE
17430) to coat on one side. ATTENTION: Check for free rotation.
IDCD596P IDCD599P
18. Lower the bearing plate. 21. Measure the depth of the bearing cup below
bearing plate surface at three places.
Average this dimension and record as Dim. A

IDCD600P IDCD510P
25. Assemble the lube pump with screws M8, torque

22. Measure the height of pump pilot surface above
32 ± 3 N·m (23.5 ± 2.0 lb·ft) (Hexagonal socket 13
mounting surface at three places.
mm).
Average this dimention and record as Dim. B.
IDCD604P
IDCD601P
26. Tap the outer front bearing ring back.

23. Select shim thickness by subtracting B Dim. from
A Dim. Shim thickness = A-B+0.0-0.05mm (+0.0-
0.002 in)
IDCD605P
IDCD602P 27. Check the shaft end play by moving the shaft up
and down.
Dial indicator should not exceed 0.05mm
24. The sealing area of the lube pump must be
(0.002 in)
cleaned and degreased. Apply sealing compound
(LOCTITE 17430) to pump flange.

IDCD606P IDCD609P
28. The housing areas must be cleaned and 31. Install the housing screws with a torque of
degreased. Apply sealing compound (LOCTITE 55 ± 5 N·m (41 ± 4 lb·ft).
17430) on one side of bearing plate.
IDCD610P
IDCD607P
32. Install the oil filter screen.

29. Before joining torque converter housing to bearing Tighten the plug with an allen head wrench.
plate, apply lubricant to lube pump ring.
IDCD611P
IDCD608P
33. Install the torque converter.

30. Install the torque converter housing.

IDCD612P
34. Mount the valve block.
ATTENTION: Tighten the screws from inner to outer

with the tightening torque of 45 ± 3 N·m (33 ± 2.2
lb·ft).

Disassembly/Assembly
Valve Body
IDCD616P
4. Dismount / mount the selection valve.
IDCD613P
1. Dismount/mount the solenoid valves of the

forward and reverse clutch.
IDCD617P
5. Dismount the modulation valve with an allen head

wrench.
IDCD614P
2. Dismount / mount the main valve.
IDCD618P
6. Dismount / mount the modulation valve.
IDCD615P
3. Dismount / mount the inching valve.

Disassembly
Axle
IDCD619P
7. Tighten the screw to fix the inner working piston of

the inching valve
IDCD621P
1. Poision the axle on a suitable support.
IDCD620P
8. Adjust the main pressure with the shims in the

screw of main valve
IDCD622P
2. Remove the disk brake adapter.
IDCD623P
3. Remove the cover-end

(Hexagon socket 13 mm)

IDCD624P IDCD627P
4. Loosen the end cover with a plastic hammer 7. Remove the gear cover.
before removing.
IDCD628P
IDCD625P
8. Loosen the gear cover by using a plastic hammer.

5. Remove the friction disks and separater disks.
IDCD629P
IDCD626P 2
9. Force the gear cover with 2 tire irons.

6. Brake parts : (1) sepratater disks,
(2) friction discs.

IDCD630P IDCD633P
10. Straighten the lock tab with a punch. 13. Remove the hub.
IDCD631P IDCD634P
11. Remove spindle nut with a special tool.(Ref. No 2) 14. Remove the inner wheel bearing (1).
1 3
2
IDCD632P
IDCD635P
12. Remove the nut (1), washer (2), shield (3) and
outer hub bearing. 15. Remove the spindle with a hexagon socket 19 mm.

IDCD636P IDCD639P
16. Remove the spindle from the axle housing. 19. Parts overview of the disassembled axle without
the differential and axle housing.
IDCD637P
17. Pull the axle shaft assembly with a pry bar and a
spindle mounting bolt.
IDCD638P
18. Remove the shaft assembly from the axle housing.

Disassembly Assembly
Shaft As Shaft As
IDCD640P IDCD642P
1. Remove the roller bearing and the ring. 1. Heat bearing to a temperature of 120°C (248°F).
IDCD641P IDCD643P
2. Pull off the inner bearing ring with an suitable 2- 2. Install the heated inner bearing ring on the shaft.
leg puller.
IDCD644P
3. Mount the bearing (1) and the washer (2).

Brake Parts
IDCD645P
4. Heat the ring to a temperature of 135°C (275°F).
IDCD647P
1. Remove the brake piston.
IDCD646P
5. Mount the heated ring with the plastic hammer.
IDCD648P
2. Lubricate the seal and sliding surface with

transmission oil.
IDCD649P
3. Mount the brake piston using a press.

Hub Drive Axle
IDCD653P
4. Press in the outer bearing cup. (Tool Ref. No 3)
IDCD650P
1. Remove the inner bearing cup with hammer and

punch.
IDCD651P
2. Remove the outer bearing cup.
IDCD652P
3. Install seal with a special tool. (Tool Ref. No 7)

Disassembly
Differential Assembly
IDCD657P
4. Lift the differential carrier out of the axle housing.
IDCD654P
1. Remove all differential carrier mounting bolts.

(hexagon socket 19mm)
IDCD658P
5. Remove the locking cotter pins.
IDCD655P
2. Install 2 jackbolts to carrier flange.
IDCD659P
6. Loosen the retainer with special tool on both sides.

(Tool Ref. No 4)
IDCD656P
3. Press off the axle drive from the axle housing.

Alternately tighten jackbolts to separate carrier
from axle housing.

Disassembly
Bevel Pinion
IDCD660P
7. Loosen the bearing bolts.

(ring spanner 19mm)
IDCD663P
1. Loosen yoke retaining nut with a special tool.

(Tool Ref. No 7) (Hexagon socket 42mm)
IDCD661P
8. Mark the bearing parts with hammer and centre

punch to guarantee correct side mounting.
IDCD664P
2. Pull off the yoke with a suitable gear puller.
IDCD662P
9. Lift the differnential assembly out of the axle

housing.
IDCD665P
3. Remove pinion from inside carrier while gently

tapping pinion shaft from yoke end using a soft
face mallet.

IDCD666P
4. Remove the bevel pinion bearing cup and seal.
IDCD667P
5. Carefully drive out the internal bevel pinion

bearing cup.

Adjustment 4. Calaulate the shimpack thickness according to the
following formula.
Shimpack thickness = A-(127+B+C)
Bevel Pinion Example) if A=160.50, B=32.00, C=+0.05
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.
IDCD668P
1. Measure the depth from center of diff. carrier to

the seat of pinion bearing cup. (Dimension A)
IDCD671
5. Shims of calculated thickness laid into bearing

seat.
2. Measure the width of pinion bearing.

(Dimension B)
IDCD672P
6. Install bearing cup.
IDCD670P
3. Check the etched value on the pinion face.

(Dimension c) IDCD673P
*unit : mm
7. Install crown gear, differential assy and lightly

torque bridge bilts.

11. When drag is correct, mark position of nuts both
8. Install bearing nuts for correct bridge position and
on nuts and bridge.
lightly torque them to achieve bearing preload.
12. After marking of position remove differential assy.

9. Tap on differential on both sides to achieve correct
bearing cone position, rotate differential (3-5
times).
10. Check drag 19.6 N.m (14.5 lb.ft) on rotating

differential.

Adjustment Assembly
Disassembly/Assembly of Bevel Pinion
Bevel Pinion
IDCD681P
IDCD679P
1. Install cup of rear pinion bearing

1. Pull the tapered roller bearing of the bevel pinion
using a two leg puller.
IDCD682P
IDCD680P
2. Install spacer and shims on pinion (basic
thickness 1.5mm (0.059 in)).
2. Install the roller bearing with a press.
IDCD683P
3. Install bearing cone.

Differential
IDCD684P
4. Tap bearing cone to correct position(Rotate pinion

3-5 times)
IDCD687P
1. Loosen differential housing bolts to disassemble

differential.
IDCD685P
5. Assemble yoke and nut and tighten flange nut to

180 ±15 N∙m (133±11 lb∙ft)
IDCD688P
2. After loosening the bolts, lift the differential

housing carefully.
IDCD686P
6. Measure the rolling torque. The value of rolling

torque should be 1.5~2.0 N∙m (1.1~1.5 lb∙ft)
7. If the rolling torque exceeds 2 N∙m, add one shim IDCD689P

and if it is lower than 1.5 N∙m, subtract one shim
8. When the adjustment is correct, disassemble the 3. Overview of the differential parts.
nut and the yoke.
Assemble the oil seal and yoke again and then
tighten the nut to 180 ±15 N∙m (133±11 lb∙ft).

IDCD690P IDCD693P
4. Grease all sliding surfaces with Molycote BR-2

7. Check the greasing of all sliding surfaces and
also during assembly.
position of the cross shaft.
IDCD691P
IDCD694P
5. Assemble cross shaft with small differential bevel

8. The flat side of the shaft must be on top. Join
gears and thrust washers and place into half the
differential housing halves so marks are aligned.
differential housing.
IDCD695P
IDCD692P
9. Secure the bolts with Loctite 242 before installing.

6. CAUTION : The thrust washer and cross shafts
have flats to prevent washer rotation with bevel
gears.

Assembly
Crown wheel/Adjustment
IDCD696P
10. Secure the bolts to the instructed torque (85 ± 6

N·m (63 ± 4.5 lb·ft).
IDCD697P
1. Torque of the crown wheel bolts 80 ± 6 N·m

(60 ± 4 lb·ft).
IDCD698P
2. Assemble the crown wheel with bearing support

and retainers.
First turn the retainers to the marked position (for
adjusting turn both retainers on the same side to
keep the constant bearing preload of the crown
wheel !) (Tool Ref. No 4)

IDCD699P IDCD702P
3. Strike the crown wheel left and right to insure

6. Rotate gears and examine contact pattern.
position.
IDCD703P
IDCD700P
7. Depth of engagement of the bevel pinion is

4. Rotate the axle drive through 100° and check the
correctly set, when the contact pattern appears as
tooth backlash at several points of the crown
shown in diagram.
wheel using a dial gauge. The tooth backlash
should be 0.15 - 0.25mm. (0.006 - 0.010 in)
IDCD704P
IDCD701P
8. The contact pattern in diagram shows too great a
depth of engagement.
5. In order to check the depth of engagement of the
bevel pinion, apply a coating of a gear tooth
pattern checking material.

IDCD705P IDCD708P
12. Before assembling the yoke, coat the seal with

9. With a contact pattern as shown in diagram the
grease.
bevel pinion has too little an engagement. The
shim of the bevel pinion should be rechecked if
the contact pattern as shown in fig. 7 is not
achieved.
IDCD709P
13. Heat the yoke to 130°C (266°F).

IDCD706P
10. If the depth of engagement is correct secure the

retainers with locking cotter pins.
IDCD710P
14. Install the yoke.
IDCD707P CAUTION : Take care that the sealing lips will not be
damaged !
11. Install the seal flush with carrier housing.
(Tool Ref. No 6)

Assembly
Carrier Diff
IDCD711P
15. Apply Loctite 242 to the yoke retaining nut.
IDCD713P
1. Install the dowels for the carrier housing.
IDCD712P
16. Tighten the nut to the instructed torque of

180 ± 15 N·m (133 ±11 lb·ft). (Tool Ref. No 8)
IDCD714P
2. Degrease the flange area and apply with Loctite

17430 sealant.
IDCD715P
3. Install the differential carrier assembly.

IDCD716P IDCD719P
4. Tighten the carrier assembly housing on the axle 7. Drive the plug flush with axle housing.
housing to the instructed torque 115 ± 15 N·m
(85 ± 11 lb·ft).
IDCD720P
IDCD717P
8. Insert the pre-assembled shaft assembly.
5. Coat the plug with Loctite 17430.
IDCD721P
IDCD718P
9. Tap the shaft assembly into the differential and
axle housing.
6. Install the plug.

IDCD722P IDCD725P
10. Install the spindle into the drive axle. Apply Loctite 13. Fully pack outer roller bearing into grease and
242 to secure bolts. install into hub. Install shield and nut.
IDCD723P IDCD726P
11. Tighten all bolts of the spindle to a torque of 14. Tighten the hub nut to 135 N·m (100 lb·ft).
115 ± 15 N·m (85 ± 11 lb·ft). (Tool Ref. No 2)
IDCD724P
IDCD727P
12. Install the inner tapered roller bearing. 15. Knock with the percussion drive and rotate the
hub drive axle to insure the seating of the
bearings.

IDCD728P IDCD731P
16. Loosen the nut of the hub drive axle to install the 19. Lock the nut with a punch.
safety washer. (Tool Ref. No 2)
IDCD732P
IDCD729P
20. Install 2 dowels on both sides.

17. Install the safety washer and the nut.
IDCD733P
IDCD730P
21. Degrease the contact area and seal with Loctite

18. Tighten the nut to 50 ± 5 N·m (37 ± 11 lb·ft). 17430.
(Tool Ref. No 2)

IDCD734P IDCD737P
25. Put on the end cover.

22. Install and tighten the gear cover to 55 ± 10 N·m
(41 ± 7.5 lb·ft).
IDCD738P
IDCD735P
26. Tighten the end cover with 28 ± 7 N·m (21 ± 5
lb·Ift)
23. Install the friction discs and plates in the gear
cover. First mount a plate outer.
IDCD739P
IDCD736P
27. Install the adapter for wheels.
24. Degrease and seal the gear cover to end
coverwith Loctite 17430.

IDCD740P
28. Tighten the adapter to 285 N·m (210 lb·ft).

Special Service Tools
Ref.No Tool Name Illustration Remark
Transmission
1 Piston return spring
Compressor
Drive Axle
Hub Bearing Lock DAEWOO Tool
2
Nut Installer No.: T059
Drive Axle
DAEWOO Tool
3 Hub Bearing Cup
No.: T020
Installer
Drive Axle
DAEWOO Tool
4 Differential
No.: T001
Retainer Installer

Ref.No Tool Name Illustration Remark
Drive Axle
5 Yoke Nut
Installer
Drive Axle
Input Shaft
6 Lip-seal
Installer
Drive Axle DAEWOO

7 Hub Lip-seal Tool
Installer No.: T022
Drive Axle
8 Yoke Nut
Installer

SB4138E00
Jan. 2004
Specifications
Systems Operation
Testing & Adjusting
Lift Trucks Vehicle Systems
D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3),
D32S-3(B3.3),D33S-3(B3.3)
WARNING
in injury or death.
publication.
available.
1
Index
Specifications Testing and Adjusting

Carriage ..................................................................... 9 Brake System ...........................................................58
Brake System Air Removal ...................................58
Hydraulic Control Valve.............................................. 5 Parking Brake Test ................................................58
Hydraulic Pump.......................................................... 6 Parking Brake Adjustment.....................................59
Lift & Tilt Mounting Group ........................................ 13 Hydraulic System......................................................41

Lift Cylinders .............................................................. 6 Flow Control Valve Adjustment .............................42
Lift Relay Group - Standard Lift................................ 10 Relief Valve Pressure Check.................................41
Lift Relay Group - Full Free Lift ................................ 11 Standard Lift Cylinder Air Removal .......................43
Lift Relay Group - Full Free Triple Lift ...................... 12
Mast and Carriage ....................................................44
Mast ........................................................................... 9 Carriage Adjustment..............................................49
Carriage and Mast Height Adjustment ..................52
Oil Cooled Disc Brakes ............................................ 17 Chain Adjustments ................................................50
Chain Wear Test....................................................51
Parking Brake .......................................................... 18 Drift Test ................................................................54
Forks Parallel Check .............................................52
Steer Axle and Wheel............................................... 16 Mast Adjustment....................................................44
Steer System Check Valve....................................... 16 Tilt Cylinder Alignment ..........................................53
Steer Wheel Mounting.............................................. 17
Steering Gear........................................................... 15 Steering System........................................................55
Steering Wheel......................................................... 14 Steer Wheel Bearing Adjustment ..........................55
Steering Axle Stop Adjustment ..............................56
Tilt Cylinders .............................................................. 8 Steering Knuckle Bearing Preload Adjustment......56
Steering System Pressure Check .........................57
Troubleshooting ........................................................33
Brake System........................................................39
Systems Operation Brake Valve ...........................................................38
Hydraulic System and Mast ..................................34
Brake System........................................................... 31 Performance Tests ................................................33
Brake Valve .......................................................... 31 Steering System ....................................................37
Oil Cooled Disc Brakes ........................................ 32 Visual Checks .......................................................33
Parking Brake ....................................................... 32
Hydraulic System ..................................................... 19

Basic Schematic - Standard Lift............................ 19
Basic Schematic - Full Free Lift or Full Free Triple
Lift......................................................................... 21
Hydraulic Control Valve ........................................ 23
Steering System....................................................... 27
Hydraulic Operation.............................................. 27
Steering Cylinder .................................................. 28
Steering Gear ....................................................... 29
Vehicle Systems 3 Index

Specifications
Hydraulic Control Valve
CONTROL VALVE 3 4
Main System Secondary 5 8 1
Relief Valve Relief Valve
Model Mast Pressure Pressure
±500 kPa ±350 kPa
(±75 psi) (±50 psi) 2
STD
D20S FFL 18,100 (2,625) 15,500 (2,250)
FFT
STD
D25S FFL 19,500 (2,825) 15,500 (2,250)
FFT
6 9
STD
D30S
FFL 21,550 (3,125) 15,500 (2,250)
D32S
FFT
STD
IDCS202S
D33S FFL 23,047 (3,342) 15,500 (2,250)
FFT
(1) Torque for bolts that hold control valve sections
together…………….40.5 ± 2.5 N·m (360 ± 24 lb·in)
(2) Adjust main system relief valve pressure for lift as

shown above.
See relief valve pressure check in Testing &
Adjusting.
(3) Adjust secondary relief valve pressure for tilt and

1 sideshift as shown above.
Adjusting.
(4) Torque for nipple assembly…………29.5 ± 1.5 N·m

(264 ± 12 lb·in)
7
(5) Torque for plug………..101 ± 5 N·m (894 ± 42 lb·in)
3
(6) Adjust tilt and sideshift flow rate by using 1/4 inch
hex-wrench if required.
See flow control valve adjustment in Testing &
Adjusting.
8
(7) Torque for plug……..55.5 ± 2.5 N·m (492 ± 24 lb·in)
2 9
(8) Torque for plug...............79 ± 4 N·m (696 ± 36 lb·in)
(9) Torque for screws…………………….12.5 ± 1.5 N·m

IDCS201S (108 ± 12 lb·in)
Vehicle Systems 5 Specifications

Hydraulic Pump Lift Cylinders
Flow rate of excess flow protectors and flow control
valve [not shown (no adjustment) ] :
D700495……..45 to 53 liter/min (12 to 14 U.S. gpm)
1 A215044…….90 to 106 liter/min (24 to 28 U.S. gpm)
Standard
IDCS203S
2
(1) Tighten mounting bolts to a torque of
…………………………...45 ± 7 N·m (396 ± 60 lb·in)
A315000 (Gear Pump with Priority Valve)
Relier Valve (No adjustment) opens at :

………………………9000 + 300kPa (1305 + 43.5 psi)
Rotation is clockwise when seen from drive end.

Type of pump : Gear
For test, use SAE 10W oil at 65°C (150°F)
Test at Full Speed :

IDCS204S
Output……………………56.3 liter/min (14.9 U.S. gpm)
At a pressure of………………….…..690 kPa(100 psi)
With pump at……………………….…………2000 rpm (1) Put pipe sealant on the last three threads of bear-
Output……………………54.4 liter/min (14.4 U.S. gpm) ing.
At a pressure of………………..….6900 kPa(1000 psi)
With pump at…………………………..………2000 rpm (2) Torque for setscrews…..…6 ± 1 N·m ( 53 ± 9 lb·in)
NOTE: All seals to be lubricated with hydraulic oil.

Test at Half Speed :

At a pressure of………..…….……..690 kPa(100 psi)
With pump at……………...…………………1000 rpm
Output……………………..27.2 liter/min (7.2 U.S. gpm)
At a pressure of………………….6900 kPa(1000 psi)
With pump at………….……..………………1000 rpm

Full Free Triple Lift and Full Free Full Free Triple Lift And Full Free
Lift Primary Lift Secondary
1 1
1
1
IDCS204S IDCS205S
(1) Put pipe sealant on the last three threads of bear- (1) Put pipe sealant on the last three threads of bear-
ing. ing.
NOTE : All seals to be lubricated with hydraulic oil. NOTE: All seals to be lubricated with hydraulic oil.

Tilt Cylinders
1 2 3
4
IDCS189S
TILT CYLINDER CHART

Tilt Gp Forward Tilt Backward Cyl.Stroke (X) Cyl. Closed (Z)
Model
Part No. Angle* Tilt Angle* mm (in) mm (in)
A215192 3° 3° 63.4 (2.50) 538.4 (21.20)
A215179 6° 3° 94.6 (3.72) 538.4 (21.20)
D20S-3
A215191 3° 5° 84.8 (3.34) 517.0 (20.35)
D25S-3
A215174 6° 5° 116.0 (4.56) 517.0 (20.35)
D30S-3
A215190 3° 8° 117.1 (4.61) 484.7 (19.08)
D32S-3
A215173 6° 8° 148.3 (5.84) 484.7 (19.08)
D33S-3
A215189 3° 10° 138.7 (5.46) 463.1 (18.23)
A215172 6° 10° 169.9 (6.69) 463.1 (18.23)
* Permissible tolerance of 1/2°
(1) Adjust pivot eye to dimension (Z) with cylinder (3) Torque for head ……………………….270 ± 30 N·m
closed. (200 ± 22 lb·ft)
(4) Torque for piston nut………………….270 ± 30 N·m
(2) Torque for bolt……….…95 ± 15 N·m ( 70 ± 10 lb·ft) (200 ± 22 lb·ft)

Mast Carriage
IDCS172S
(1) With mast at 475 mm (18.7 in) channel lap,

equally shim both sides until contact (A) is made IDCS173S
(zero clearance) between bearings and mast
uprights.
(1) Select bearings from the chart to obtain minimum
clearance (C) between bearings and channel leg
(2) With mast at full extension, shim behind pads until
for full channel length. Use same bearing at all six
there is clearance (B) between the mast uprights
locations.
and the pads of …………………...0.80 mm (.031 in)
(2) Equally shim both sides until contact (A) is made
(3) Select lower bearings from the chart to obtain
(zero clearance) between bearings and inner mast
minimum clearance (C) between bearing and
at narrowest point.
channel leg for full channel length. Use same
bearing on left and right side.
(3) Shim bolt as needed to obtain a 6.0 to 9.0 mm
(.236 to .354 in) overlap (B) between bolt (3) and
(See Mast Adjustment in Testing & Adjusting).
the carriage stop on the inner upright.
(See Carriage Adjustment in Testing & Adjusting).
MAST BEARING CHART
108.60mm (4) Torque for screw………..34 ± 7 N·m (360 ±24 lb·in)
D581814 Undersize
(4.276in)
109.60mm CARRIAGE BEARING CHART
D581815 Standard
(4.315in)
110.70mm Part No. Bearing Size Bearing OD*
D581816 Oversize
(4.358in) D581814 Undersize 108.60mm (4.276in)
* Permissible tolerance of ± 0.08 mm (.003 in). D581815 Standard 109.60mm (4.315in)
D581816 Oversize 110.70mm (4.358in)
*Permissible tolerance of ± 0.08 mm (.003 in).

Lift Relay Group - Standard Lift
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.
1 2
(1) Put LOCTITE NO. 242 Thread Lock on the threads
of the relay group locknuts after adjustment of the
lift chains is completed.
(2) Maximum chain wear…………………Less than 2%

(See Chain Wear Test in TESTING &
ADJUSTING).
(3) Distance from bottom of inner mast to bottom of

lower bearing on carriage must be even (flush) with
the inner mast.
IDCS174S

Lift Relay Group - Full Free Lift
WARNING
1 2
(1) Tighten bolts until contact is made with guard.


(See Chain Wear Test in TESTING &
ADJUSTING).

2 lower bearing on carriage must be 41±1.5 mm
(1.61 ±0.6 in).
Bottom of inner mast must be even (flush) with
bottom of stationary mast. Adjust inner first.
3
IDCS175S

Lift Relay Group - Full Free
WARNING
Triple Lift
indication is 2% or more. A Reading of 2% or more
1
(See Chain Wear in TESTING &
ADJUSTING).

2
3 (3) Tighten bolts until contact is made with guide
assembly.

1 lower bearing on carriage must be 41±1.5 mm
(1.61 ± 0.6 in).
Bottom of inner mast be even (flush) with bottom of
stationary mast. Adjust inner mast first
IDCS193S

(1) (Standard Mast or Full Free Triple Lift mast Only)
Lift & Tilt Mounting Group With chains adjusted for equal tension, run mast to
full lift. If mast does not kick (move) to one 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)

……………………...….4.5± 0.8 mm (.177 ± .031 in).
(3) Tilt cylinder installation shown.
(4) Bearing split to be located at angle (D) 45±15°
(5) Install bearing outer race to a depth of (G)

………………………....4.5± 0.8 mm (.177 ± .031 in).
(6) (Full Free Lift Mast Only):

Tighten nuts until U-bolt is firm against cylinder, do
not apply standard torque.
(7) (Full Free Lift Mast Only):

With chains adjusted for equal tension run mast to
full lift. If mast does not kick (move) to one side, no
shims are needed. If mast does kick (move) to one
side, hold lift cylinder tube on that side and loosen
bearing 1/4 turn and check mast again. Loosen
bearing until kicking (movement) stops or gap (H)
reaches 3.0 mm (.12 in) (approximately 1.5 turns),
whichever is less. Insert shims (8) under bearing (it
may be necessary to loosen bearing an additional
amount of turns to install shims). Tighten bearing
IDCS176S again.
6 7
8 DETAIL E H
IDCS177S

Steering Wheel
IDCS206S
(1) Torque for steering wheel nut…………..80 ± 6 N·m

(60 ± 4 lb·ft)
(2) Torque for setscrews……………….2.25 ± 0.25 N·m

(20 ± 2 lb·in)

Steering Gear
VIEW B-B VIEW C-C
TIGHTENING SEQUENCE
FOR BOLTS
SECTION A-A
IDCS180S
(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…………..14.1 ± 2.8 N·m
(125 ± 25 lb·in)
Tighten to a final torque of…………..28.2 ± 2.8 N·m
(250 ± 25 lb·in)
(5) Torque for plug…………………11.3 N·m (100 lb·in)
Plug to be flush (even) with or below mounting

surface.

Steer System Check Valve
D700213
Maximum system pressure……….6900 kPa (1000 psi)

Cracking pressure………………………...35 kPa (5 psi)
Pressure drop at 15 liter/min (4 U.S. gpm) with 10 W
oil at 50°C (122°F)……………………..100 kPa (15 psi)
Steer Axle and Wheel

3
9 10
IDCS182S
(9) tapered Roller Bearing Axles Only:

Torque for bolts that hold cover
A 4 ……………………………..55 ± 6 N·m (40 ± 5 lb·ft)
(10) Add or remove shims under cover until torque

5 required to turn knuckle assembly is
.…….………………..4.5 to 6.8 N·m (40 to 60 lb·in)
See Steering Knuckle Bearing Preload Adjustment in

Testing & Adjusting.
1
2
IDCS181S 6 7 8
NOTE: Steer axles with tapered roller bearings shown.
(1) Do the steps that follow for steer wheel bearing

adjustment.
a. Tighten nut (1) slowly to 135 N·m (100 lb·ft)

while turning the wheel.
b. Loosen nut (1) completely.

Tighten it again to…...50 ± 5 N·m (37 ± 4 lb·Ift)
c. Bend lock (2) over nut (1).
(3) Torque for bolt that holds pin

…………………………….11 ± 1 N·m (100 ± 9 lb·ft)
(4), (6) Loosen nuts (5) and (7) on both sides. Adjust
bolts to get steering knuckle turning angle (A) of
………………………………………………..78 to 80°
See Steering Axle Stop Adjustment in Testing And
Adjusting section.
(8) Tapered Roller Bearing Axles Only:

Torque for bolts that hold steer cylinder to axle
beam…………………300 ± 40 N·m (220 ± 30 lb·Ift)

Steer Wheel Mounting Oil Cooled Disc Brakes
1 1
2
IDCS210S IDCS211S
(1) Torque for bolts that hold steer wheel (1), (2) Put LOCTITE NO.17430 Liquid Gasket on
.…….…………………….120 ± 20 N·m (90 ±15 lb·ft) contact surface area of the axle flange cover
assembly and cover before installation.
(3) Thickness of one new Plate

…………..………2.50 ± .064 mm (.100 ± .0025 in)
Thickness of one new friction disc:
…………..……………4.59 ±.13 mm (.181 ± .005 in)
Minimum depth of grooves before the replacement

of frictiondine is necessary:
……………………………………...0.32 mm (.013 in)
Soak new discs in drive axle oil for one hour before
installing.

Parking Brake
6
4
1
2
3
IDCS212S
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 N·m

(50 to 60 lb·in)
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.

Systems Operation
Hydraulic System
Basic Schematic - Standard Lift
1
1
2
4 3
6
5
9
7
10 11
8
13
14 16
15
IDCS213S
12
Basic Hydraulic Schematic With Standard Lift

(1) Lift Cylinders. (2) Excess Flow Protector. (3) Sideshift Cylinder(if equipped). (4) Lowering Flow Control Valve.
(5) Hydraulic Control Valve. (6) Tilt Cylinders. (7) Relief Valve (lift). (8) Relief Valve (tilt and sideshift). (9) Hydraulic Oil Filter.
(10) Hydraulic Oil Tank. (11) Priority Valve. (12) Oil line (13) Oil line. (14) Hydraulic Strainer. (15) Hydraulic Pump.
(16) Oil line to Brake Valve And Steering Gear.
Vehicle Systems 19 Systems Operation

The hydraulic system has a hydraulic oil tank (10),
which holds the oil for gear-type hydraulic pump (15)
with priority valve (11). Hydraulic pump (15) with pri-
ority valve sends pressure oil to the hydraulic brake
and steering systems. Pump oil flows from pump (15)
to priority valve (11) where the oil flows to the power
brakes brake valve and to the steering gear through
line (12).
The control valve levers move the valve spools in

control valve (5) to let the pump oil in the control valve
go to lift cylinders (1), tilt cylinders (6), sideshift
cylinder (3) or other attachment.
The tilt forward, tilt back and sideshift speeds are

controlled by flow control valves in hydraulic control
valve (5). There is an anti-cavitation valve inside the
tilt spool to prevent cavitation (development of air
pockets) in tilt cylinders (6).
The return hydraulic oil from the cylinders flows

through hydraulic control valve (5), line (13), into filter
(9) and hydraulic tank (10). Relief valve (7) in the
control valve body will make the flow control valve
release extra pressure to the hydraulic tank when the
pressure in the lift goes higher than relief valve
pressure shown in the Control Valve section of
Specifications. Relief valve (8) does the same thing for
the tilt and sideshift circuit when it goes higher than
the secondary relief valve pressure shown in the
Control Valve section of Specifications.
The maximum speed at which the lift cylinder(s) are

lowered is controlled by lowering flow control valve (4).
Excess flow protector (2) will act as flow control valve

if an oil line between them and flow control valve (4) is
broken when the mast is raised or lowered. This
prevents a sudden fall of the mast or carriage if an oil
line is broken.
REFERENCE : For the Hydraulic Systems Schematics.

Basic Schematic - Full Free Lift or Full Free Triple Lift
17
18
1
4
3
6
5
7
9 11
8
10
13
14 12
15 16
IDCS214S
Basic Hydraulic Schematic Full Free Lift Or Full Free Triple Lift
(1) Lift Cylinders. (2) Excess Flow Protectors. (3) Sideshift Cylinder(if equipped). (4) Lowering Flow Control Valve.
(5) Hydraulic Control Valve. (6) Tilt Cylinders. (7) Relief Valve(lift). (8) Relief Valve(Tilt And Sideshift). (9) Hydraulic Oil Filter.
(10) Hydraulic Oil Tank. (11) Priority Valve. (12) Oil Line. (13) Oil Line. (14) Hydraulic Strainer. (15) Hydraulic Pump.
(16) Oil Line to Brake Valve And Steering Gear. (17) Lift Cylinder (Primary). (18) Excess Flow Protectors.

The hydraulic system has a hydraulic oil tank (10),
which holds the oil for gear-type hydraulic pump (15)
with priority valve (11). Hydraulic pump (15) with
priority valve sends pressure oil to the hydraulic brake
and steering systems. Pump oil flows from pump (15)
to priority valve (11) where the oil flows to the power
brakes brake valve and to the steering gear through
line (12).
The control valve levers move the valve spools in

control valve (5) to let the pump oil in the control valve
go to lift cylinders (1) and/or (17), tilt cylinders (6)
sideshift cylinder (3) or other attachment.
The tilt forward, tilt back and sideshift speeds are

controlled by flow control valves in hydraulic control
valve (5). There is an anti-cavitation valve inside the
tilt spool to prevent cavitation (development of air
pockets) in tilt cylinders (6).
The return hydraulic oil from the cylinders flows

through hydraulic control valve (5), line (13), into
filter (9) and hydraulic tank (10). Relief valve (7) in the
control valve body will make the flow control valve
release extra pressure to the hydraulic tank when the
pressure in the lift goes higher than relief valve
pressure shown in the Control Valve section of
Specifications. Relief valve (8) does the same thing for
the tilt and sideshift circuit when it goes higher than
the secondary relief valve pressure shown in the
Control Valve section of Specifications.
The maximum speed at which the lift cylinder(s) are

lowered is controlled by lowering flow control valve (4).
Excess flow protectors (2) and (18) will act as flow

control valve if an oil line between them and flow
control valve (4) is broken when the mast is raised or
lowered. This prevents a sudden fall of the mast or
carriage if an oil line is broken.
REFERENCE : For the Hydraulic Systems Schematics.

CAUTION
Hex head must face out of
valve toward spring and plug.
4
5 2
7
6
3
9
3
8
10
IDCS215S
(1) Relief Valve - Hydrostat. (2) Inlet/Outlet Body. (3) Center Spring. (4) Center Body. (5) Spool. (6) Tie Stud.
(7) Quick Disconnect Gauge Body. (8) Check Valve. (9) Seal Rings. (10) Main Relief Valve.
Assembly And Construction
Above figure is a cross-section view showing Passages between the bodies connect each section to
construction and assembly of a three-section valve. the common inlet and tank ports.
The Quick Disconnect Gauge Body section also Seal rings between the sections seal the connecting
contain a relief valve assembly. passages, Sections are held together by studs and
nuts.

Valve Operation Lift Spool
4
1
6
OUT -
CENTER -
IN -
INLET OUTLET
OUT Pressure to “A”

“B” blocked
By-pass blocked
2
3 5 7 CENTER “A” and “B” blocked

By-pass open
IN “A” to tank
IDCS103S “B” blocked
(1) Control Valve Sensing Orifice. By-pass open
(2) Flow Control And Relief Valve-Hydrostat.
IDCS104S
(3) Tank Passage.
(4) By-pass Flow Control Orifice.
(5) Cylinder Ports. Lift spool - used for control of single acting cylinder
(6) Pressure Passage. applications. It directs flow to only one end of a
(7) By-pass Passage. cylinder, as in the lift mechanism of a lift truck.
Return flow is from the same end of the cylinder and
relies on gravity or mechanical means to retract.
Above figure is a schematic illustration of a three
section valve, showing the inlet and outlet ports and
the by-pass, pressure and tank passages.
The pressure passage is used to carry fluid to the
cylinder ports when the spools are shifted. The by-
pass passage permits flow directly to the outlet when
the spools are not being operated. The tank passage
also carries fluid to the outlet; either return flow from
the cylinder ports or fluid diverted past the flow control
and relief valve.
The spools are shown in the centered or neutral

position. Under these conditions, fluid in the pressure
passage is blocked from the cylinder ports by the
spool lands. Flow through the valve is through the by-
pass and tank passages to the outlet.
IDCS105S

Tilt Spool Auxiliary Spool
IN Pressure to “B”
IN Pressure to “B” “A” to tank
“A” to tank By-pass blocked
By-pass blocked
CENTER “A” and “B” blocked
CENTER “A” and “B” blocked By-pass open
By-pass open
OUT Pressure to “A”
OUT Pressure to “A” “B” to tank
“B” to tank By-pass open
By-pass blocked IDCS108S
IDCS106S
Tilt spool - a counterbalance spool normally used to Auxiliary spool - directs flow to either end of a double
control the tilt function of a lift truck. acting cylinder. Flow from the end that is not under
The counterbalance feature prevents the forks from pressure is returned to tank via internal coring of the
tilting forward faster than pump can supply oil, valve section.
preventing tilt.
IDCS107S IDCS109S

Flow Control And Relief Valve Flow Control
The partial flow by-pass system in the control valve

makes use of a compound type flow control and relief
valve arrangement. 4
1
6
Sensing the pressure drop across an orifice at the OUT -
CENTER -
entrance to the by-pass, the valve acting as a control IN -
to limit flow through the by-pass to approximately INLET OUTLET
seven gallons per minute. The balance of the pump
delivery is diverted through the reservoir passage.
This arrangement greatly reduces pressure drop
through the valve in the neutral position.
When a spool is shifted to operate a portion of a

machine, the flow control is inoperative and full pump
volume is available to the system. The control valve 2
then functions as an overload relief valve. System
pressure is limited to a prescribed maximum by the 3 5 7
action of this valve. Full pump volume is available to
the system at all times.
IDCS103S
Use of the optional secondary relief valve allows the (1) Control Valve Sensing Orifice.
use of lower pressure for tilt and attachment function (2) Flow Control And Relief Valve-Hydrostat.
while higher pressure is provided for the lift function. (3) Tank Passage.
(4) By-pass Flow Control Orifice.
NOTE : The secondary relief valve must be set at a (5) Cylinder Ports. (6) Pressure Passage.
lower relief setting than the main system relief. (7) By-Pass Passage.
Above figure shows the valve operation in

neutral with flow in excess of 26.5 Lpm. Flow across
the by-pass orifice result in a pressure drop.
Decreased pressure is sensed at the spring end of the
valve sub-assembly through a sensing orifice. The
slightly higher pressure at the other end of the valve
permits it to shift down, diverting excess flow to the
reservoir passage. With flow at less than 26.5 Lpm
there would be negligible pressure drop across the by-
pass orifice. Then the control valve would be held
closed by the large spring and all flow would be
through the by-pass passage.

Steering System
Hydraulic Operation (Load Sensing Closed Center Steer Gear)
9 10
5 6 8
4 7 11
3
2
1
16 17
13 15
12 14
IDCS216S
Steering System Schematic (Load Sensing Closed Center)

(1) Steering gear. (2) Hose (to hydraulic tank). (3) Brake Valve. (4) Check Valve. (5) Hose (Load Sensing). (6) Tube.
(7) Hose(from hydraulic tank). (8) Hose(to hydraulic Control valve). (9) Hose(to steer cylinder). (10) Hose (to steer cylinder).
(11) Steering Cylinder. (12) Load Sensing Signal Hose (Steering). (13) Check Valve. (14) Passage to brake.
(15) Hose (to Steer gear). (16) Hydraulic Pump. (17) Hydraulic Tank.
REFERENCE : For the Hydraulic System Schematics. When the steering gear is moved, oil starts to flow to
steer cylinder (11). The pressure in line (15) and the
The steering system is a load sensing closed center priority valve internal sensing line will drop. As
type and uses hydraulic oil for its operation. Oil flow pressure drops in these lines, the priority valve
through the steering system is closed unless the metering spool will shift to meet the flow demand. As
steering wheel is turned. The flow through the the metering spool shifts, more oil flow is diverted to
steering gear is sensed by the priority valve, which hose (15) than to hose (8). The priority valve
then allows additional oil flow to the steering system. metering spool will shift back and forth to meet the
The priority valve also fills the requirements of the steering flow demand while maintaining the 1035
power brakes (if equipped) and then the mast. kPa(150 psi) differential between load sense hose (12)
and the priority valve internal sensing line.
Hydraulic oil is pulled from hydraulic tank (17) through At times flow to hose (8) will be closed completely. The
a strainer to hydraulic pump (16). The pump sends the combination of flow restrictors in the lines and spring
oil through hose (7) to brake valve (3). When the tension on the priority valve metering spool work
steering gear and brake valve are in together to maintain this balance.
NEUTRAL position, pressure in hose (15) and the
priority valve internal sensing line rises to 1035 kPa Check valve (13) is in hose (15) near the steering gear
(150 psi). When this pressure is at least 1035 kPa to prevent oil flow back to brake valve (3), which could
(150 psi) more than load sensing signal hose (12) the cause a sudden jerk of the steering wheel.
priority valve metering spool shifts to stop oil flow to Relief valve in the priority valve body will open if the
the steer gear. Oil flows through hose (8) to the steering pressure goes above 8275 kPa (1200 psi).
hydraulic control valve.

Steering Cylinder
Steering cylinder (1) gives power assistance
throughthe use of pressure oil at either end of the
cylinder piston.
The steering cylinder is double ended and the body of

the cylinder is mounted stationary to the steer axle.
The rod assembly is connected to the steering link
assembles at both ends of the cylinder which allows
the cylinder to move the link assemblies.
Steering Cylinder (Typical Example)

(1) Steering cylinder.

Steering Gear
A B
2 3 4 5 6
8 9 10 11 12
IDCS113S
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 flow Oil from the priority valve goes through inlet (4) into
to steering gear only when needed) steering gear. the control section of the steering gear. When the
steering wheel is turned, the control section sends the
All lift truck hydraulic lines serve a dual purpose in that oil to and from the metering section and also to and
they serve both the steering and cylinder hydraulics from the steering cylinder.
through the use of a priority valve. The priority valve
sends oil to the steering gear before the needs of the The metering section is a small hydraulic pump. It
cylinder hydraulics are met. controls (meters) the oil that goes to the steering
cylinder. As the steering wheel is turned faster, there is
The steering gear has two main sections: control an increase in the flow of oil to the steering cylinder.
section (A), and pump or metering section (B). These This increased flow causes the main valve spool to
two sections work together to send oil to the steering move farther. As the spool moves farther, more oil can
cylinder. 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 5 6 8
the steering gear 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 12

IDCS114S
the sleeve and causes drive (12) to turn also. The
drive causes a rotation of gear (5) inside gear (6). This Pump Gears In Metering Section
rotation of the gear sends a controlled (metered) flow (5) Internal pump gear. (6) External pump gear. (8) Pin. (12)
of pilot oil back through body (11). This oil flows to port Drive.
(9) or (10) and then to the steering cylinder. Port (9) or
(10), that is not used for pressure oil to the steering
cylinder, is used for return oil from the other end of the If the steering wheel rotation is stopped, springs (7)
steering cylinder. will move sleeve (2) back in alignment with spool (1)
(NEUTRAL position). This will close passages
between the metering section and control section and
the steering gear will be in the NEUTRAL position.
When the engine is off, the steering gear 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 Valve
6 1 4 5 3 2 7
IDCS218P
(1) Large Piston Cavity. (2) Inlet Cavity. (3) Work Port. (4) Sleeve. (5) Small Piston. (6) Large Piston. (7) Spool.
The brake valve assembly provides two modes of dead-band in the brake actuator as well as build
braking : adequate braking pressure. The function of the large
the power braking mode, and the two stage manual piston (6) is to remove the dead-band between the
braking mode. disk materials in the actuator with a relatively large
The power braking system is load sensing which volume of oil at low pressure with minimum spool
incorporates a shuttle sensing check valve to connect travel. With the brake actuator “primed” the small
the sensing lines of the brake valve with the steering piston creates the higher pressure required for braking
unit and priority valve. while the large piston is relieved of pressure to keep
the input forces at a reasonable level.
Power mode : When the engine is not running, there is no signal
When vehicle is running, the pump provides signal pressure from the pump to open the pilot operated
pressure to the pilot operated check in the large check. Therefore, it remains closed. As the spool is
piston(6) to reduce the large piston feedback pressure. pulled out, the large piston cavity(1) closes, the inlet
When spool(7) is pulled out, the large piston cavity(1) cavity(2) opens to work port(3) and the transfer
closed except for the pilot operated check flow path, sleeve(4) seats against small piston(5). After large
and inlet cavity(2) opens to the work port(3) and piston flow primes the actuator, it relieves and small
metering begins between transfer sleeve(4) and small piston creates high pressure.
piston(5).
The transfer sleeve seats against the small piston
which creates maximum inlet and work ports pressure.
Manual Mode :
The manual braking mode allows braking to occur
even if inlet oil is not available to the brake valve. The
two piston design enables the operator to remove the

Oil Cooled Disc Brakes Parking Brake
1 2
3
IDCD124P
Parking Brake Linkage
(1) Cable Assembly. (2) Switch. (3) Lever.
The band-type parking brake is installed on the input

3 shaft clutch pack inside the transmission. The parking
8 7 5 6 4 brake control assembly is mounted on the cowl. The
parking brake is controlled with a lever. The control
lever is connected to the parking brake with a cable
IDCS211-1S
assembly (1).
Disc Brake Assembly
(1) Inlet (from brake valve). (2) Passage. (3) Plates (five). (4) The parking brake is activated when the control lever
Discs (four). (5) Piston. (6) Seal. (7) Seal. is pulled. When the operator pulls the control lever,
(8) Passage (for cooling oil). cable assembly (1) pulls lever (3) which will turn cam
and push strut (5). This will tighten brake band (6) on
the input shaft clutch pack and stop any lift truck
When the brake pedal is pushed down, the brake movement.
valve pushes brake liquid through the brake valve
outlet, the brake lines, to inlet (1) of each disc brake To prevent driving when the parking brake is activated
assembly. Liquid flows through inlet (1), passage (2) (engaged) switch (2) is opened. This will put the
and pushes on piston (5). Piston (5) pushes against transmission in neutral so the lift truck can not be
plates (3) and friction discs (4) to stop any movement driven.
of the lift truck. The five separator plates (3) are
splined to the wheel cover and the four
friction discs (4) are splined to the hub. During brake
activation the piston seals (6) and (7) are deflected by
the brake piston movement.
When the brake pedal is released, the brake liquid

pressure is released and seals (6) and (7) return to
their original position. This seal retraction gives the
running clearance needed between plates (3) and
discs (4). This action will release the brakes on the lift 5
4
truck. As the seals retract brake liquid is returned to
the brake valve. The piston automatically slides 6
outward from the cylinder bore as the friction discs IDCD591P
wear. This new location then becomes the beginning Parking Brake
or at rest position of the seals. This will maintain the (4) Cam. (5) Strut. (6) Brake Band.
proper clearances of the discs and plates.
When the brakes are activated, heat is generated by

plates (3) and discs (4). Drive axle oil in a separate
brake cooling circuit flows through passage (8) and
cools the plates and discs during normal operation.

Testing and Adjusting Visual Checks
A visual inspection of the hydraulic system and its
Troubleshooting components is the first step when a diagnosis of a
problem is made. Lower the carriage to the floor and
follow these inspections;
Troubleshooting can be difficult. A list of possible
problems and corrections are on the pages that follow. 1. Measure the oil level. Look for air bubbles in the oil
tank.
This list of problems and corrections will only give an
indication of where a problem can be and what repairs 2. Remove the filter element and look for particles
are needed. Normally, more or other repair work is removed from the oil by the filter element. A
needed beyond the recommendations on the list. magnet will separate ferrous particles from nonf-
Remember that a problem is not necessarily caused errous particles (piston rings, O-ring seals, etc.).
only by one part, but by the relation of one part with
other parts. This list can not give all 3. Check all oil lines and connections for damage or
possible problems and corrections. The serviceman leaks.
must find the problem and its source, then make the 4. Check all the lift chains and the mast and carriage
necessary repairs. welds for wear or damage.
Tools Needed
Fittings Group 1
Performance Tests
The Fitting Group is used to make the pressure tests
of the hydraulic system. Before any test is made, The performance tests can be used to find leakage in
visually inspect the complete hydraulic system for the system. They can also be used to find a bad valve
leakage of oil and for parts that have damage. or pump. The speed of rod movement when the
cylinders move can be used to check the condition of
the cylinders and the pump.
WARNING Lift, lower, tilt forward and tilt back the forks several
times.
To prevent personal injury when testing and
1. Watch the cylinders as they are extended and
adjusting the hydraulic system, move the machine
retracted. Movement must be smooth and regular.
to a smooth horizontal location and lower the mast
and carriage to the ground. If the mast and 2. Listen for noise from the pump.
carriage can not be on the ground, make sure they
are blocked correctly to keep them from a fall that 3. Listen for the sound of the relief valve. It must not
is not expected. Move away from machines and open except when the cylinders are fully extended
personnel that are at work. There must be only one or retracted without load on forks.
operator. Keep all other personnel away from the
machine, or where the operator can see the other
personnel.
Hydraulic Oil Temperature
Before any hydraulic pressure plug, line or (Too Hot)
component is removed, make sure all hydraulic
pressure is released. When the temperature of the hydraulic oil gets over
98.8°C (210°F), polyurethane seals in the system start
to fail. High oil temperature causes seal failure to
become more rapid. There are many reasons why the
temperature of the oil will get this hot.
1. Hydraulic pump is badly worn.
2. Heavy hydraulic loads that cause the relief valve to

open.
3. The setting on the relief valve is too low.
4. Too many restrictions in the system.
Vehicle Systems 33 Testing & Adjusting

5. Hydraulic oil level in the tank is too low. Hydraulic System and Mast
6. High Pressure oil leak in one or more circuits.
Problem : The hydraulic system will not lift the
7. Very dirty oil. load.
8. Air in the hydraulic oil. Probable Hydraulic Cause :
NOTE: If the problem is because of air in the oil, it 1. There is an air leak, which lets air into the hydraulic
must be corrected before the system will operate at system on the inlet side of the hydraulic pump.
normal temperatures. There are two things that cause
air in the oil (aeration). These are: 2. The relief valve opens at low oil pressure.
a. Return oil to the tank goes in above the level of 3. The hydraulic pump has too much wear.
the oil in the tank.
4. The priority valve does not work correctly.
b. Air leaks in the oil suction line between the
pump and the tank. 5. The load is not correct.
Probable Mechanical Cause:

Hydraulic System and Mast
1. The mast is not in alignment with the other lifting
During a diagnosis of the hydraulic systems, components and does not move freely.
remember that correct oil flow and pressure are
necessary for correct operation. The output of the 2. Not enough lubricant on the parts of the mast that
pump (oil flow) increases with an increase in engine move.
speed (rpm) and decreases when engine speed (rpm)
is decreased. Oil pressure is caused by resistance to 3. The carriage or mast rollers and bearings are worn
the flow of oil. and do not move (seized).
Visual checks and measurements are the first step 4. Mast shimmed too tight.
when troubleshooting a possible problem. Then do the
operation checks and finally, do instrument tests 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 lift 3. Relif pressure set too low.
truck. Pressures that are too high will cause a
decrease in the life of hoses and components.
Probable Mechanical Cause:
2. Drift rates in the cylinders. Cylinder drift is caused
by a leakage past cylinder pistons, O-ring seals in 1. The mast is not in alignment with the other lifting
the control valve, check valves that do not seat components and does not slide freely.
correctly or poor adjustment or fit in the control
valve spools. 2. Not enough lubricant on the parts of the mast that
move.
3. Cycle times in the lift and tilt circuits : Cycle times
that are too long are the result of leakage, pump 3. The carriage or mast rollers and bearings are worn
wear and/or pump speed (rpm). and do not move (seized).
4. Mast shimmed too tight.

Problem: Mast does not move smoothly. Probable Mechanical Cause:
Probable Hydraulic Cause: 1. Damage or failure of the tilt cylinders.
1. Air in the hydraulic system. 2. Mast mounting pins seized.
2. Relief valve sticks or defective.
3. Damaged cylinders. Problem: The carriage will not lower correctly.
Probable Mechanical Cause: Probable Hydraulic Cause:
1. Not enough lubricant on the parts of the mast that 1. There are restrictions in the lift line.
move.
2. The lift spool in the control valve has a restriction
2. Load rollers defective or not adjusted correctly. caused by foreign material and does not operate
freely.
3. Mast rollers not shimmed correctly.
3. The lift cylinder flow control valve has a restriction.
4. Mast assembly is damaged or not in alignment.
4. Air in the hydraulic system.
Problem: Mast will not lower completely or will not

lower at all. Probable Mechanical Cause:
Probable Hydraulic Cause: 1. The mast is not in alignment with the other lifting
components and does not move freely.
1. Lift cylinder damaged or bent.
2. Carriage chains need an adjustment.
2. Defective flow control valve.
3. Not enough lubricant on the part of the mast that
Probable Mechanical Cause: moves.
1. Load rollers defective or not adjusted correctly. 4. The carriage or mast rollers (bearings) are worn and
do not move (seized) or shimmed too tight.
2. Not enough lubricant on the parts of the mast that
move.
Problem: The mast does not tilt correctly or moves

too slowly.
Probable Hydraulic Cause:
1. There is a restriction in the hydraulic tilt lines.
2. There is an air leak, which lets air into the hydraulic

system on the inlet side of the hydraulic pump.
3. The relief valve opens at low oil pressure.
4. The hydraulic pump has too much wear.
5. The internal valve of the tilt spool is stuck.
6. Control valve tilt spool has a restriction.
7. The priority valve does not work correctly
8. Seals in tilt cylinder worn or damaged.

Problem: The lift or tilt cylinders do not hold their Problem: Leakage on the shaft seal.
position with the valve control levers in neutral
position. Probable Cause:
Probable Cause: 1. The shaft seal is worn.
1. The valve spools do not hold their positions 2. There is a broken gasket behind the seal.
because the springs for the valve spools are weak
or broken. 3. The inner parts of the pump body are worn.
2. Control valve leakage caused by worn valve spools 4. Operation with too low oil level in tank causes
or seals. suction on the seal.
3. The check valves in the control valve are defective. 5. Seal cut on shoulder of pump or keyway during
installation.
4. Leakage of the cylinder lines or piston seals.
6. Seal lips are dry and hardened from heat.
5. There is foreign material in the control valve.
Problem: There is failure of the pump to deliver
fluid.
Hydraulic Pump
Probable Cause:
Problem: Noise in the pump.
1. Low level of the oil in the tank.
Probable Cause: 2. There is a restriction in the pump inlet line.
1. The oil level is low.
3. There is air leakage in the pump inlet line.
2. The oil is thick (viscosity too high) or seals..
4. The viscosity of the oil is wrong
3. The pump inlet line has a restriction in it.(strainer
plugged). 5. The pump has too much wear.
4. Worn parts in the pump. 6. Failure of the pump shaft or coupling.

5. Oil is dirty. 7. The bolts of the pump do not have the correct
torque.
6. Air leaks into the inlet line.
8. Filter by-pass not working or installed backwards.
Problem: The oil temperature is too high.
Probable Cause: Hydraulic Control Valve

1. The oil level is low.
Problem: The control spools do not move freely.
2. There is a restriction in an oil passage.
Probable Cause:
3. The relief valve setting is too low.
4. The oil is too thin. 1. The temperature of the oil is too high.
5. There is air leakage in the system. 2. There is foreign material in the fluid.
6. The pump has too much wear. 3. The fitting connections in the valve body are too
tight.
7. The system operates at too high a pressure.
4. The mounting bolts of the valve assembly do not
a. Relief valve setting too high.
have the correct torque and have twisted the body.
b. Attachment components cause a restriction
during movement. 5. Linkage of the lift and tilt levers does not operate
smoothly.
c. Restrictions in flow control valve, load check
valve and in oil lines. 6. Bent lift or tilt spools.
8. Severe hydraulic usage. 7. Damage to the return springs of the spools.
8. The valve is not at normal temperature for operation.

Problem: Control valve spools have leakage Lift and Tilt Cylinders
around the seals.
Probable Cause: Problem: Leakage around the cylinder rod.
1. There is foreign material under the seal. Probable Cause:
2. The valve spools are worn. 1. Cylinder head (bearing) seals are worn.
3. The seal plates are loose. 2. Cylinder rod is worn, scratched or bent.
4. The seals have damage or are badly worn.

Problem: There is leakage of oil inside the
cylinder or loss of lift or tilt power.
Problem: The load lowers when the lift spool is
moved from the neutral position to the raise Probable Cause:
position.
1. The piston seals are worn and let oil go through.
Probable Cause: 2. Cylinder has damage.
1. There is foreign material in the load check valve
area. Problem: The piston rods show wear.
2. The load check valve and seat show wear.
Probable Cause:
3. Sudden loss of pump oil pressure.
1. The cylinders are not in correct alignment.
4. Damage to the relief valve which causes low oil 2. Oil is dirty.
pressure.
Problem: Foreign material behind the wiper rings

Problem: Spools do not return to neutral. causing scratches on the cylinder rod.
Probable Cause: Probable Cause:

1. The springs are broken. 1. The wiper rings show wear and do not remove dirt
and foreign material.
2. The spool is bent.
3. The system or valve has foreign particles in it.
4. The control linkage is not in alignment.

Steering System
5. The fastening bolts of the valve have too much
torque. Problem: Too much force needed to turn steering
wheel.
Problem: No motion or slow, then a too sudden Probable Cause:

action of the hydraulic system.
1. Priority valve releases pressure oil at a low setting.
Probable Cause:
2. Pump oil pressure is low, worn pump.
1. The relief valve is not correctly set, or will not move 3. Steering gear covers are too tight.
in base and/or is worn.
4. Steering column not aligned with steering gear.
2. There is air in the system.
5. Priority valve spool is held in one position.
3. Dirt or foreign particles between relief valve control
6. Steering gear without lubrication.
poppet and its seat.
7. Low fluid level in the hydraulic supply tank.
4. Valve body has a crack inside.
8. Steer axle damaged.
5. Spool not moved to a full stroke.
9. Worn steer cylinder piston seal.

Problem: Steering wheel does not return to Problem: Lift truck does not turn when steering
center position correctly. wheel is slowly turned.
Probable Cause: Probable Cause:
1. Steering gear covers are too tight. 1. The oil level of the tank is low.
2. Steering column is not in correct alignment. 2. There is air in the steering system.
3. Valve spool in the steering gear has a restriction. 3. The pump operation is not correct.
4. Priority valve check valve permits lift and tilt 4. Dirt in the steering system.
hydraulic oil to affect steering hydraulic circuit.
5. Steering gear operation is not correct.
6. Steering cylinder has worn parts.

Problem: Oil leakage at the pump.
7. Restriction in the steer axle linkage.
Probable Cause:
1. Loose hose connections.

Problem: The temperature of the oil is too hot.
2. Detective shaft seal.
Probable Cause:
1. The viscosity of the oil is wrong.

Problem: Low oil pressure.
2. Air mixed with the oil.
Probable Cause:
3. The relief valve is set too high (priority valve).
1. Low oil level.
4. There is a restriction in the line circuit.
2. Priority valve relief valve spring weak.
5. Unit being held in relief mode for long periods of
3. Relief valve (priority valve) will not move from the time.
open position.
4. Oil leakage inside or outside of the system.
5. Defective pump. Brake Valve

Problem: Low power braking pressure or loss of
Problem: Pump makes noise and the steering power braking
cylinder rod does not move smoothly.
Probable Cause:
Probable Cause:
1. Insufficient pedal stroke.
1. Air in the steering hydraulic circuit.
2. Lines connected to wrong ports.
2. The pump has too much wear.
3. Insufficient load sense signal.
3. Loose connection of the oil line on the inlet side of
the pump. a. Load sense line kinked or leaking.
4. The viscosity of the oil is wrong. b. Load sense orifice missing from fitting.
5. The oil level in the hydraulic tank is low. c. Shuttle valve leaking in brake valve.
6. Worn steer cylinder piston seal. d. Priority valve malfunction.
4. Pilot operated check stuck closed due to

contamination or excessive assembly torque.
5. Flow limiter spool stuck or plugged.

Problem: Low manual braking pressure or loss of Brake System
manual braking
Probable Cause: NOTE: If excessive force is applied to the brake pedal,

the pedal can be forced to the end of the stroke. This
1. Insufficient pedal stroke. is normal and should not be interpreted as a problem.
2. Air in lines.
Problem: Pedal resistance is not solid (spongy)
3. Damaged piston, transfer sleeve or internal O-rings. (under normal pedal pressure).
4. Relief valve leaking or not opening. Probable Cause:
5. Spool/bore leakage due to contamination. 1. Leakage or low oil level.
6. Inlet check valve leaking. 2. Air in the brake hydraulic system.
7. Pilot operated check stuck closed due to contami- 3. Brake valve is loose.
nation or excessive assembly torque.
8. Brake line leaking. Problem: Pedal gradually goes to the floor (under
normal pedal pressure).
Problem: Pedal instability Probable Cause:
Probable Cause: 1. Leakage or low oil level.
1. Air in lines. 2. Defective brake valve.
2. Load sense orifice missing from fitting. 3. Defective piston seals.
3. Incorrect sensing hose size.

Problem: Extra (excessive) pedal travel (under
4. Priority valve malfunction. normal pedal pressure).
Probable Cause:
Problem: External leakage
1. Pedal adjustment is not correct.
Probable Cause:
2. Leakage or low oil level.
1. End cap gasket damaged.
3. Air in the brake hydraulic system.
2. Brake valve spool damaged.
4. Defective brake valve.
3. Casting porosity.
4. Fitting or line leakage. Problem: Brake will not make application.
Probable Cause:
1. Leakage or low oil level.
2. Air in the brake hydraulic system.
3. Linkage is not in correct adjustment or is bent.
5. Bent plates or discs.
6. Piston seals worn or defective.

Problem: Hard pedal.
Probable Cause:
1. Mechanical resistance at pedal or disc assembly.
2. Restriction in the brake line.
4. Brake discs look like glass (glazed) or are worn.
Problem: Both brake disc assemblies will not

release all the way (drag).
Probable Cause:
1. Brake disc assemblies defective (pistons stuck).
2. Brake disc uneven (out of flat).
3. Restriction in the brake line.
Problem: Brakes will not make application after

being bled.
Probable Cause:
1. Leak in hydraulic line or connection.
2. Damaged seals in the brake valve.
Problem: Brake oil low in master cylinder reservoir,

fluid must be added frequently.
Probable Cause:
1. Leak in hydraulic line or connection.
2. Damaged seals in the brake valve.
3. Leak in the disc assemblies.
Parking Brakes
Problem: Brake will not make application.
Probable Cause :
1. Parking brake assembly out of adjustment.
2. Parking brake control cable out of adjustment.
3. Worn brake band.

Hydraulic System
1
Relief Valve Pressure Check
Tools Needed 2
Fittings Group
CONTROL VALVE
Main Relief Tilt, Auxiliary
Valve Relief Valve IDCD087P
Model Mast Pressure Pressure Pressure Tap Location
±500 kPa ±350 kPa (1) Cap. (2) Nipple assembly.
(±75 psi) (±50 psi)
STD With the engine off, remove cap (1) from nipple
D20S FFL 18,100 (2,625) 15,500 (2,250) assembly (2) and connect the 28,000 kPa (4000 psi)
FFT gauge to the nipple assembly.
STD
D25S FFL 19,500 (2,825) 15,500 (2,250)
FFT
STD Lift Relief Valve Check and Adjustment
D30S
FFL 21,550 (3,125) 15,500 (2,250)
D32S
FFT 1. Start the engine and activate the hydraulics until the
STD hydraulic oil is at the normal operating
D33S FFL 23,047 (3,342) 15,500 (2,250) temperature.
FFT
Use the Fittings Group to check the relief valve 2. Lift mast to maximum fork height without load on
pressure. forks. Increase engine rpm to high idle. Hold the
lift control lever in the lifting position and watch the
gauge. The gauge indication is the pressure that
WARNING opens the relief valve at the end of lift cylinder
stroke.
Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump have Caution: Make sure there is adequate ceiling height.
been stopped. Personal injury can be caused if Lift cylinder must be fully extended. Mast should be in
this pressure is not released before any work is the vertical position and truck parked on level ground.
done on the hydraulic system. To prevent possible
injury, lower the carriage to the ground, turn the 3. The correct pressure setting is shown in the chart.
engine 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.
3 4
IDCD087P
Relief Valve Adjustment.
(3) Lock Nut. (4) Stud.

Tilt and Sideshift Relief Valve
Check and Adjustment WARNING
1. Start the engine and activate the hydraulics until the Hydraulic oil, under pressure can remain in the
hydraulic oil is at the normal operating temperature. hydraulic system after the engine and pump have
Put the mast in the full tilt back position. been stopped. Personal injury can be caused if
this pressure is not released before any work is
2. With the enigne at high idle, hold the tilt control done on the hydraulic system. To prevent possible
lever in the full tilt back position and watch the injury, lower the carriage to the ground, turn the
gauge. The gauge indication is the pressure that engine off and move the control levers to make
opens the relief valve. sure all hydraulic pressure is released before any
3. The correct pressure setting is shown in the chart. tightened, removed or adjusted. Always move the
4. If an adjustment to the relief valve setting is the travel of other machines. Be sure that other
necessary, loosen nut (5). personnel are not near the machine when the
made.
Lift Section
Remove nut
5
6 Tie stud here
IDCD087P
Relief Valve Adjustment 1
(5) Locknut. (6) Stud.
IDCS121P
5. Turn setscrew (6) clockwise to increase or

counterclockwise to decrease the pressure setting 1. Remove the nut from the slotted tie-stud of main
of the relief valve. hydraulic valve
6. Tighten the locknut and check the pressure setting 2. Remove the slotted tie-stud from the valve.
again for correct adjustment.
3. Use Hex Wrench (6mm or 1/4 inch), turn the flow
control adjuster (1) clockwise to increase the flow
or counterclockwise to decrease the flow.
Flow Control Valve Adjustment 4. Assemble the tie stud in the valve. Torque the stud
to 40.5 ± 2.5 N·m (360 ± 24 lb·in)
The tilt and first attachment speeds can be adjusted at
the control valves. They can be adjusted by turning the 5. Reinstall the nut on the tie bolt.
plug in the hydraulic control valve body. The lift speed
can not be adjusted. Do the procedure that follows to
change the flow control assembly.

Standard Lift Cylinder Air Removal 6. Repeat Steps 4 and 5 until there are no air bubbles
at the setscrews.
After the standard lift cylinder has been disassembled 7. After all the air is removed, tighten the setscrews to
and then assembled again, it may be necessary to a torque of 5 to 7 N·m (45 to 60 lb·in).
remove the air (bleed) from the cylinder.
8. Fill the hydraulic tank to the full mark.
1. With no load, lift and lower the mast and carriage
through one complete cycle. 9. Lift and lower the mast and carriage again through
one complete cycle. If the mast does not operate
2. With the forks on the floor, check the oil level in the smoothly, repeat Steps 3 through 9.
hydraulic tank. Add oil (if necessary) to bring the oil
level to the full mark.
3. With no load, lift and lower the mast and carriage

again through four complete cycles.
WARNING
The oil will have high pressure present. To prevent
personal injury, do not remove the bleed screws
completely. Keep hands and feet away from any
parts of the truck that move, because the forks will
lower when the bleed screw is loosened.
4. Lift the forks high enough to put a load on all stages

of the lift cylinders.
IDCS212P
Setscrew Locations
(Standard Cylinders)
NOTE: The Standard Lift mast has two secondary

cylinders and no primary cylinders. The Full Free and
Full Free Triple Lift mast has one primary and two
secondary cylinders.
5. Locate the setscrew on each lift cylinder. Slowly

open setscrews no more than one turn. The weight
of the carriage will force air and hydraulic oil out of
the cylinders through the setscrews. Close the
setscrews before all the pressure is out of the
cylinders. This will prevent air from entering
through the setscrews.

Mast and Carriage Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.*
D581814 Under Size 108.6 mm(4.276 in)
Mast Adjustment D581815 Standard 109.6 mm(4.135 in)
D581816 Over Size 110.7 mm(4.358 in)
NOTE: The Standard, Full Free Lift and Full Free * Permissible tolerance ±0.08mm (.003in)
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.
To make the mast clearance adjustments, mast must

be removed from the lift truck.
Carriage, chain and lift cylinder must be removed from

the mast for easy adjustments.
Use the procedure that follows to adjust the load

bearings.
IDCD036P
A. Lower Bearing Adjustment of
Intermediate Mast 2. Find narrowest point by ruler on the stationary mast
in the area where the bearings make contact at
475 mm (18.7 in) channel lap.
3 4 5 6
C
IDCS123S
Mast Adjustment Lower Bearings
(A) Zero clearance. (B) Minimum clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
1. 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

3 4 5 6
IDCD037P
IDCS123S

IDCD033P (A) Zero clearance. (B) Minimum clearance. (C) Zero
clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
3. Install 1 mm shim to each bearing of intermediate
lower and stationary upper basically. Lifting by
crane, insert intermediate mast into stationary mast
from the upper side.
NOTE: When installing shims (5) behind bearing (4),

make sure the amount of shim is divided equally when
positioned behind each bearing (4).
IDCD039P
4. Make surer intermediate mast lower bearings are

properly shimmed in the stationary mast by rolling
up and down and moving intermediate 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.

B. Upper Bearing Adjustment of Stationary
Mast
IDCD039P
5. 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. IDCD033P
If intermediate mast is stuck and cannot move by
rolling up and down, there might be excessive
shims. Pull out the intermediate mast from the 1. Lift by crane, and pull out intermediate mast from
stationary mast and remove shim 0.5 mm to both stationary mast. Install 1 mm shim to each bearing
intermediate lower bearings. Repeat same of stationary mast upper. Bearing should be part
procedure of above until properly shimmed. There number D581814 under size bearing.
is to be contact zero clearance (C) between
intermediate lower bearings and stationary channel
at approximately 475 mm (18.7 in) channel lap.
D E
9 7
10 E
IDCS124S
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.

C. Upper Pad Adjustment
D E
F
IDCD038P
9 7
2. Make sure stationary mast upper bearings are
properly shimmed by rolling up and down and
moving intermediate mast to right and left. If 8
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 stationary upper bearings. 10 E
IDCS124S
Mast Adjustment Upper Bearings

(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
IDCD014P
3. In case of standard and full free mast, stationary IDCD033P

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 shims. Pull out the intermediate mast
from the stationary mast and remove shim 0.5 mm
to both stationary upper bearings. Repeat same
procedure of above until properly shimmed. There
stationary upper bearings and the widest point of
intermediate mast to be checked before.

1. Install shims (8) behind each pad (7) until there is Mast And Carriage Bearings
0.80 mm (.031 in) maximum clearance (E) between
the pads and the inner and intermediate masts with Part No. Bearing Size Bearing O.D.*
the masts at full extension. Lift by crane, and pull D581814 Under Size 108.6 mm(4.276 in)
out intermediate mast from stationary mast and D581815 Standard 109.6 mm(4.135 in)
insert the shims behind each pad. In case of D581816 Over Size 110.7 mm(4.358 in)
standard and full free mast, the pads of stationary * Permissible tolerance ± 0.08mm (.003in)
upper can be easily extruded by pulling down the
inner mast from the bottom of stationary mast.
D. Lower Bearing Adjustment of Inner Mast
3 4 5 6
IDCD040P
2. 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 475 mm (18.7 in).
IDCS123S
Mast Adjustment Lower Bearings IDCD031P
(A) Zero Clearance. (B) Minimum Clearance. (C) Zero
Clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
3. Install 1 mm shim to each bearing of inner lower
and intermediate upper basically. Lift by crane,
1. Select lower bearings (3) and (4) from the chart to insert inner mast into intermediate mast from the
obtain minimum clearance (B) between bearing upper side.
and channel leg for full channel length. Use same

Carriage Adjustment
Note: The standard, Full Free Lift and Full Free Triple
Lift carriage load bearings are all adjusted the same
4 5 6 way. The Full Free Triple Lift carriage is shown in the
3
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.
3 4 B 5
A
A
B C
VIEW A-A
C A A
6
IDCS123S B B C
(A) Zero Clearance. (B) Minimum Clearance. (C) Zero clearance.
(3) Bearing. (4) Bearing. (5) Shims. (6) Shims.
VIEW B-B
7
C C
4. Make sure inner mast lower bearings are properly A
shimmed in the intermediate mast by rolling up and
down and moving inner mast to right and left. If
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 inner mast is stuck and C VIEW C-C 8 A
cannot move by rolling up and down, there might
be excessive shim. Pull out the inner mast from IDCS125S
the intermediate mast and remove shim 0.5 mm to Carriage Adjustment
both inner lower bearings. Repeat same procedure (3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
of above until properly shimmed. There is to be (7) Middle Bearings. (8) Lower Bearings. (A) Zero Clearance.
contact zero clearance (C) between inner lower (B) 6.0 to 9.0 mm. (.236 to .354 in) Clearance.
bearings and intermediate channel at narrowest (C) Minimum Clearance.
point.
1. Select lower bearings from the chart to obtain
E. Upper Bearing Adjustment of intermediate minimum clearance (B) between bearings and
Mast
bearing in all six locations.
Follow same procedure with above B.
F. Upper Pad Adjustment of Intermediate

Mast
Follow same procedure with above C.

Mast And Carriage Bearings
Part No. Bearing Size Bearing O.D.*
D581814 Under Size 108.6 mm(4.276 in)
D581815 Standard 109.6 mm(4.135 in)
D581816 Over Size 110.7 mm(4.358 in)
* Permissible tolerance ±0.08mm (.003in)
IDCD016P
5. Tighten screw (5) that holds the top bearings to the

carriage to a torque of 34±7 N·m (25±5 lb· ft)
IDCD014P
2. Find narrowest point by ruler on the inner mast in

the area where the bearings make contact.
11
3. Install enough shims (4) that have been divided into
two equal groups behind bearings (3). At
installation, there is to be contact [zero clearance
IDCD009P
(A)] between the bearings and the narrowest point
of inner mast.
6. Shim stop bolt (11) as required to obtain a 6 to 9
mm (.24 to .35 in) lap with top carriage stop on the
4. Do step 2 through 3 for other sets of bearings. inner upright.
Chain Adjustments
Chain Adjustment Check
IDCD015P
IDCS006P
Chain Adjustment Check
Lift the carriage and mast high enough to put their full
weight on the carriage and mast chains. Check 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 chain
procedure that follows: links and pins. Do the steps that follow to check chain
wear.
WARNING 1. Lift the mast and carriage enough to put tension on

the lift chains.
Personal injury can be caused by sudden
movement of the mast and carriage. Blocks must 2. Measure precisely ten links of chain distance at the
be used to prevent the mast and carriage from any center of pins in millimeter.
movement while the adjustments are made. Keep A chain wear gauge can also be used.
hands and feet clear of any parts that can move.
3. Calculate chain wear rate.
New one pitch = 19.05 mm (D20/25/30/32S Model)

25.40 mm (D33S Model)
Chain wear rate (%)

Actual measurement - 190.5 x100 (D20/32S Model)
=
190.5
= Actual measurement - 254 x100 (D33S Model)

254
1
IDCD007P
Inner Lift Chains
(1) Chain Anchor Nuts.
WARNING
1. Lift the mast and carriage and put blocks under the Do not put a lift truck into service if the chain wear
mast and carriage to release the tension from the indication is 2% or more. A reading of 2% or more
lift chains. could cause damage or injury to persons.
2. Make adjustments to chain anchor nuts (1) or bolts

(2) for equal tension of the mast and carriage 4. If the chain wear indication is 2% or more, replace
chains. the lift chain.
3. Put LOCTITE NO.242 Thread Lock on the threads

of the locknuts after the adjustment is completed.
IDCD023P
Outer Lift Chains
(2) Chain Anchor Bolts.

Carriage and Mast Height Adjustment Forks Parallel Check
1. Move the mast either forward or backward so it is in 1. Lift the mast and operate the tilt control lever, until
the vertical position. the top surface of the forks is parallel with the floor.
Place two straight bars, that are the same width as
2. Lower the carriage completely. 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.
IDCS191S
3. On Full Free Lift and Full Free Triple Lift models, the
IDCD130P
bottom of the inner mast must be even with the
Forks Parallel Check
bottom of the stationary mast.
(Typical Example)
4. Measure the distance from the bottom of the inner
upright to the bottom of carriage bearing.
5. The measurement (A) must be as follows:

STD………………………………………………..Zero
FFL & FFTL…………..…41 ±1.5 mm (1.61 ± .06 in)
NOTE: On Standard Lift models the bearing must be

even (flush) with the inner mast.
If the above measurements are not correct, make
adjustments to the chains to get the correct
measurement. See Chain Adjustments in TESTING
AND ADJUSTING.

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
IDCS009P
Tilt Cylinder Length 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.
IDCD008P Tilt Cylinders With Tilt Back Limiting Group

Tilt Angle Check (Typical Example)
The tilt angle of the mast must be checked in the full

tilt back and full tilt forward positions. A tilt indicator or
a protractor can be used to measure the angle. Both
sides of the mast must be checked to make sure that
the mast is not twisted.
The tilt angle is determined by the tilt cylinders used.

See tilt cylinders in specifications to determine the tilt
angle from the cylinder being used.
IDCS129S
Tilt Cylinder Adjustment
(1) Pivot eye. (2) Bolt. (3) Rod. (4) Shims. (5) Spacer.
(6) Head.
1. With the mast at full forward tilt, loosen bolt (2).
2. Slide spacer (5) back so rod (3) can be turned into

or out of pivot eye (1) to obtain the correct length or
angle.

Drift Test
WARNING
Tilt cylinder pivot eyes can loosen if the torque on Drift is movement of the mast or carriage that is the
the pivot eye clamping bolt is not tight enough. result of hydraulic leakage in the cylinders or control
This will let the tilt cylinder rod turn in the tilt valve. Before testing the drift:
cylinder eye. The cylinder rod may then twist our
of the pivot eye and the tilt cylinder will be out of
alignment or may let the mast fall and cause WARNING
personal injury or damage. When the rod lengths
are made even, the tilt angle differences or the Personal injury can be caused by sudden
mast alignment will no longer be a problem. movement of the mast or carriage. Use wood
blocks and clamps to hold the mast in this
position. Keep hands and feet clear of any parts
3. Tighten bolt (2) and the nut to a torque of 95 ± 15 that can move.
N·m (70 ± 10 lb·ft).
4. With mast at full back tilt, install shims (4) as 1. Check the chain adjustment and tilt cylinder
required to permit no gap between spacer (5) and alignment and make necessary adjustments.
head (6). Shim so mast does not twist at full tilt
back. 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

period. Drift for all models shall not exceed 100.0
mm (4.00 in).

Drift Test For The Tilt System Steering System
1. Put a rated capacity load on the forks on the lift
truck. Operate the lift truck through a complete lift
Steer Wheel Bearing Adjustment
and tilt cycle until the oil is at normal temperature
for operation, 45 to 55 °C (113 to 131 °F).
2. Put the mast in a vertical position. Raise a rated

capacity load to a height of 2.5 meters (8.2 ft). In 2
the case of trucks with less than 2.5 meters (8.2 ft)
height extension, raise the load to the truck’s
maximum height.
1
IDCS192P
Bearing Adjustment
(1) Nut. (2) Lock.
1. Tighten nut (1) slowly to 135 N·m (100 lb·ft) while

the wheels is rotated in both directions put the
bearings into position. Use tool numbered T059.
IDCS009P 2. Loosen nut (1) completely. Tighten nut (1) again to

Tilt Drift Check. 50 ± 5 N·m (37 ± 4 lb·ft) .
3. The tilt drift is measured as the charge in the tilt 3. Bend lock (2) over nut (1) to hold the nut in position.
cylinder stroke. Measure any drift of the mast for
ten minute period.
Drift for shall not exceed 35.5 mm (1.40 in).

Steering Axle Stop Adjustment Steering Knuckle Bearing Preload
Adjustment
1
6
2
A
3
4 5
IDCS132S 7 8 9
Steer Angle
(1) Bolt. (2) Nut. (3) Bolt. (4) Nut. (5) Bolts. (A) 80° angle.
IDCS133S
Use the procedure that follows to make an adjustment Steering Knuckle Bearing Preload Adjustment
to the steer axle turning angle. (6) Steering link. (7) Shims. (8) Cover. (9) Bolts.
1. Adjust the cylinder rod extension so it is equal on

1. During assembly of the steering knuckle, install the
both sides of the axle.
upper bearing cup, cone and seal.
2. Loosen nuts (2) and (4) on both sides of the steer
2. Install lower bearing group cover (8) without shims.
axle.
Tighten two opposed cover bolts (9) to a torque of
5.6 N·m (50 lb·in).
3. Turn the steer wheel one direction until the steer
cylinder rod extension measures 94mm(3.7 in)
3. Measure the clearance between cover (8) and the
more than the straight ahead measurement.
axle beam at each bolt with a feeler gauge.
4. Adjust stop bolt (1) on one side and stop bolt (3) on
4. Take an average of the measurements found in
the other.
Step 3. Select shims (7) equal in thickness to the
average clearance.
5. Tighten nut (2) on one side and nut (4) on the other
side. Turn the steer wheel the opposite direction
5. Remove the bearing group and install shims (7),
and do the same procedure for the
cover (8) and bolts (9). Tighten bolts (9) to a torque
opposite stop bolts. This will give a maximum
of 55±6 N·m (40±5 lb·ft).
cramp angle of 80°
6. With steering links (6) disconnected from the
steering cylinder, check knuckle for 4.5 to 6.8
N·m(40 to 60 lb·in) of rolling torque. Add or remove
shims from cover (8) to obtain the proper rolling
torque.
7. Connect links (6) to the steering cylinder. Tighten

cylinder mounting bolts (5) to a torque of 460 ± 60
N·m (340 ± 40 lb·ft).

Steering System Pressure Check 6. If the indication is not correct, then there is steering
hydraulic failure in the components.
If the steering system does not work correctly, check
the hydraulic tank for the correct oil level and the
hoses and connections for leakage. If all these items
are correct, use the Pressure Gauge Kit to check the
steering hydraulic system and its relief pressure (6)
setting.
(5)
Hydraulic Steering Gear

(1) Elbow (Pressure line from priority valve).
M10 X 1.0 THD
WARNING
(4)
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all IDCS134S
hydraulic pressure is released in the steering (4) Pressure-Checking Adapter. (5) Pressure-Tube.
system. Move the steer wheels to the left and right (6) Pressure Gauge.
and then to the straight forward direction.
a. With the engine running, turn the steer wheels in

Check steering system relief pressure as follows: any directions and read the indication on pressure
gauge (6).
1. Turn the engine off.
b. If the indication is approximately the pressure
2. Remove plug from elbow(1) shown in Step 5, then the steering gear has a
Install pressure-checking adapter(4) and connect hydraulic failure.
pressure-tube (5) and pressure gage (6). Pressure
gage(6) has a range of 28000 kpa (4000psi). c. If the indication is too low or too high, then the
priority valve or its components must be replaced.
3. Move the seat to the normal position for operation, 7. If the steering gear and the priority valve are
turn the key switch to the ON position and activate working properly, the steering cylinder is defective
the hydraulic controls until the oil is at a temper- and must be repaired.
ature for normal operation.
8. Correct the problem and check steering relief valve
4. Turn the steer wheels to the left or right against the pressure again.
stops and make a note of the indication on the
pressure gauge.
5. The indication on the pressure gauge must be the

priority valve relief setting of 9000 + 300 kPa
(1305+43.5 psi). If the indication is correct and a
problem exists, then there is possibly a mechanical
failure in the steering system.

Brake System Parking Brake Test
Brake System Air Removal

WARNING
When the brake pedal resistance is spongy (not solid) To prevent personal injury, the operator must be
it is usually an indication that there is air in the brake ready to use the service brake if the parking brake
hydraulic system. The cause may be low fluid or oil is not adjusted correctly and the lift truck starts to
level, leakage in the system, a broken brake line or a move.
brake line that is not connected.
To remove air from the brake system, do the
procedure that follows.
1. Drive the fully loaded lift truck forward up a 15%
incline.
1 2. Half way up the incline, stop the lift truck with the
service brakes. Make an application of the parking
brake.
3. If the parking brake has the correct adjustment, the

lift truck will be held in this position.
IDCS213P
4. If the parking brake does not hold, do the steps in
Right Bleed Screw Location (Left Not Shown)
Parking Brake Adjustment.
(1) Bleed Screw.
1. Check the hydraulic oil level and fill if needed. See

Operation and Maintenance Manual.
2. Start the engine and keep it at low idle.
3. Put pressure on the brake pedal and open bleed

screw (1) to let air out of the system. Close bleed
screw (1), while pressure is still on the brake pedal,
then let the pedal return to the original position.
4. Do Step 3 again as many times as necessary until

the brake liquid is free of air.
5. Use the procedure in Steps 3 and 4 again, except

this time use the left bleed screw (not shown).
6. Check the hydraulic oil level and fill as required.

See Operation and Maintenance Manual.

Parking Brake Adjustment
7
5
6
4
1
2
3
IDCS212S IDCS219S
Parking Brake Adjustment Parking Brake Adjustment
(1) Screw. (2) Nut. (3) Stop. (4) Lever. (5) Lock. (6) Nut (7) Switch Assembly. (8) Screws.
8. Loosen screws (8).

NOTICE
Turn the adjustment screw clockwise to tighten. 9. Adjust switch assembly (7) until switch actuation
Turning the screw too far counterclockwise could allow occurs between the 4th and 5th click as the
parts to fall into the bottom of the transmission. The parking brake is engaged. Tighten screws (8).
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.
5. Loosen nut (2).
6. Tighten screw (1) to a torque of 5.6 to 6.8 N·m (50

to 60 lb·in).
7. Loosen screw (1) 1.2 to 1.5 turns, hold in this

position and tighten nut (2).

SB4139E00
Jan. 2004
Disassembly &
Assembly
Lift Trucks Vehicle Systems
D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3),
D32S-3(B3.3),D33S-3(B3.3)
WARNING
in injury or death.
publication.
available.
1
Index
Backrest...................................................................... 7
Brake Valve............................................................... 54
Carriage ...................................................................... 7
Counterweight........................................................... 71
Creeper & Brake Control .......................................... 69
Drive Axle.................................................................. 72
Engine....................................................................... 78
Forks........................................................................... 7
Hood (with seat) Assembly ......................................... 5

Hydraulic Control Valves........................................... 65
Hydraulic Pump (with Priority Valve)......................... 39
Mast .......................................................................... 13
Overhead Guard ......................................................... 6
Primary Lift Cylinder ................................................. 32
Secondary Lift Cylinders........................................... 29

Standard Lift Cylinders.............................................. 26
Steer Axle.................................................................. 60
Steer Wheels & Bearings.......................................... 56
Steering Cylinder ...................................................... 62
Steering Knuckles, Kingpins & Bearings................... 59
Steering Unit ............................................................. 44
Steering Wheel ......................................................... 43
Tie Rods.................................................................... 58
Tilt Cylinders ............................................................. 35
Transmission............................................................. 74
Universal Joint .......................................................... 70
WARNING
Disconnect batteries before performance of any
service work.

Disassembly & Assembly
Hood (with seat) Assembly

3
Remove & Install Hood (with seat)

Assembly
IDCD053P
5. Remove the washers and four bolts (3).
1
4
IDCD051P
5
WARNING
The hood and seat assembly can fall when nut (1)
IDCD054P
is removed from the support cylinder rod. To avoid
personal injury, support the seat and hood
assembly before removing nut (1). 6. Release latch (5). Use the hoist to remove hood and
seat assembly (4). The hood and seat assembly
weighs 52 kg (115 lb).
1. Raise the hood. Support the hood with a hoist. 7. Install the hood and seat assembly in the reverse
order of removal.
2. Remove nut (1) from the support cylinder. Remove
the cylinder rod from the bracket.
3. Lower the hood.
IDCD052P
4. Remove the bolts (2) from the cover. Remove cover.
Vehicle Systems 5 Disassembly & Assembly

Overhead Guard
Remove & Install Overhead Guard
IDCD057P
3. Remove the washers, nuts, and two bolts (3).
4. Remove front overhead guard (1), Front overhead

IDCD055P guard (1) weighs 30 kg (66 lb).
1. Support overhead guard (1) with lifting straps and a

hoist.
5
4
IDCD058P
5. Remove the washers, nuts, and four bolts (4).
IDCD056P 6. Remove rear Leg (5).

2. Remove the washers, nuts, and two bolts (2).
7. Install front overhead guard (1) and rear leg (5) in
the reverse order of removal.

Forks Backrest
Remove & Install Forks Remove & Install Backrest
2
2
IDCD001P IDCD003P
1. Fasten a hoist to the backrest. Remove bolts(2) that

fasten the backrest to the carriage.
2. Remove backrest (1). Backrest(1) weighs 40 kg

(90 lb).
3. Install backrest(1) in the reverse order of removal.
Carriage
IDCD002P
Remove & Install Carriage
1. Remove stopper bolt and washer (3).
Tools Needed A
2. Lift fork pin (1).
Retaining Ring Pliers 1
3. Use a suitable C-clamp, strap and hoist to support
the fork as shown. Start By:
4. Slide the fork to slot (2) in the middle of the carriage. a. Remove forks.
5. Remove the fork. The weight of the fork is 50 kg b. Remove backrest.

(110 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).

NOTE: For purposes of reassembly, identify and mark
2 all hydraulic lines and connectors before removing or
disconnecting.
IDCD004P
IDCD006P
3. Remove four bolts(8) from the chain guard/hose

support assembly(6). Set the hoses aside, clear of
the primary cylinder and cross head.
4
10
IDCD005P
1. Raise carriage(1). Position a wooden block as

shown. Lower carriage(1) onto the wooden block.
2. Disconnect two hydraulic lines(4) from side shifter

cylinder (2). Plug and cap all openings to prevent 9
contamination and debris from entering system. IDCD007P
4. Remove two bolts (10) from the hose mounting

WARNING bracket. Set the hoses aside. Remove two nuts(9)
from the chain anchors. Set the chains aside, clear
To prevent personal injury be sure pressure in the of the mast.
hydraulic system has been released before
disconnecting any hydraulic lines. 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.

11
12
15
IDCD008P
5. Use tool(A) to remove retainer ring(11) from the

cross head shaft.
14
6. Remove cross head(12) from the shaft.
IDCD010P
8. Raise the inner mast to pull out carriage as shown.
9. Remove carriage from bottom of inner mast(15).

13 Carriage(14) weighs 116kg (255 lb).
NOTE: Use the following steps to install the carriage.
10. Raise the inner mast to put in the carriage onto the
mast, and lower the inner mast to cover
carriage(1) bearing fully.
IDCD009P
7. Remove carriage bolts(13).

13
IDCD009P
11. Install carriage bolts(13).

11
4
12
IDCD008P IDCD005P
12. Install cross head(12) and retaining ring(11). 15. Connect two hydraulic line(4) in their original
positions.
10 End By:
a. Install backrest.
b. Install forks.
9
Disassemble Carriage
IDCD007P
Start By:
13. Put the chains in position over cross head(12). a. Remove carriage.
Install nuts(9) onto the chain anchors to a torque
of 270 ± 40 N·m (200 ± 30 lb·ft).
Install bolts(10) onto the hose mounting bracket. 1
2
IDCD011P
Typical Example
IDCD006P
1. Remove the roll pins and pins(2) to disconnect
chains(1).
14. Install chain guard/hose support assembly(6) and
four bolts(8) to a torque of 8 ± 2 N·m (6 ± 1.5
lb·fft).

3 4 B 5
A
3 VIEW A-A
A A
6
IDCD012P
B B C
2. Remove four lower roller bearings(3) and the shims
from the carriage.
VIEW B-B
7
C C
4
A
A
5 C VIEW C-C 8
IDCS125S
6
IDCD013P
Carriage Adjustment
(3)Upper bearings. (4) Shims. (5) Bolt. (6) Screw.
(7)Middle bearings. (8) Lower bearings. (A) Zero
3. Remove screw(5) and washer(4). Remove top roller clearance. (B) 6.0 to 9.0 mm. (.236 to .354 in)
bearings(6) and the shims. clearance. (C) Minimum clearance.
1. Select lower bearings from the chart to obtain

minimum clearance (B) between bearings and
Assemble Carriage bearing in all six locations.

NOTE : The standard, Full Free Lift and Full Free Part No. Bearing Size Bearing O.D. *
Triple Lift carriage load bearings are all adjusted the D581814 Under Size 108.6 mm (4.276 in)
same way. The Full Free Triple Lift carriage is shown D581815 Standard 109.6 mm (4.276 in)
in the following illustrations. D581816 Over Size 110.7 mm (4.358 in)
* Permissible tolerance ± 0.08 mm (.003in)
To make the carriage clearance adjustments, carriage
must be removed from the mast.
Use the procedure that follows to adjust carriage load

bearings.

11
IDCD014P IDCD009P
2. Find narrowest point by ruler on the inner mast in 6. Shim stop bolt (11) as required to obtain a 6 to 9
the area where the bearings make contact. mm (.24 to .35 in) lap with top carriage stop on the
inner upright.
3. Install enough shims (4) that have been divided into
two equal groups behind bearings (3). At installation,
8
there is to be contact [zero clearance (A)] between 6
the bearings and the narrowest point of inner mast.
7
4. Do step 2 through 3 for other sets of bearings (8), 9
(9).
IDCD011P
7. Position chains(6) on the carriage. Install pins(7)

and the roll pins.
3 End By:
IDCD015P
a. Install carriage, raise the inner mast and insert the
carriage from the bottom of inner mast.
IDCD016P
5. Tighten screw (5) that holds the top bearings to the

carriage to a torque of 34 ±7 N·m (25 ±5 lb·ft)

Mast
4
Remove & Install Mast

Start By:
6
a. Remove forks.
5
7
IDCD019P
1
3. Disconnect two hydraulic lines(4).
2
WARNING
Tilt cylinders(7) can drop when pin(6) is removed.
IDCD017P To avoid component damage or personal injury,
support tilt cylinder(7) while removing pin(6).
1. Support mast assembly(2) with a hoist and two

straps (1) as shown. 4. Remove bolt(5) from each side of mast assembly(2).
5. Remove pin(6) from the tilt cylinders on each side of

the mast assembly(2).
IDCD018P
IDCD020P
NOTICE
Place identification marks on all hydraulic connectors
and hoses to assure proper installation. Plug and cap 6. Tilt forward mast assembly(2) about 8° with the
all hydraulic connectors and hoses to avoid debris and hoist. Remove bolts(8) from each side of the base
contamination from entering the system. of mast assembly(2).
2. Disconnect hose(3).

Disassemble Mast
WARNING
Start By:
Loosen the tension of straps to be connected with
hoist when mast assembly(2) is tilted forward.
a. Remove primary lift cylinder.
If straps are too tight, mast assembly(2) could
slide off when bolts(8) are removed.
b. Remove mast.
NOTE: The following disassembly and assembly

7. Use the hoist to remove mast assembly(2) from the
procedure is for a full free triple lift mast.
machine.
8. Install the mast in the reverse order of removal.
End By:
a. Install forks.
b. Fill hydraulic oil to tank*.
1
* Refer to the Operation And Maintenance Manual for
further information. IDCD021P
1. Remove hoses(1) along with the hose support

clamps.

3
6
IDCD023P IDCD025P
2. Remove hose sheave (3). 5. Remove top cylinder retainer bolt(6) from each side
of the mast.
3. Remove chain nut(4) from the top of the mast(each
side).
IDCD026P
IDCD024P
6. Remove cylinder retainer brackets(8) from each
cylinder.
4. Disconnect and remove chains(5) from the bottom
of the mast.

9 12
IDCD027P IDCD030P
7. Fasten a nylon strap and hoist to secondary 10. Check the condition of the bearings(12) located in
cylinder(9) as shown. Remove secondary each of the mast mounting bores.
cylinders(9). Each cylinder weighs 50 kg(110 lb). Replace the bearings(12) with new if worn or
damaged.
13
10
IDCD028P
IDCD031P
8. Check the condition of bearings(10) located in each

of the tilt cylinder pin bores. Replace 11. Fasten nylon straps and hoist to inner channel(13).
bearings(10) with new if worn or damaged. Remove inner channel(13). The weight of the
inner channel is 150kg(330 lb).
11
14
IDCD029P
IDCD032P
9. Remove mast mounting pins(11) from the mast

12. Remove rollers(14) and the shims from the inner
mounting bores.
channel mast.

15 18
19
IDCD033P IDCD035P
13. Fasten nylon straps and a hoist to the intermediate 16. Remove rollers(18) and the shims from the
mast channel(15). Remove mast channel(15). The stationary mast channel.
intermediate mast channel weighs 168kg (370 lb).
17. Remove nylon pads(19) and the shims.
16
17
IDCD034P
14. Remove rollers(16) and the shims from the

intermediate mast channel.
15. Remove nylon pads(17) and the shims.

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 IDCD036P
replacement.
4. Find narrowest point by ruler on the staionary mast
A. Lower Bearing Adjustment of
in the area where the bearings make contact at 475
Intermediate Mast
mm (18.7 in) channel lap.
NOTE: When installing shims (2) behind bearings (1),

3 4 5 6
make sure the amount of shim is divided equally when
positioned behind each bearing (1).
5. Install the correct amount of shim (2) behind rollers

until contact (zero clearance) is made between the
rollers.
IDCS123S

(A) Zero clearance. (B)Minimum clearance. (C)Zero clearance.
(3)Bearing. (4)Bearing. (5)Shims. (6)Shims.

obtain minimum clearance (B) between bearing and
channel leg for full channel length. Must use same

Part No. Bearing Size Bearing O.D. *
D581814 Under Size 108.6 mm (4.276 in)
D581815 Standard 109.6 mm (4.276 in)
D581816 Over Size 110.7 mm (4.358 in)
* Permissible tolerance ± 0.08 mm (.003 in)

NOTICE 4 5 6
3
When the correct amount of shim has been installed
behind rollers (1) there will be contact (zero clearance)
between the rollers and the inner mast at most narrow
point of mast (refer to step 4)
1 2
C
IDCD037P
IDCS123S
IDCD033P
6. Install 1 mm shim to each bearing of intermediate

lower and stationary upper basically. Lifting by IDCD039P
crane, insert intermediate mast into stationary mast
from the upper side.
7. Make sure intermediate mast lower bearings are
NOTE: When installing shims (5) behind bearings (4), properly shimmed in the stationary mast by rolling
make sure the amount of shim is divided equally when up and down and moving intermediate mast to right
positioned behind each bearing (4). 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.

D E
7
IDCD039P
9
8. In case of standard and full free mast, inner lower 8

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
10 E
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 IDCS124S
until properly shimmed. There is to be contact zero Mast Adjustment Upper Bearings
clearance (C) between intermediate lower bearings (D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
and stationary channel at approximately 475 mm (F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
(18.7 in) channel lap.
B. Upper Bearing Adjustment of Stationary

Mast
IDCD038P
10. Make sure stationary mast upper bearings are

properly shimmed by rolling up and down and
IDCD033P moving intermediate mast to right and left. If
9. Lift by crane, and pull out intermediate mast from pull out the intermediate mast from the stationary
stationary mast. Install 1 mm shim to each bearing mast with crane and add shim 0.5 mm or 1 mm to
of stationary mast upper basically. Bearing should both stationary upper bearings.
be selected D581814 under size bearing.

C. Upper Pad Adjustment
D E
8
IDCD039P
F
11. In case of standard and full free mast, stationary
upper bearings can be easily extruded by pulling 9 7
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 8
excessive shim. Pull out the intermediate mast
from the stationary mast and remove shim 0.5 mm
to both stationary upper bearings. Repeat same 10 E
IDCS124S
stationary upper bearings and the widest point of Mast Adjustment Upper Bearings
intermediate mast to be checked before. (D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
IDCD033P
12. 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 intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
stationary mast and insert the shims behind each
pad. In case of standard and full free mast, the
pads of stationary upper can be easily extruded by
pulling down the inner mast from the bottom of
stationary mast.

D. Lower Bearing Adjustment of Inner Mast
3 4 5 6
IDCD040P
A 14. Find narrowest point by ruler on the intermediate

mast in the area where the inner lower bearings
make contact full length of intermediate mast
B excluding minimum channel lap 475 mm (18.7 in).
IDCS123S

obtain minimum clearance (B) between bearing
and channel leg for full channel length. Must use IDCD031P
same bearing on left and right side.
Mast And Carriage Bearings 15. Install 1 mm shim to each bearing of inner lower
Part No. Bearing Size Bearing O.D. * and intermediate upper basically. Lifting by crane,
D581814 Under Size 108.6 mm (4.276 in) insert inner mast into intermediate mast from the
D581815 Standard 109.6 mm (4.276 in) upper side.
D581816 Over Size 110.7 mm (4.358 in)
* Permissible tolerance ± 0.08mm (.003in)

E. Upper Bearing Adjustment of intermediate Mast
3 4 5 6
Follow same procedure with above B.
F. Upper Pad Adjustment of Intermediate Mast
Follow same procedure with above C.
C
IDCD041P
IDCS123S
17. If the bearings were removed from the mast
(3)Bearing. (4)Bearing. (5)Shims. (6)Shims. mounting blocks, install new ones.
16. 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 inner mast is stuck and
cannot move by rolling up and down, there might
11
be excessive shim. Pull out the inner mast from
the intermediate mast and remove shim 0.5 mm to
IDCD042P
both inner lower bearings. Repeat same
is to be contact zero clearance (C) between inner 18. Put a small amount of clean grease on mounting
lower bearings and intermediate channel at pins (11). Install mounting pins (11) into mast
narrowest point. mounting blocks.

14
IDCD043P IDCD025P
19. If the bearings were removed from the tilt 22. Install top retainer bolts (14) for the secondary
cylinder pin bores, install new ones. cylinders.
12
13° 15°
IDCD027P
20. Fasten a hoist and nylon strap to secondary

cylinder (12). Install secondary cylinders (12) into IDCS322S
the stationary mast.
23. Install hydraulic steel tube to each secondary
cylinder. When install the steel tube, assembling
angle should be kept as shown in above figure.
16
13
IDCD026P
21. Install secondary cylinder mounting brackets (13) IDCD024P

over the secondary cylinders.
24. Connect chains (16) at the bottom of the mast.

18
16
IDCD023P IDCD045P
25. Connect chains (16) at the chain bracket of 28. Install primary lift cylinder.
stationary mast upper.
26. Install sheave (18) of lift hose.
19
IDCD044P
27. Install the lift hose support bracket(19) and hoses. IDCD010P
29. Install carriage assembly from the bottom of inner

mast
20
IDCD008P
30. Install cross head(20) to primary lift cylinder.

Standard Lift Cylinders
Disassemble Standard Lift
Cylinders
Start By:
a. Remove standard lift cylinders.
IDCD007P 1
31. Install carriage chains to primary lift cylinder.
IDCD399P
22 1. Put standard lift cylinder (1) in position on vise (A).

21
IDCD005P
2
32. Install hydraulic hose (21) of side shifter to side
shifter cylinder (22).
B
IDCD007P
2. Loosen set screw (2) with wrench (B).
IDCD017P
33. Install mast to lift truck.

C
IDCD407P IDCD410P
3. Remove bearing (3) with wrench (C). 6. Remove O-ring seal (6) and back-up ring (7) from
the bearing.
9
4 8
IDCD409P
IDCD411P
4. Remove rod (4) from the cylinder body.

7. Remove wiper seal (8) and seal (9) from the
bearing.
IDCD409P
5. Remove split rings (5) from the cylinder rod.

Assemble Standard Lift
Cylinders
2
1
5
IDCD409P
4. Install split rings (5) on the cylinder rod.
IDCD411P
1. Install seal (2) in the bearing.
2. Install wiper seal (1). Install the seal with the lip 6
toward the outside.
IDCD408P
3
5. Install cylinder rod (6) in the cylinder body.
IDCD410P
C
NOTE : Install back-up ring (4) with the curved side

contacting the O-ring seal.
7
3. Install O-ring seal (3) and back up ring (4) into the
bearing.
IDCD407P
6. Install bearing (7) on the cylinder rod and tighten

using wrench (C).

Secondary Lift Cylinders
8 Disassemble Secondary Lift
Cylinders
Tools Needed A B
Hydraulic Cylinder Repair Stand 1
Wrench Assembly 1
B
Start By:
IDCD406P
a. Remove standard lift cylinders.

7. Tighten setscrew (8) with wrench (B) to a torque of
6±1 N·m (53±9 lb·in).
End By: A
1
a. Install standard lift cylinders.
IDCD201P
1. Put standard lift cylinder (1) in position on tool (A).
IDCD203P
2. Remove bearing (2) with tool (B).

13
3
12
11
IDCD204P IDCD208P
3. Remove rod (3) from the cylinder body. 7. Remove ring (11), wear ring (12) and O-ring (13)
from the bearing.
5
4
16
14
6
IDCD206P 7 15
IDCD209P
4. Remove stop ring (4) from the cylinder rod.

8. Remove wiper seal (14) and retaining ring (15) from
5. Remove wear ring(5), U-packing(6) and backup the bearing.
ring(7).
9. Remove U-packing (16).
9
8
10
IDCD207P
6. Remove retaining ring(8), spacer(9) and check

valve(10).

Assemble Secondary Lift
Cylinders 10 11
12
IDCD206P 13
2
3 5. Install stop rings (10) on the cylinder rod.
IDCD209P 6. Install wear ring (11), U-packing (12) and backup

ring (13).
1. Install U-packing (1) in the bearing.
2. Install wiper seal (2) and retaining ring (3). Install 14

the seal with the lip toward the outside.
5 IDCD204P
6 7. Install cylinder rod (14) in the cylinder body.
IDCD208P
B
3. Install O-ring (4), wear ring (5) and ring (6) in the
15
bearing.
IDCD203P
8. Install bearing (15) on the cylinder rod and tighten

using tool (B).
8 9
7
IDCD207P
End By :
4. Install check valve (7), retaining ring (8) and spacer a. Install secondary lift cylinders.
(9).

Primary Lift Cylinder
Remove & Install Primary Lift
Cylinder 3
2
Start By:
a. Remove carriage.
IDCD440P
WARNING
To prevent personal injury, move the control levers 3. Pull the cylinder out far enough to disconnect elbow
backward and forward to release any pressure in (2). Remove primary lift cylinder (3). Weight is 27
hydraulic system. Slowly loosen the cap of the kg (60 lb).
hydraulic tank to release any pressure in the tank.
Be cautious of hot hydraulic oil when any lines are NOTE : The following steps are for the installation of
disconnected in the hydraulic system. the primary lift cylinder.
4. Put primary lift cylinder (3) in position on the mast.
5. Connect elbow (2).
1 6. Install bolt bolts (1).
End By:
a. Install carriage.
IDCD059P
1. Fasten nylon straps and hoist to the primary lift

cylinder.
2. Remove bolts (1).

Disassemble Primary Lift
Cylinders
4
Tools Needed A B
Wrench Assembly 1
Start By:
IDCD211P
a. Remove primary lift cylinder.
4. Remove piston seal (4).

1
IDCD210P
1. Remove flow protector valve (1) from the cylinder

IDCD212P
body.
5. Remove retaining ring (5), and check valve (6).

2
A
3
IDCD215P 7
2. Remove rod cover (2) with tool (A). IDCD213P
6. Remove O-ring (7).

3. Remove rod (3) from the cylinder body.

8
10
IDCD214P IDCD213P
7. Remove wiper seal (8) and retaining ring (9) and U- 3. Install O-ring seal (4).
packing (10) from the rod cover.
Assemble Primary Lift 5

Cylinders
6
Tools Needed A B
Wrench Assembly 1
IDCD212P
2
4. Install check valve (5), retaining ring (6).
3
IDCD214P 7
1. Install U-packing (1) in the rod cover.

IDCD211P
2. Install wiper seal (2) and retaining ring (3). Install 5. Install wear ring (7), piston seal (8) on the cylinder
the seal with the lip toward the outside. rod.

10
3
9 A
1
IDCD215P IDCD061P
6. Install cylinder rod (9) in the cylinder body.

WARNING
7. Install rod cover (10) on the cylinder body. Use tool
To prevent personal injury, move the control levers
(A) to tighten bearing.
backward and forward to release any pressure in
hydraulic system. Slowly loosen the cap of the
hydraulic tank to release any pressure in the tank.
11 Be cautious of hot hydraulic oil when any lines are
disconnected in the hydraulic system.
1. Disconnect elbow (2). Remove retainer bolt (3) and

pin (1).
IDCD210P
8. Install flow protector valve (14) on the cylinder body. 6
End By:
a. Install primary lift cylinder. 4 5
IDCD062P
Tilt Cylinders 2. Remove retainer bolt (6) from pin (5). Remove pin
(5).
Remove & Install Tilt Cylinders
NOTE: The procedure for removing and installing the 3. Remove tilt cylinder (4).
tilt cylinders is the same for both cylinders.
4. Install the tilt cylinder in the reverse order of
removal.
WARNING
If both tilt cylinders are removed at the same time
the mast can fall. To avoid possible personal injury,
make sure the mast is securely held in place or
supported by a hoist before removing the tilt
cylinders.

Disassemble & Assemble Tilt 4. Remove piston and seal assembly (4) from the
Cylinders cylinder rod.
5. Remove head assembly (5).
Tools Needed A
Spanner Wrench 1
6 7
Start By:
a. Remove tilt cylinder.
8
1
IDCD423P
6. Remove spacer (6) from the cylinder rod.
7. Loosen the nut and bolt on the rod eye.

Remove cylinder rod (7) and shims (8).
2
IDCD421P 10
1. Use tool (A) to remove head (1) from the cylinder

body. 9
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.
IDCD424P
2. Remove rod assembly (2) from the cylinder body.
8. Remove seal assembly (10) and O-ring seal (9)
from the piston.
3
4
5
IDCD422P
3. Remove nut (3) from the cylinder rod.

11
14
15
16
IDCD253P IDCD426P
9. Remove seal (11) from the spacer. 12. Install seal (14) in the head. Position the lip of the
seal toward the inside of the head.
12
13. Install seal (15).
14. Install seal (16) in the cylinder head. Position the

lip of seal (16) toward the outside of the cylinder
13
head.
12
IDCD425P
10. Remove O-ring seal (12) and back-up ring (13)

from the head. 13
IDCD425P
NOTE: The curved side of back up ring (13) should

contact O-ring seal (12).
14
15 15. Install O-ring seal (12) and back-up ring (13).
Make sure the curved side of back-up ring (13) is
16
in contact with O-ring seal (12).
IDCD426P
11. Remove seals (14), (15), and (16) from the head.
NOTE: Use the following steps to assemble the tilt

cylinder.

10
11
IDCD258P IDCD424P
16. Install seal (11) in the spacer. 19. Install seals (10) and O-ring seal (9) on the piston
2 5
8 6
4
IDCD423P IDCD422P
17. Install spacer (6). 20. Install head assembly (5) on the cylinder rod.
18. Install shims (8) and rod eye (2). Tighten the bolt 21. Install piston assembly (4) onto the cylinder rod.
on rod eye (2) to a torque of 95±15 N·m (70±11
lb·ft). 22. Install nut (3). Tighten nut (3) to a torque of
270±30 N·m (200±22 lb·ft).
IDCD427P
23. Install the rod assembly in the cylinder body.

Hydraulic Pump 5
(with Priority Valve) 4
Disassemble Hydraulic Pump

2
1
IDCD229P
4. Remove Seal-O-ring (6) and spool assembly (4)

from priority valve part (5).
IDCD420P
7
1. Remove eight cap screws (1) and washers.
2. Remove shaft seal (2) and washer from the housing.
4
IDCD230P
5. Remove seal-O-rings (7) from the spool assembly

3 (4).
IDCD228P
3. Remove hydraulic pump part (3) from pump

assembly. 9
IDCD215P
6. Remove gear assemblies(8) from the body(9).

10
13
IDCD216P IDCD219P
7. Remove wear plate (10). 10. Remove seal O-ring (13).
11
12
IDCD217P
8. Remove seal (11) and back up gasket (12) from the

wear plate.
9
IDCD218P
9. Remove body (9).

Assemble Hydraulic Pump
4
1. It is important that the relationship of the backplate,
body, wear plate and front plate is correct. There
are two half moon cavities in the body.
NOTE: The smaller half moon port cavity must be on

the pressure side of the pump. The side of wear plate
with midsection cut out must be on suction side of
pump. Suction side of backplate is always side with IDCD217P
larger port boss.
4. Install new seal (3) and new backup gasket (4) in to
wear plate. Note in the middle of the backup gasket
2
a flat section or support. This area must face away
from the wear plate inside the seal.
IDCD219P
2. Install O-ring (1) in groove of front plate (2).
IDCD216P
5. Place new wear plate (5), seal, and backup gasket

into gear pocket with seal and backup gasket next
to front plate. The side of the wear plate with the
mid section cut-away must be on the suction side of
pump.
IDCD218P
3. Apply a thin coat of petroleum jelly or hydraulic oil to

both milled gear pockets of body. Slip body onto
front plate with half moon port cavities in body
facing away from front plate.
IDCD215P
6. Dip gear assemblies (6) into oil and slip into front
plate bushings and gears into pockets of body.

13
7
8
IDCD230P IDCD420P
7. Install seal-O-rings (7) to the spool assembly (8). 10. Place washer over drive shaft into housing.
Liberally oil shaft seal (13) and install over drive
shaft, carefully so that rubber sealing lips are not
9
cut.
10
11
IDCD229P
8. Install seal-O-ring (11) and spool assembly (10) to

priority valve part (9).
12
IDCD228P
9. Install hydraulic pump part (12) to pump assembly.

Steering Wheel 3. Use hammer (A) to remove the steering wheel from
the shaft.
Remove & Install Steering Wheel NOTE : Use the following steps to install the steering
wheel.
4. Put the steering wheel on the steering wheel shaft

in its original position.
1
5. Install cup (3) and nut (2). Tighten nut (2) to a
torque of 80 ± 7 N·m (60 ± 5 lb·ft).
6. Install cap (1).
IDCD063P
1. Remove cap (1) from the steering wheel.
IDCD064P
2. Remove nut (2) and cup (3) from the steering wheel
shaft. Put location marks on the steering wheel and
the steering wheel shaft for installation purposes.

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.
3
1
NOTE : Identify and mark all hydraulic hoses for
purposes of reassembly.
4. Disconnect five hoses from steering unit (5).
NOTICE
IDCD065P Steering unit (5) and column (2) can separate after
bolts (4) have all been removed, causing unit (5) to fall.
1. Open the access cover for the fuse panel. To avoid damaging components, support the steering
pump while removing bolts (4).
2. Loosen four bolts (1). Slide directional control switch
(3) off of steering column (2). Set switch (3) aside,
clear of the steering column. 5. Support steering unit (5) while removing the
remaining two bolts (4). Remove steering unit (5)
and steering column (2).
6. Install the steering unit in the reverse order of

removal.
4 End By :
5
a. Install steering wheel.
IDCD066P
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.
End Cap Cap Screw

Seal
Gerotor (Meter) End
IDCD279S
2. Remove 5/16 inch cap screws and washers if

applicable (7 each).
3. Remove end cap.
4. Remove seal from end cap.
Seal
IDCD278S
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.
Spacer(s)
IDCD280S
5. Remove meter. Be careful not to drop star.
6. Remove seal from meter.
7. Remove drive spacer(s).

Control End
Spacer Plate
Seal Drive
IDCD281S IDCD282S
8. Remove drive. 11. Remove housing from vise. Place housing on a

clean soft cloth to protect surface finish. Use a thin
9. Remove spacer plate. bladed screwdriver to pry retaining ring from
housing.
10. Remove seal from housing.
Seal Gland
Bushing
IDCD283S
12. Rotate spool and sleeve until pin is horizontal.

Push spool and sleeve assembly forward with
your thumbs just far enough to free gland bushing
from housing. Remove bushing.

Quad
Ring
Seal
Seal
Dust Gland
Seal Bushing
Pin
IDCD284S IDCD286S
13. Remove quad ring seal from seal gland bushing. 16. Remove spool and sleeve assembly from 14 hole
end of housing.
14. Use a thin bladed screwdriver to pry dust seal from
seal gland bushing. Do not damage ATTENTION: Do not bind spool and sleeve in housing.
bushing. Rotate spool and sleeve assembly slowly when
removing from housing.
17. Push pin from spool and sleeve assembly.
Needle Bearing
Thrust Race
Bearing
Bearing
Race
IDCD285S
15. Remove 2 bearing races and the needle thrust

bearing from spool and sleeve assembly.

Seal
Check Ball
Check Ball Seat
IDCD287S IDCD288S
18. Push spool partially from control end of sleeve, 21. Remove check ball seat.
then remove 4 centering springs from spool
carefully by hand. 22. Tip housing to remove check ball.
19. Push spool back through and out of sleeve. Rotate

spool slowly when removing from sleeve.
20. Remove seal from housing.

Assemble Steering Unit
Spring Slot
Check all mating surfaces. Replace any parts that Control Sleeve
have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry with air. Spring Slot
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 Identification Control
Marks Spool
grind these parts.
NOTE: Lubricate all seals with clean petroleum jelly

such as Vaseline. IDCD290S
Do not use excessive lubricant on seals for meter

6. Assemble spool and sleeve carefully so that the
section.
spring slots line up at the same end. Rotate spool
Refer to parts listings covering your steering unit when
while sliding parts together. Some spool and sleeve
ordering replacement parts. A good service policy is to
sets have identification marks, align these marks.
replace all old seals with new seals.
Test for free rotation. Spool should rotate smoothly
in sleeve with finger tip force applied at splined end.
Check Ball
Seat
Check Ball
IDCD289S
IDCD291S
1. Use a needle nose pliers to lower check ball
retainer into check valve hole of housing. Make
7. Bring spring slots of both parts in line and stand
sure retainer is straight (not tilted on edge) in
parts on end of bench. Insert spring installation tool
housing.
through spring slots of both parts. Position 2 pairs
of centering springs on bench so that extended
2. Install check ball in housing
edge is down and arched center section is together.
In this position, insert one end of entire spring set
3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm [.30
into spring installation tool, with spring notches
in.] ID seal. Install seals on check ball seat as
facing sleeve.
shown.
8. Compress extended end of centering spring set and
4. Lubricate check ball seat and seals thoroughly
push into spool sleeve assembly withdrawing
before installing seat in housing. When installing
installation tool at the same time.
seat do not twist or damage seals. Install check ball
seat in housing, insert open end of seat first. Push
9. Center the spring set in the parts so that they push
check ball seat to shoulder of hole.
down evenly and flush with the upper surface of the
spool and sleeve.
5. Install set screw. Use a 1/4 inch hex key to torque
set screw to 11 N·m [100 lb·in]. To prevent
10. Install pin through spool and sleeve assembly until
interference make sure top of set screw in slightly
pin is flush at both sides of sleeve.
below housing mounting surface.

Needle
Thrust
Bearing Bearing
Race(2)
Seal
Pin
IDCD292S
11. Position the spool and sleeve assembly so that the IDCD293S
splined end of the spool enters the 14 hole end of
housing first.
12. Place housing on clean lint free cloth. Install 47.5
ATTENTION: Be extremely careful that the parts do mm [1.86 in.] ID seal in housing.
not tilt out of position while inserting. Push parts gently
into place with slight rotating action, keep pin nearly 13. Install 2 bearing races and the needle thrust
horizontal. Bring the spool assembly entirely within the bearing in the order shown.
housing bore until the parts are flush at the meter end
or 14 hole end of housing. 14. Install 25 mm [1 in.] ID dust seal in seal gland
Do not pull the spool assembly beyond this point to bushing, flat or smooth side must face down
prevent the cross pin from dropping into the discharge towards bushing.
groove of the housing. With the spool assembly in this
flush position, check for free rotation within the 15. Install the quad ring seal in seal gland bushing.
housing by turning with light finger tip force at the Smooth seal in place with your finger. Do not use
splined end. any seal that falls freely into pocket of bushing.

Retaining
Ring
Seal
Gland
Bushing
(with seals)
IDCD294S IDCD296S
16. Install seal gland bushing over the spool end with 18. Clamp housing in vise. Clamp lightly on edges of
a twisting motion. Tap the bushing in place with a mounting area. Do not over tighten jaws.
rubber hammer. Make sure the bushing is flush
against the bearing race. NOTE: Check to insure that the spool and sleeve are
flush or slightly below the 14 hole surface of the
housing.
ATTENTION: Clean the upper surface of the housing

Screwdriver
by wiping with the palm of clean hand. Clean each of
Dust Seal
the flat surfaces of the meter section parts in a similar
Retaining way when ready for reassembly. Do not use cloth of
Ring
Seal Gland
paper to clean surfaces.
Bushing
Quad Ring
Seal
IDCD295S
17. Install retaining ring in housing. After installing ring,

tap on ring end or pry with screwdriver around
IDCD293S
entire circumference of ring to properly seat ring in
groove.
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.

Seal Groove this Side of Gerotor (Meter)
Star Valley A
Port Face Drive

B
Pin Parallel
with Port
Face Drive
(Marked) C
D
Pin
IDCD298S
21. Rotate spool and sleeve assembly until pin is

parallel with port face. Install drive, make sure you
engage drive with pin. To assure proper alignment, Pin Port Face
mark drive as shown. Note relationship between IDCD300S
slotted end of drive to splined end of drive when
marking.
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.
Seal
IDCD299S
22. Install 73.5 mm [2.89 in.] ID seal in spacer plate or

gerotor (meter).

24. Install drive spacer (s) when used, in meter.
Seal 25. Install 73.5 mm [2.89 in.] ID seal in gerotor (meter)

Drive Spacer(s) or end cap, see notes.
26. Install end cap on gerotor, align holes.
IDCD301P
Actual
Displacement Spacer IDCD302P
㎤/r(in/r)
3
Length mm [in.]
45 [2.8] None 27. Install 7 dry cap screws in end cap. Pretighten
60 [3.6] None screws to 11-17 N·m [100-150 lb·in] then torque
75 [4.5] None screws to specifications.
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]

Brake Valve
Remove & Install Brake Valve
5
4 IDCD069P
4. Support the brake valve. Remove the washers, nuts

1
and two bolts (5).
2
IDCD067P 5. Remove the brake valve.
1. Remove the cotter pin from pins (1). Remove pins 6. Install the brake valve in the reverse order of
(1). Remove springs (2). removal.
2. Remove four bolts (3). Remove the shaft assembly 7. Bleed the brake system. Refer to the Testing and
(4). Adjusting Manual for further information.
NOTE : Plug and cap all openings to avoid

contamination and debris from entering the system
after removing any tubes or lines.
IDCD068P
3. Disconnect the hoses and the tubes of the brake

valve.

Disassemble & Assemble Brake
Valve
3 1
2
10
IDCD404P
6. Remove retaing ring (10).

IDCD401P
13
1. Remove four bolts (1) and cap (2).
2. Remove spool assembly (3).
4 9
10
11 12
IDCD405P
7. Remove transfer sleeve (12) and transfer sleeve

base (11).
8. Remove retaining ring (13).

8
IDCD402P
15
5
14 13
6
IDCD398P
7
IDCD403P
9. Remove relief sleeve (14).
3. Remove fitting (4).
10. Remove two O-rings (15).
4. Remove spring (5), spool (6) and Disc (7).
11. Assemble brake valve in the reverse order of
5. Remove large piston (8) and slipper ring (9) from disassembly.
the spool assembly.

Steer Wheels & Bearings
Remove Steer Wheels & Bearings
4
Tools Needed A B C
Floor Jack 1
Dirver Set 1
T059 Lock Nut Installer 1
NOTE : The procedure to remove the steer wheels is 5

IDCD072P
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
6
A
IDCD070P
7
1. Support the steer axle with a floor jack (A).
2. Remove wheel cap (1).

IDCD073P
7. Remove seal (6) from the back of steer wheel (5).
8. Remove bearing cone (7) and the bearing cup from

2
3
the back of steer wheel (5).
IDCD071P
3. Bend the tab in locking washer (2) clear of the slot

in nut (3).
4. Use tool (C) to remove nut (3). Remove locking

washer (2)

5
IDCD074P
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. Use tool (C) to tighten nut (3) to a torque of

135 N·m (100 lb·ft) while slowly rotating steer
wheel (5).
b. Use tool (C) to loosen nut (3) completely.
c. Use tool (C) to tighten nut (3) again to a torque
of 50 ± 5 N·m (37 ± 4 lb·ft).
d. Bend a tab of locking washer (2) into a slot of
nut (3).
13. Install wheel cap (1).
14. Remove tooling (A) and lower the lift truck.

Tie Rods
Remove And Install Tie Rods 5
Tools Needed A B
Floor Jack 1
Driver Set 2
Start By :
a. Remove steer wheels. IDCD082P
NOTE : The procedure to remove and install the tie 4. Use tooling (B) to remove bearings (5) from the tie
rod is the same for each steer wheel. rod.
5. Use tooling (B) to install new bearings (5) in the tie

rod.
1
6. Install the tie rod in the reverse order of removal.
3
IDCD075P
1. Support the steer axle with a floor jack (A). Position

the wheel to gain access to the tie rods.
2. Remove two pin retaining bolts (2). Remove pins (1).
3. Remove tie rod (4) and dust seals (3).

Steering Knuckles, Kingpins,
And Bearings
3
Remove And Install Steering
Knuckles, King Pins And Bearings 4
Tools Needed A
Drive Set 1
Start By: IDCD077P
a. remove steer wheels

3. Remove four bolts (3) and cover (4).
NOTE : The procedure to remove and install the
steering knuckles, kingpins, and bearings is the same
for both sides of the lift truck.
6
5
IDCD078P
1
2
4. Remove four bolts (5) and cover (6).
IDCD076P
1. Remove pin retaining bolt (2). Remove pin (1).
2. Position the tie rod away from the steering knuckle.
7
IDCD079P
5. Remove the nut and bolt (7). For purposes of

reassembly, the torque for bolt (7) is 11 ± 1
N·m(100 ± 9 lb·ft).

Steer Axle
Remove & Install Steer Axle
Tools Needed A
8 Jack Stand 4
9 WARNING
IDCD080P
Be sure the pressure in the hydraulic system is
6. Remove kingpin (8) and knuckle (9). released before any lines or hoses have been
disconnected.
9
10
11 12
13
IDCD081P
1
IDCD083P
7. Remove spacer (11), bearing cup (13) and bearing
cone (12).
1. Put the lift truck in position on tooling (A).
8. Check the condition of lip type seal (10). Replace
seal (10) with new if worn or damaged. 2. Disconnect tube (1). Plug and cap all openings to
prevent contamination and debris from entering the
9. Repeat steps 7 and 8 for the remaining seal, system.
bearing and spacer in the other side of knuckle (9).
NOTICE
Check the condition of all seals, bearings and

components. If any parts are worn or damaged use
new parts for replacement.
10. Lubricate the pins, king pins and bearings.
11. Install the steering knuckle, kingpins and bearings

in the reverse order of removal.
End By:
a. Install steer wheels.

2
4
IDCD084P IDCD084P
3. Support the steel axle with a floor jack. 7. Remove steer axle (4). The steer axle weighs 200
kg (440 lb).
4. Loosen mounting bolts (2) until approximately two
bolt threads are left in the mounting bosses. NOTE : Use the following steps to install the steer axle.
5. Lower the steer axle onto the bolt heads with the
floor jack
4
IDCD084P
2
IDCD083P 8. Use a floor jack to position steer axle (4).
6. Remove bolts (2) and mounting caps (3) from the

steer axle.

NOTE : Use bolts (2) and cap (3) to align steer axle Steering Cylinder
(4) with the mounting bosses while raising steer axle
(4) into position with the floor jack.
Remove & Install Steering Cylinder
9. Seat steer axle (4) as follows:
a. Install bolts (2) through cap (3) and into the Start By:
mountig bosses approximately two bolt threads.
b. Use the floor jack to raise steer axle (4) into the a. Remove steer axle.
mounting boss.
c. Tighten bolts (2).
1
IDCD085P
1
IDCD083P
1. Remove the pin retaining bolt and pin (2) from the
tie rod at each end of steering cylinder (1).
11. Connect tube (1).
3
IDCD086P
2. Remove four bolts (3). For installation purposes, the

torque for bolts (3) is 300 ± 40 N·m (220 ±30 lb·ft).
3. Remove steering cylinder (1).
4. Install steering cylinder (1) in the reverse order of

removal.

Disassemble Steering Cylinder
Start By :
a. Remove steering cylinder.
4. Remove piston seal (3) and wear ring (4).
1. Put location marks on end caps (1) as to their

position on the steering cylinder tube.
2. Remove end caps (1) from the steering cylinder.
3. Remove cylinder tube (2) from the rod assembly.
5. Disassemble each rod cover as follows.

a. Remove retaining ring (5) and dust wiper (6).
b. Remove U-packing (7).
c. Remove O-ring (8) and back up ring (9).
d. Remove DU-bush (10).

Assemble Steering Cylinder
3. Install cylinder tube (2) on the rod assembly.
4. Install rod covers (1) on cylinder tube (2).

1. Assemble each rod cover as follows ;
a. Install DU-bush (10). End By :
b. Install back up ring (9) and O-ring (8)
c. Install u-packing (7). a. Install the steering cylinder.
d. Install dust wiper (6) and retaining ring (5).
2. Install piston seal (3) and wear ring (4).

Hydraulic Control Valves
Remove And Install Hydraulic
Control Valves
5
WARNING
3
Hydraulic oil under pressure can remain in the
hydraulic system after the engine and pump have
been stopped. Personal injury can result if the IDCD088P
pressure is not released before any work is done
to the hydraulic system. To prevent possible 3. Support control valve (3). Remove three bolts (5),
personal injury, turn the engine off and move the nut and control valve (3).
control levers to make sure the hydraulic pressure
is released before any fitting, plug, hose or 4. Install the control valve in the reverse order of
component is loosened, tightened, removed or removal.
adjusted. Always move the lift truck to a clean and
level location away from the travel of other 5. Fill the hydraulic tank to the correct level with fluid.
machines. Refer to the Operation And Maintenance Manual for
further information.
3 4
IDCD087P
NOTE : For purposes of reassembly, put identification

marks on all lines, tubes and hoses before any
disconnections are made.
1. Disconnect seven lines (4) from control valve (3).
2. Remove the cotter pins, washers and pins (1) from

linkages (2).

Disassemble Hydraulic
Control Valves
Start By :
a. Remove hydraulic control valve.
8 9 7
IDCD075P
3. Remove attachment valve spool (7) from the valve

body.
1
4. Remove seal (8) and spring (9) from the valve spool.
IDCD216P
10 10
10 10
NOTE : For purposes of assembly, put identification
marks on all valve sections.
1. Remove bolts (1) to separate the valve sections.
5 6 10
10
IDCD221P
5. Remove O-ring seals (10) from the valve body.
4
IDCD218P
2. Remove dust bolts (5), cover (4) and retainer (6)

from the valve.

11
12
12
19
18
17
13
IDCD222P IDCD224P
6. Remove lift and tilt valve spool assemblies (11) from 11. Remove relief plugs (17), springs (18) and poppets
the valve body. (19).
7. Remove seals (12) from the valve spools.
8. Remove springs (13) from the valve spools.
15
16 14
IDCD223P
9. Remove plug (14) and spring (15).
10. Remove hydrostat (16).

Assemble Hydraulic Control Valves
9
8
1 7
2
3
IDCD222P
IDCD224P 5. Install springs (7) and seals (8) on the valve spools.
6. Install lift and tilt spool assemblies (9) to the valve

1. Make sure all valve parts are clean and free of dirt. body.
2. Install poppets (1), springs (2), and relief plugs (3).

10 10
10 10
4 6 10
10
IDCD075P
IDCD223P
7. Install O-ring seals (10) to the valve body.
3. Install hydrostat (4).
4. Install spring (5) and plug (6).
IDCD075P
8. Install seal (11) and spring (12) to the attachment

valve spool (13).
9. Install valve spool (13) to the valve body.

Creeper And Brake Control
14
Remove Creeper And Brake Control

Group
4
3
15
16
IDCD226P 1
1
10. Install retainer (14), dust cover (15) and bolt (16) to
each section.
IDCD130P 2
1. Remove cotter pins and pins (1). Remove the

springs (2).
2. Remove four bolts (3). Remove the shaft assembly

(4).
8
17
5
IDCD216P 6
11. Install bolts (17) to assemble the valve sections.

7
IDCD123P
3. Remove nut (5), spring (6), cotter pins and pins (7).
4. Remove inching linkage (8).

Universal Joint
10
Remove And Install Universal Joint
9
11
IDCD124P
5. Remove three bolts (9) and two bolts (10). Remove 1

bracket (11). 2
3
IDCD090P
6. Install creeper brake control in the reverse order of
removal.
1. Remove four bolts (1).
2. Remove four bolts and nuts (2) and flange assem-

bly (3).
3. Remove yoke shaft assembly (4).

Use the following steps to assemble the universal
joint.
4. Install the yoke shaft assembly (4) into transmission.
5. Put the flange assembly in the position between the

drive axle and the yoke shaft assembly (4).
6. Apply loctite #242 thread lock to threads of the bolts

(1) and the bolts (2).
7. Tighten the bolts (1) and the bolts (2) to a torque of

75 ± 5 N·m (55.4 ± 3.7 lb·ft).

Counterweight
5
Remove & Install Counterweight 4
Tools Needed A
Lin Bracket 4
NOTE : Steps 1 through 3 are for L.P. Gas model

machines only. Steps 4 is for Diesel model machines
IDCD098P
only. After steps 1 through 4 have been done, the
removal procedure is the same for all models. For
gasoline model machines, go to step 5. 4. Remove the washers and bolts (4) and exhaust pipe
(5).
1. Remove the L.P. fuel tank. Refer to the Operation &
Maintenance manual for further information.
1 6
IDCD091P
2. Disconnect fuel line (1) from the LP converter.
IDCD093P
5. Support counter weight (6) with a hoist and tooling

(A) as shown.
IDCD092P
3. Remove the washers and bolts (2) from each side

of L.P. tank mounting bracket (3). Remove
mounting bracket (3).

7
Drive Axle
Remove And Install Drive Axle
Tools Needed A
8 Stand 1
Start By :
a. Remove mast*.
IDCD096P
*Refer to the topic “Mast” in this module for further
6. Remove towing pin (7). information.
7. Remove the washer plate and bolts (8). 1. Raise the machine until the tires are approximately
1 to 2 inches off of the floor. Position the machine
on tooling (A).
IDCD097P
1
8. Remove the washers, shims and bolts (9). IDCD099P
9. Use the hoist and tooling (A) to remove counter

weight (6). The weight of the counterweight is NOTE : Put identification marks on all wiring, hoses
approximately 1753 kg (3865 lb). and lines to assure proper installation.
NOTE : The following steps are for installation of the 2. Loosen the clamps and disconnect three hoses (1).
counterweight.
10. Put counterweight (6) in position on the frame, and

install bolt (8) and bolts (9). Tighten the bolts to a
torque of 400 ± 50 N·m (300 ± 37 lb·ft).
11. Install towing pin (7).
NOTE : This completes the installation of the counter

weight for gasoline model machines. For L.P. Gas
model machines, reverse the procedures and Steps 1
through 3 and 5 to complete installation of the L.P.
tank mounting bracket and gas line. For diesel model
machines, reverse the procedures and steps 4 through
5 to complete installation of exhaust pipe and cover.

NOTE : The following steps are for installing the drive
axle
4
WARNING
2
Drive axle assembly (3) can drop if not supported
by a floor jack, wooden blocks or suitable support.
To avoid personal injury or damage to the drive
3 axle assembly, make sure drive axle assembly (3)
IDCD100P is properly supported with a floor jack. Position
the floor jack beneath the center of he drive axle.
3. Disconnect brake lines (2) from each front wheel
assembly.
7. Support drive axle (3) with a floor jack. Move drive
axle (3) into position so that the holes for bolts (4)
4. Support drive axle assembly (3) with floor jack and
are aligned.
wood block.
8. Install drive axle mounting bolts (4). Tighten the
bolts to a torque of 488 ± 27N·m (360 ± 20 lb·ft).
WARNING 9. Remove the floor jack supporting drive axle (3).
Drive axle assembly (3) can drop if not supported 10. Reverse the procedures and steps 1 through 3 to
by a floor jack, wooden blocks or suitable support. complete the installation of the drive axle
To avoid personal injury or damage to the drive assembly.
axle assembly, make sure drive axle assembly (3)
is properly supported before removing the floor 11. Bleed the brake system. Refer to the topic “Brake
jack. Position the floor jack beneath the center of System Air Removal” in the Testing And Adjusting
the drive axle assembly. manual.
12. Fill all fluids to their the correct levels. Refer to the
5. Remove drive axle mounting bolts (4). Operation and Maintenance manual for further
information.
6. Use the floor jack to move drive axle assembly (3)
from beneath the machine. Drive axle assembly End By :
a. Install mast*
*Refer to the topic “Mast” in this module for further
information.

Transmission
Tools Needed A
Link Bracket 1 7 8 9
Start By :
a. Remove overhead guard*
b. Remove hood assembly *

IDCD089P
*Refer to the topics “Overhead guard” and “Hood
Assembly” in this module for further information. 4. Remove washers and four bolts (7).
5. Remove cotter pin and pin (9) from linkage.
6. Remove floor plate (8).
13
11
1
2
IDCD101P 12
1. Loosen two bolts (1) and remove floor plate (2). 10
IDCD123P
6
5 7. Remove nut (10), spring (11), cotter pins and pins

(12).
4 3
3 8. Remove inching linkage (13).
IDCD130P
2. Remove cotter pins and pins (3). Remove the

springs (4).
3. Remove four bolts (5) and the shaft assembly (6).

14
15
19
20
18
16
IDCD124P IDCD124P
9. Remove two bolts (14) and clamp. 12. Disconnect four hoses (18) from hydraulic pump
(20).
10. Remove the cotter pin and pin (15), Clear of
parking cable (16). 13. Remove two bolts (19) and hydraulic pump (20).
24
21
17 23 22
IDCD099P IDCD090P
14. Remove four bolts (21) from U-joint mounting

NOTE : Put identification marks on all wiring, hoses
flange.
and lines to assure proper installation.
15. Remove four bolts and nuts (22) and flange
11. Loosen the clamps and disconnect three hoses
assembly (23).
(17) from transmission circulation pump.
16. Remove yoke shaft assembly (24).

25
30 31
IDCD128P IDCD125P
17. Loosen the clamps and disconnect two torque 20. Remove two bolts and nuts (30).
converter cooler hoses (25).
21. Push console assembly (31) forward.
28
32
27
29
26
33
IDCD113P
IDCD126P
18. Disconnect two transmission solenoid connectors

(26). 22. Remove two screws (32).
19. Remove two bolts (27) and cover (28) push wiring 23. Loosen hour meter mounting bracket (33) to
(29) back toward the engine. prevent interference when transmission is
removed.
24. Remove air cleaner. Refer to the topic “Engine” in

this module for further information.

A
35
36
34
IDCD128P IDCD127P
25. Remove the six bolts (34) that hold the torque
27. Support transmission with a hoist and tooling (A)
converter to the flywheel.
as shown.
NOTE : At this point, make a final check to be sure all
28. Remove bolts (35) from the converter housing.
removals and disconnections have been made from
the transmission.
29. Remove the two bolts (36) from the converter
housing mounts.
A NOTICE
Make sure the transmission is supported underneath
by suitable wooden blocks. Failure to support the
transmission will result in possible damage.
30. Remove the transmission. The transmission

IDCD118P 31. Install the transmission in the reverse order of

removal.
26. Support engine with a hoist and tooling (A) as End By :

shown.
a. Install overhead guard *
b. Install hood assembly*
* Refer to the topics “Overhead guard” and “Hood

assembly” in this module for further information.

Engine
Remove & Install Engine
3
Tools Needed A 1
Link Bracket 1
Start By :
a. Remove Overhead guard* 2

IDCD087P
b. Remove counterweight*
2. Disconnect the two battery cables (1). Remove the
c. Remove hood assembly* washers, two bolts (2) and battery assembly (3).
* Refer to the topics “Overhead guard”

“Counterweight” and “Hood assembly” in this module
IDCD104P
2
IDCD101P 3. Loosen the clamps and disconnect air cleaner

hoses (4).
1. Remove two bolts (1) and floor plate (2).

6
5
IDCD103P
4. Remove mounting bracket (5) and air cleaner (6).

7
15
11 13
10
14
IDCD105P IDCD108P
5. Loosen clamp assembly (7).

9. Loosen clamps and disconnect two radiator hoses
(13).
10. Loosen clamps and disconnect the two

ransmission cooler hoses (14).
11. Loosen the clamp and disconnect radiator over

flow hose (15).
8
9
IDCD106P
6. Remove the washers, two bolts (8) and tube

assembly (9)
17
7. Remove the washers, two bolts (10) and muffler
assembly (11). 16
IDCD109P
12. Remove, eight bolts (16) and baffle assembly (17).
12
IDCD107P
18
8. Loosen cock-drain (12) and drain coolant.

IDCD107P
13. Remove radiator mounting bolts (18).

20 NOTICE
Place identification marks on all wires and connectors
to assure proper assembly
19
IDCD075P
25
26
14. For easy removal of radiator, loosen four bolts (19)
and remove radiator (20).
IDCD113P
22
17. Disconnect two connectors (25) from transmission
solenoid valves.
18. Disconnect engine wire harness (26).
21
IDCD111P 28
15. Disconnect wires (21) from starter assembly (22).
27
24
IDCD114P
19. Disconnect wire (27) from circuit breaker (28).

To remove engine from the truck, other wires or
connectors not shown should be disconnected.
23
IDCD112P
16. Disconnect wires (23) from alternator (24).

A
29 30
35
IDCD115P IDCD118P
20. Remove nut (29) and accel cable (30). 23. Support engine with a hoist and tooling (A) as
shown.
24. Remove the washers and bolts (35) from the

converter housing.
33
32 31
IDCD116P
36
21. Remove two bolts (31). Push wiring (32) back

toward the engine. Remove cover (33). IDCD120P
25. Remove the nuts and washers (36) from two

engine mounts, located on each side of the engine.
34
IDCD128P
22. Remove the six bolts (34) that hold the converter
to the flywheel.
NOTE : At this point, make a final check to be sure all

removals and disconnections have been made from
the engine.

NOTICE
Make sure the engine is supported underneath by
suitable wooden blocks. Failure to support the engine
will result in possible clamage.
26. Remove the engine with a hoist as shown. The

engine weighs 180 kg (400 lb).
27. Install the engine in the reverse order of removal.
End By :
a. Install overhead guard*
b. Install counterweight*
c. Install hood assembly*
*Refer to the topics “Over head guard”

“Counterweight” and “Hood assembly” in this module.

SB4156E00
Jun. 2004
Specifications
Systems Operation
Testing & Adjusting
Lift Trucks Vehicle Systems - Supplement
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
G20P-3, G25P-3, G30P-3, G32P-3, G33P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
With G424E, G430E Tier Engine
WARNING
in injury or death.
publication.
available.
1
Index
Specifications
Hydraulic Control Valve .............................................. 5
Hydraulic Pump .......................................................... 6
Lift Cylinders ............................................................... 6
Standard.................................................................. 6
Steer Tire Installation (GC Models Only) .................... 8
Tilt Cylinders ............................................................... 7
Systems Operation
Steering System.......................................................... 9
Hydraulic Operation ................................................ 9
Steering Cylinder................................................... 10
Testing and Adjusting

Hydraulic System...................................................... 11
Flow Control Valve Adjustment ............................. 12
Relief Valve Pressure Check................................. 11
Mast and Carriage .................................................... 13
Chain Wear Test.................................................... 13
Steering System........................................................ 14
Steering System Pressure Check ......................... 14

Specifications
CONTROL VALVE
Main 3 4
Secondary
System 5 8 1
Relief Valve
Relief Valve
Model Mast Pressure
Pressure
±350 kPa
±500 kPa
(±50 psi) 2
(±75 psi)
STD
18,100 15,500
G/GC20E/P FFL
(2,625) (2,250)
FFT
STD
19,500 15,500
G/GC25E/P FFL
(2,825) (2,250)
FFT
STD
6 9
21,550 15,500
G/GC30/32E/P FFL
(3,125) (2,250)
FFT
STD
23,047 15,500 IDCS202S
G33P FFL
(3,342) (2,250)
FFT
(1) Torque for bolts that hold control valve sections

together…………….40.5 ± 2.5 N·m (360 ± 24 lb·in)
(2) Adjust main system relief valve pressure for lift as

shown above.
Adjusting.
1 (3) Adjust secondary relief valve pressure for tilt and

sideshift as shown above.
Adjusting.
(4) Torque for nipple assembly…………29.5 ± 1.5 N·m

7 (264 ± 12 lb·in)
(5) Torque for plug………..101 ± 5 N·m (894 ± 42 lb·in)

3
(6) Adjust tilt and sideshift flow rate by using 1/4 inch
hex-wrench if required.
See flow control valve adjustment in Testing &
Adjusting.
8
2 9 (7) Torque for plug……..55.5 ± 2.5 N·m (492 ± 24 lb·in)
(8) Torque for plug...............79 ± 4 N·m (696 ± 36 lb·in)
IDCS201S
(9) Torque for screws…………………….12.5 ± 1.5 N·m
(108 ± 12 lb·in)

Hydraulic Pump Lift Cylinders
Flow rate of excess flow protectors and flow control
valve [not shown (no adjustment) ] :
D700495……..45 to 53 liter/min (12 to 14 U.S. gpm)
1 A215044…….90 to 106 liter/min (24 to 28 U.S. gpm)
Standard
IDCS203S
2
(1) Tighten mounting bolts to a torque of
…………………………...45 ± 7 N·m (396 ± 60 lb·in)
Gear Pump with Priority Valve
Relier Valve (No adjustment) opens at :

………8700 + 250 kPa (1262 + 36 psi) for G/GCxxE
………9000 + 300 kPa (1305 + 43.5 psi) for G/GCxxP
Rotation is clockwise when seen from drive end.

Type of pump : Gear
For test, use SAE 10W oil at 65°C (150°F)
Test at Full Speed : IDCS204S

At a pressure of………………….…..690 kPa(100 psi) (1) Put pipe sealant on the last three threads of bear-
With pump at……………………….…………2000 rpm ing.
At a pressure of………………..….6900 kPa(1000 psi) (2) Torque for setscrews…..…6 ± 1 N·m ( 53 ± 9 lb·in)
With pump at…………………………..………2000 rpm
NOTE: All seals to be lubricated with hydraulic oil.
Test at Half Speed :

At a pressure of………..…….……..690 kPa(100 psi)
With pump at……………...…………………1000 rpm
Output……………………..27.2 liter/min (7.2 U.S. gpm)
At a pressure of………………….6900 kPa(1000 psi)
With pump at………….……..………………1000 rpm

Tilt Cylinders
1 2 3
4
IDCS189S
TILT CYLINDER CHART

Forward
Tilt Gp Backward Cyl.Stroke (X) Cyl. Closed (Z)
Model Tilt
Part No. Tilt Angle* mm (in) mm (in)
Angle*
A215192 3° 3° 63.4 (2.50) 538.4 (21.20)
A215179 6° 3° 94.6 (3.72) 538.4 (21.20)
G20E/P-3
A215191 3° 5° 84.8 (3.34) 517.0 (20.35)
G25E/P-3
A215174 6° 5° 116.0 (4.56) 517.0 (20.35)
G30E/P-3
A215190 3° 8° 117.1 (4.61) 484.7 (19.08)
G32E/P-3
A215173 6° 8° 148.3 (5.84) 484.7 (19.08)
G33P-3
A215189 3° 10° 138.7 (5.46) 463.1 (18.23)
A215172 6° 10° 169.9 (6.69) 463.1 (18.23)
D700741 3° 3° 43.5 (1.71) 525.1 (20.67)
D700467 6° 3° 64.7 (2.55) 525.1 (20.67)
D700742 3° 5° 58.3 (2.30) 510.3 (20.09)
GC20E/P-3
D700466 6° 5° 79.5 (3.13) 510.3 (20.09)
GC25E/P-3
D700743 10° 5° 107.2 (4.22) 510.3 (20.09)
GC30E/P-3
D700744 3° 8° 80.8 (3.18) 487.8 (19.20)
GC32E/P-3
D700465 6° 8° 102.0 (4.02) 487.8 (19.20)
D700745 3° 10° 95.9 (3.78) 472.7 (18.61)
D700464 6° 10° 117.1 (4.61) 472.7 (18.61)
D700746 10° 10° 144.8 (5.70) 472.7 (18.61)
* Permissible tolerance of 1/2°
(1) Adjust pivot eye to dimension (Z) with cylinder (3) Torque for head……………………….270 ± 30 N·m
closed. (200 ± 22 lb·ft)
(4) Torque for piston nut………………….270 ± 30 N·m
(2) Torque for bolt……….…95 ± 15 N·m ( 70 ± 10 lb·ft) (200 ± 22 lb·ft)

Steer Tire Installation
(GC Models Only)
IDCS184S
GC20E/P-3, GC25E/P-3 Models
IDCS209S
GC30E/P-3, GC32E/P-3 Model
(1) Install tires to dimension (A) or (B) of

.…….…………………..…...17 ± 2 mm (.67 ± .08 in)

Systems Operation
Steering System
Hydraulic Operation (Load Sensing Closed Center Steer Gear)
9 10
5 6 8
4 7 11
3
2
1
16 17
13 15
12 14
IDCS216S
Steering System Schematic (Load Sensing Closed Center)

(1) Steering gear. (2) Hose (to hydraulic tank). (3) Brake Valve. (4) Check Valve. (5) Hose (Load Sensing). (6) Tube.
(7) Hose(from hydraulic tank). (8) Hose(to hydraulic Control valve). (9) Hose(to steer cylinder). (10) Hose (to steer cylinder).
(11) Steering Cylinder. (12) Load Sensing Signal Hose (Steering). (13) Check Valve. (14) Passage to brake.
(15) Hose (to Steer gear). (16) Hydraulic Pump. (17) Hydraulic Tank.
REFERENCE : For the Hydraulic System Schematics. When the steering gear is moved, oil starts to flow to
steer cylinder (11). The pressure in line (15) and the
The steering system is a load sensing closed center priority valve internal sensing line will drop. As
type and uses hydraulic oil for its operation. Oil flow pressure drops in these lines, the priority valve
through the steering system is closed unless the metering spool will shift to meet the flow demand. As
steering wheel is turned. The flow through the the metering spool shifts, more oil flow is diverted to
steering gear is sensed by the priority valve, which hose (15) than to hose (8). The priority valve
then allows additional oil flow to the steering system. metering spool will shift back and forth to meet the
The priority valve also fills the requirements of the steering flow demand while maintaining the 1035
power brakes (if equipped) and then the mast. kPa(150 psi) differential between load sense hose (12)
and the priority valve internal sensing line.
Hydraulic oil is pulled from hydraulic tank (17) through At times flow to hose (8) will be closed completely. The
a strainer to hydraulic pump (16). The pump sends the combination of flow restrictors in the lines and spring
oil through hose (7) to brake valve (3). When the tension on the priority valve metering spool work
steering gear and brake valve are in together to maintain this balance.
NEUTRAL position, pressure in hose (15) and the
priority valve internal sensing line rises to 1035 kPa Check valve (13) is in hose (15) near the steering gear
(150 psi). When this pressure is at least 1035 kPa to prevent oil flow back to brake valve (3), which could
(150 psi) more than load sensing signal hose (12) the cause a sudden jerk of the steering wheel.
priority valve metering spool shifts to stop oil flow to Relief valve in the priority valve body will open if the
the steer gear. Oil flows through hose (8) to the steering pressure goes above 8700 + 250 kPa (1262 +
hydraulic control valve. 36 psi) for G/GCxxE and 9000 + 300 kPa (1305 + 43
psi) for G/GCxxP.
Steering Cylinder
Steering cylinder (1) gives power assistance
throughthe use of pressure oil at either end of the
cylinder piston.
The steering cylinder is double ended and the body of

the cylinder is mounted stationary to the steer axle.
The rod assembly is connected to the steering link
assembles at both ends of the cylinder which allows
the cylinder to move the link assemblies.
Steering Cylinder (Typical Example)

(1) Steering cylinder.

Testing and Adjusting
Hydraulic System
1
Relief Valve Pressure Check
Tools Needed 2
Fittings Group
IDCD087P
CONTROL VALVE Pressure Tap Location

(1) Cap. (2) Nipple assembly.
Main Relief Tilt, Auxiliary
Valve Relief Valve
With the engine off, remove cap (1) from nipple
Model Mast Pressure Pressure
assembly (2) and connect the 28,000 kPa (4000 psi)
±500 kPa ±350 kPa
gauge to the nipple assembly.
(±75 psi) (±50 psi)
STD
18,100 15,500
G/GC20E/P FFL
(2,625) (2,250)
FFT
Lift Relief Valve Check and Adjustment
STD
19,500 15,500
G/GC25E/P FFL
(2,825) (2,250) 1. Start the engine and activate the hydraulics until the
FFT
hydraulic oil is at the normal operating
STD temperature.
G/GC30E/P 21,550 15,500
FFL
G/GC32E/P (3,125) (2,250)
FFT 2. Lift mast to maximum fork height without load on
STD forks. Increase engine rpm to high idle. Hold the
23,047 15,500
G33P FFL lift control lever in the lifting position and watch the
(3,342) (2,250)
FFT gauge. The gauge indication is the pressure that
Use the Fittings Group to check the relief valve opens the relief valve at the end of lift cylinder
pressure. stroke.
Caution: Make sure there is adequate ceiling height.

WARNING Lift cylinder must be fully extended. Mast should be in
the vertical position and truck parked on level ground.
Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump have
3. The correct pressure setting is shown in the chart.
been stopped. Personal injury can be caused if
done on the hydraulic system. To prevent possible
injury, lower the carriage to the ground, turn the
engine off and move the control levers to make
sure all hydraulic pressure is released before any
tightened, removed or adjusted. Always move the
the travel of other machines. Be sure that other
personnel are not near the machine when the
3 4
made. IDCD087P
Relief Valve Adjustment.
(3) Lock Nut. (4) Stud.

Tilt and Sideshift Relief Valve
Check and Adjustment WARNING
1. Start the engine and activate the hydraulics until the Hydraulic oil, under pressure can remain in the
hydraulic oil is at the normal operating temperature. hydraulic system after the engine and pump have
Put the mast in the full tilt back position. been stopped. Personal injury can be caused if
2. With the enigne at high idle, hold the tilt control done on the hydraulic system. To prevent possible
lever in the full tilt back position and watch the injury, lower the carriage to the ground, turn the
gauge. The gauge indication is the pressure that engine off and move the control levers to make
opens the relief valve. sure all hydraulic pressure is released before any
3. The correct pressure setting is shown in the chart. tightened, removed or adjusted. Always move the
4. If an adjustment to the relief valve setting is the travel of other machines. Be sure that other
necessary, loosen nut (5). personnel are not near the machine when the
made.
Lift Section
Remove nut
6 Tie stud here
5
IDCD087P
Relief Valve Adjustment 1
(5) Locknut. (6) Stud.
IDCS121P
5. Turn setscrew (6) clockwise to increase or

counterclockwise to decrease the pressure setting 1. Remove the nut from the slotted tie-stud of main
of the relief valve. hydraulic valve
6. Tighten the locknut and check the pressure setting 2. Remove the slotted tie-stud from the valve.
again for correct adjustment.
3. Use Hex Wrench (6mm or 1/4 inch), turn the flow
control adjuster (1) clockwise to increase the flow
or counterclockwise to decrease the flow.
Flow Control Valve Adjustment 4. Assemble the tie stud in the valve. Torque the stud
to 40.5 ± 2.5 N·m (360 ± 24 lb·in)
The tilt and first attachment speeds can be adjusted at
the control valves. They can be adjusted by turning the 5. Reinstall the nut on the tie bolt.
plug in the hydraulic control valve body. The lift speed
can not be adjusted. Do the procedure that follows to
change the flow control assembly.

Mast and Carriage
Chain Wear Test
Chain wear test is a measurement of wear of the chain

links and pins. Do the steps that follow to check chain
wear.
1. Lift the mast and carriage enough to put tension on

the lift chains.
2. Measure precisely ten links of chain distance at the

center of pins in millimeter.
A chain wear gauge can also be used.
3. Calculate chain wear rate.
New one pitch = 19.05 mm

25.40 mm (only for G33P Model)
Chain wear rate (%)

Actual measurement - 190.5 x100
=
190.5
= Actual measurement - 254 x100 (only for G33P Model)

254
WARNING
4. If the chain wear indication is 2% or more, replace

the lift chain.

Steering System 5. The indication on the pressure gauge must be the
priority valve relief setting of 9300 + 250 KPa
(1349+36 psi) for G/GCxxE and 9600 + 300 kPa
Steering System Pressure Check (1392+43.5 psi) for G/GCxxP. If the indication is
correct and a problem exists, then there is possibly
If the steering system does not work correctly, check a mechanical failure in the steering system.
the hydraulic tank for the correct oil level and the
hoses and connections for leakage. If all these items 6. If the indication is not correct, then there is steering
are correct, use the Pressure Gauge Kit to check the hydraulic failure in the components.
steering hydraulic system and its relief pressure
setting.
(6)
Hydraulic Steering Gear

(1) Elbow (Pressure line from priority valve).
(5)
WARNING
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all M10 X 1.0 THD
hydraulic pressure is released in the steering
system. Move the steer wheels to the left and right
(4)
and then to the straight forward direction.
IDCS134S
Check steering system relief pressure as follows: (4) Pressure-Checking Adapter. (5) Pressure-Tube.
(6) Pressure Gauge.
1. Turn the engine off.
2. Remove plug from elbow(1) a. With the engine running, turn the steer wheels in
Install pressure-checking adapter(4) and connect any directions and read the indication on pressure
pressure-tube (5) and pressure gage (6). Pressure gauge (6).
gage(6) has a range of 28000 kpa (4000psi).
b. If the indication is approximately the pressure
3. Move the seat to the normal position for operation, shown in Step 5, then the steering gear has a
turn the key switch to the ON position and activate hydraulic failure.
the hydraulic controls until the oil is at a temper-
ature for normal operation. c. If the indication is too low or too high, then the
priority valve or its components must be replaced.
4. Turn the steer wheels to the left or right against the
stops and make a note of the indication on the 7. If the steering gear and the priority valve are
pressure gauge. working properly, the steering cylinder is defective
and must be repaired.
8. Correct the problem and check steering relief valve

pressure again.

SB4140E00
Jan. 2004
Schematic
Lift Trucks Hydraulic System
D20S-3(B3.3), D25S-3(B3.3)
D30S-3(B3.3), D32S-3(B3.3)
D33S-3(B3.3)
SB4157E00
Jun. 2004
Schematic
Lift Trucks Hydraulic Systems
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
G20P-3, G25P-3, G30P-3, G32P-3, G33P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
SB4141E00
Jan. 2004
Schematic
Lift Trucks Electric System
D20S-3(B3.3), D25S-3(B3.3),
D30S-3(B3.3), D32S-3(B3.3),
D33S-3(B3.3)
SB4158E00
Jun. 2004
Schematic
Lift Trucks Electric Systems
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
G20P-3, G25P-3, G30P-3, G32P-3, G33P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
WIRING SCHEMATIC - ELEC
MODEL : G(C)20/25/30/32E-3(G424E)
A334021
WIRING SCHEMATIC - ELEC
MODEL : G(C)20/25/30/32P-3(G430E)
G33P-3(G430E)
A334022
SB2302E06
Operation &
Maintenance Manual
LIFT TRUCKS
D20S-3, D25S-3, D30S-3, D33S-3
G20E-3, G25E-3, G30E-3
GC20E-3, GC25E-3, GC30E-3
G20P-3, G25P-3, G30P-3, G33P-3
GC20P-3, GC25P-3, GC30P-3
D32S-3 (6,500lb@24"L.C.)
G32E-3 (6,500lb@24"L.C.)
G32P-3 (6,500lb@24"L.C.)
GC32E-3 (6,500lb@24"L.C.)
GC32P-3 (6,500lb@24"L.C.)
WARNING
Do not start, operate or service this machine unless you have read and understood
these instructions and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training
before operating or maintaining the machine.
This manual should be kept with the machine for reference and periodically
reviewed by the machine operator and by all personnel who will come into contact
with it.
The following warning is provided pursuant to California Health & Safety Code Sections
25247.5 et, seq,
WARNING
California Proposition 65
Engine Exhaust, some of its constituents, and certain vehicle components contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
WASH HANDS AFTER HANDLING.
Information Section
Table of Contents
Information Section Maintenance Section
Foreword................................................................ 2 Inspection, Maintenance and Repair of Lift Truck

Literature Information............................................. 2 Forks ..................................................................124
Tire Inflation Information.....................................128
Safety Section Torque Specifications .........................................129
Cooling System Specifications ...........................131
Fuel Specifications .............................................133
Important Safety Information ................................. 4 Lubricant Information .........................................135
Safety..................................................................... 5 Lubricant Viscosities and Refill Capacities.........137
Warning Signs and Labels.................................. 5 Maintenance Intervals ........................................138
Parking brake...................................................... 9 When Required ..................................................142
General Hazard Information ............................. 10 Every 10 Service Hours or Daily ........................152
Operation Information....................................... 11 First 50 - 100 Service Hours or a Week .............157
Maintenance Information .................................. 14 First 250 Service Hours or a Month ...................162
Operator Restraint System(If Equipped) .......... 17 Every 250 Service Hours or Monthly..................163
Avoiding Lift Truck Tipover ............................... 21 Every 500 Service Hours or 3 Months ...............170
Safety Rules ..................................................... 23 Every 1000 Service Hours or 6 Months .............179
How to Survive in a Tipover.............................. 28 Every 1500 Service Hours or 9 Months .............185
Every 2000 Service Hours or Yearly ..................188
General Section Every 2500 Service Hours or 15 Months ...........195
Every 3000 Service Hours or 18 Months ...........198
Specifications....................................................... 30 Every 4500 Service Hours or two Years ............199
Noise and Vibration ............................................. 50
Capacity Chart ..................................................... 51
Serial Number...................................................... 61 Index Section
Operator's Warning and Identification Plate ........ 64
Index...................................................................200
Operation Section
Operator's Station and Monitoring Systems ........ 65

Lift Truck Controls................................................ 69
Refueling.............................................................. 72
Before Starting the Engine................................... 75
Starting the Engine .............................................. 78
Dual Fuel System (If G424 Dual Fuel Engine
Equipped) ............................................................ 81
Dual Fuel System (G424E Engine Only) ............. 83
Lift Truck Operation ............................................. 86
G424E/G430E Electronic Controlled LP Engines
(If Equipped) ........................................................ 89
Advanced Diagnostics ....................................... 104
Table a. MI-04 Diagnostic Fault Codes (Flash
Codes) ............................................................... 106
Auto Shift Controller ASC-100 (If Equipped) ..... 112
Operating Techniques........................................ 115
Parking the Lift Truck ......................................... 119
Lift Fork Adjustment ........................................... 120
Storage Information ........................................... 121
Transportation Hints........................................... 122
Towing Information............................................. 123
-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 DAEWOO operator
compartment in the literature holder or seat back restraint system.
literature storage area.
SAFE and EFFICIENT OPERATION of a lift truck
This manual contains safety, operation, depends to a great extent on the skill and alertness
transportation, lubrication and maintenance on the part of the operator. To develop this skill the
information. operator should read and understand the Safe
Driving Practices contained in this manual.
Some photographs or illustrations in this publication
show details or attachments that can be different Forklift trucks seldom tipover, but in the rare event
from your lift truck. Guards and covers might have they do, the operator may be pinned to the ground
been removed for illustrative purposes. by the lift truck or the overhead guard. This could
result in serious injury or death.
Continuing improvement and advancement of
product design might have caused changes to your Operator training and safety awareness is an
lift truck which are not included in this publication. effective way to prevent accidents, but accidents
Read, study and keep this manual with the lift truck. can still happen. The DAEWOO operator restraint
system can minimize injuries. The DAEWOO
Whenever a question arises regarding your lift truck, operator restraint system keeps the operator
or this publication, please consult your DAEWOO substantially within the confines of the operator’s
dealer for the latest available information. compartment and the overhead guard.
This manual contains information necessary for

Safety Safe Operation. Before operating a lift truck, make
sure that the necessary instructions are available
The Safety Section lists basic safety precautions. In and understood.
addition, this section identifies the text and
locations of warning signs and labels used on the
lift truck.
Read and understand the basic precautions listed
in the Safety Section before operating or
Operation
performing lubrication, maintenance and repair on The Operation Section is a reference for the new
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
Photographs and illustrations guide the operator
maintenance information for the DAEWOO 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
WARNING are basic. Skill and techniques develop as the
operator gains knowledge of the lift truck and its
Your DAEWOO truck comes equipped with an capabilities.
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DAEWOO
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 DAEWOO INDUSTRIAL VEHICLE
DIVISION 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

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons
must also have the necessary training, skills and tools before attempting to perform these functions.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
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.
DAEWOO 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 DAEWOO
is used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DAEWOO dealers have the most current
information available.
-4-
Safety Section
Safety
The safety rules and regulations in this section are Warning Signs and Labels
representative of some, but not all rules and
regulations noted under the Occupational Safety There are several specific safety signs on your lift
and Health Act (OSHA) and are paraphrased truck. Their exact location and description of the
without representation that the OSHA rules and hazard are reviewed in this section. Please take the
regulations have been reproduced verbatim. time to familiarize yourself with these safety signs.
Make sure that you can read all warning and
Please refer to 1910. 178 in Federal Register Vol. instruction labels. Clean or replace these labels if
37, No. 202, the National Fire Protection you cannot read the words or see the pictures.
Association No. 505 (NFPA), American National When cleaning the labels use a cloth, water and
Standard, ANSI B56. 1 Safety Standard for Low lift soap. Do not use solvent, gasoline, etc.
and High Lift Trucks and subsequent revisions for a You must replace a label if it is damaged, missing
complete list of OSHA rules and regulations as to or cannot be read. If a label is on a part that is
the safe operation of powered industrial lift trucks. replaced, make sure a new label is installed on the
Since regulations vary from country to country replaced part. See your dealer for new labels.
outside in U.S.A., operate this lift truck in
accordance with local regulations. Traing Required To Operate or Service
Warning
DAEWOO lift trucks are manufactured according to
the regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives
89/655/EC and 89/391/EC and its amendments for
the safe use of DAEWOO 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, Located on the right side of the steering wheel.
defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and WARNING
authorized to do so.
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
DAEWOO Lift Truck dealers.
This label also provides allowable lift truck capacity

information
-5-
Safety Section
General Warning to Operator 5. Travel with load as low as possible and tilted
back. If load interferes with visibility, travel with
load trailing.
6. On grade operations travel with load up grade.
7. Watch out for pedestrians and obstructions.

Check overhead clearances.
8. Do not permit riders on forks or machine at any

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

elevated portion of any machine.
Located on the right side of the operator's seat
10. Be sure operating surface can safely support
(STD).
machine.
11. Operate machine and attachments only from

operator's position.
12. Do not handle unstable or loosely stacked

loads.
13. Use minimum tilt when picking up or depositing

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

wide loads.
Located on the overhead guard (If Convenience 15. Forks should be completely under load and
Package Equipped). spread apart as far as load permits.
16. Machine should be equipped with overhead

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

before “ON - OFF” switch is turned on.
4. Start, turn and brake smoothly. Slow down for

turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid running
over loose objects or holes in the roadway
surfaces. Use extreme caution when turning on
inclines.
-6-
Safety Section
Pressure Warning No Standing On Fork Warning

WARNING No Standing Under Fork Warning
Contents under pressure may be hot. Allow to WARNING
cool before opening.
Do not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do not
stand or walk under the forks.
Located on the radiator top tank by the radiator

cap.
Located on the lift cylinder.
Hand Placement Warning
WARNING Load Backrest Must Be In Place
Warning
WARNING
Operation without this device in place may be
hazardous.
No hands. Do not place hands in this area. Do
not touch, lean on, or reach through the mast or
permit others to do so.
Located on the 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
fan.
Operation without this device in place may be
hazardous. This guard conforms to
A.N.S.I.B56.1 and F.E.M.Section IV. This design
has been tested with an impact of appropriate
valve.
Located inside the engine compartment cover.
Located on the Overhead Guard.
No Riders Warning
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
Located beside the operator's station (STD) or on

front of the hood (Convenience Package).
-8-
Safety Section
Parking brake
Pull the lever BACK to engage the

parking brake.
Push the lever FORWARD to release

the parking brake.
Applying the parking brake puts the transmission in

NEUTRAL. The parking brake must be applied
when leaving the lift truck and when starting the
engine. If the operator leaves the seat without
applying the parking brake, an audible alarm will
sound.
WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied.
Alarm will sound if parking brake is not applied.
WARNING
Correct adjustment is necessary to provide
adequate braking. See the MAINTENANCE section
for adjustment procedures. The lift truck may creep
at engine idle and can cause damage, injury or
death. Always apply the parking brake when
leaving the lift truck. The parking brake is NOT
automatically applied.
-9-
Safety Section
General Hazard Information Always use the overhead guard. The overhead
guard is intended to protect the lift truck operator
from overhead obstructions and from falling
objects.
A truck that is used for handing small objects or

uneven loads must be fitted with a load backrest.
If the lift truck must be operated without the

overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is 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
start switch or controls before servicing or repairing Do not raise loads any higher than necessary and
the lift truck. never raise a load higher than 1830 mm (72 in) with
the overhead guard removed.
Do not start or service the lift truck when a “DO
NOT OPERATE” or similar warning tag is attached Always use load backrest extension when the
to the start switch or controls. carriage or attachment does not fully support the
load. The load backrest extension is intended to
Wear a hard hat, protective glasses and other prevent the load or any part of the load from falling
protective equipment as required by job conditions. backwards into the operator's station.
Know the width of your attachments so proper When operating the lift truck, do not depend only on
clearance can be maintained when operating near flashing lights or back-up alarm (if equipped) to
fences, boundary obstacles, etc. warn pedestrians.
Do not wear loose clothing or jewelry that can catch Always be aware of pedestrians and do not
on controls or other parts of the lift truck. proceed until the pedestrians are aware of your
presence and intended actions and have moved
Keep the lift truck, especially the deck and steps, clear of the lift truck and/or load.
free of foreign material such as debris, oil tools and
other items which are not part of the lift truck. Do not drive lift truck up to anyone standing in front
of an object.
Secure all loose items such as lunch boxes, tools
and other items which are not part of the lift truck. Obey all traffic rules and warning signs.
Know the appropriate work-site hand signals and Keep hands, feet and head inside the operator
who gives them. Accept signals from one person station. Do not hold onto the overhead guard while
only. operating the lift truck. Do not climb on any part of
the mast or overhead guard or permit others to do
so.
Do not allow unauthorized personnel to ride on the

forks or any other part of the lift truck, at any time.
When working in a building or dock, observe floor

load limits and overhead clearances.
-10-
Safety Section
Inhaling Freon gas through a lit cigarette or other Operation Information

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

entering or leaving the operator's station.
Never get on or off a moving lift truck. Never jump

off the lift truck.
Keep hands and steering wheel free of slippery

material.
Before Starting the Lift Truck

Perform a walk-around inspection daily and at the
Inspect the part of the chain that is normally start of each shift. Refer to the topic “Walk-around
operated over the crosshead roller. When the chain Inspection” in “Every 10 Service Hours or Daily”
bends over the roller, the movement of the parts section of this manual.
against each other causes wears.
Adjust the seat so that full brake pedal travel can
Inspect to be sure that chain link pins do not extend be obtained with the operator's back against the
outside of the bore hole. seat back.
If any single link pin is extended beyond its Make sure the lift truck is equipped with a lighting
connecting corresponding link, it should be system as required by conditions.
suspected of being broken inside of its bore hole.
Make sure all hydraulic controls are in the HOLD
Inspect the chain anchor and the anchor links for position.
wear.
Make sure the direction control lever is in the
Do not change any factory set adjustment values NEUTRAL position.
(including engine rpm setting) unless you have both
authorization and training. Especially Safety Make sure the parking brake is engaged.
equipment and switches may not be removed or
adjusted incorrectly. Repairs, adjustments and Make sure no one is standing and/or working on,
maintenances that are not correct can make a underneath or close to the lift truck before operating
dangerous operating condition. the lift truck.
For any checkup, repair, adjustments, maintenance Operate the lift truck and controls only from the
and all other work concerning your forklift truck, operator's station.
please contact your DAEWOO dealer. We would
like to draw your attention to the fact that any
secondary damages due to improper handling,
insufficient maintenance, wrong repairs or the use
of other than original DAEWOO spare parts waive
any liability by DAEWOO.
-11-
Safety Section
Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck
equipped) and all other devices are working
properly. Always keep the lift truck under control.
Check for proper operation of mast and Obey all traffic rules and warning signs.
attachments. Pay particular attention to unusual
noises or erratic movement which might indicate a Never leave the lift truck with the engine operating,
problem. or with the parking brake disengaged.
Make sure service and parking brakes, steering, Operate the engine only in a well ventilated area.
and directional controls are operational.
Lower a mast, with or without load, before turning
Make sure all personnel are clear of lift truck and or traveling. Tip over could result. Watch out for
travel path. overhead obstructions.
Refer to the topic “Lift Truck Operation” in the Always observe floor load limits and overhead
“Operation Section” of this manual for specific clearance.
starting instructions.
Start, turn, and brake smoothly. Slow down for
turns, grades, slippery or uneven surfaces.
Starting the Lift truck
Do not start the engine or move any of the controls Use special care when operating on grades. Do not
if there is a “DO NOT OPERATE” or similar warning angle across or turn on grades. Do not use lift truck
tag attached to the start switch or controls. on slippery grades. Travel with forks downgrade
when unloaded. Travel with load upgrade.
Before Operating the Lift Truck
Do not overload, or handle offset, unstable, or
Test brakes, steering controls, horn and other loosely stacked loads. Refer to load capacity plate
devices for proper operation. Report any faulty on the lift truck. Use extreme caution when
performance. Do not operate lift truck until repaired. handling suspended, long, high or wide load.
Learn how your lift truck operates. Know its safety
devices. Know how the attachments work. Before
moving the lift truck, look around. Start, turn and
brake smoothly.
An operator must constantly observe his lift truck

for proper operation.
-12-
Safety Section
Loading or Unloading Trucks/Trailers

Do not operate lift trucks on trucks or trailers which
are not designed or intended for that purpose. Be
certain truck or trailer brakes are applied and wheel
chocks in place (or be certain unit is locked to the
loading dock) before entering onto trucks or trailers.
If trailer is not coupled to tractor, make sure the

trailer landing gear is properly secured in place. On
some trailers, extra supports may be needed to
prevent upending or corner dipping.
Be certain dock plates are in good condition and

Tilt the elevated load forward only when directly properly placed and secured. Do not exceed the
over unloading area and with load as low as rated capacity of dock boards or bridge plates.
possible.
Lift Truck Parking
Do not stunt ride or indulge in horseplay.
When leaving the operator station, park the lift truck
Always look and keep a clear view of the path of in authorized areas only. Do not block traffic.
travel.
Travel in reverse if load or attachment obstructs

visibility. Use extreme caution if visibility is
obstructed.
Stay in designated travel path, clear of dock edges,

ditches, other drop-offs and surfaces which cannot
safely support the lift truck.
Slow down and use extra care through doorways,

intersections and other location where visibility is
reduced.
Slow down for cross aisles, turns, ramps, dips, z Park the lift truck level, with the forks lowered and
uneven or slippery surfaces and in congested areas, the mast tilted forward until the fork tips touch the
avoid pedestrians, other vehicles, obstruction, pot floor.
holes and other hazards or objects in the path of
travel. z Move the direction control lever to NEUTRAL.
Always use overhead guards except where z Engage the parking brake.
operation conditions do not permit. Do not operate
lift truck in high stacking areas without overhead z Turn the key switch off and remove the key.
guards.
z Turn the disconnect switch to OFF (if equipped).
When stacking, watch for falling objects. Use load
backrest extension and overhead guard. z Block the drive wheels when parking on an
incline.
Refer to the topic “Operation Techniques” in the
“Operation Section” of this manual.
-13-
Safety Section
Maintenance Information They will throw or cut any object or tool that falls or
is pushed into them.
Perform all maintenance unless otherwise specified
as follows: Do not use a kinked or frayed wire rope cable.
Wear gloves when handling the wire rope cable.
z Park the lift truck in authorized areas only.
z Park the lift truck level, with the forks lowered and Retainer pins, when struck with force, can fly out
the mast tilted forward until the fork tips touch the and injure nearby persons. Make sure the area is
floor. clear of people when driving retainer pins.
z Place the transmission controls in neutral.
z Engage the parking brake. 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
disconnect switch OFF (if equipped). Chips or other debris can fly off objects when struck.
z Block the drive wheels when parking on an Make sure no one can be injured by flying debris
incline. before striking any object.
Pressure Air Falling Objects Protective Structure (FOPS)

Pressure air can cause personal injury. When using This is an attached guard located above the
pressure air for cleaning, wear a protective face operator's compartment and secured to the lift
shield, protective clothing and protective shoes. truck.
The maximum air pressure must be below 205 kPa To avoid possible weakening of the Falling Objects
(30 psi) for cleaning purposes. Protective Structure (FOPS), consult a DAEWOO
dealer before altering, by adding weight to, welding
Fluid Penetration on, or cutting or drilling holes into the structure.
Always use a board or cardboard when checking The overhead guard is not intended to protect
for a leak. Escaping fluid under pressure, even a against every possible impact. The overhead guard
pinhole size leak, can penetrate body tissue, may not protect against some objects penetrating
causing serious injury, and possible death. If fluid is into the operator's station from the sides or ends of
injected into your skin, it must be treated by a the lift truck.
doctor familiar with this type of injury immediately.
The lift truck is equipped with an overhead guard
Crushing or Cutting Prevention and FOPS as standard. If there is a possibility of
Support equipment and attachments properly when overhead objects falling through the guard, the
working beneath them. Do not depend on hydraulic guard must be equipped with smaller holes or a
cylinders to hold it up. Any attachment can fall if a Plexiglas cover.
control is moved, or if a hydraulic line breaks.
Any altering done that is not specifically authorized
Never attempt adjustments while the lift truck is by DAEWOO invalidates DAEWOO's FOPS
moving or the engine is running unless otherwise certification. The protection offered by this FOPS
specified. will be impaired if it has been subjected to structural
damage. Structural damage can be caused by an
Where there are attachment linkages, the overturn accident, by falling objects, etc.
clearance in the linkage area will increase or
decrease with movement of the attachment. Do not mount any item such as fire extinguishers,
first aid kits and lights by welding brackets to or
Stay clear of all rotating and moving parts. drilling holes in any FOPS structure. See your
DAEWOO dealer for mounting guidelines.
Keep objects away from moving fan blades.
-14-
Safety Section
Burn Prevention Fire or Explosion Prevention

Coolant All fuels, most lubricants and some coolant
mixtures are flammable.
At operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines to
Fuel leaked or spilled onto hot surfaces 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.
Steam can cause personal injury.
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 filter cap is cool enough to remove
with your bare hand.
Batteries in series can be located in separate
compartments. When using jumper cables always
Remove the cooling system filter cap slowly to
connect positive(+) cable to positive(+) terminal of
relieve pressure.
battery connected to starter solenoid and
negative(-) cable from external source to starter
Cooling system additive contains alkali that can
negative(-) terminal.
cause personal injury. Avoid contact with the skin
(If not equipped with starter negative(-) terminal,
and eyes and do not drink.
connect to engine block.)
Allow cooling system components to cool before
See the Operation Section of this manual for
draining.
specific starting instructions.
Oils
Clean and tighten all electrical connections. Check
Hot oil and components can cause personal injury. daily for loose or frayed electrical wires. Have all
Do not allow hot oil or components to contact the loose or frayed electrical wires tightened, repaired
skin. or replaced before operating the lift truck.
At operation temperature, the hydraulic tank is hot Keep all fuels and lubricants stored in properly
and can be under pressure. marked containers and away from all unauthorized
persons.
Remove the hydraulic tank filter cap only after the
engine has been stopped and the filter cap is cool Store all oily rags or other flammable material in a
enough to remove with your bare hand. protective container, in a safe place.
Remove the hydraulic tank filter cap slowly to Do not weld or flame cut on pipes or tubes that
relieve pressure. contain flammable fluids. Clean them thoroughly
with nonflammable solvent before welding or flame
Relieve all pressure in air, oil fuel or cooling cutting on them.
systems before any lines, fittings or related items
are disconnected or removed. Remove all flammable materials such as fuel, oil
and other debris before they accumulate on the lift
Batteries truck.
Batteries give off flammable fumes which can Do not expose the lift truck to flames, burning brush,
explode. etc., if at all possible.
Do not smoke when observing the battery Shields, which protect hot exhaust components
electrolyte levels. from oil or fuel spray in the event of a line, tube or
seal failure, must be installed correctly.
Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes. Do not operate in areas where explosive gases
exist or are suspected.
Always wear protective glasses when working with
batteries.
-15-
Safety Section
Fire Extinguisher z End fittings damaged or leaking.

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
serviced as recommended on its instruction plate.
part of hose.
z Armoring embedded in the outer cover.
Ether
z End fittings displaced.
Ether is poisonous and flammable.
Make sure that all clamps, guards and heat shields
Breathing ether vapors or repeated contact of ether are installed correctly to prevent vibration, rubbing
with skin can cause personal injury. against other parts, and excessive heat during
operation.
Use ether only in well-ventilated areas.
Do not smoke while changing ether cylinders. Tire Information
Explosions of air-inflated tires have resulted from
Use ether with care to avoid fires.
heat-induced gas combustion inside the tires. The
heat, generated by welding or heating rim
Do not store replacement ether cylinders in living
components, external fire, or excessive use of
areas or in the operator's compartment.
brakes can cause gaseous combustion.
Do not store ether cylinders in direct sunlight or at
A tire explosion is much more violent than a
temperatures above 39°C (102°F).
blowout. The explosion can propel the tire, rim and
axle components as far as 500 m (1500 ft) or more
Discard cylinders in a safe place. Do not puncture
from the lift truck. Both the force of the explosion
or burn cylinders.
and the flying debris can cause personal injury or
death, and property damage.
Keep ether cylinders out of the reach of
unauthorized personnel.
Lines, Tubes and Hoses

Do not bend or strike high pressure lines. Do not
install bent or damaged lines, tubes or hoses.
Repair any loose or damaged fuel and oil lines,

tubes and hoses. Leaks can cause fires. Contact
your DAEWOO dealer for repair or replacement.
Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or
cardboard to check for leaks. See Fluid Penetration
in the Safety Section for more details. Tighten all Do not approach a warm tire closer than the
connections to the recommended torque. Replace if outside of the area represented by the shaded area
any of the following conditions are found. in the above drawing.
-16-
Safety Section
Dry nitrogen (N2) gas is recommended for inflation Operator Restraint System(If
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure. Equipped)
Nitrogen mixes properly with air.
Warning Signs and Labels
Nitrogen inflated tires reduce the potential of a tire Your DAEWOO 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 over-inflation. A tire etc. You must replace a label if it is damaged,
blowout or rim failure can result from improper or missing or cannot be read. If a label is on a part
misused equipment. that is replaced, make sure a new label is installed
on the replaced part. See you DAEWOO Lift Truck
Stand behind the tread and use a self-attaching dealer for new labels.
chuck when inflation a tire. The most effective method of preventing serious
injury or death to yourself or others is to familiarize
Servicing, changing tires and rims can be yourself with the proper operation of the lift truck, to
dangerous and should be done only by trained be alert, and to avoid actions or conditions which
personnel using proper tools and procedures. If can result in an accident.
correct procedures are not followed while servicing
tires and rims, the assemblies could burst with
WARNING
explosive force and cause serious personal injury
or death. Follow carefully the specific information Tipover can occur if the truck is improperly
provided by your tire or rim servicing personnel or operated. In the event of tipover, injury or death
dealer. could result.
-17-
Safety Section
WARNING
Do NOT place your hand or fingers under the
seat. Injury may occur as the seat suspension
mechanism moves up and down.
NOTICE
Before getting on the truck, adjust the level of the
suspension using the grip in the rear of the seat.
The “Survive in tipover” warning is located on the

overhead guard. It shows the proper use of the
operator restraint system.
Seat Adjustment
WARNING
When raising and lowering the seat backrest,
avoid placing hand or fingers in the hinge area
indicated by the circle. Injury may occur.
Move the lever, slide the seat to the desired

position, and release the lever.
Adjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.
-18-
Safety Section
If Optional Suspension Seat (weight Seat Belt

adjusting type) Equipped The Operator Restraint System, Prevents the
operator from jumping from the operator’s
compartment in the event of a forward or side
tipover. The system is designed to keep the
operator on the seat and in the operator’s
compartment in the event of a tipover.
Inspection
1. If the seat belt is torn, if pulling motion is

interrupted during extension of the belt, or if the
belt cannot be inserted into the buckle properly,
replace the seat belt assembly.
2. Belt Maintenance - Every 500 service hours.

Check that the belt fastening works properly
and that winding device is free from run lock
when jerked. Check that the belt is suitably
fastened to the seat. Check that the seat is
correctly secured to the hood and the chassis.
On visual inspection, fastenings must be intact,
otherwise, contact the safety manager.
WARNING
Your DAEWOO truck comes equipped with a
DAEWOO operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DAEWOO operator restraint system.
-19-
Safety Section
3. In the event of a tipover, the seat and restraint 4. Be sure to fasten the belt across your hips, not
system should be inspected for damage and across your abdomen.
replaced, if necessary.
NOTE: The belt is designed to automatically adjust
NOTE: Operator restraints shall be examined at to your size and movement. A quick pull on
the regular truck service intervals. It is the belt will confirm that the automatic
recommended that they be replaced if any adjuster will hold the belt position in the
of the following conditions are found: event of an accident.
Cut or frayed strap Worn or damaged hardware
Release the Seat Belt
including anchor points Buckle or retractor
malfunction
z Loosen 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
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.
1. Grip the plate (connector) of the belt and pull the

belt from the retractor. Then insert the plate into
the slot of the buckle until a snap is heard. Pull
on the belt to confirm it is latched.
2. Make sure the belt is not twisted.
WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen in an accident.
-20-
Safety Section
Avoiding Lift Truck Tipover Stability and Center of Gravity

Lift Truck Stability
The stability of the lift truck is determined by the

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

Center of Gravity (CG)
z tire pressure
z dynamic forces created when the lift truck is

accelerated, braked or turned
z condition and grade of surfaces on which the lift

truck is operated
The point within an object, at which the whole

weight of the object may be regarded as being
concentrated, is called the center of gravity or CG.
If the object is uniform, its geometric center will
coincide with its CG. If it is not uniform, the CG
could be at a point outside of the object. When the
lift truck picks up a load, the truck and load have a
new combined CG.
These same factors are also important for unloaded
lift trucks. They tip over sideways easier than a
loaded lift truck carrying its load in the lowered
position.
-21-
Safety Section
Lift Truck Stability Base 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 NOTICE
to the side), the CG must stay within the area of the 1. Capacity/Nameplates originally attached to
lift truck stability base – a triangular area between forklifts sold by DAEWOO shall not be removed,
the front wheels and the pivot of the steer wheels. If altered or replaced without DAEWOO’s approval.
the CG moves forward of the front axle, the lift truck
will tip forward. If the CG moves outside of the line 2. DAEWOO assumes no responsibility for lift
on either side of the stability base, the lift truck will trucks placed in service without a valid DAEWOO
tip to the side. Nameplate.
WARNING 3. If necessary to change your specification, contact

your DAEWOO lift truck dealer.
Dynamic forces (braking, acceleration, turning)
also affect stability and can produce tipover
even when the CG is within the stability
triangle.
Capacity Load (Weight and Load Center)
The capacity load of the lift truck is shown on the

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

horizontal distance from the front face of the forks,
or the load face of an attachment, to the CG of the
load. The location of the CG in the vertical direction
is the same as the horizontal dimension.
Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
-22-
Safety Section
Safety Rules
Do not operate a lift truck unless you are in the

operator's seat.
Only properly trained and authorized personnel Keep arms, legs and head inside the confines of
should operate forklift trucks. Wear a hard hat and the operator's area. Keep hands and feet out of the
safety shoes when operating a lift truck. Do not mast assembly.
wear loose clothing.
Do not start, stop, turn or change direction

Inspect and check the condition of your forklift truck suddenly or at high speed. Sudden movement can
using the operator's check list before starting work. cause the lift truck to tip over. Slow the speed of
Immediately report to your supervisor any obvious your truck and use the horn near corners, exits,
defects or required repairs. entrances, and 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.
-23-
Safety Section
Do not raise anyone on the forks of your lift truck Do not overload. Always handle loads within the
unless using an approved safety cage. rated capacity shown on the capacity plate.
Do not let other people ride on the truck. Do not add extra counterweight to the truck. An
Lift trucks are designed to carry loads, not people. 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.
-24-
Safety Section
Do not elevate the load with the mast tilted forward.

Do not permit anyone to stand or walk under the
Do not tilt the elevated loads forwards.
load or lifting mechanism. The load can fall and
This will cause the lift truck to tip over forward.
cause injury or death to anyone standing below.
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.
-25-
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
death.
crossing, cross the railroad diagonally so one wheel
crosses at a time.
Do not operate on bridge plates unless they can

support the weight of the truck and load.
Avoid running over loose objects.
Make sure that they are correctly positioned.
Look in the direction of travel. Look out for other
Put blocks on the vehicle you enter to keep it from
persons or obstructions in your path of travel.
moving.
An operator must be in full control of his lift truck at
all times.
-26-
Safety Section
Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully
Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in
make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and
Never overtake other vehicles. turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work.
Do not use your lift truck to push or tow another

truck.
Do not let another push or tow your truck.
If a truck will not move, call a service technician.
Forklift trucks may only be refueled at specially

reserved locations. Switch off the engine when
refueling.
Smoking and handling of naked flames during
refueling are strictly prohibited. This prohibition also
applies during the changing of the LPG (liquefied
propane gas) tank.
Mop up spilt fuel and do not forget to close the fuel
tank before restarting the engine.
-27-
Safety Section
How to Survive in a Tipover

WARNING
In the event of a tipover, the risk of serious injury or

death will be reduced if the operator is using the
operator restraint system and follows the
instructions provided.
Hold on tight.
Always use operator restraint system.
Brace your feet and keep them within the operator’s

compartment.
DON’T jump.
-28-
Safety Section
Lean away from the direction of fall.
Lean forward.
-29-
General Section
Specifications
CHARACTERISTICS
1 Manufacturer DHI&M DHI&M
2 Model D20S-3 D25S-3
3 Capacity at rated load center kg 2000 2500
4 Load center distance mm 500 500
5 Power type electric, diesel, gasoline, LPG diesel diesel
6 Operator type stand-on, rider seated rider - seated rider - seated
7 Tires* c = cushion, p = pneumatic p p
8 Wheels (x = driven) number, front/rear X2/2 X2/2
DIMENSIONS
9 maximum fork height with rated load mm 3230 3230
Lift with STD
10 free lift mm 152 152
two - stage mast
11 special free lift mm
12 Fork carriage ISO class ll ll
13 thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050
Forks
fork spacing (minimum X maximum) mm 275 X 1035 275 X 1035
14 Tilt of mast forward/backward deg 6/10 6/10
15 length without forks mm 2505 2573
16 width mm 1170 1170
17 Overall mast lowered height mm 2170 2170
18 dimensions mast extended height mm 4470 4470
19 overhead guard height mm 2183 2183
20 seat height mm 1026 1026
21 Outside turning radius mm 2220 2265
22 Load moment constant (from center of front wheel to fork face) mm 485 485
23 90° stacking aisle (add load length and clearance) mm 2705 2750
23a 90° intersecting aisle mm 1970 2000
PERFORMANCE
24 travel, loaded/unloaded km/h 19.5/20 19.4/19.9
25 Speeds lift, loaded/unloaded mm/s 550/600 530/600
26 lowering, loaded/unloaded mm/s 510/460 510/460
28 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1610/ 1620/
30 Gradeability at 1.6 km/h, loaded/unloaded % 28.6/ 24.9/
31 Acceleration time traveling loaded/unloaded s
WEIGHT
32 Total weight at unloaded kg 3910 4280
33 with load front/rear kg 5180/730 5925/855
Axle load
34 without load front/rear kg 1970/1940 1910/2370
CHASSIS
35 number of front/rear 2/2 2/2
36 Tires front size 7.00 X 15 - 12PR 7.00 X 15 - 12PR
37 rear size 6.50 X 10 - 10PR 6.50 X 10 - 10PR
38 Wheelbase mm 1625 1625
39 Tread front/rear mm 975/1000 975/1000
40 at the lowest point mm 115 115
Ground clearance
41 at the center of wheelbase mm 153 153
42 Service brake foot/hydraulic foot/hydraulic
43 Parking brake hand/mechanical hand/mechanical
DRIVE
45 Battery voltage/capacity V/AH 12/85 12/85
49 manufacturer/model DHI&M/DB33A DHI&M/DB33A
50 rated output (at rpm) gas/LPG kW 44.1(2300) 44.1(2300)
51 Engine max. torque (at rpm) gas/LPG kg - m 20(1600) 20(1600)
52 cycle/cylinders/displacement cc 4/4/3268 4/4/3268
53 fuel consumption l/hr
55 type Powershift Powershift
Transmission
56 number of speeds forward/reverse 1/1 1/1
* Solid soft rider tires are available instead of pneumatic as an option.
-30-
General Section
DHI&M DHI&M 1
D30S-3 D32S-3 2
3000 3000(6500lb) 3
500 600(24in) 4
diesel diesel 5
rider - seated rider-seated 6
p p 7
X2/2 X2/2 8
3230 3230 9
152 152 10
11
lll lll 12
45 X 125 X 1050 45X125X1050
286 X 1044 286X1044 13
6/10 6/10 14
2636 2690 15
1197 1197 16
2160 2160 17
4470 4470 18
2183 2183 19
1026 1026 20
2364 2414 21
485 485 22
2849 2899 23
2050 2100 23a
19.2/19.7 19.0/19.5 24
520/600 520/600 25
510/460 510/460 26
1705/ 1705/ 28
23.0/ 23/ 30
31
4715 5070 32
6705/1010 6810/1260 33
1890/2825 1810/3260 34
2/2 2/2 35
28 X 9 X 15 - 12PR 28X9X15-12PR 36
6.50 X 10 - 10PR 6.50X10-10PR 37
1625 1625 38
982/1000 982/1000 39
105 105 40
153 153 41
foot/hydraulic foot/hydraulic 42
hand/mechanical hand/mechanical 43
12/85 12/85 45
DHI&M/DB33A DHI&M/DB33A 49
44.1(2300) 44(2300) 50
20(1600) 20/1600 51
4/4/3268 4/4/3268 52
53
Powershift Powershift 55
1/1 1/1 56
-31-
General Section
Specifications
CHARACTERISTICS TIER - II
2 Model D20S-3 D25S-3
5 Power type electric, diesel, gasoline, LPG diesel diesel
DIMENSIONS
Lift with STD
two - stage mast
thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050
13 Forks
16 width mm 1170 1170
17 mast lowered height mm 2170 2170
Overall dimensions
18 mast extended height mm 4470 4470
PERFORMANCE
24 travel, loaded/unloaded km/hr 19.5/20 19.5/20
28 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1850 1860
30 Gradeability at 1.6 km/h, loaded/unloaded % 32 28
WEIGHT
Axle load
CHASSIS
37 rear size 6.50 X 10 - 10PR 6.50 X 10 - 10PR
Ground clearance
DRIVE
49 manufacturer/model CUMMINS/B3.3 CUMMINS/B3.3
51 Engine max. torque (at rpm) gas/LPG kg - m 20.5(1600) 20.5(1600)
Transmission
-32-
General Section
TIER - II
DHI&M DHI&M DHI&M 1
D30S-3 D32S-3 D33S-3 2
3000 3000(6500lb) 3250 3
500 600(24in) 500 4
diesel diesel diesel 5
rider - seated rider-seated rider-seated 6
p p p 7
X2/2 X2/2 X2/2 8
3230 3230 3230 9

152 152 152 10
11
lll lll lll 12
45 X 125 X 1050 45X125X1050 45X125X1050
13
286 X 1044 286X1044 286X1044
6/10 6/10 6/10 14
2636 2690 2690 15
1197 1197 1197 16
2160 2160 2160 17
4470 4470 4470 18
2183 2183 2183 19
1026 1026 1026 20
2364 2414 2414 21
485 485 485 22
2849 2899 2899 23
2050 2100 2100 23a
19.0/19.5 19.0/19.5 19.0/19.5 24

520/600 520/600 500/600 25
510/460 510/460 510/460 26
1890 1890 1900 28
25 25 23.5 30
31
4715 5070 5070 32

6705/1010 6810/1260 7030/1290 33
1890/2825 1810/3260 1810/3260 34
2/2 2/2 2/2 35

28 X 9 X 15 - 12PR 28X9X15-12PR 28X9X15-12PR 36
6.50 X 10 - 10PR 6.50X10-10PR 6.50X10-10PR 37
1625 1625 1625 38
982/1000 982/1000 982/1000 39
105 105 105 40
153 153 153 41
foot/hydraulic foot/hydraulic foot/hydraulic 42
hand/mechanical hand/mechanical hand/mechanical 43
12/85 12/85 12/85 45

CUMMINS/B3.3 CUMMINS/B3.3 CUMMINS/B3.3 49
43.4(2200) 43.4(2200) 43.4(2200) 50
20.5(1600) 20.5(1600) 20.5(1600) 51
4/4/3260 4/4/3260 4/4/3260 52
53
Powershift Powershift Powershift 55
1/1 1/1 1/1 56
-33-
General Section
Specifications
CHARACTERISTICS
2 Model G20E-3 G25E-3
5 Power type electric, diesel, gasoline, LPG gasoline / LPG gasoline / LPG
DIMENSIONS
10 Lift with STD two - stage mast free lift mm 152 152
13 Forks
16 Overall width mm 1170 1170
17 dimensions mast lowered height mm 2170 2170
18 mast extended height mm 4470 4470
PERFORMANCE
24 travel, loaded/unloaded km/hr 18.2/19.3 18.0/19.3
WEIGHT
Axle load
CHASSIS
37 rear size 6.50 X 10 - 10PR 6.50 X 10 - 10PR
Ground clearance
DRIVE
49 manufacturer/model DHI&M/G424 DHI&M/G424
Transmission
-34-
General Section
DHI&M DHI&M 1
G30E-3 G32E-3 2
3000 3000(6500lb) 3
500 600(24in) 4
gasoline / LPG LPG 5
rider - seated rider-seated 6
p p 7
X 2/2 X2/2 8
3230 3230 9
152 152 10
11
lll lll 12
45 X 125 X 1050 45X125X1050
13
286 X 1044 286X1044
6/10 6/10 14
2636 2690 15
1197 1197 16
2160 2160 17
4470 4470 18
2183 2183 19
1026 1026 20
2364 2414 21
485 485 22
2849 2899 23
2050 2100 23a
17.0/18.4 17.0/18.0 24
500/600 500/600 25
510/460 510/460 26
1550/ 1550/ 28
20.8/ 20.8/ 30
31
4530 4830 32
6605/925 6690/1140 33
1790/2740 1680/3150 34
2/2 2/2 35
28 X 9 X 15 - 12PR 28X9X15-12PR 36
6.50 X 10 - 10PR 6.50X10-10PR 37
1625 1625 38
982/1000 982/1000 39
105 105 40
153 153 41
12/45 12/45 45
DHI&M/G424 DHI&M/G424 49
34.5(2300) 34.5(2300) 50
16.3(1600) 16.3(1600) 51
4/4/2350 4/4/2350 52
53
1/1 1/1 56
-35-
General Section
Specifications
CHARACTERISTICS
2 Model GC20E-3 GC25E-3
5 Power type electric, diesel, gasoline, LPG gasoline / LPG gasoline / LPG
7 Tires* c = cushion, p = pneumatic c c
8 Wheels (x = driven) number, front/rear X 2/2 X 2/2
DIMENSIONS
Lift with STD
two - stage mast
13 Forks
16 width mm 1110 1110
PERFORMANCE
24 travel, loaded/unloaded km/h 17.5/17.9 17.4/17.8
WEIGHT
Axle load
CHASSIS
36 Tires front size 21 X 7 - 15 21 X 7 - 15
37 rear size 16 X 5 - 10.5 16 X 5 - 10.5
Ground clearance
DRIVE
Transmission
-36-
General Section
DHI&M DHI&M 1
GC30E-3 GC32E-3 2
3000 3000(6500lb) 3
500 600(24in) 4
gasoline / LPG LPG 5
rider - seated rider - seated 6
c c 7
X2/2 X2/2 8
3230 3230 9
152 152 10
11
lll lll 12
45 X 125 X 1050 45 X 125 X 1050
13
282 X 954 282 X 954
6/8 6/8 14
2333 2368 15
1110 1100 16
2125 2125 17
4470 4470 18
2150 2150 19
1038 1038 20
2105 2135 21
374 374 22
2479 2509 23
1872 1907 23a
17.3/17.7 17.3/17.7 24
500/600 500/600 25
510/460 510/460 26
1540/ 1540 28
24/ 24/ 30
31
4140 4310 32
6290/850 6450/860 33
1430/2710 1380/2930 34
2/2 2/2 35
21 X 8 - 15 21 X 8 -15 36
16 X 5 - 10.5 16 X 6 -10.5 37
1410 1410 38
907/956 907/956 39
90 90 40
135 135 41
12/45 12/45 45
34.5(2300) 34.5(2300) 50
16.3(1600) 16.3(1600) 51
4/4/2350 4/4/2350 52
53
1/1 1/1 56
-37-
General Section
Specifications
CHARACTERISTICS
2 Model G20P-3 G25P-3
5 Power type electric, diesel, gasoline, LPG LPG LPG
7 Tires* c = cushion, p = pneumatic P P
DIMENSIONS
Lift with STD
two - stage mast
13 Forks
16 width mm 1170 1170
PERFORMANCE
30 Gradeability at 1.6 km/h, loaded/unloaded % 30.0 25.7
WEIGHT
Axle load
CHASSIS
37 rear size 6.50 X 10 - 10PR 6.50 X 10 - 10PR
Ground clearance
42 Service brake foot/hyd foot/hyd
43 Parking brake hand/mech hand/mech
DRIVE
Transmission
-38-
General Section
DHI&M DHI&M 1
G30P-3 G32P-3 2
3000 3000(6500lb) 3
500 600(24in) 4
LPG LPG 5
P p 7
X2/2 X2/2 8
3230 3230 9
152 152 10
11
lll lll 12
45 X 125 X 1050 45 X 125 X 1050
13
286 X 1044 286 X 1044
6/10 6/10 14
2636 2690 15
1197 1197 16
2160 2160 17
4470 4470 18
2183 2183 19
1026 1026 20
2364 2414 21
485 485 22
2849 2899 23
2050 2100 23a
18.8/20.5 18.8/20.5 24
500/600 500/600 25
510/460 510/460 26
1705 1705 28
23.1 23.1 30
31
4530 4830 32
6605/925 6690/1140 33
1790/2740 1680/3150 34
2/2 2/2 35
28 X 9 X 15 - 12PR 28 X 9 X 15 -12PR 36
6.50 X 10 - 10PR 6.50 X 10 - 10PR 37
1625 1625 38
982/1000 982/1000 39
105 105 40
153 153 41
foot/hyd foot/hyd 42
hand/mech hand/mech 43
12/65 12/65 45
43.4(2200) 43.4(2200) 50
20.5(1800) 20.5(1800) 51
4/4/2967 4/4/2967 52
53
1/1 1/1 56
-39-
General Section
Specifications
CHARACTERISTICS
2 Model GC20P-3 GC25P-3
5 Power type electric, diesel, gasoline, LPG LPG LPG
7 Tires* c = cushion, p = pneumatic C C
DIMENSIONS
9 Lift with STD maximum fork height with rated load mm 3230 3230
10 two - stage mast free lift mm 152 152
13 Forks
16 width mm 1110 1110
PERFORMANCE
WEIGHT
33 Axle load with load front/rear kg 4730/650 5470/710
CHASSIS
37 rear size 16 X 5 - 10.5 16 X 5 - 10.5
Ground clearance
DRIVE
Transmission
-40-
General Section
DHI&M DHI&M 1
GC30P-3 GC32P-3 2
3000 3000(6500lb) 3
500 600(24in) 4
LPG LPG 5
C C 7
X2/2 X 2/2 8
3230 3230 9
152 152 10
11
lll lll 12
45 X 125 X 1050 45 X 125 X 1050
13
282 X 954 282 X 954
6/8 6/8 14
2333 2368 15
1110 1100 16
2125 2125 17
4470 4470 18
2150 2150 19
1038 1038 20
2105 2135 21
374 374 22
2479 2509 23
1872 1907 23a
17.1/18.0 17.1/18.0 24
500/600 500/600 25
510/460 510/460 26
2000 2000 28
28.8 28.8 30
31
4140 4310 32
6290/850 6450/860 33
1430/2710 1380/2930 34
2/2 2/2 35
21 X 8 - 15 21 X 8 -15 36
16 X 5 - 10.5 16 X 6 -10.5 37
1410 1410 38
907/956 907/956 39
90 90 40
135 135 41
12/65 12/65 45
43.4(2200) 43.4(2200) 50
20.5(1800) 20.5(1800) 51
4/4/2967 4/4/2967 52
53
1/1 1/1 56
-41-
General Section
Specifications
CHARACTERISTICS Tier-2
1 Manufacturer DHI DHI
2 Model GC20E-3 GC25E-3
5 Power type electric, diesel, gas, LPG-gas LPG LPG
6 Operator type stand-on, ride- seated rider - seated rider - seated
8 Wheels (x = driven) number of front/rear X2/2 X2/2
DIMENSIONS
12 Forks
15 width mm 1110 1110
22 90° stacking aisle mm 2374 2419
PERFORMANCE
31 Acceleration time time reached at max speed, loaded/unloaded s
WEIGHT
33 at loaded, fornt/rear kg 4730/650 5470/710
Axle load
34 at unloaded, fornt/rear kg 1490/1890 1420/2260
CHASSIS
37 rear size 16 X 5 - 10.5 16 X 5 - 10.5
40 at loaded, the lowest point mm 90 90
Ground clearance
41 at loaded, center of wheelbase mm 135 135
DRIVE
49 manufacturer/model DHI/G424E DHI/G424E
50 rated output / rpm ps(kw) 52/2600 52/2600
Engine
51 max. torque / rpm kg - m 17(1600 17/1600
Transmission
-42-
General Section
Tier-2
DHI DHI 1
GC30E-3 GC32E-3 2
3000 3000(6500lbs) 3
500 600 4
LPG LPG 5
C C 7
X2/2 X 2/2 8
3230 3230 9
152 152 10
lll lll 12
45 X 125 X 1050 45 X 125 X 1050
13
282 X 954 282 X 954
6/8 6/8 14
2333 2368 15
1110 1110 16
2125 2125 17
4470 4470 18
2150 2150 19
1038 1038 20
2105 2135 21
374 374 22
2479 2509 23
1872 1907 23a
18.0/18.0 18.0/18.0 24
500/600 500/600 25
510/460 510/460 26
1540 1540 28
24 24 30
31
4140 4310 32
6290/850 6450/860 33
1430/2710 1380/2930 34
2/2 2/2 35
21 X 8 - 15 21 X 8 -15 36
16 X 5 - 10.5 16 X 6 -10.5 37
1410 1410 38
907/956 907/956 39
90 90 40
135 135 41
12/45 12/45 45
DHI/G424E DHI/G424E 49
52/2600 52/2600 50
17/1600 17/1600 51
4/4/2350 4/4/2350 52
1/1 1/1 56
-43-
General Section
Specifications
CHARACTERISTICS Tier-2
2 Model GC20P-3 GC25P-3
DIMENSIONS
12 Forks
15 width mm 1110 1110
PERFORMANCE
WEIGHT
Axle load
CHASSIS
37 rear size 16 X 5 - 10.5 16 X 5 - 10.5
Ground clearance
DRIVE
Engine
51 max. torque / rpm kg - m 19/1800 19/1800
Transmission
-44-
General Section
Tier-2
DHI DHI 1
GC30P-3 GC32P-3 2
3000 3000(6500lbs) 3
500 600 4
LPG LPG 5
C C 7
X2/2 X 2/2 8
3230 3230 9
152 152 10
lll lll 12
45 X 125 X 1050 45 X 125 X 1050
13
282 X 954 282 X 954
6/8 6/8 14
2333 2368 15
1110 1100 16
2125 2125 17
4470 4470 18
2150 2150 19
1038 1038 20
2105 2135 21
374 374 22
2479 2509 23
1872 1907 23a
17.5/17.5 17.5/17.5 24
500/600 500/600 25
510/460 510/460 26
2000 2000 28
29 29 30
31
4170 4340 32
6240/890 6370/1050 33
1430/2740 1380/2960 34
2/2 2/2 35
21 X 8 - 15 21 X 8 -15 36
16 X 5 - 10.5 16 X 6 -10.5 37
1410 1410 38
907/956 907/956 39
90 90 40
135 135 41
12/65 12/65 45
61/2500 61/2500 50
19/1800 19/1800 51
4/4/2967 4/4/2967 52
1/1 1/1 56
-45-
General Section
Specifications
CHARACTERISTICS 2004 YEAR (Tier-2)
2 Model G20E-3 G25E-3
DIMENSIONS
12 Forks
15 width mm 1170 1170
19 seat height mm
PERFORMANCE
WEIGHT
Axle load
CHASSIS
36 Tires front size 7.00 X 15 - 12 7.00 X 15 - 12
37 rear size 6.50 X 10 - 10 6.50 X 10 - 10
Ground clearance
DRIVE
Engine
Transmission
-46-
General Section
2004 YEAR (Tier-2)

DHI DHI 1
G30E-3 G32E-3 2
3000 3000(6500lbs) 3
500 600 4
LPG LPG 5
P P 7
X2/2 X 2/2 8
3230 3230 9
152 152 10
lll lll 12
45 X 125 X 1050 45 X 125 X 1050
13
286 X 1044 286 X 1044
6/10 6/10 14
2636 2690 15
1197 1197 16
2160 2160 17
4470 4470 18
2183 2183 19
20
2364 2414 21
485 485 22
2849 2899 23
2050 2100 23a
19.0/19.5 19.0/19.5 24
500/600 500/600 25
510/460 510/460 26
1550 1550 28
21 20 30
31
4530 4830 32
6605/925 6690/1140 33
1790/2740 1680/3150 34
2/2 2/2 35
28 X 9 X 15 - 12 28 X 9 X 15 - 12 36
6.50 X 10 - 10 6.50 X 10 - 10 37
1625 1625 38
982/1000 982/1000 39
105 105 40
153 153 41
12/45 12/45 45
52/2600 52/2600 50
17/1600 17/1600 51
4/4/2350 4/4/2350 52
1/1 1/1 56
-47-
General Section
Specifications
CHARACTERISTICS 2004 YEAR (Tier-2)
2 Model G20P-3 G25P-3
5 Power type electric, diesel, gas, LPG-gas LP LP
DIMENSIONS
12 Forks
15 width mm 1170 1170
19 seat height mm
PERFORMANCE
WEIGHT
Axle load
CHASSIS
36 Tires front size 7.00 X 15 - 12 7.00 X 15 - 12
37 rear size 6.50 X 10 - 10 6.50 X 10 - 10
Ground clearance
DRIVE
50 rated output / rpm ps(kw) 61/2500) 61/2500
Engine
Transmission
-48-
General Section
2004 YEAR (Tier-2)

DHI DHI DHI 1
G30P-3 G32P-3 G33P-3 2
3000 3000(6500lbs) 3250 3
500 600 500 4
LP LP LP 5
rider - seated rider - seated rider - seated 6
P P P 7
X2/2 X 2/2 X 2/2 8
3230 3230 3230 9

152 152 152 10
lll lll lll 12
45 X 125 X 1050 45 X 125 X 1050 45 X 125 X 1050
13
286 X 1044 286 X 1044 286 X 1044
6/10 6/10 6/10 14
2636 2690 2690 15
1197 1197 1197 16
2160 2160 2160 17
4470 4470 4470 18
2183 2183 2183 19
20
2364 2414 2414 21
485 485 485 22
2849 2899 2899 23
2050 2100 2100 23a
19.0/20.5 19.0/20.0 19.0/20.0 24

500/600 500/600 500/600 25
510/460 510/460 510/460 26
1705 1705 1700 28
23.5 23.5 23.5 30
31
4530 4830 4830 32

6605/925 6690/1140 6900/1180 33
1790/2740 1680/3150 1680/3150 34
2/2 2/2 2/2 35

28 X 9 X 15 - 12 28 X 9 X 15 - 12 28 X 9 X 15 - 12 36
6.50 X 10 - 10 6.50 X 10 - 10 6.50 X 10 - 10 37
1625 1625 1625 38
982/1000 982/1000 982/1000 39
105 105 105 40
153 153 153 41
foot/hyd foot/hyd foot/hyd 42
hand/mech hand/mech hand/mech 43
12/65 12/65 12/65 45

DHI/G430E DHI/G430E DHI/G430E 49
61/2500 61/2500 61/2500 50
19/1800 19/1800 19/1800 51
4/4/2967 4/4/2967 4/4/2967 52
Powershift Powershift Powershift 55
1/1 1/1 1/1 56
-49-
General Section
Noise and Vibration

Noise
Noise Level [Unit : dB(A)]
Sound Pressure Level Guaranteed Sound
Sound Pressure Level
Model at By-stander position Power level(LWA )
at Operator’s ear (Leq.)
(AS 3713) by new Directive
AS 3713 prEN 12053 Drive-By Lifting Mode 2000/14/EC
W/O Cabin 80.5 82.7 80 81 107

(DB33A E/G)
D20S-3 With Cabin 84.4 85.8 79 82 107
D25S-3
D30S-3
D32S-3 With Low Noise
79.2 81.7 78 79 107
Cabin
TIER - II (B3.3 E/G)

D20S-3,D25S-3,D30S-3,D32S-3,
77.2 79.3 76 76 104
D33S-3
(W/O Cabin)
G20E-3,G25E-3,G30E-3,G32E-3
78.3 81.5 80 82 106
(W/O Cabin)
G20P-3,G25P-3,G30P-3,G32P-3
78.0 81.0 81 84 *NA
(W/O Cabin)
GC20E-3,GC25E-3,GC30E-3,
GC32E-3 78.0 81.0 81 84 *NA
(W/O Cabin)
GC20P-3,GC25P-3,GC30P-3,
GC32P-3 78.0 81.0 81 84 *NA
(W/O Cabin)
* NA : Not Applicable
Vibration (weighted overall value)

unit: m/sec2
Measuring Place
Model
Steering Floor
Seat
Wheel Plate
(DB33A E/G)
0.48 2.28 0.41
D20S-3, D25S-3, D30S-3, D32S-3
TIER - II (B3.3 E/G)
0.8 1.2 0.4
D20S-3, D25S-3, D30S-3, D32S-3, D33S-3
G20E-3, G25E-3, G30E-3, G32E-3 0.3 0.7 0.3
G20P-3, G25P-3, G30P-3, G32P-3 0.4 0.8 0.4
GC20E-3, GC25E-3, GC30E-3, GC32E-3 0.2 0.5 0.3
GC20P-3, GC25P-3, GC30P-3, GC32P-3 0.3 0.6 0.4
-50-
General Section
Capacity Chart
SINGLE TIRE
STD, FFL FFT
D20S-3, G20E-3, G20P-3
A. 3900 - 4290mm MFH MAST

B. 4730mm MFH MAST
B. 4960mm MFH MAST
C. 5560mm MFH MAST
D. 6010mm MFH MAST
D25S-3, G25E-3,G25P-3

B. 4960mm MFH MAST
B. 4730mm MFH MAST
C. 5560mm MFH MAST
D. 6010mm MFH MAST
D30S-3, G30E-3,G30P-3

B. 4960mm MFH MAST
B. 4730mm MFH MAST
C. 5560mm MFH MAST
D. 6010mm MFH MAST
D33S-3
A. 2030 - 4350mm MFH MAST A. 2030 - 4290mm MFH MAST

B. 4960mm MFH MAST B. 4730mm MFH MAST
C. 5560mm MFH MAST
D. 6010mm MFH MAST
-51-
General Section
DOUBLE TIRE
STD, FFL FFT
D20S-3, G20E-3,G20P-3

C. 5560mm MFH MAST
D. 6010mm MFH MAST
D25S-3, G25E-3,G25P-3

C. 5560mm MFH MAST
D. 6010mm MFH MAST
D30S-3, G30E-3,G30P-3
A. 2030 - 4350mm MFH MAST A. 3900 - 4730mm FORK HEIGHT

C. 6010mm MFH MAST
D33S-3
A. 2030 - 4960mm MFH MAST A. 3900 - 4730mm FORK HEIGHT

B. 5560mm MFH MAST
C. 6010mm MFH MAST
-52-
General Section
Capacity Chart
NARROW TIRE
STD, FFL FFT
GC20E-3,GC20P-3

C. 5560mm MFH MAST
D. 6010mm MFH MAST
GC25E-3,GC25P-3

B. 4960mm MFH MAST
B. 4730mm MFH MAST
C. 5560mm MFH MAST
D. 6010mm MFH MAST
GC30E-3,GC30P-3
STD MAST
B. 4960mm MFH MAST
FFL MAST A. 3900 - 4730mm MFH MAST
C. 2580mm MFH MAST B. 5560mm MFH MAST
C. 6010mm MFH MAST
-53-
General Section
WIDE TIRE
STD, FFL FFT
GC20E-3,GC20P-3

C. 5560mm MFH MAST
D. 6010mm MFH MAST
GC25E-3,GC25P-3

B. 4960mm MFH MAST A. 3900 - 4290mm MFH MAST
B. 4730mm MFH MAST
C. 5560mm MFH MAST
D. 6010mm MFH MAST
GC30E-3,GC30P-3
STD MAST
FFL MAST
B. 4960mm MFH MAST
C. 2580mm MFH MAST
B. 5560mm MFH MAST
C. 6010mm MFH MAST
-54-
General Section
Capacity Chart (with Side Shifter)

SINGLE TIRE
STD, FFL FFT
D20S-3, G20E-3,G20P-3
A. 2030 - 3230mm MFH MAST A. 3900mm MFH MAST

B. 3500 - 3950mm MFH MAST B. 4290mm MFH MAST
C. 4350mm MFH MAST C. 4730mm MFH MAST
D. 4960mm MFH MAST D. 5560mm MFH MAST
E. 6010mm MFH MAST
D25S-3, G25E-3,G25P-3
A. 3900mm MFH MAST

B. 4290mm MFH MAST
B. 3500 - 3950mm MFH MAST
C. 4730mm MFH MAST
C. 4350mm MFH MAST
D. 5560mm MFH MAST
D. 4960mm MFH MAST
E. 6010mm MFH MAST
D30S-3, G30E-3.G30P-3

E. 6010mm MFH MAST
D33S-3

D. 5560mm MFH MAST
E. 6010mm MFH MAST
-55-
General Section
DOUBLE TIRE
STD, FFL FFT
D20S-3, G20E-3,G20P-3
A. 3900mm MFH MAST

A. 2030 - 3230mm MFH MAST B. 4290mm MFH MAST
B. 3500 - 3950mm MFH MAST C. 4730mm MFH MAST
C. 4350mm MFH MAST D. 5560mm MFH MAST
D. 4960mm MFH MAST E. 6010mm MFH MAST
D25S-3, G25E-3,G25P-3

E. 6010mm MFH MAST
D30S-3, G30E-3,G30P-3

E. 6010mm MFH MAST
D33S-3

D. 5560mm MFH MAST
E. 6010mm MFH MAST
-56-
General Section
Capacity Chart (with Side Shifter)

NARROW TIRE
STD, FFL FFT
GC20E-3,GC20P-3

E. 6010mm MFH MAST
GC25E-3,GC25P-3

E. 6010mm MFH MAST
GC30E-3,GC30P-3
A. 3900mm MFH MAST

B. 4290mm MFH MAST
C. 4730mm MFH MAST
D. 5560mm MFH MAST
E. 6010mm MFH MAST
-57-
General Section
WIDE TIRE
STD, FFL FFT
GC20E-3,GC20P-3

E. 6010mm MFH MAST
GC25E-3,GC25P-3

E. 6010mm MFH MAST
GC30E-3,GC30P-3
A. 3900mm MFH MAST

B. 4290mm MFH MAST
C. 4730mm MFH MAST
D. 5560mm MFH MAST
E. 6010mm MFH MAST
-58-
General Section
Capacity Chart: 3,000kg@600mm L.C. (6,500lb@24”)

MODEL SINGLE TIRE STD, FFL FFT
D32S-3, G32E-3, G32P-3

B. 4960mm MFH MAST
B. 4730mm MFH MAST
C. 5560mm MFH MAST
D. 6010mm MFH MAST
DOUBLE TIRE
A. 2030-4960mm MFH MAST A. 3900-4730mm MFH MAST

B. 5560mm MFH MAST
C. 6010mm MFH MAST
NARROW TIRE
GC32E-3,GC32P-3

B. 4960mm MFH MAST A. 3900-4730mm MFH MAST
B. 5560mm MFH MAST
C. 6010mm MFH MAST
WIDE TIRE

B. 4960mm MFH MAST A. 3900-4730mm MFH MAST
B. 5560mm MFH MAST
C. 6010mm MFH MAST
-59-
General Section
Capacity Chart (with Side Shifter):3,000kg@600mm L.C. (6,500lb@24”)

MODEL SINGLE TIRE STD, FFL FFT
D32S-3, G32E-3, G32P-3

A. 3900mm MFH MAST
B. 4350mm MFH MAST
B. 4290mm MFH MAST
C. 4960mm MFH MAST
C. 4730mm MFH MAST
D. 5560mm MFH MAST
E. 6010mm MFH MAST
DOUBLE TIRE

D. 5560mm MFH MAST
E. 6010mm MFH MAST
NARROW TIRE
GC32E-3,GC32P-3

D. 5560mm MFH MAST
E. 6010mm MFH MAST
WIDE TIRE

D. 5560mm MFH MAST
E. 6010mm MFH MAST
-60-
General Section
Serial Number
Serial Number Locations
For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.
2.4 liter Gasoline, LP-Gas, Dual Fuel Engine Serial

Number(G424)
•_____________________________
Lift Truck Serial Number

•_____________________________
3.0 liter LP-Gas Engine Serial Number(G430)

•_____________________________
3.3 liter (DB33A) Diesel Engine Serial Number

•_____________________________
3.3 liter (B3.3) Diesel Engine Serial Number

•_____________________________
-61-
General Section
2.4 liter LP and Dual Fuel Engine (G424E) Power Shift Transmission Serial Number
•_____________________________ •_____________________________
3.0 liter LP and Dual Fuel Engine (G430E) Drive Axle Serial Number
•_____________________________ •_____________________________
Typical Example
Side Shifter Serial Number (If Equipped)
•_____________________________
-62-
General Section
Attachment Abbreviations
(Includes Special Forks)
SC -Special Carriage-increased width,
height or outreach
SSS -Shaft-type Sideshift Carriage
HSS -Hook-type Sideshift Carriage (ITA)
CW -Counterweight
SF -Special Forks
SWS -Swing Shift, Sideshift
RAM -Ram or Boom
DBCBH -Double Cube Block Handler
HFP -Hydraulic Fork Positioner
CR -Crane Arm or Crane Boom
TH -Tire Handler
CTH -Container Handler
LPP -Load Push-Pull Device
CC -Carton Clamp
RC -Roll Clamp
LS -Load Stabilizer
PWH -Pulp Wood Handler
SS-ST Sideshift-Side Tilt Carriage
-63-
General Section
Operator's Warning and Identification Plate

Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT APACITY and
ATTACHMENT PLATES. DO NOT exceed capacity as equipped load ratings.
Operator's Warning Plate Identification, Lift Capacity and

Attachment Plate
Located on the right side of the operator's seat.
Located on the cowl to the right side of the steering

If Convenience Package Equipped column.
Below are abbreviations that may appear on the

IDENTIFICATION, LIFT CAPACITY and
ATTACHMENT PLATES and their meanings.
Mast Abbreviations
STD - Standard Mast (single inner member,
low free lift)
FF - Full Free Lift Mast (single inner member
with high free lift duplex cylinder)
FFT - Triple Lift Mast (two inner members)
with either low or full free lift
characteristics.
QUAD - Quadruple (Quad) Mast(with three inner
Located on the overhead guard. members)
NOTE: When only a mast-type is listed on the

identification plate, a standard carriage and
forks are used.
-64-
Operation Section
Operator's Station and Monitoring Systems

Instrument Panel 3. Diesel Engine Start Preheat
Indicator Light - The light will come ON
Diesel when the key is turned to the ON position
from the OFF position. This indicates that
the glow plugs are preheating the pre-combustion
2 5 6 chambers for easier starting.
1 7
The amount of time needed to preheat the

pre-combustion chambers is approximately seven
seconds, depending on the surrounding air
temperature. When the light goes OFF the
maximum pre-combustion chamber temperature
has been reached and the key can be turned to the
START position to start the engine.
9 3 4
ILOO001P 4. Diesel Engine Water in Fuel Filter
Indicator Light - Indicates when the
LPG/GAS engine is running, there is water in the
fuel filter exceeds 100cc.
2 5 6 The light will come ON when the ignition switch is

1 7 turned to the ON position. The light should go off
after the engine is started. If the light turns on with
the engine running, park the lift truck and stop the
engine.
Drain some fuel (and any water) until clean fuel
flows from the filter which approximately takes 5 to
6 seconds.
5. Fuel Level Gauge - Indicates fuel
9 8 level (Gas, Diesel, or Dual Fuel Trucks
IB1O003L Only)
6. Engine Coolant Temperature Gauge
1. Engine Oil Pressure Indicator Light - Indicates coolant temperature. If the
- Indicates insufficient engine oil pressure. pointer moves beyond the green band
The light will come on when the ignition while operating the lift truck, overheating
switch is turned to the ON position. The is indicated. Park the lift truck and stop the engine.
light should go off after the engine is started. If the
light turns on while operating the lift truck, Check the cooling system for a malfunction. The
insufficient engine oil pressure is indicated. Park pointer will be at the end of the green band when
the lift truck and stop the engine. the coolant temperature reaches approximately
106°C (223°F) on all engines.
2. Alternator Indicator Light - Indicates if
the battery charging system is operational. 7. Transmission Oil Temperature
The light will come on when the ignition Gauge - Indicates transmission oil
switch is turned to the ON position. temperature. If the pointer moves beyond
the green band while operating the lift truck,
The light should go off after the engine is started, excessive transmission oil temperature is indicated.
indicating the alternator is producing sufficient Park the lift truck and stop the engine.
voltage to charge the battery. If the light turns on
with the engine running, check the alternator
charging system for a malfunction.
-65-
Operation Section
8. G424E/G430E Engine Malfunction

Indicator Lamp (MIL)
G424E and G430E engine control
systems are equipped with built-in fault
diagnostics. Deteted system faults can be
displayed by the Malfunction Indicator Lamp (MIL)
as Diagnostic Fault Codes (DFC) or flash codes,
and viewed in detail with the use of service tool
software. When the ignition key is turned ON the
MIL will perform a self-test, illuminate once and
then go OFF. If a detected falut condition exists, the
fault or faults will be stored in the memory of the
engine control module (ECM). Once a fault occurs
the MIL will illuminate and remain ON. This signals 10. Horn Switch - Push on the horn
the operator that a faults has been detected by the button to sound the horn.
SECM.
9. Seat Belt Warning Light (If

Equipment)
Indicates when the seat belt dose not
fastened by operator.
The light will come on when the ignition switch is
turned to the on position.
The light should go off after engine is started.
11. Service hour Meter - Indicates the

total number of hours the engine and the
lift truck have operated. The hour meter
will operate when the ignition switch is in the ON
position, whether the engine is running or not. The
hour meter is used to determine lubrication and
maintenance intervals.
-66-
Operation Section
Electrical Disconnect Switch (If Engine Compartment

Equipped)
1. The engine compartment is accessible by pulling

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

support cylinder. Make certain the air cylinder is
operating properly and securely hold the hood up
before doing anything in the engine
compartment.
-67-
Operation Section
CAUTION Fuel Selector Switch (G424 Dual

When closing the engine hood, be careful not to Fuel Only)
pinch your hand.
Circuit Breaker
NOTE: The switch is located in the engine

compartment.
1. LPG - This position supplies electrical

Circuit Breaker -Protects the main power to the LP fuelock solenoid, when
electrical circuits. To reset the circuit the ignition switch is in the ON or the
breaker, push the button in. Located in the START position.
engine compartment. 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.
Seat
NOTE: Seat arrangements may vary. 2. OFF - This position shuts off all fuel
Basic operation will be similar. supply to the carburetor and is used
when changing from Gasoline to LP-Gas
Seat adjustment should be checked at the or LP-Gas to Gasoline fuel.
beginning of each shift and when operators
change. Electrical power shuts off the gasoline fuelock valve
and the LP fuelock solenoid. Before switching to
Lock the seat into position before operating, to the LPG position, allow the engine to run until all of
prevent an unexpected seat change. the gasoline in the carburetor is consumed and the
engine stops.
Adjust seat to allow full brake pedal travel with
operator’s back against seat back. 3. GAS - This position supplies electrical
power to gasoline fuelock solenoid. This
will allow gasoline fuel to flow from the
tank through the fuel filter and fuel
pump to the carburetor.
NOTE: The seat can only be correctly adjusted

with the operator fully seated.
-68-
Operation Section
Fuel Selector Switch 3. Reverse - Pull the lever back for

REVERSE direction travel.
(G424E/G430E Dual Fuel Only)
Plate for Function of Pedals (If Equipped)
1. LPG - This position supplies electrical

power to the LP fuelock solenoid, when
the ignition switch is in the ON or the It shows the function of each pedal i.e. inching
START position. (clutch), brake and accelerator.
With the LP-Gas fuel tank valve open, LP-Gas can
then flow the tank through the converter to the
carburetor. Transmission Inching Control
2. OFF – This position shuts off all fuel Pedal
supply to the carburetor/injector.
3. GAS - This position supplies electrical

power to gasoline fuel pump and injector
This will allow gasoline fuel to flow from
the tank through the fuel filter and fuel
pump to the injector.
Lift Truck Controls

Direction Control Lever
Inching Control Pedal - Pushing down on
the inching pedal, modulates the hydraulic
pressure to the clutch packs, permitting disc
slippage.
Further pushing on the pedal completely relieves

clutch pack pressure and applies the service
brakes to stop and hold the lift truck.
NOTE: The purpose of the inching control pedal is

to provide precise inching control at slow
travel speed, with high engine rpm. This is
used for fast hydraulic lift during load
1. Forward - Push the lever forward for approach, pickup or positioning.
FORWARD direction travel.
2. Neutral - Move the lever to center

position for NEUTRAL.
-69-
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
Push DOWN on the pedal to increase NOTE: To prevent a sudden change of position of
engine rpm (speed). the load, operate all lift, tilt and attachment
controls smoothly.
RELEASE the pedal to decrease engine
rpm (speed). 1. Lower Position - Push the lever
FORWARD smoothly to lower the load.
2. Hold Position - When the lever is

released it will return to the HOLD or
center position. Lifting or lowering action
will stop.
3. Lift Position - Pull the lever BACK

smoothly to lift the load.
-70-
Operation Section
Tilt Control Sideshift Attachment (If Equipped)
1.Mast Tilt Forward - Push the lever 1.Sideshift Left - Push the lever
FORWARD smoothly to tilt the mast FORWARD to shift the carriage to the left.
forward.
2.Sideshift Hold - When the lever is
2.Mast Hold - When the lever is released it released it will return to the HOLD or
will return to the HOLD or center position. center position. Sideshifting action will
Tilting action will stop. stop.
3. Mast Tilt Back - Pull the lever BACK 3.Sideshift Right - Pull the lever BACK to
smoothly to tilt the mast backward. shift the carriage to the right.
-71-
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
refueling. 1. Park the lift truck only at a designated safe
location. Place the transmission in NEUTRAL.
Lower the forks to the ground. Engage the
NOTICE parking brake. Stop the engine.
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 2. Open the filter cap.
gets warm and may overflow.
3. Fill the fuel tank slowly. Close the filter cap.
If spillage occurs, wipe off excess fuel and was
down area with water.
NOTE: Drain water and sediment from fuel tank as

required by prevailing conditions. Also,
drain water and sediment from the main
fuel storage tank weekly and before the
tank is refilled. This will help prevent water
or sediment being pumped from the
storage tank into the lift truck fuel tank.
-72-
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 or any other place where LP-Gas could
collect in a pocket causing a potentially
dangerous condition. 2. Close the fuel shut off valve at the LP - Gas
tank. Run the engine until it stops, then turn off
Examine all LP-Gas containers before filling the ignition switch and the disconnect switch (if
and again before reuse, for damage to various equipped).
valves, liquid gauge, fittings and hand valve
wheels.
3. Disconnect the fuel supply line.
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.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to indoor locations.
Stop the engine and get off the lift truck during
refueling.
The careless handling of LP-Gas containers can
result in a serious accident.
Use extreme care when transporting containers
to prevent damage to them. If Swing out type LP-Cradle Equipped
1. Park the lift truck on level ground, with the

parking brake applied, the transmission in
NEUTRAL, the forks lowered and the engine
running at low idle.
4. Loosen the retaining clamps and remove the

tank.
5. Check the mounting to be sure the locating pin

(dowel) is not missing or broken.
-73-
Operation Section
NOTICE
If the location pin (dowel) is missing or broken, be
sure the pin is replaced.
11. Position the replacement tank so that the

locating pin (dowel) is in place.
CAUTION
The LP-Gas tank must not extend past the

6. Check to be sure that the LP - Gas warning counterweight
plate is in position on the lift truck, and is
legible.
12. Clamp the tank securely.
7. Check to be sure the replacement tank is of the
correct type. 13. Connect the fuel supply line.
8. Inspect the replacement tank for damage such 14. Open the fuel valve by slowly turning it
as dents, scrapes or gouges and for indication counterclockwise. If the fuel valve is opened too
of leakage at valves or threaded connections. quickly, a back pressure check valve will shut
off the fuel supply. If this happens, close the
fuel valve completely. Wait five seconds and
then open the fuel valve very slowly.
15. Inspect the LP - 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

deterioration, damage or missing flexible seals.
-74-
Operation Section
Before Starting the Engine

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

loose or missing mounting bolts.
8. Inspect the hydraulic system for leaks, worn

hoses or damaged lines.
9. Look for transmission and drive axle leaks on

the truck and on the ground.
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.
4. Inspect the mast and lift chains for wear, broken

links, pins and loose rollers.
DB33A Diesel Engine
5. Inspect the carriage, forks or attachments for

wear, damage and loose or missing bolts.
6. Inspect the tires and wheels for cuts, gouges, B3.3 Diesel Engine
foreign objects, inflation pressure and loose or
missing bolts. 10. Inspect the engine compartment for oil, coolant
and fuel leaks.
-75-
Operation Section
DB33A Diesel Engine DB33A Diesel Engine
B3.3 Diesel Engine B3.3 Diesel Engine
11. Measure the engine crankcase oil level with the 12. Observe the engine coolant level in the coolant
dip stick. Maintain the oil level between the recovery bottle. With the engine cold, maintain
MAX. and MIN., (or FULL and ADD) notches on the level to the COLD mark. If the recovery
the dip stick. bottle is empty, also fill the radiator at the top
tank.
13. Observe the fuel level gauge after starting the

truck. Add fuel if necessary.
-76-
Operation Section
WARNING
Personal injury may occur from accidents
caused by improper seat adjustment. Always
adjust the operator’s seat before starting the lift
truck engine.
Seat adjustment must be done at the beginning
of each shift and when operators change.
14. To position the seat, PUSH the lever away from

the seat track and move the seat forward or
backward to a comfortable position.
-77-
Operation Section
Starting the Engine

Prestart Conditions 2.4 Liter Gasoline Engine(G424)
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. Depress the accelerator pedal completely and

then release it.
2. Then, depress the accelerator pedal more than

1/2 of its stroke and hold in this position.
3. Turn the ignition switch to the START position

to crank the engine.
1. Engage the parking brake, if not already
engaged. Place the transmission directional 4. Release it when the engine starts.
control lever in the NEUTRAL position.
2. Lift trucks equipped with electrical disconnect

switches; the engine will not start unless the
disconnect switch is in the ON (closed) position.
-78-
Operation Section
LP - Gas Engine Diesel Engine

WARNING Starting a Cold Diesel Engine
1. Turn the key to the ON position. The start pre
LP - Gas fuel is flammable and can cause
personal injury. heat light will come ON. The preheat light will
stay ON approximately seven seconds,
Inspect LP - Gas fuel lines and fitting for leaks. depending on the surrounding air temperature.
Inspect tank for secure mounting.
NOTICE
Do not engage the starter for more than 10
seconds.
2. When the preheat light goes OFF, turn the key

to the START position, with the accelerator
pedal 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
1. Turn the tank fuel valve ON by slowly turning
thru 3.
the valve counterclockwise. Observe the LP -
Gas gauge (if equipped).
2. Turn the ignition switch to the START position. Starting a Warm Diesel Engine
Release it when the engine starts. 1. Turn the key to the ON position and then to
START position, without waiting for the preheat
3. If the engine does not start, do not press on the light to go OFF. At the same time fully depress
accelerator pedal. Turn the starter switch to the accelerator.
OFF position, then repeat step 2 and depress
the accelerator pedal slightly during cranking. 2. Release the key when the engine starts and
release the accelerator pedal to a low idle
4. Allow the engine to warm up slowly. position.
-79-
Operation Section
Starting From a 12 Volt External

Source
WARNING
Sparks occurring near the battery could cause
vapors to explode.
Always connect the external power source
ground cable to a point away from and below
the battery, and well clear of fuel system
components.
NOTICE
Do not reverse battery cables. It can cause
damage to the alternator.
Always connect the external power source
cables in parallel with the lift truck battery
cables : POSITIVE(+) to POSITIVE(+) and
NEGATIVE( - ) to NEGATIVE( - ).
Attach ground cable last, remove first. All lift
trucks equipped with DAEWOO built internal
combustion engines are NEGATIVE( - ) ground.
-80-
Operation Section
Dual Fuel System (If G424 Dual Fuel Engine Equipped)

Changing From Gasoline to LP –
Gas
6. Open the fuel valve, on the LP - Gas tank, by

slowly turning the valve counterclockwise.
NOTE: The Underwriter’s Laboratory (U.L.) 7. 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
area with the forks lowered, the parking brake 1. Park the lift truck level in an authorized
applied, the transmission in NEUTRAL and the refueling area with the forks lowered, the
engine running. parking brake applied, the transmission in
NEUTRAL and the engine running.
2. Raise the hood and seat assembly. Make certain
the air lift cylinder securely holds the hood open.
2. Close the fuel valve on the LP - Gas tank. Allow

the engine to run until the fuel in the line runs
3. Move lever (1), on the fuel selector switch to the out and the engine stops. Turn the ignition
OFF (2) position. Leave lever (1) in this position switch to the OFF position.
until the gasoline in the carburetor is used and
the engine stops. 3. Raise the hood and seat assembly. Make
certain the air lift cylinder securely holds the
4. Move lever (1) to the LPG (3) position. hood open.
5. Lower the hood and seat assembly.
-81-
Operation Section
4. Move lever (1) from the LPG (3) position to the

GAS (4) position.
6. Turn the ignition switch key to the ON position.
NOTE: On trucks equipped with electric fuel pumps

wait approximately 15 seconds to fill the
carburetor with gasoline.
7. Turn the ignition switch key to the START

position and start the engine. Release it when
the engine starts.
-82-
Operation Section
Dual Fuel System (G424E/G430E Engine Only)

Changing From Gasoline to LP –
Gas
3. Open the fuel valve, on the LP - Gas tank, by

slowly turning the valve counterclockwise.
NOTE: The Underwriter’s Laboratory (U.L.) 4. Move lever (1) from the GAS (2) position to LPG
requires that the gasoline tank must be at (3) position.
least one - quarter full when operating on
LP - Gas. This will allow the lift truck to be 5. Lower the hood and seat assembly.
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 area with the forks lowered, the
parking brake applied, the transmission in
NEUTRAL and the engine running.
2. Raise the hood and seat assembly. Make

2 3 certain the air lift cylinder securely holds the
hood open.
1. Park the lift truck level in an authorized refueling

area with the forks lowered, the parking brake
applied, the transmission in NEUTRAL and the
engine running. 2 3
2. Raise the hood and seat assembly. Make certain
the air lift cylinder securely holds the hood open.
1
3. Move lever (1) from the LPG (3) postion to the

GAS (2) position.
-83-
Operation Section
4. Close the fuel valve on the LP - Gas tank. Allow

the engine to run until the fuel in the line runs
out and the engine stops.
When Stop the Engine (G424E

Dual Fuel Only)
Engine wiring harness includes timer relay. The

purpose of it is to prevent backire to exhaust when
stop engine by turning key switch OFF. Because of
it, engine stop time can be delayed 1 or 2 seconds
when turn key switch OFF to stop engine.
-84-
Operation Section
After Starting the Engine 2. The alternator indicator light (2), should not
come ON during normal operation. The
Observe all indicator lights and gauges frequently alternator is not charging if the light comes ON
during operation, to make sure all systems are with the engine running.
working properly. The entire indicator lights will
come ON with the ignition switch in the ON position 3. The G424/430E engine MIL(Malfunction
before the engine is started. Indicator Light) will not come ON with the
engine running, unless the fault or faults are
stared in the memory of the engine control
Diesel module(ECM). Stop the engine and check the
electric engine control system if the light comes
2 5 6 ON. Refer G424E/G430E Engines of this
1 7 section.
4. The diesel engine water in fuel filter indicator

light(4), will not come ON with the engine
running, unless water in fuel filter exceeds
100cc. Stop the engine immediately and drain
the water if the light comes ON.
5. Observe the fuel level gauge (5) for fuel level in

3 4 the tank.
ILOO001P
6. The engine coolant temperature gauge pointer
LPG/GAS (6) will be in the green band with the engine
running, unless the coolant temperature is
excessive.
2 5 6
1 7 7. The transmission oil temperature gauge pointer
(7) will be in the green band with the engine
running, unless the oil temperature is excessive.
8
IB1O003L
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.
8. Observe the hour meter to make sure it is

operating properly.
If the excessive valve noise

occurs (G424 and G424E Engine
Only)
In normal case, the recommended engine oil for
G424 engine is SAE 10W30.
But, if the excessive valve noise occurs up to five

minutes after a cold start and if the maximum
ambient temperature is lower than 10 C (50 F), it is
recommended to change engine oil to SAE 5W30
for that application.
-85-
Operation Section
Lift Truck Operation

Power Shift Transmission/ Drive WARNING
axle A lift truck with the engine running but without
an operator can move slowly (creep) if the
transmission is engaged.
1. Start the engine. See topic “Starting the
Engine”. This could result in personal injury.
Always place the transmission control lever in
the NEUTRAL (center) position and apply the
parking brake before dismounting the lift truck.
2. 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 5. Release the service brake.
the directional control can be used.
6. Push down on the accelerator pedal to obtain
the desired travel speed. Release the pedal to
decrease travel speed.
WARNING
Sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift
truck to tip over.
Stop the loaded lift truck completely, before
shifting to reverse.
Failure to comply could result in personal
injury.
4. Select the direction of travel by pushing the NOTE: Where conditions permit, directional
directional lever FORWARD for forward changes can be made under full power at
direction or by pulling the lever BACK for speeds up to 6 km/h (3.73 mph). A speed
reverse direction. of 6 km/h (3.73 mph) is a fast walk.
Directional shift changes at speeds above
6 km/h (3.73 mph) are considered abusive.
Bring the lift truck to a complete stop where
load stability or other factors prevent safe
operation under full power shifts.
-86-
Operation Section
7. To change the lift truck direction of travel, 11. To stop the lift truck when traveling in either
release the accelerator pedal. direction, release the accelerator pedal.
8. Push down on the service brake pedal to 12. Push down on the service brake pedal and
reduce the lift truck speed as necessary. bring the lift truck to a smooth stop.
9. Move the directional lever to the desired

direction of travel. Slowly push down on the
accelerator pedal as the lift truck changes
direction.
10. When the direction change is completed,

continue to push down on the accelerator pedal
to obtain the desired travel speed.
-87-
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.
1. To inch (creep) in either direction, slowly push

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

accelerator pedal to control the inching speed
and distance.
3. Pushing down further on the inching pedal will

disengage the transmission completely and apply
the service brakes fully to stop and hold the lift
truck. This will provide full engine power for fast
hydraulic lift.
-88-
Operation Section
G424E/G430E Electronic Controlled LP and Dual Fuel Engines

(If Equipped)
General Description
The MI-04 is a closed loop system utilizing a ratio is required. A small engine control module
catalytic muffler to reduce the emission level in the (SECM) uses a heated exhaust gas oxygen sensor
exhaust gas. In order to obtain maximum effect (HEGO) in the exhaust system to monitor exhaust
from the catalyst, an accurate control of the air fuel gas content.
MI-04 LP System
Fault Light Fuel Filter
LP Fuel Line
Key switch
Fuel Lock
Main
Foot Pedal Smart Coil
PWR
APP
Relay Converter
VacuumLine
Air Cleaner Fuel Trim Valve
Coolant Line
Mixer
DBW Throttle TPS
TMAP SECM
Oxygen
Engine Distributor
Catalytic
Muffler
VR Sensor
Coolant Temp Sensor
The SECM makes any necessary corrections to the (DBW) system connecting the accelerator pedal to
air fuel ratio by controlling the inlet fuel pressure to the electronic throttle through the electrical harness,
the air/fuel mixer by modulating the fuel trim valve mechanical cables are not used. A throttle position
(FTV) connected to the regulator. Reducing the fuel sensor (TPS) monitors throttle position in relation to
pressure leans the air/fuel mixture and increasing the accelerator pedal position sensor (APP)
the fuel pressure enriches the air/fuel mixture. To feedback. Even engine coolant temperature and
calculate any necessary corrections to the air fuel adequate oil pressure is monitored by the SECM.
ratio, the SECM uses a number of different sensors The SECM controller has full adaptive learning
to gain information about the engines performance. capabilities, allowing it to adapt control function as
Engine speed is monitored by the SECM through a operating conditions change. Factors such as
variable reluctance (VR) sensor. Intake manifold air ambient temperature, fuel variations, ignition
temperature and absolute pressure is monitored component wear, clogged air filter, and other
with a (TMAP) sensor. The MI-04 is a drive by wire operating variables are compensated.
-89-
Operation Section
MI-04 Dual Fuel System
LP Fuel Line
Fault Light Key switch
LP Fuel Filter
Foot Pedal Main Fuel Lock
PWR Fuel Select Switch
Relay
APP
Vacuum Line Converter
Air Cleaner
Coolant Line Fuel
Fuel Trim Select
Valve Relay
1&2
2
Mixer
Fuel Pump
Fuel Injector
DBW Throttle TPS 1 SECM

TMAP
Engine
Oxygen Sensor
Distributor
Smart Coil
VR Sensor
Oil Pressure Switch
Coolant Temp Sensor
Catalytic Muffler
-90-
Operation Section
Basic Troubleshooting(LPG)
The MI-04 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.

Engine Cranking Fuel container empty Fill fuel container
z Do not exceed 80% of liquid
but Will Not Start
capacity
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Leak test
z See Maintenance Section, Fuses
replacement
z See Maintenance Section, LP Fuel
Filter replacement
collapsed hose
z See G424E/G430E Engine Service
Manual
malfunction z See G424E/G430E 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
-91-
Operation Section

capacity
Filter replacement
air
z Leak test
collapsed hose
malfunction z See G424E/G430E Engine Service
Manual
capacity
Incorrect air/fuel or ignition control See Advanced Diagnostics
Engine Mechanical See Engine Service Manual
-92-
Operation Section

Continuously
capacity
Filter replacement

air
test
z -35F minimum
Check coolant hoses
z Watch for kinks and/or pinched
hoses
return hose
Manual
Incorrect idle speed or ignition See Advanced Diagnostics
problem
Accelerate/Hesita
tion During capacity
Acceleration Excess flow valve closed Reset excess flow valve
-93-
Operation Section

z See Maintenance
Accelerate/Hesita
z 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
capacity
Filter replacement
air
test
-94-
Operation Section

Manual
collapsed hose
z -35F minimum
z Watch for kinks and/or pinched
hoses
return hose
Manual
manifold
z Between intake manifold and
cylinder head
Manual
Rough Idle Faulty vapor connection between Check connection

collapsed hose
Manual
manifold
cylinder head
Manual
-95-
Operation Section

Rough Idle Incorrect Idle speed control See Advanced Diagnostics & See
Incorrect timing or spark control G424E/G430E Engine Service Manual
High Idle Speed Incorrect Idle speed control See Advanced Diagnostics & See
Throttle sticking G424E/G430E Engine Service Manual
Foot pedal sticking or incorrect Check pedal return spring travel for binding
pedal signal z See Advanced Diagnostics
z See Maintenance section, Fuel
Performance
Filter replacement
air
test
collapsed hose
Manual
Manual
Incorrect ignition control
See Advanced Diagnostics & See
Incorrect air/fuel control
G424E/G430E Engine Service Manual
-96-
Operation Section

Consumption/LP
Manual
G Exhaust Smell Air filter clogged Check air filter
Vacuum leak Check system vacuum hoses from
regulator to FTV and mixer
Pressure regulator malfunction/fuel Test pressure regulator operation
pressure too high z See G424E/G430E Engine Service
Manual
Faulty FTV Check FTV for housing cracks or
obstructions
z See Advanced Diagnostics FTV
operation
Weak ignition and/or spark control See Advanced Diagnostics
Incorrect air/fuel control See Advanced Diagnostics
-97-
Operation Section
Basic Troubleshooting (Gasoline)

Engine Cranking Fuel tank empty Fill fuel container
z The tank should be at least ¼ 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 (LPG) 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
z See G424E/G430E Dual Fuel
Engine Service Manual
Fuel Injector malfunction Test Injector operation
Incorrect air/fuel or ignition/ spark See Advanced Diagnostics
control
No VR Sensor Signal Verify the VR signal is present
-98-
Operation Section

Difficult to Start Fuel tank almost empty Fuel Pump Cavitations
(Gas)
properly prime the fuel pump
z Fuel select switch is not on GAS
z See Maintenance section, Primary
replacement
Electric Fuel Pump malfunction Check electrical connection
(GAS) z Check Relay and fuse Turn key ON
and verify pump is operating
Incorrect air/fuel or ignition control See Advanced Diagnostics
Will Not Run Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Continuously running the lift truck on LPG If the problem does not exist in LPG mode
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

Fuel tank almost empty Fuel Pump Cavitations
replacement
-99-
Operation Section

Will Not Run Electric Fuel Pump malfunction Check electrical connection
Continuously (GAS) z Check Relay and fuse Turn key ON
and verify pump is operating
(Gas) z See G424E/G430E Dual Fuel

Incorrect idle speed or ignition See Advanced Diagnostics
problem
Will Not Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Accelerate/Hesita running the lift truck on LPG If the problem does not exist in LPG mode
tion During below.
Acceleration or
Engine Stalls If the problem also exists in LPG mode then
(Gas) the root cause is most likely to be

Fuel tank almost empty Fuel Pump Cavitations

replacement


z See Chapter 9 Tests and
Adjustments
-100-
Operation Section

Will Not Throttle butterfly valve not opening See Advanced Diagnostics
Accelerate/Hesita or sticking
tion During Foot Pedal signal incorrect or
Acceleration or intermittent
Engine Stalls Incorrect air/fuel or ignition control
(Gas)
Rough Idle (Gas) Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
running the lift truck on LPG If the problem does not exist in LPG mode
below.

z See Advanced Diagnostics &

G424E/G430E Dual Fuel Engine
Service Manual
replacement
manifold
cylinder head
-101-
Operation Section

Rough Idle (Gas) Incorrect Idle speed control See Advanced Diagnostics &
Incorrect timing or spark control G424E/G430E Dual Fuel Engine Service
Manual
High Idle Speed Incorrect Idle speed control See Advanced Diagnostics &
(Gas) G424E/G430E Dual Fuel Engine Service
Manual
Throttle sticking
Foot pedal sticking or incorrect Check pedal return spring travel for binding
pedal signal
See Advanced Diagnostics
-102-
Operation Section

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

See Advanced Diagnostics &

G424E/G430E Dual Fuel Engine Service
Manual
z See Maintenance section, Fuel
Filter replacement
air
test
collapsed hose

Poor High Speed Air/Fuel Mixer malfunction Check mixer
Performance
Manual
(Gas) Restricted exhaust system Check exhaust system
Incorrect ignition control See Advanced Diagnostics &
Incorrect air/fuel control G424E/G430E Dual Fuel Engine Service
Incorrect throttle position Manual
-103-
Operation Section
Advanced Diagnostics Reading Diagnostic Fault Codes
Advanced Diagnostics fault codes are retrieved (displayed) the MIL will
flash for each digit with a short pause (.5 seconds)
The MI-04 systems are equipped with built-in fault between digits and a long pause (1.2 seconds)
diagnostics. Detected system faults can be between fault codes. A code 12 is displayed at
displayed by the Malfunction Indicator Lamp (MIL) the beginning of the code list.
as Diagnostic Fault Codes (DFC) or flash codes,
and viewed in detail with the use of service tool EXAMPLE: A code 26 has been detected
software. When the ignition key is turned ON the (ETCSticking) and the engine has shutdown and
MIL will perform a self-test, illuminate once and the MIL has remained ON. When the codes are
then go OFF. If a detected fault condition exists, the displayed the MIL will flash one time (1), pause,
fault or faults will be stored in the memory of the then flash two times (2). This identifies a twelve
small engine control module (SECM). Once a fault (12), which is the beginning of the fault list. It will
occurs the MIL will illuminate and remain ON. This then pause for 1.2 seconds (long pause) and flash
signals the operator that a fault has been detected two times (2), pause, then flash six times (6). This
by the SECM. identifies a twenty-six (26), 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
flashes (2). This identifies a twelve meaning the
fault list will begin again.
(1) Malfunction Indicator Lamp(MIL) for Engine control system
-104-
Operation Section
Displaying Fault Codes (DFC) From

SECM Memory

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
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
activated if a foot pedal fault condition exists. This
feature enables the service technician to view the
fault codes by turning the key to the ON position, if
a foot pedal malfunction is preventing the retrieval
of the stored fault codes from the SECM.
Malfunction Indicator Light (MIL)
= CODE 12
ON OFF ON ON OFF
-105-
Operation Section

NONE NONE None, used as a beginning and end
12
the fault list
ECTSensorInputLow Stored Fault Code Check ECT sensor connector and

14
GND
ECTSensorInputHigh Stored Fault Code Check if ECT sensor connector is

15
circuit circuit
ECTRangeHigh Delayed Engine Check coolant system for radiator

Engine Overheating Shutdown blockage, proper coolant level and
for leaks in the system. Possible ECT
short to GND, check ECT signal
16 wiring
z Check regulator for coolant

leaks
ThrottleSensorInputLo Disable Throttle Check throttle connector connection

circuit
22 (Expected faults when ETC
connector is unplugged
CODES: 22 & 24)
ThrottleSensorInputHi Disable Throttle Check throttle connector and TPS1

TPS1 sensor failure or shorted sensor wiring for a shorted circuit
23
circuit
ThrottleSensorRangeLo Stored Fault Code Check the throttle connector and pins
Improper TPS reading may be due
24
to dirt or oxidation on the sensor
traces.
ThrottleSensorRangeHi Stored Fault Code Check the throttle connector and pins
Improper TPS reading may be due
25
traces.
-106-
Operation Section

throttle body or the ETC driver signal z Check throttle-plate shaft for
is open bearing wear

open circuit
27 PredictedTPSDifference Engine Shutdown Check for manifold leaks between

Measured TPS1 is different than the throttle and the engine
TPS. This fault means that the
throttle and our calculated prediction
for throttle do not agree. This code
often comes up as suspected during
transient manuevers. It is not system
trouble. If the fault really sets, then
the engine will shut down.
28 ETCSpringTestFailed Power Limit Perform throttle spring test by cycling

Upon initial key-up the internal the ignition key and re-check for fault
throttle return spring has become
weak
29 ETCDriverFault Disable Throttle Check ETC driver wiring for a

Throttle driver over-current or driver shorted circuit
signals shorted

circuit or sensor malfunction
(Expected faults when TMAP
CODES: 33 & 38)

TMAP sensor failure or shorted signal wiring for a shorted circuit
circuit

TMAP sensor failure or shorted (MIL Only) signal wiring for a shorted circuit
circuit

or sensor malfunction
-107-
Operation Section

Coil driver signal low or (MIL Only) connector for shorts
under-current
Coil driver signal high or (MIL Only) circuit or disconnected connector
over-current
51 InjectorFault Stored Fault Code Check Gasoline Injector (INJ) for an

(MIL, Disable open wire or injector connector being
Adaptive learns) disconnected
52 LowOilPressure Delayed Engine Check engine oil level

Low Engine Oil Pressure Shutdown
Check electrical connection to the oil
pressure switch
Battery voltage measured below (MIL Only) z Perform maintenance check
+8.0 VDC on electrical connections to
the battery and chassis
ground
running to verify charging
system and alternator
function

with a multimeter

+15.9 VDC Check battery voltage during starting
and with the engine running
Check voltage regulator, alternator
and charging system
Check battery and wiring for
with a multimeter

+5VDC Transducer power TMAP connector with a multimeter
supplied by the SECM to the
sensors is below +4.60VDC Verify transducer power at the SECM
(Expected faults when Transducer with a multimeter
power is lost
CODES: 22, 24, 33, 62, 64, 66, 68 & Verify transducer power at ETC with
69) a multimeter
Verify transducer power to the foot

pedal with a multimeter
-108-
Operation Section

by the SECM to the sensors is above
+5.20VDC Verify transducer power at the SECM
with a multimeter

a multimeter
Verify transducer power to the foot

pedal with a multimeter

maximum RPM set point z Check for ETC Sticking or
other ETC faults
z Verify if the lift truck was
motored down a steep grade
61 Pedal1SensorInputLo MIN Power Limit Check foot pedal connector

APP1 signal disconnected, open
(Expected faults when APP
CODES: 61 & 66)
62 Pedal1SensorInputHi MIN Power limit Check foot pedal connector

APP1 sensor failure or shorted circuit
63 Pedal1SensorRangeLo Stored Fault Code Check foot pedal connector

APP1 potentiometer malfunction. (MIL Only)
Improper APP1 reading may be due
traces.
64 Pedal1SensorRangeHi Stored Fault Code Check foot pedal connector

traces
-109-
Operation Section

65 Pedal2SensorInputLo MIN power Limit Check foot pedal connector
APP2 sensor failure or shorted circuit
66 Pedal2SensorInputHi MIN power Limit Check foot pedal connector

APP2 signal disconnected, open
(Expected faults when APP
CODES: 61 & 66)
67 Pedal2SensorRangeLo Stored Fault Code Check foot pedal connector

traces.
68 Pedal2SensorRangeHi Stored Fault Code Check foot pedal connector

traces.
69 Pedal1ToPedal2Difference MIN power Limit Check foot pedal connector

Measured APP2 pedal position
signal is different than APP1 signal
FTV modulation driver signal fault (MIL, Disable connector being disconnected
Adaptive learns)
72 AFRTrimValveLowerDC Stored Fault Code Engine measured Air/Fuel ratio at the

FTV duty cycle at lower (lean) limit (MIL, Disable O2 sensor is excessively lean.
Adaptive learns) If LP-Gas fuel in LP tank is not
z Check for intake manifold

leaks
hose) connection at the
regulator
pressure (see N2001
Regulator section)
-110-
Operation Section

73 AFRTrimValveUpperDC Stored Fault Code Engine measured Air/Fuel ratio at the
FTV duty cycle at high (rich) limit (MIL, Disable O2 sensor is excessively rich
(Expected fault when FTV connector Adaptive learns)
open circuit

operation (see N2001
Regulator section)
74 O2SensorSwitching Stored Fault Code Note : If LP-Gas fuel in LP tank is not

O2 sensor is not switching across (MIL, Disable enough, this fault code can be set. If
the reference AFR voltage Adaptive learns) LP tank is frozen, this fault code can
Check the FTV for proper operation

Check FTV Hose Connections

O2 sensor SECM driver signal is (MIL, Disable +5VDC or Battery.
shorted to power Adapts)
(AFRTrimValveLowerDC fault
should also occur)
-111-
Operation Section
Auto Shift Controller ASC-100 (If Equipped)

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

Improper operation or maintenance could result
in injury or death. Do not operate or work on the z SW1 is not used.
lift truck unless you are properly trained. For
safe operation, carefully read and follow this
Operation and Maintenance Manual.
Adjustment Switch
-112-
Operation Section
Diagnostics Features Operation

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

This information is given during normal operating mode)
when something special happens. z Start the engine. See topic “Starting the engine”.
For example, on ASC-100’s with the speed sensor, z Push down on the service brake pedal to hold the
one of the indicators is used to indicate a sensor lift truck until ready to move it.
problem. z Release the parking brake.
z Check diagnostics display on controller. See
Display Description Remark “Diagnostics Features”.
A Automatic operation
P Speed sensor open Flashing NOTICE
F Controller fault Flashing
The parking brake must be released before the
6 Forward Sol. Short Flashing direction control lever can be used.
7 Reverse Sol. Short Flashing
z The gear direction is selected with the direction
Display for Troubleshooting control lever.
This information is input signal for diagnostics. z In automatic mode, if the turbine speed in a for
This test is used to verify an operation of direction ward direction is higher than direction inhibit
control lever. speed, though the reverse gear is selected by
operator, the direction of travel will not be
Display Description Remark changed until the speed is reduced sufficiently by
pushing down on the service brake pedal.
A Automatic operation
3 Forward s/w input Lever input test
4 Reverse s/w input Lever input test WARNING
When you want to change the direction of travel,
you must push down on the service brake pedal
to reduce the travel speed.
In automatic mode, the lift truck’s stopping
distance may be longer than in manual mode.
BE CAUTIOUS!
z When the directional change is completed,

continue to push down on the accelerator pedal
to obtain the desired travel speed.
-113-
Operation Section
Manual Mode (Fail-Safe mode)

The system still allows movement of the vehicle in
case of controller breakdown by selecting the
manual mode with the Fail-Safe mode Switch in the
controller.
WARNING
In the manual mode, direction inhibition
function can not be operated normally. The
sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift
truck to tip.
If the controller fails

An operator can operate the truck manually by
selecting the Manual mode with the Fail-Safe mode
switch on the PCB (Printed Circuit Board).
Fail-Safe mode switch
NOTICE
Direction Inhibit Function is usable in factory-setting
controller. If you don’t want to use this function,
make sure to select the manual mode with the
Fail-Safe mode switch on PCB.
-114-
Operation Section
Operating Techniques
Inching into Loads Lifting the Load
1. Lift the load carefully and tilt the mast back a
short distance.
Typical Example
1. Move the lift truck slowly FORWARD into

position and engage the load. The lift truck Typical Example
should be square with load, forks spaced
evenly between pallet stringers and as far apart 2. Tilt the mast further back to cradle the load.
as load permits.
Typical Example
Typical Example
3. Operate the lift truck in reverse until the load is
2. Move the lift truck FORWARD until the load clear of the other material.
touches the carriage.
4. Lower the cradled load to the travel position.
NOTE: Lift and tilt speeds are controlled by engine

rpm.
-115-
Operation Section
Traveling With the Load Unloading
NOTICE
Travel with the load as low as possible, while still
maintaining ground clearance.
Typical Example
1. Move the lift truck into the unloading position.
Typical Example
1. Travel with the load uphill on upgrades and

downgrades.
Typical Example
2. Tilt the mast FORWARD only when directly

over the unloading area.
WARNING
Do not tilt the mast forward with the load unless
Typical Example
directly over the unloading area, even if the
power is off.
2. For better vision, travel in reverse with bulky
loads.
-116-
Operation Section
Turning
Typical Example
3. Deposit the load and BACK away carefully to

disengage the forks. 1. When turning sharp corners, keep close to the
inside corner. Begin the turn when the inside
drive wheel meets the corner.
Typical Example
4. Lower the carriage and forks to the travel

position or to the park position. 2. In narrow aisles, keep away from the stockpile
when turning into the aisle. Allow for counter
weight swing.
-117-
Operation Section
Lifting Drums or Round Objects Operating in hot weather
Keep the following points in mind when you operate

the lift truck in hot weather.
1. Check the radiator. Clogging can cause

overheating. Clean them out regularly with a
blast of compressed air, also, check for leakage
of water.
2. Check the fan belt tension and adjust to proper

tension.
3. Even if the engine overheats and the coolant

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

the load is cradled on the forks.
-118-
Operation Section
Parking the Lift Truck

5. Turn the key in the ignition switch to the OFF
position and remove the key.
NOTE: Park the lift truck level with the fork lowered
and the mast tilted forward until the fork
touches the floor. Block the drive wheels
when parking on an incline. NOTE: If a LP - Gas equipped lift truck is stopped
or parked for an indefinite or prolonged
1. Park in an authorized area only. Do not block period of time, shut off the LP - Gas fuel
traffic. If LP - Gas equipped, do not park near tank valve.
elevator shafts or any other area where LP - Gas
could collect in a pocket (low area), causing a 6. Actuate each loading lever several times to
potentially dangerous condition. remove the residual pressure in the respective
cylinders and hoses.
If Parking Brake Alarm Equipped
2. Place the transmission controls in NEUTRAL.
3. Engage the parking brake.

WARNING
4. Tilt the mast forward and lower the fork to the
ground. When leaving machine apply parking brake!
Parking brake is not automatically applied.
Alarm will sound if parking brake is not applied.
WARNING
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.
-119-
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.
-120-
Operation Section
Storage Information
Before Storage To Operate the Lift Truck after a
Before storing your lift truck, clean and inspect as Long Time Storage
the following procedures. z Remove covers and antirust from each of the
components and exposed parts.
z Wipe away grease, oil, etc. adhering to the body z Drain the engine crankcase, transmission (clutch
of the truck with waste cloth, and use water, if type machine), differential and final reduction
needed. gear, clean the inside of them and add new oil.
z While cleaning the truck, check general condition z Drain off foreign matter and water from the
of the truck. Especially check the truck body for hydraulic oil tank and fuel tank.
dents or damage and tires for wear or nails or z Remove the head cover from the engine cylinder.
stones in the tread. Oil valves and rocker shaft and check each valve
z Fill the fuel tank with fuel specified. for proper operation.
z Check for leakage of hydraulic oil, engine oil, fuel, z Add cooling water to the specified level.
or coolant, etc. z Charge the battery and mount it on the machine.
z Apply grease, where needed. Connect the cables.
z Check for looseness of nuts and bolts, especially z Perform pre - operational checks carefully. (refer
hub nuts. to “Before Starting the Engine”)
z Check mast rollers to see that they rotate z Warm up the machine.
smoothly.
z Prime the oil into the lift cylinders by actuating the
lift lever all the way several times.
z Drain off coolant completely in cold weather, if
antifreeze is not used.
Long Time Storage

Perform the following service and checks in
addition to the “Parking the lift truck” services.
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.
z Cover components such as the breather and air
cleaner which may be caught with humidity.
z The machine should be operated at least once a
week. Fill the cooling system, if cooling water is
discharged, and mount the battery. Start the
engine and warm up thoroughly. Move the
machine a little forwards and backwards.
Operate the hydraulic controls several times.
-121-
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
Improper lifting or tiedowns can allow load to shift
To prevent the lift truck from slipping while loading,
and cause injury and/or damage.
or shifting in transit, remove ice, snow or other
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 DAEWOO.
NOTICE 2. Use proper rated cables and slings for lifting.
Obey all state and local laws governing the height, Position the crane for level lift truck lift.
weight, width and length of a load.
Observe all regulations governing wide loads. 3. Spreader bar widths should be sufficient to
prevent contact with the lift truck.
NOTICE 4. Use the tiedown locations provided for lift truck

tiedown.
Remove ice, snow or other slippery material from
the shipping vehicle and the loading dock. Check the state and local laws governing weight,
width and length of a load.
Contact your DAEWOO 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.
Tilt the mast forward and lower forks to the floor.
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.
-122-
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
towing a disabled lift truck incorrectly. rear could be required. This will prevent
Block the lift truck wheels to prevent movement uncontrolled rolling.
before releasing the brakes. The lift truck can
roll free if it is not blocked. The different situation requirements cannot be
given, as minimal towing lift truck capacity is
Follow the recommendations below, to properly
perform the towing procedure. required on smooth level surfaces to maximum on
inclines or poor surface conditions.
These towing instructions are for moving a disabled Consult your DAEWOO Lift Tuck dealer for towing
lift truck a short distance, at low speed, no faster a disabled lift truck.
than 2 km/h (1.2 mph), to a convenient location for
repair. These instructions are for emergencies only.
Always haul the lift truck if long distance moving is
required.
Shield must be provided on the towing lift truck to

protect the operator if the tow line or bar should
break.
Do not allow riders on the lift truck being towed

unless the operator can control the steering and/or
braking.
Before towing, make sure the tow line or bar is in

good condition and has enough strength for the 1. Release the parking brake.
towing situation involved. Use a towing line or bar
with a strength of at least 1.5 times the gross
weight of the towing lift truck for a disabled lift truck NOTICE
stuck in the mud or when towing on a grade.
Release the parking brake to prevent excessive
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.
3. Key switch is in the OFF position.
Quick lift truck movement could overload the tow
line or bar and cause it to break. Gradual and 4. Direction control lever is in neutral.
smooth lift truck movement will work better.
5. Fasten the tow bar to the lift truck.
Normally, the towing lift truck should be as large as
the disabled lift truck. Satisfy yourself that the 6. Remove the wheel blocks. Tow the lift truck
towing lift truck has enough brake capacity, weight slowly. Do not tow any faster than 2 km/h (1.2
and power, to control both lift trucks for the grade mph).
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.
-123-
Maintenance Section
Inspection, Maintenance and Repair of Lift Truck Forks

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

stamped on the fork in a readily visible area. This is
generally on the top or side of the fork shank.
z A fork rated at 1500 pounds at 24 inch load

center will be stamped 1500x24.
z A fork rated at 2000 kg at 600 mm load center

will be stamped 2000x600.
The manufacturer identification and year and date

of manufacture are also usually shown.
-124-
Maintenance Section
Causes of Fork Failure z Repetitive Overloading
Improper Modification or Repair Repetitive cycling of loads which exceeds the

fatigue strength of the material can lead to fatigue
Fork failure can occur as a result of a field
failure. The overload could be caused by loads in
modification involving welding, flame cutting or
excess of the rated fork capacity and by use of the
other similar processes which affect the heat
forks tips as pry bars. Also, by handling loads in a
treatment and reduces the strength of the fork.
manner which causes the fork tips to spread and
the forks to twist laterally about their mountings.
In most cases, specific processes and techniques
are also required to achieve proper welding of the
z Wear
particular alloy steels involved. Critical areas most
likely to be affected by improper processing are the
Forks are constantly subjected to abrasion as they
heel section, the mounting components and the
slide on floors and loads. The thickness of the fork
fork tip.
blade is gradually reduced to the point where it may
not be capable of handling the load for which it was
designed.
Bent or Twisted Forks
Forks can be bent out of shape by extreme z Stress Risers
overloading, glancing blows against walls or other
solid objects or using the fork tip as a pry bar. Scratches, nicks and corrosion are points of high
stress concentration where cracks can develop.
Bent or twisted forks are much more likely to break These cracks can progress under repetitive loading
and cause damage or injury. They should be in a typical mode of fatigue failure.
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.
-125-
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
Establish a daily and 12 month inspection routine 4,” in the “2000 Service Hours or Yearly” in
by keeping a record for the forks on each lift truck. “Maintenance Intervals”
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,

making sure the following information is included. Daily Inspection
z Actual wear conditions, such as percent of 1. Visually inspect forks for cracks, especially in
original blade thickness remaining. the heel section, around the mounting brackets,
and all weld areas. Inspect for broken or jagged
z Any damage, failure or deformation which might fork tips, bent or twisted blades and shanks.
impair the use of the truck.
2. Make sure positioning lock is in place and
z Note any repairs or maintenance. working. Lock the forks in position before using
the truck. See “2000 Service Hours or Yearly” in
An ongoing record of this information will help in “Maintenance Intervals”.
identifying proper inspection intervals for each
operation, in identifying and solving problem areas 3. Remove all defective forks from service.
and in anticipating time for replacement of the
forks.
-126-
Maintenance Section
12 Months Inspection With the fork restrained in the same manner as

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

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

NOT be attempted.
z Flame cutting holes or cutouts in fork

blades.
z Welding on brackets or new mounting
hangers.
z Repairing cracks or other damage by
welding.
z Bending or resetting.
3. The following repairs MAY be performed.
z Forks may be sanded or lightly ground, to

remove rust, corrosion or minor defects
from the surfaces.
z 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.
z Repair or replace the positioning locks on

hook type forks.
z Repair or replace most fork retention

devices used with other fork types.
4. A fork should be load tested before being

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

repaired fork to be tested with a load 2.5 times
the specified capacity and at the load center
marked on the fork arm.
-127-
Maintenance Section
Tire Inflation Information

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

Size
Strength Index
kPa psi
6.5X10 10 790 115
7.0X15 12 825 120
28X9-15 12 825 120
1
Standard tire, ply rating and inflation pressures.
The operating inflation pressure is based on the

weight of a ready - to - work machine without
WARNING attachments, at rated payload, and in average
Personal injury or death could result when tires operating conditions. Pressures for each
are inflated incorrectly. application may vary and should always be
obtained from your tire supplier.
Use a self - attaching inflation chuck and stand
behind the tread when inflating a tire.
NOTE: Fill tires to the recommended pressures
Proper inflation equipment and training in using listed ± 35 kPa (5 psi). Tires can be filled
the equipment are necessary to avoid with nitrogen.
over-inflation. A tire blowout or rim failure can
result from improper or misused equipment.
Tire Inflation Pressures

Adjustment
NOTICE Tire inflation in a warm shop area, 18° to 21°C (65°
Set the tire inflation equipment regulator at no more to 70°F), will be underinflated if the machine works
than 140 kPa (20 psi) over the recommended tire in freezing temperatures. Low pressure shortens
pressure. the life of a tire.
-128-
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
or better quality.
NOTE: For proper fit, use only metric tools on
metric hardware. Non-metric tools might
slip and cause injury.
Torques for Bolts and Nuts with
Standard Threads
Torque for Standard Hose Clamps
- Worm Drive
Thread Size Standard Nut and Bolt Torque
Inch N•m lb•ft
NOTICE
1/4 12 ± 4 9±3
The chart below gives the torques for initial
installation of hose clamps on new hose and for 5/16 25 ± 7 18 ± 5
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 9/16 150 ± 20 110 ± 15
Clamp Width Torque On New Hose 5/8 200 ± 25 150 ± 18
1
N•m lb•in 3/4 360 ± 50 270 ± 37
16 mm (.625 in) 7.5 ± 0.5 65 ± 5 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
Retightening 1 3/8 1600 ± 200 1180 ± 150
Clamp Width
Torque On Existing Hose 1 1/2 2000 ± 275 1480 ± 200
1 1
N•m lb•in 1 Newton meter (N•m) is approximately the same as 0.1 kg •m.
16 mm (.625 in) 4.5 ± 0.5 40 ± 5

13.5 mm (.531 in) 3.0 ± 0.5 25 ± 5
8 mm (.312 in) 0.7 ± 0.2 6±2
1
1 Newton meter (N•m) is approximately the same as 0.1 kg•m.
-129-
Maintenance Section
Torques for Taperlock Studs Torque for Metric Fasteners
Thread Size Standard Taperlock Stud Torque

NOTICE
Inch N•m1 lb•ft Be very careful never to mix metric with U.S.
1/4 8±3 6±2 customary (standard) fasteners. Mismatched or
incorrect fasteners will cause lift truck damage or
5/16 17 ± 5 13 ± 4 malfunction and may even result in personal injury.
3/8 35 ± 5 26 ± 4
7/16 45 ± 10 33 ± 7 Original fasteners removed from the lift truck should
be saved for reassembly whenever possible. If new
1/2 65 ± 10 48 ± 7 fasteners are needed, they must be of the same
5/8 110 ± 20 80 ± 15 size and grade as the ones that are being replaced.
3/4 170 ± 30 125 ± 22 The material strength identification is usually shown
7/8 260 ± 40 190 ± 30 on the bolt head by numbers (8.8, 10.9, etc.). This
chart gives standard torques for bolts and nuts with
1 400 ± 60 300 ± 45 Grade 8.8.
1/8 500 ± 700 370 ± 50
NOTE: Metric hardware must be replaced with
1/4 650 ± 80 480 ± 60
metric hardware. Check parts book.
3/8 750 ± 90 550 ± 65
1/2 870 ± 100 640 ± 75 Thread Size Standard Torque
1
1 Newton meter (N•m) is approximately the same as 0.1 kg•m. Metric N•m1 lb•ft
M6 12 ± 4 9±3
M8 25 ± 7 18 ± 5
M10 55 ± 10 41 ± 7
M12 95 ± 15 70 ± 11
M14 150 ± 20 110 ± 15
M16 220 ± 30 160 ± 22
M20 450 ± 70 330 ± 50
M24 775 ± 100 570 ± 75
M30 1600 ± 200 1180 ± 150
M36 2700 ± 400 2000 ± 300
1
1 Newton meter (1 N•m) is approximately the same as 0.1
kg•m.
2
ISO - International Standards organization.
-130-
Maintenance Section
Cooling System Specifications

Coolant Information Filling at over 20 liters (5 U.S. gallons) per minute
can cause air pockets in the cooling system.
NOTE: The following information is generic and
valid for lift trucks. After draining and refilling the cooling system,
operate the engine with the radiator cap removed
Engine operating temperatures have increased to until the coolant reaches normal operating
improve engine efficiency. This means proper temperature and the coolant level stabilizes. Add
cooling system maintenance is especially important. coolant as necessary to fill the system to the proper
Overheating, overcooling, pitting, cavitation erosion, level.
cracked heads, piston seizures, and plugged
radiators are classic cooling system failures. In fact, Never operate without a thermostat in the cooling
coolant is as important as the quality of fuel and system. Cooling system problems can arise without
lubricating oil. a thermostat.
NOTICE
DAEWOO recommends that the coolant mixture
contain 50% commercially available automotive
antifreeze, and 50% water.
The coolant mix with concentration of antifreeze

smaller than 30% does not provide sufficient
corrosion protection. Concentrations over 60%
adversely affect freeze protection and heat transfer
rates.
Never add coolant to an overheated engine, engine

damage can result. Allow the engine to cool first.
If the machine is to be stored in, or shipped to, an
area with freezing temperatures, the cooling system
must be protected to the lowest expected outside
(ambient) temperature.
The engine cooling system is normally protected to

-28°C (-20°F) with antifreeze, when shipped from
the factory unless special requirements are defined.
Check the specific gravity of the coolant solution

frequently 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.
-131-
Maintenance Section
Coolant Water Antifreeze

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

concentration of antifreeze to use.
Antifreeze Concentrations
Protection Temperature Concentrations
Protection to -15°C (5°F) 30% antifreeze and 70% water
Protection to -23°C (-10°F) 40% antifreeze and 60% water
-132-
Maintenance Section
Fuel Specifications
General Fuel Information Crude oil is used to describe oils/fuels that are not
refined and are in the original state as when
Use only fuel as recommended in this section. pumped from the ground. Certain types of crude
oils can be burned in DAEWOO Engines.
NOTICE
PREFERRED DISTILLATE FUEL
Fill the fuel tank at the end of each day of FOR DISEL ENGINES
operation to drive out moisture laden air and to Specifications Requirements*
prevent condensation. Maintain a constant level Aromatics (AST D1319) 35% Max.
near the top of the day tank to avoid drawing
moisture into the tank as the level decreases. Ash (ASTM D482) 0.02% Weight Max.
Do not fill the tank to the top. Fuel expands as it Cetane Number 35Min. for 45 max.
gets warm and can overflow. (ASTM D613) 40 Min. for DI Engines
Do not fill the fuel filters with fuel before Not Above Lowest Expected
Could Point (ASTM D287)
installing them. Contaminated fuel will cause Ambient Temperature
accelerated wear to the fuel system parts. Gravity API (ASTM D287) 30 Min. and 45 Max.
6°C (10°F) Below Ambient
Pour Point (ASTM D97)
Drain the water and sediment from main fuel Min.
storage tank before it is refilled. This will help Sulfur (ASTM D2788, 0.5% Max.
prevent water and/or sediment from being pumped
D3605 or D1552) (See Sulfur Topic)
from the fuel storage tank into the engine fuel tank.
Viscosity, Kinematic @ 20.0 cSt Max.
38°C (100°F) (ASTM D445) 1.4 cSt Min.
Diesel Specifications Water & Sediment
0.01% Max.
(ASTM D1796)
Fuel Types *As delivered to fuel system
DAEWOO Diesel Engines have the ability to burn a
wide variety of fuels. These fuels are divided into
two general groups, preferred and permissible.
Fuel Sulfur Content
The percentage of sulfur in the fuel will affect the
The Preferred Fuels provide maximum engine engine oil recommendations. Fuel sulfur is
service life and performance. They are distillate chemically changed during combustion to form both
fuels. They are commonly called diesel fuel, MDO sulfurous and sulfuric acid. These acids chemically
diesel, furnace oil, gas oil or kerosene (for cold attack metal surfaces and cause corrosive wear.
weather operation).
Certain additives used in lubricating oils contain
Experience has proven that distillate fuels meeting alkaline compounds that are formulated to
the following basic specifications will result in neutralize these acids. The measure of this reserve
optimum engine performance and durability. alkalinity in lubricating oil is known as its Total Base
Number (TBN). TBN is essential to neutralize the
DAEWOO strongly encourages the use of fuels that acids from combustion gases and to minimize
meet the Preferred Fuels specification. corrosive wear.
The permissible fuels are crude oils or blended Any API classification performance of oil should
fuels. Use of these fuels can result in higher have sufficient TBN for fuels with less than 0.5%
maintenance costs and reduced engine service life. sulfur. For fuels with 0.5% to 1.5% sulfur by weight,
engine oil must have a TBN of 20 times the
percentage of fuel sulfur as measured by the ASTM
(American Society of Testing Materials) D-2896
method. (ASTM D-2896 can normally be found at
your local technological society, library or college).
-133-
Maintenance Section
DAEWOO recommends infrared analysis (in Gasoline Specifications

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

from your fuel supplier. Fuel sulfur content can LP-Gas Specifications
change with each bulk delivery.
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 DAEWOO 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 (C 3 H8 ) 90.0 %
Propylene up to 5 %
Butane (C4 H10 ) 2.0 %
iso - Butane 1.5 %
Methane (CH4 ) 1.5 %
Total 100 %
-134-
Maintenance Section
Lubricant Information
Lubricant Information Hydraulic Oil (HYDO)
Certain abbreviations follow Society of Automotive The following commercial classifications can be
Engineers (SAE) J754 nomenclature and some used in the hydraulic system.
classifications follow SAE J183 abbreviations.
z ISO 6743/4 HM
The MIL specifications are U.S.A. Military z AFNOR NFE 48-603 HM
Specifications. z DIN 51524 TEIL 2 H-LP
z HAGGLUNDS DENISON HFO-HF2
The recommended oil viscosities can be found in the z CINCINNATI P68,69,70
Lubricant Viscosities chart in this publication.
Viscosity: ISO VG32
Grease is classified by the National Lubricating
Grease Institute (NLGI) based on ASTM D217-68 Industrial premium hydraulic oils that have passed
Worked Penetration characteristics which are given the Vickers vane pump test (35VQ25).
a defined consistency number. These oils should have antiwear, antifoam, antirust
and antioxidation additives for heavy duty use as
stated by the oil supplier. ISO viscosity grade of 32
Engine Oil (DEO and EO) would normally be selected.
The following oil specifications provide guidelines for

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

listing of oil brands.
NOTE: The percentage of sulfur in the fuel will

affect the engine oil recommendations.
For fuel sulfur effects, the Infrared Analysis
or the ASTM D2896 procedure can be used
to evaluate the residual neutralization
properties of engine oil. The sulfur products
formation depends on the fuel sulfur content,
oil formulation, crankcase blow-by, engine
operating conditions and ambient
temperature.
-135-
Maintenance Section
Drive Axle Oil Transmission Oil

NOTE: Do not use Gear Oil in the final drives or
differentials. Gear Oil can cause seal
material to fail and possibly leak oil. NOTICE
This oil is formulated for transmissions and drive
NOTE: Failure to follow the recommendation will trains only, and should not be used in engines.
cause shortened life due to excessive gear Shortened engine life will result.
wear.
NOTE: Multi-grade oils are not blended by
The API CD/TO-2 specification or MIL-L-2104D, Eor
DAEWOO for use in transmissions.
F oils could be used.
Multi-grade oils which use high molecular
weight polymers as viscosity index
NOTE: Multi-grade oils are not blended by
improvers lose their viscosity effectiveness
DAEWOO for use in transmissions.
by permanent and temporary shear of the
Multi-grade oils which use high molecular
viscosity index improver and therefore, are
weight polymers as viscosity index
not recommended for transmission and
improvers lose their viscosity effectiveness
drive train compartments.
by permanent and temporary shear of the
viscosity index improver and therefore, are
NOTE: Failure to follow this recommendation can
not recommended for transmission and
cause shortened transmission life due to
drive train compartments.
material incompatibility, inadequate
frictional requirements for disk materials
and/or excessive gear wear.
Lubricating Grease (MPGM)
The API CD/TO - 2 specification or MIL - L 2104D, E
Use Multipurpose Molybdenum Grease (MPGM) for
or F oil could be used.
all lubrication points. If MPGM grease can not be
used, multipurpose type grease which contains 3%
to 5% molybdenum disulfide can be used.
NLGI No.2 grade is suitable for most

temperatures. Use NLGI No.1 or No.0 grade for
extremely low temperature.
-136-
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities
LUBRICANT VISCOSITIES REFILL CAPACITIES - (APPROXIMATE)
FOR AMBIENT (OUTSIDE) TEMPERATURES Compartment or System Liters U.S Gal.
Compartment Oil °C °F Engine Crankcase w/Filter
or System Viscosities Min Max Min Max G424 & G424E 2.4liter 4.0 1.06
G424(E) Gasoline & LP - Gas
SAE 10W30 -20 +40 -4 +104
Engine Engine Crankcase w/Filter
Crankcase G430 & G430E 3.0liter 4.7 1.24
(Gasoline and LP - Gas
SAE 5W30 -30 +30 -22 +86 Engine Crankcase w/Filter
LP-Gas)
7.0 1.84
API SL DB33A Diesel
G430(E) Engine Crankcase w/Filter
SAE 10W30 -20 +40 -4 +104 7.5 1.98
B3.3 Diesel
Engine
Cooling System
Crankcase
w/Coolant Recovery Bottle
(LP-Gas) SAE 5W30 -30 +30 -22 +86 10.5 2.77
G424 & G424E 2.4liter
API SL
Gasoline & LP - Gas
Engine
Cooling System
Crankcase w/Coolant Recovery Bottle
(Diesel) SAE 15W40 -15 +50 -5 +122 11.5 3.04
G430 & G430E 3.0liter
API CH4, LP - Gas
ACEA E5 Cooling System
Power Shift w/Coolant Recovery Bottle 15.0 4.0
SAE 10W -20 +22 -4 +72
Transmission DB33A Diesel
& Drive Axle Cooling System
Housing SAE 30 +10 +50 +50 +122 w/Coolant Recovery Bottle 13.0 3.43
API CD/TO-2 B3.3 Diesel
Hydraulic and Fuel Tank - G, D Series
ISO VG 22 -30 +20 -22 +68 52 13.74
Gasoline or Diesel
Power
ISO VG 32 -20 +30 -4 +86 Fuel Tank - GC Series
Steering 40 10.56
ISO VG 46 -10 +40 +14 +104 Gasoline
System
G Series 15.2kg 33.5lb
ISO 6743/4 LP - Gas
ISO VG 68 0 +50 +32 +122 GC Series 15.2kg 33.5lb
HM
Powershift G, D Series 13.0 3.43
The SAE grade number indicates the viscosity of oil. Transmission GC Series 11.2 3.0
A proper SAE grade number should be selected G, D Series 9.2 2.43
according to ambient temperature. Drive Axle
GC Series 10.0 2.64
Hydraulic & Power Steering System 34 8.98
-137-
Maintenance Section
Maintenance Intervals
First 250 Service Hours or a Month
NOTICE Hydraulic Return Filter – Change.......................162
Engine Valve Lash (B3.3 Diesel Engine Only) -
All maintenance and repair, except Every 10
Check, Adjust .....................................................162
Service Hours or Daily, on the lift truck must be
performed by qualified and authorized personnel
only. Every 250 Service Hours or Monthly
Air Intake System - Check, Clean ......................163
Hydraulic Oil Level – Check ...............................165
NOTICE Drive Axle Oil Level - Check...............................166
Mast, Carriage, Lift Chains & Attachments - Inspect,
Careless disposal of waste oil can harm the
Lubricate.............................................................166
environment and can be dangerous to persons.
Steering Mechanism - Check, Lubricate ............166
Always dispose of waste oil to authorized personnel
Battery Terminal - Clean, Inspect .......................167
only.
Engine Oil & Filter (DB33A Diesel, LP-Gas &
Gasoline Engine Only) - Change .......................167
Quick Reference to Maintenance Schedule....…….133 PCV Valve System - Inspect, Clean...................168
Wheel Bolts & Nuts - Inspect..............................169
When Required
Engine Valve Lash (DB33A Diesel Engine Only) - Every 500 Service Hours or 3 Months
Check, Adjust..................................................... 142 Belts - Check, Adjust ..........................................170
Fuel Tank Filter Cap and Screen (If Equipped) - Mast Hinge Pin – Lubricate ................................170
Clean ................................................................. 142 Tilt Cylinders - Check, Adjust, Lubricate ............170
Seat, Hood Latch & Support Cylinder - Check, Crosshead Rollers - Inspect...............................171
Lubricate ............................................................ 143 Transmission Oil Filter – Change .......................172
Fuses, Bulbs, Circuit Breaker & Relay - Change, Overhead Guard – Inspect.................................172
Reset ................................................................. 144 Drive Axle Oil & Strainer - Change, Clean .........172
Fuse & Relay (G424E/G430E Only).................. 145 Steer Suspension – Inspect ...............................173
Priming the Fuel System (Diesel Engine Only) . 147 Parking Brake - Test, Adjust ...............................173
Tires and Wheels (D, G-Series) - Inspect, Check Inching & Braking Control Shaft - Lubricate .......174
........................................................................... 150 Horn and Lights (If Equipped) - Check...............174
Carriage Roller Extrusion – Adjust..................... 151 Engine Oil & Filter (B3.3 Diesel Engine Only) -
Change...............................................................174
Every 10 Service Hours or Daily Fuel Strainer (B3.3 Diesel Engine Only)
– Clean ...............................................................176
Inspect Engine for Fluid Leaks .......................... 152
Inspect Vacuum Lines and Fittings (G424E/G430
Engine Oil Level - Check ................................... 152
Engine Only).......................................................177
Coolant Level – Check ...................................... 152
Fuel Trim Valve(FTV) Inspection........................177
Air Cleaner Indicator-Check .............................. 153
(G424E/G430E Engine Only).............................177
Inspect Foot Pedal Operation (G424E/G430E Only)
Inspect Electrical System (G424E/G430E Engine
........................................................................... 153
Only)...................................................................177
Inspect Engine for Exhaust Leaks ..................... 153
Inspect VR Sensor – Clean (G424E/G430E engine
Walk-Around Inspection - Inspect...................... 154
only)....................................................................177
Mast Channels – Lubricate................................ 155
Fuel Filter (B3.3 Diesel Engine Only) - Change.178
Transmission Oil Level – Check ........................ 155
Parking Brake - Inspect ..................................... 156
Every 1000 Service Hours or 6 Months
First 50 - 100 Service Hours or a Week Hydraulic Return Filter, Breather & Strainer - Check,
Change...............................................................179
Engine Oil & Filter (DB33A Diesel Engine Only) -
Transmission Oil, Oil Filter & Strainer - Check,
Change .............................................................. 157
Clean, Change ...................................................180
Transmission Oil, Oil Filter & Strainer - Check,
Lift Chains - Test, Check, Adjust ........................180
Clean, Change................................................... 158
Universal Joint – Inspect ....................................182
Drive Axle Oil - Change ..................................... 159
Carburetor (LP-Gas, Gasoline & Dual Fuel Engine
Parking Brake - Test, Adjust............................... 160
Only) - Adjust, Clean ..........................................182
Air Intake System - Change ...............................183
-138-
Maintenance Section
Inspect Coolant Hoses (LP Engine Only) .......... 183 Every 3000 Service Hours or 18 Months
LP Regulator/Converter Inspection (LP Engine
Only) .................................................................. 183 Timing Belt [G424(E) LP-Gas, Gasoline Dual Fuel
Fuel Lines & Fittings - Check............................. 184 Engine Only] - Change ....................................198
Inspect Mixer Assembly (G424E/G430E Engine Timing Belt for Counterbalance Shaft [G424(E)
Only) .................................................................. 184 LP-Gas, Gasoline & Dual Fuel Engine Only]
Inspect Throttle Assembly (G424E/G430E Engine - Change.............................................................198
Only) .................................................................. 184
Fuel Filter (DB33A Diesel Engine Only) - Change Every 4500 Service Hours or two Years
........................................................................... 184 Replace Oxygen Sensor (G424E/G430E Engine
Only)...................................................................199
Inspect Ignition System (LP-Gas, Gasoline & Dual
Fuel Engines Only) ............................................ 185
Replace Spark Plugs (LP-Gas, Gasoline & Dual
Fuel Engines Only) ............................................ 185
Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
Engine Only) ...................................................... 186
Fuel Filter(LP-Gas Engine Only) ....................... 187
Testing Fuel Lock-off Operation (LP-Gas Engine
Only) .................................................................. 187
Every 2000 Service Hours or Yearly

Fuel Filter(G424 Gasoline & Dual Fuel Engine
Only) - Change .................................................. 188
Engine Valve Lash (B3.3 Diesel Engine Only) –
Check, Adjust..................................................... 188
Steer Wheel Bearings - Reassemble................. 189
Drive Wheel Bearing (Power Shaft and Drive
Wheel) – Reassemble ....................................... 191
Cooling System - Clean, Change ...................... 192
Forks – Inspect .................................................. 193

Hydraulic Oil - Check, Clean, Change............... 195
Inspect Battery System...................................... 195
Checking the TMAP Sensor (G424E/G430E Engine
Only) .................................................................. 196
Inspect for Intake Leaks (G424E/G430E Engine
Only) .................................................................. 197
Replace PCV Valve and breather element - Change
(LP-Gas, Gasoline and Dual Fuel Engines) ...... 197
-139-
Maintenance Section
Quick Reference to Maintenance Schedule FIRST EVERY
2500 Service Hours or15 Months
3000 Service Hours or18 Months

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

250 Service Hours or a Months
4500 Service Hours or 2 Years

250 Service Hours or a Month
2000 Service Hours or a Year

10 Service Hours or a Day
ITEMS SERVICES PAGE
When Required
Air Cleaner Indicator Check 153 O
Air Intake System Check, Clean 163 O
Air Intake System Change 183 O
Battery Terminal Clean, Inspect 167 O
Belts Check, Adjust 170 O
Carburetor
Adjust, Clean 182 O
(LP-Gas, Gasoline & Dual Fuel E/G Only)
Carriage Roller Extrusion Adjust 151 O
Coolant Level Check 152 O
Cooling System Clean, Change 192 O
Crosshead Rollers Inspect 171 O
Drive Axle Oil Change 159 O
Drive Axle Oil & Strainer Change, Clean 172 O
Drive Axle Oil Level Check 166 O
Drive Wheel Bearing(Power Shaft & Drive Wheel) Reassemble 191 O
Engine Oil & Filter
Change 167 O
(DB33A Diesel, LP-Gas & Gasoline E/G Only)
Engine Oil & Filter(DB33A Diesel E/G Only) Change 157 O
Engine Oil & Filter(B3.3 Diesel E/G Only) Change 174 O
Engine Oil Level Check 152 O
Engine Valve Lash(DB33A Diesel E/G Only) Check, Adjust 142 O
Engine Valve Lash(B3.3 Diesel E/G Only) Check, Adjust 162 O O
Forks Inspect 193 O
Fuel Filter
Change 188 O
(G424 Gasoline & Dual Fuel E/G Only)
Fuel Filter (G424E/G430E Dual Fuel Engine Only) Change 186 O
Fuel Filter(DB33A Diesel Engine Only) Change 184 O
Fuel Filter(B3.3 Diesel Engine Only) Change 178 O
Fuel Lines & Fittings Check 184 O
Fuel Strainer(B3.3 Diesel E/G Only) Clean 176 O
Fuel Tank Filter Cap & Screen(If Equipped) Clean 142 O
Fuses, Bulbs, Circuit Breaker & Relay Change, Reset 144 O
Horn & Lights(If Equipped) Check 174 O
Check, Clean,
Hydraulic Oil 195 O
Change
Hydraulic Oil Level Check 165 O
Hydraulic Return Filter Change 162 O
Hydraulic Return Filter, Breather & Strainer Check, Change 179 O
-140-
Maintenance Section
Quick Reference to Maintenance Schedule FIRST EVERY

50-100 Service Hours or a Week

250 Service Hours or a Month
250 Service Hours or a month
2000 Service Hours or a Year
4500 Service Hours or 2 Years

10 Service Hours or a Day
ITEMS SERVICES PAGE
When Required
Inspect VR Sensor(G424E/G430E Engine Only) Clean 177 O
Inching & Braking Control Shaft Lubricate 174 O
Lift Chains Test, Check, Adjust 180 O
Mast Channels Lubricate 155 O
Mast Hinge Pins Lubricate 170 O
Mast, Carriage, Lift Chains & Attachments Inspect, Lubricate 166 O
Overhead Guard Inspect 172 O
Oxygen Senser Change 199 O
Parking Brake Inspect 156 O
160,
Parking Brake Test, Adjust O O
173
PCV Valve System Inspect, Clean 168 O
Priming the Fuel System(Diesel E/G Only) Bleed, Drain 147 O
Seat, Hood Latch & Support Cylinder Check, Lubricate 143 O
Steer Suspension Inspect 173 O
Steer Wheel Bearings Reassemble 189 O
Steering Mechanism Check, Lubricate 166 O
Check, Adjust,
Tilt Cylinders 170 O
Lubricate
Timing Belt for Counterbalance Shaft (LP-Gas,
Change 198 O
Gasoline & Dual Fuel E/G Only)
Timing Belt
Change 198 O
(LP-Gas, Gasoline & Dual Fuel E/G Only)
Tires & Wheels (D,G-Series) Inspect, Check 150 O
Transmission Oil Filter Change 172 O
Transmission Oil Level Check 155 O
Check, Clean, 158,
Transmission Oil, Oil Filter & Strainer O O
Change 180
Universal Joint Inspect 182 O
Walk-Around Inspection Inspect 154 O
Wheel Bolts & Nuts Inspect 169 O
-141-
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.
Engine Valve Lash (DB33A Diesel Fuel Tank Filter Cap and Screen
Engine Only) - Check, Adjust (If Equipped) - Clean
Park the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
NOTICE engine stopped.
The valve clearances are to be adjusted at the
times of the following situations.
z When the engine is overhauled and the
cylinder heads are disassembled.
z When severe noise comes from valve train.
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.
1. Remove the filter cap assembly. Clean in clean,
Hot engine components can cause burns. Allow nonflammable solvent.
additional time for the engine to cool before
measuring valve clearance. 2. Dry cap assembly.
3. Install filter cap assembly.

NOTICE
Measure the valve lash with the engine stopped. To WARNING
obtain an accurate measurement, allow at least 20
minutes to cool the engine cylinder head and block Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
temperature.
Set the clearance to the nominal appropriate 4. Drain moisture and sediment from fuel tank as
clearance given in the “Valve Clearance Setting” required by prevailing conditions.
shown below.
Valve Clearances
Engine Valve Clearance
3.3 liter Exhaust Valves .40 mm (.016 in)
(DB33A) Diesel Intake Valves .40 mm (.016 in)
Refer to the “Service Manual” for the complete

valve adjustment procedure.
NOTE: In regards to G424 and G430 Engines,

valve adjustment is not necessary because
of automatic adjusting system.
-142-
Maintenance Section
Seat, Hood Latch & Support

Cylinder - Check, Lubricate
1. Check the operation of the seat adjuster rod.

Make sure that the seat slides freely on its
track.
Lightly oil the seat slider tracks if necessary.
Typical Example
3. Lightly oil the hood latch mechanism and the

rod for the hood support cylinder.
2. Push the lever down to raise the hood and seat

assembly (D, G-Series). Pull the latch to raise
the hood and seat assembly (GC Series). Make
certain the support cylinder will hold the hood
open.
(Note: Unlock latch before pulling it - if key
equipped)
-143-
Maintenance Section
Fuses, Bulbs, Circuit Breaker & Fuses are identified as follows:

1.Horn - 10 amps.
Relay - Change, Reset 2.Head/Rear Lamp - 15 amps.
3.Fwd./Rev. Solenoid, lamp Relay & Back-up
Fuses Lamp/alarm - 10 amps.
NOTE: If a fuse filament separates, use only the 4.Instrument Panel & Fuel Shutoff - 15 amps.
same type and size fuses for replacement. 5.Turn Signal Lamp, Stop/Strobe Lamp & C.S.D.
If the filament in a new fuse separates, (DB33A Diesel only) - 15 amp.
have the circuits and instruments checked. 6.Start Relay - 5 amp.
NOTICE Bulbs
Bulbs are identified as follows:
Always replace fuses with ones of the correct
1. Bulb-head lamp halogen (12V-35W)
ampere rating.
*2. Bulb-back up (12V-10W)
*3. Bulb-turn signal (12V-23W)
*4. Bulb-stop & tail (12V-23/8W)
*Optional lamp or light
Circuit Breaker
Remove the front cover from the fuse box located

under the cowl.
Fuse - Protects an electrical circuit from an

overload. Opens (filament separates) if an overload
occurs.
1. Raise the hood and seat assembly. Make sure
the support cylinder securely holds the hood
open.
Typical Example
Check the fuses. Use a flashlight, if necessary.
2. The main circuit breaker is located on the rear

of the support for the hydraulic controls.
NOTE: To reset circuit breakers push in on the

button. The button should stay in if the
breaker is reset. If the button will not stay in,
or comes out shortly after reset, have the
circuits checked.
-144-
Maintenance Section
Fuse & Relay (G424E/G430E Only)

G25E-3 (G20/25/30E-3)
Located on the frame left side.
Located rear side of valve mounting bracket. GC25P-3 (GC20/25/30/32P-3)
G25P-3 (G20/25/30/33P-3)
Located on the left side of engine.
Located rear side of valve mounting brackcet.
GC25E-3 (GC20/25/30E-3)
Located on the frame left side.
Located on the top of engine.
-145-
Maintenance Section
G20/25/30/32E-3 (Dual fuel Only) G20/25/30/33p-3 (Dual fuel Only)

Main power relay, main fuse, fuel fuse
Located on the right frame rail.
Located rear side of valve mounting bracket.
Fuel select relay1, relay2
Located on the left frame.
Located on the left frame.
Located rear side of valve mounting bracket.
-146-
Maintenance Section
Priming the Fuel System (Diesel

Engine Only)
Bleeding the Fuel System
After changing the fuel filter cartridge assembly, or
after having serviced any part of the fuel system,
make sure that the air is bled from the system.
DB33A Diesel Engine
DB33A Diesel Engine
B3.3 Diesel Engine
2. Push the priming pump on top of the fuel filter

housing against the spring to allow air mixed
with fuel to escape through the bleeding screw.
Ensure that excess fuel is collected in a
container or rag to prevent fuel from getting
onto engine parts.
B3.3 Diesel Engine 3. Repeat the pumping action until no bubbles are
visible in the flowing fuel.
1. Remove a clamp (1) on overflow pipes to
injection nozzles. 4. Assemble the clamp.
5. Start the engine and check fuel system for

leaks.
-147-
Maintenance Section
Draining the Water from the Fuel Filter B3.3 Diesel Engine
DB33A Diesel Engine 1. Check "Diesel Engine Water in fuel filter
indicator light" in instrument panel. Refer to,
1. Check "Diesel Engine Water in fuel filter "Diesel Engine Water in Fuel Filter Indicator
indicator light" in instrument panel. Refer to, Light" in Operator's Station and Monitoring
"Diesel Engine Water in Fuel Filter Indicator Systems section.
Light" in Operator's Station and Monitoring
Systems section.
2. Turn the wing nut counter clockwise more than

six turns to open the drain valve on the bottom
2. Turn the wing nut (1) counter clockwise more of the fuel filter.
than two turns. The wing nut (1) is located near
fuel's inlet side. Some times later, "w" marking 3. Drain some fuel (and any water) until the clean
will be added as illustrated in Top View below. fuel flows out from the filter.
3. Turn the wing nut (2) counter clockwise more

than six turns to open the drain valve on the
bottom of the fuel filter.
4. Drain some fuel (and any water) until the clean

fuel flows out from the filter
-148-
Maintenance Section
Test Fuel System for Leaks(LP and Dual

Fuel Engines Only)
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.
-149-
Maintenance Section
Tires and Wheels (D, G-Series) - When tires are changed, be sure to clean all rim
parts and, if necessary, repaint to stop detrimental
Inspect, Check effects of corrosion. Sand blasting is recommended
for removal of rust.
WARNING
Servicing and changing tires and rims can be Check all components carefully and replace any
dangerous and should be done only by trained cracked, badly worn, damaged and severely rusted
personnel using proper tools and procedures. or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
If correct procedures are not followed while
servicing tires and rims, the assemblies could parts.
burst with explosive force and cause serious
physical injury or death. Do NOT, under any circumstances, attempt to
rework, weld, heat or braze any rim components.
Follow carefully the specific information
provided by your tire servicing man or dealer.
Check Inflation and Damage

Inspect tires for wear, cuts, gouges and foreign
objects. Look for bent rims and correct seating of
locking ring.
Check tires for proper inflation. See “Tire Inflation

Pressures”.
To inflate tires always use a clip-on chuck with a

minimum 60 cm (24 inches) length of hose to an
in-line valve and gauge.
Always stand behind the tread of the tire. NOT in

front of the rim.
Do NOT re-inflate a tire that has been run while flat

or underinflated, without first checking to make sure
the locking ring on the rim is not damaged and is in
the correct position.
-150-
Maintenance Section
Carriage Roller Extrusion – Adjust

1. Set the mast vertical.
2. Lower the carriage completely.
3. On full free lift and full free triple lift models, the
bottom of the inner mast must be flush with the
bottom of the stationary mast.
4. Measure the distance from the bottom of the

inner upright to the bottom of carriage bearing.
5. The measurement (A) must be as follows in

Chart below.
Height of carriage roller extrusion (A)

STD mast FF mast FFT mast
0 41 41
-151-
Maintenance Section
Every 10 Service Hours or Daily

Inspect Engine for Fluid Leaks Coolant Level – Check

1. Start the engine and allow it to reach dperating WARNING
temperatures.
At operating temperature, the engine coolant is
2. Turn the engine off. hot and under pressure.
3. Inspect the entire for oil and/or coolant leaks. Steam can cause personal injury.
4. Repair as necessary before continuing. Check the coolant level only after the engine
has been stopped and the filter cap is cool
enough to touch with your bare hand.
Remove the filter cap slowly to relieve pressure.
Engine Oil Level - Check
Cooling system conditioner contains alkali.
1. Raise the hood and seat assembly. Avoid contact with the skin and eyes to prevent
personal
WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.
Gasoline and LP-Gas Engines
DB33A Diesel Engine
2. Maintain oil level between the MAX. and MIN.

marks on the dipstick.
Diesel Engines
B3.3 Diesel Engine
3. Maintain oil level between the MAX. and MIN.

marks on the dipstick.
-152-
Maintenance Section
1. Observe the coolant level with engine cold. Air Cleaner Indicator-Check
Maintain coolant level to the proper line on
expansion bottle. If the expansion bottle has no Checking Service Indicator
coolant, it will be necessary to check coolant at
the radiator filter neck.
2. Remove the radiator cap. Fill radiator to the top

of the filter neck. Inspect radiator cap. Replace
if damaged. Install the radiator cap.
1. Observe the air cleaner service indicator.
2. Service the air cleaner when the RED band in

the service indicator, locks in the visible position.
See topic, “Air Intake System - Check, Clean” in
“Every 250 Service Hours or Monthly”.
3. Start and run the engine to stabilize the coolant
NOTE: Service the element more frequently, as
level in the filter neck. If low, add coolant until it
required, in severe dust or lint conditions.
reaches the top of the filter neck. Install the
Also, service it more frequently where the
radiator cap. Observe coolant level in the
operator is required to wear a respirator.
expansion bottle. If necessary, add coolant to
bring the coolant to the appropriate line on the
3. Close hood and seat assembly.
expansion bottle.
4. Stop the engine.

Inspect Foot Pedal Operation
5. Inspect the cooling system for leaks, hose (G424E/G430E Only)
cracks or loose connections.
1. Verify foot pedal travel is smooth without
sticking.
WARNING
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a WARNING
protective face shield, protective clothing and
protective shoes. When the acceleration pedal harness is
connected or disconnected, should be worked
Maximum air pressure must be less than 205 key OFF condition.
kPa (30 psi) for cleaning purposes.
If not, occured malfunction, can cause the
6. Blow any dust and lint from the radiator fins. personal injury.
Inspect Engine for Exhaust Leaks

1. Start the engine and allow it to reach operating
temperatures.
2. Perform visual inspection of exhaust system.

Repair any/all leaks found.
-153-
Maintenance Section
Walk-Around Inspection - Inspect

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

needed.
DB33A Diesel Engine
1. Inspect the tires and wheels for cuts, gouges,

foreign objects, inflation pressure and loose or
missing bolts. B3.3 Diesel Engine
2. Inspect the mast and lift chains for wear, broken 8. Inspect the cooling system for leaks, worn
links, pins and loose rollers. hoses and debris buildup.
3. Inspect the hydraulic system for leaks, worn 9. Inspect engine compartment for oil, coolant and
hoses or damaged lines. fuel leaks.
4. Look for transmission and drive axle leaks on 10. Inspect the forks.
the lift truck and on the ground.
z Visually inspect forks for cracks, especially in the
heel section, around the mounting brackets, and
all weld areas.
z Inspect for broken or jagged fork tips, bent or
twisted blades and shanks.
z Make sure positioning lock is in place and
working.
Lock the forks in position before using the truck.
See Step 7 of “Forks” in “Every 2000 Service
Hours or Yearly”.
z Remove all defective forks from service.
5. Inspect the operator’s compartment for loose

items and cleanliness.
6. Inspect the instrument panel for broken gauges

and indicator lights.
7. Test the horn and other safety devices for

proper operation.
-154-
Maintenance Section
Mast Channels – Lubricate Transmission Oil Level – Check

WARNING
contact skin.
1. Start and operate the lift truck until the engine

reaches normal operating temperature.
2. Park the lift truck level with the forks lowered,

parking brake applied and the transmission
controls in NEUTRAL.
The channels on the roller-type mast require a 3. With the service brake applied and the engine
break-in period. Apply a light film of lubricant on the at low idle, shift the directional control lever to
channels where the rollers ride. This will prevent forward and then to reverse, to fill the clutches.
metal peel until the rollers set a pattern. 4. Shift the direction control lever to the NEUTRAL
position.
5. Remove the dip stick/filter cap. Observe the oil

level.
6. Maintain the oil level between the Min and Max

marks on the dip stick/filter cap.
When the oil temperature is 40°C approximately,
the cold side mark on the dipstick is applicable.
the hot side mark on the dipstick is applicable.
-155-
Maintenance Section
Parking Brake - Inspect PARKING BRAKE
Inspection from Operator's Seat, Engine NOTE: The parking brake is required to be
OFF adjusted to hold the lift truck with capacity
load on a 15% grade.
If there is a 15% grade in your workplace,
engage a capacity load and drive over to
the grade. If the maximum grade in your
workplace is less than 15% or if the
maximum load carried by the lift truck is
less than the lift truck's load capacity, pick
up the maximum load and drive to the
steepest grade in your workplace.
1. Raise the forks or load engaging attachment

about 30 cm (12 in) from the floor.
2. Drive forward up the grade, or in reverse down

1. Grasp the parking brake lever with your hand the grade, and stop the lift truck with the service
and press down the release button with your brakes.
thumb. The lever should move freely forward
and backward. 3. Engage the parking brake and release the
service brakes.
2. Remove your thumb from the release button.
The lever should resist movement when pulled 4. If the lift truck moves down the grade, control its
fully back and a clicking sound should be heard. speed with the service brakes, release the
The lever should remain fully back until you parking brake and return directly to the
press the release button with your thumb. inspection area.
3. Report a missing, damaged or loose parking 5. Park the lift truck, engage the parking brake, shift
brake lever, any inability or difficulty engaging the direction control lever to NEUTRAL, lower the
and releasing the parking brake lever, or any forks or load engaging attachment to the floor,
restricted movement of the parking brake lever. shut OFF the engine, remove the key, chock the
tires, terminate the inspection, tag the lift truck
"Do Not Operate" and immediately report the
Inspection from Operator's Seat, Engine failure of the parking brake to hold the lift truck.
ON
PARKING BRAKE SWITCH
1. With the parking brake engaged, the direction

control lever in NEUTRAL and the engine
running, shift the direction control lever to
FORWARD.
2. The lift truck should not move forward or feel

like it wants to move forward, even when the
engine is accelerated briefly.
3. Repeat this procedure in REVERSE. Report

truck movement or tendency to move under
power with the parking brake engaged.
-156-
Maintenance Section
First 50 - 100 Service Hours or a Week

Engine Oil & Filter (DB33A Diesel

Engine Only) - Change
DB33A Diesel Engine crankcase
engine oil recommendations. If the fuel has over
0.5% sulfur content, the CD engine oil must have a
TBN of 20 times the percentage of fuel sulfur (TBN
as measured by the ASTM D-2896 method). Your
oil supplier should be able to furnish the correct
oils.
Typical Example
1. Operate lift truck a few minutes to warm oil.
Park the lift truck with the forks lowered, parking 4. Raise the hood and seat assembly.
engine stopped. 5. Remove and discard oil filter element.
2. Raise rear of lift truck off ground and block 6. Wipe sealing surface of oil filter element
securely. mounting base. Make sure the entire old gasket
is removed.
WARNING 7. Before installing a new filter element, apply a
Hot oil and components can cause personal injury. small amount of clean engine oil to the filter
Do not allow hot oil or components to contact skin. element gasket.
8. Install the new filter element. When the gasket

contacts the base, tighten it 3/4 of a turn more.
Do not over-tighten.
9. Raise the lift truck, remove the blocking and

lower the lift truck.
Typical Example
3. Remove the crankcase drain plug and allow oil

to drain into a suitable container. Clean and
install drain plug.
Typical Example
10. Fill the crankcase. See “Refill Capacities”.
-157-
Maintenance Section
11. Start the engine and allow the oil to fill the filter Transmission Oil, Oil Filter &
and passages.
Strainer - Check, Clean, Change
12. Check for oil leaks.
WARNING
contact skin.
Park the lift truck level, with the forks lowered,

parking brake engaged, direction control lever in
NEUTRAL and the engine stopped.
13. Stop the engine and measure the oil level.

Maintain the oil level between the MAX and
MIN marks on dip stick.
NOTICE
Servicing of the engine oil and oil filter element
will largely affect the engine performance as 1. Remove drain plug (1). Allow the oil to drain
well as the engine life. into a suitable container. Clean the magnetic
Engine oil and filter element must be changed drain plug. Check O-ring seal and replace if
after the first 50 hours. necessary. Remove the spring and the strainer.
2. Wash the strainer assembly in clean,

nonflammable solvent and dry it. Install the
strainer assembly.
-158-
Maintenance Section
12. Maintain the oil level between the Min and Max
marks on the dip stick/filter cap.
the cold side mark on the dipstick is applicable.
the hot side mark on the dipstick is applicable.
13. Check for oil leaks at the filters and drain plug.
14. Stop the engine. Install the floor mat and floor
plate.
3. Remove the floor mat and the floor plate. Drive Axle Oil - Change
Remove and discard the oil filter.
Park the lift truck on a level surface. Apply the
4. Wipe off the filter base. Make certain that all of parking brake. Place the directional control lever in
the old seal is removed. NEUTRAL and stop the engine.
5. Apply a small amount of clean oil on the seal of

the new filter.
6. Install the filter by hand. When the filter

contacts the base, tighten an additional 3/4
turn.
1. Remove drain plug. Allow the oil to drain into a

suitable container. Clean the magnetic drain
plug. Check O - ring seal and replace if
necessary.
2. Install the drain plug.
7. Remove the dip stick/filter cap. Fill the 3. Remove the dip stick/filter cap.
compartment with oil. See “Refill Capacities”. Fill the drive axle housing with oil.
Install the dip stick/filter cap. See “Refill Capacities”.
8. Start the engine. 4. Start the lift truck.

With the engine at low idle, place the directional
9. With the service brake applied and engine at control lever to the NEUTRAL.
low idle, shift the direction control lever to
forward and reverse to fill the clutches. 5. Maintain the oil level between lower mark and
upper mark on the dip stick/filter cap.
10. Shift the direction control lever into NEUTRAL.
Engage the parking brake.

level.
-159-
Maintenance Section
6. Install the dip stick/filter cap. 4. Engage the parking brake and shift the
transmission to NEUTRAL. Slowly release the
NOTE: Tighten the dipstick plug fully not to allow service brakes.
foreign parts(rain, water etc) to enter into
drive axle. 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
Parking Brake - Test, Adjust truck on the grade.
Parking Brake Testing 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
NOTICE parking brake and reverse slowly down the
grade controlling your speed with the service
OSHA requires the parking brake to hold the lift
truck, with capacity load, on a 15% grade. brakes.
Testing requires a test load equal to the
capacity of the truck and a 15% grade. WARNING
If the maximum grade in the workplace is less
than its capacity, use the Parking Brake To prevent personal injury, the operator MUST
inspection procedure covered in ‘Inspection be ready to use the service brake if the parking
from Operator’s Seat, Engine On’ in “Every 10 brake is not adjusted correctly and the lift truck
Service Hours or Daily” section. starts to move.
1. Pick up capacity load and drive over to a 15%

grade. Parking Brake Adjusting
2. Drive forward up the 15% grade. Halfway up 1. Park the lift truck on a level surface, lowered
the grade, stop the lift truck with its service the forks, shift the transmission to NEUTRAL
brakes. and shut OFF the engine and block the wheels
securely.
3. Engage the parking brake and slowly release
the service brake. 2. Chock the lift truck's tires to prevent
unintentional movement.
-160-
Maintenance Section
3. Remove the floor mat and floor plate. 7. Loosen lock nut (5). Tighten screw (6) to 6 to 7
N•m (50 to 60 lb•in). Loosen the screw (6) 1 1/6
4. Make sure the parking brake lever is released. turns and tighten the lock nut (5).
NOTICE
Turn the adjustment screw (6) clockwise to
tighten. Turning the screw (6) too far
counterclockwise could allow parts to fall into
the bottom of the transmission.
The transmission would than require
disassembly to remove the parts.
8. Reinstall the floor plate and floor mat.
9. Engage the parking brake, remove the tire

chocks and test the parking brake. Refer to
5. Make sure the brake lever (1) is held against ‘Parking Brake Testing’ in the preceding
stop pin (2). If the brake lever (1) is held against section.
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).
-161-
Maintenance Section
First 250 Service Hours or a Month

Hydraulic Return Filter – Change Engine Valve Lash (B3.3 Diesel

Engine Only) - Check, Adjust
WARNING
injury. Do not allow hot oil or components to NOTICE
contact skin.
The valve clearances are to be adjusted at the
times of the following situations.
Park the lift truck level with the forks lowered, z When the engine is overhauled and the
parking brake engaged, transmission in NEUTRAL cylinder heads are disassembled.
and the engine stopped. z When severe noise comes from valve train.
z When the engine is not normally operated
1. Loosen the bolts of the hydraulic tank top plate even though there is no trouble in the fuel
assembly. system.
WARNING
To prevent possible injury when adjusting
diesel engines, do not use the starter motor to
turn the flywheel.
Hot engine components can cause burns. Allow

additional time for the engine to cool before
measuring valve clearance.
NOTICE
2. Remove the return filter from tank top plate Measure the valve lash with the engine stopped.
assembly. To obtain an accurate measurement, allow at
least 20 minutes to cool the engine cylinder
3. Change the return filter. head and block temperature.
4. Install the tank top plate assembly and fasten Set the clearance to the nominal appropriate
the bolts. clearance given in the “Valve Clearance Setting”
shown below.
5. Start the engine and operate the hydraulic
controls, and the steering system, through a Valve Clearances
few cycles to fill the lines. Look for oil leaks. Engine Valve Clearance
3.3 liter Exhaust Valves .50 mm (.020 in)
6. Stop the engine and check the oil level. With all (B3.3) Diesel Intake Valves .35 mm (.014 in)
cylinders retracted, maintain the oil level to the
FULL mark on the dip stick/filter cap assembly.
Refer to the “Service Manual” for the complete
valve adjustment procedure.
NOTE: In regards to G424 and G430 Engines,

valve adjustment is not necessary because
of automatic adjusting system.
-162-
Maintenance Section
Every 250 Service Hours or Monthly

Air Intake System - Check, Clean Service the air cleaner when the red target in the
service indicator stays locked in the visible position
Precleaner (If Equipped) with the engine stopped.
1. To service the air cleaner, raise the hood and

NOTICE seat assembly. Make certain the support
cylinder securely holds the hood open. Loosen
Never service precleaner with the engine the cover latches and remove the cover.
running.
2. Rotate the element slightly to separate it from

1. Check the precleaner bowl for dirt build-up. its base and remove it from the air cleaner
If the dirt is up to the line, remove the housing.
precleaner bowl and empty it. Periodically wash
the cover and bowl in water. 3. Clean and inspect the element or replace with a
new element. See topic, “Cleaning Primary
Servicing Filter Element Filter 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 air cleaner
housing.
5. Check the air cleaner housing for loose latches.
6. Reset the air cleaner service indicator.
7. Install the air filter element.
-163-
Maintenance Section
8. Install the cover and tighten the cover latches. Air-205 kPa (30 psi) Maximum Pressure
9. Start the engine and observe the position of the

indicator. If the indicator shows RED after the
installation of the primary element, install
another clean or a new element or, replace the
secondary element. See topic, “Air Intake
System-Change” in “Every 1000 Service Hours
or 6 months section
10. Stop the engine and close the hood and seat
assembly.
Cleaning Primary Filter Elements

Direct air on the inside and outside of the element
WARNING along the length of the pleats. Check the element
for any tears, rips or damage
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a Water-280kPa (40 psi) Maximum Pressure
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.
NOTICE
Do not clean the elements by bumping or
tapping them.
Inspect filter elements after cleaning. Do not
use a filter with damaged pleats, gaskets or
seals.
When cleaning with pressure air, use 205 kPa Direct water on the inside and outside of the
(30 psi) maximum pressure to prevent filter element along the length of the pleats. Air dry it
element damage.
thoroughly and then examine it.
When cleaning with pressure water, use 280
kPa (40 psi) maximum pressure to prevent filter Detergent
element damage.
1. Wash the element in warm water and mild
household detergent.
Have spare elements on hand to use while cleaning
used elements. 2. Rinse the element with clean water.
See instructions in preceding topic for cleaning
The primary element should be replaced after 6 with water.
months service or after cleaning no more than 3
times. 3. Air dry it thoroughly, and then examine it.
-164-
Maintenance Section
Checking Element Hydraulic Oil Level – Check

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

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

level to the FULL mark on the dip stick/filter
cap.
-165-
Maintenance Section
Drive Axle Oil Level - Check 5. Raise and lower the carriage a few times to
allow lubricant to enter into the chain links.
Park the lift truck on a level surface. Apply the
parking brake. The engine at low idle. Place the
directional control lever in NEUTRAL. NOTICE
Lubricate chains more frequently than normal in
applications where the lift truck is operating in an
atmosphere which could cause corrosion of
components or when lift truck must work in rapid lift
cycles.
6. Inspect the chain anchors and individual links

for wear, loose pins or cracked leaves.
Steering Mechanism - Check,

Lubricate
level.
2. Maintain the oil level between the lower mark

and upper marks on the dip stick/filter cap.
Mast, Carriage, Lift Chains &

Attachments - Inspect, Lubricate
1. Operate the lift, tilt and attachment controls.
Listen for unusual noises. These may indicate a
need for repair.
1. Lubricate the steer axle king pins, total of four
fittings. Two on the right side and two on the left
2. Inspect for loose bolts and nuts on the carriage.
side.
Remove any debris from the carriage and mast.
2. Lubricate the steering link bearings, total of four
3. Inspect the forks and attachments for free
fittings. Two on the right side and two on the left
operation and damage. Have repairs made if
side
necessary.
3. Check for any worn or loose components of the
steering mechanism. Remove any debris or
trash as
4. Brush a film of oil on all links of the chain.
-166-
Maintenance Section
Battery Terminal - Clean, Inspect Engine Oil & Filter (DB33A Diesel,
LP-Gas & Gasoline Engine Only) -
WARNING
Change
Batteries give off flammable fumes that can
explode. DB33A Diesel Engine Crankcase
Do not smoke when observing the battery See topic, “Engine Oil & Filter (DB33A Diesel
electrolyte levels. Engine Only)-Change” in “First 50-100 Service
Electrolyte is an acid and can cause personal Hours”
injury if it contacts skin or eyes.
Always wear protective glasses when working Gasoline, LP-Gas Engine Crankcase
with batteries. 1. Operate lift truck a few minutes to warm oil.
engine stopped.
2. Raise rear of lift truck off ground and block

securely.
WARNING
contact skin.
1. Clean the top of the battery and terminals.
2. Check terminals for corrosion. Coat terminals

with heavy grease.
3. Remove the crankcase drain plug and allow oil

install drain plug.
4. Raise the hood and seat assembly.
-167-
Maintenance Section
PCV Valve System - Inspect,

Clean
G424 Gasoline, LP-Gas and Dual Fuel
Engines
5. Remove and discard oil filter element.
6. Wipe sealing surface of oil filter element

mounting base. Make sure the entire old gasket
is removed.
7. Before installing a new filter element, apply a

small amount of clean engine oil to the filter G430 LP-Gas Engines
element gasket.


11. Start the engine and allow the oil to fill the filter
and passages.
12. Check for oil leaks. 1. Loosen the hose clamps and remove the PCV
valve.
2. Shake the PCV valve. If it rattles, reinstall it. If it

does not rattle, replace it.
3. Tighten the hose clamps

Maintain the oil level to the FULL mark on the
dip stick.
14. Close hood and seat assembly
-168-
Maintenance Section
Wheel Bolts & Nuts - Inspect

Inspect Tightness (D, G - Series) Inspect Tightness (GC - Series)
Steer Wheels Drive Wheels
Typical Example Typical Example
1. Inspect tightness of wheel bolts in a sequence 1. Inspect tightness of wheel bolts in a sequence
opposite each other 110 N•m (75 lb•ft). opposite each other to 245 N•m (180 lb•ft).
Drive Wheels
Typical Example
2. Inspect tightness of wheel nuts in a sequence

opposite each other to 610 N•m (450 lb•ft).
-169-
Maintenance Section

Belts - Check, Adjust Mast Hinge Pin – Lubricate
Typical Example Typical Example
1. Check the condition and adjustment of the belt. 1. Lower the forks and tilt the mast forward.
Correct adjustment allows 10 mm (3/8 inch)
deflection under 110 N (25 lb) of force. 2. Lubricate the two fittings for the mast hinge pins,
one on each side of the mast.
Tilt Cylinders - Check, Adjust,

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

and wear.
-170-
Maintenance Section
Mast Pivot Eyes-Lubricate
Typical Example
Typical Example 3. To adjust the cylinder rod extension, move the

spacer to the rear and loosen the pinch bolt on
1. Lubricate two fittings for the mast pivot eyes, the clevis.
one on each side of the pin.
4. Turn the cylinder rod in or out of the clevis to
2. Check the pivot eye pins for loose retainer bolts obtain the proper adjustment. Turning the rod
and wear. into the clevis shortens the stroke. Turning the
rod out of the clevis lengthens the stroke.
Cylinder Rod Extension-Adjust 5. Tighten the pinch bolts to a torque of 95±15

NOTE: The following description is for forward tilt. Name (70 ± 10 abaft). Check the cylinder rods
For cylinder rod back tilt, the collar should again for even travel.
be stationary by the tilt eye. If it is not, the
O-ring inside the collar may need to be
replaced. To adjust back tilt, spacers must Crosshead Rollers - Inspect
be added or removed.
Check Operation
1. Operate the mast through a lift cycle. Watch the
chains move over the crosshead rollers. Make
sure the chain is tracking over the rollers
properly.
Typical Example
1. Check to make sure the tilt cylinders extend

and retract evenly.
2. If one cylinder continues to move after the other Typical Example

cylinder has stopped in full forward or backward
tilt, an adjustment must be made to one 2. Check for damaged crosshead rollers, guards
cylinder. and retainer rings.
-171-
Maintenance Section
Transmission Oil Filter – Change 9. Maintain the oil level between the Min and Max
marks on the dip stick/filter cap. When the oil
temperature is 40°C approximately, the cold
WARNING
side mark on the dipstick is applicable. When
Hot oil and components can cause personal the oil temperature is 80°C approximately, the
injury. Do not allow hot oil or components to hot side mark on the dipstick is applicable.
contact skin.
10. Check for oil leaks at the filters.
parking brake engaged, direction control lever in 11. Stop the engine. Install the floor mat and floor
NEUTRAL and the engine stopped. plate.
Overhead Guard – Inspect
1. Remove the floor mat and the floor plate.

Remove and discard the oil filter.
2. Wipe off the filter base. Make certain that all of 1. Check tightness of overhead guard mounting
the old seal is removed. bolts at 95 N•m (70 lb•ft).
3. Apply a small amount of clean oil on the seal of 2. Check overhead guard for bent or cracked
the new filter. sections. Have repairs made if needed.
4. Install the filter by hand. When the filter

contacts the base, tighten an additional 3/4 Drive Axle Oil & Strainer - Change,
turn.
Clean
5. Start the engine.
6. With the service brake applied and engine at

low idle, shift the direction control lever to
forward and reverse to fill the clutches.
7. Shift the direction control lever into NEUTRAL.

Engage the parking brake.

level.

parking brake engaged, transmission in NEUTRAL
and engine stopped.
-172-
Maintenance Section
1. Remove drain plug. Allow the oil to drain into a Steer Suspension – Inspect
suitable container. Clean the magnetic drain
plug. Check O - ring seal and replace if
necessary.
2. Install the drain plug.
1. Inspect the suspension mounting bolts. Tighten

suspension mounting bolts, if necessary, to 240
± 30 N•m (180 ± 20 lb•ft).
3. Wash the strainer assembly in clean, non

flammable solvent and dry it. Install the strainer
assembly and reconnect the hose.
4. Remove the dip stick/filter cap. Fill the drive

axle housing with oil.
See “Refill Capacities.”
5. Start the lift truck with engine at low idle, place

the directional control lever to the NEUTRAL.
6. Maintain the oil level between lower mark and

upper mark on the dip stick/filter cap. 2. Look for leaks at the power steering hose
connections.
3. Remove any trash buildup on the suspension or

the steer axle.
Parking Brake - Test, Adjust

See topic, “Parking Brake - Test, Adjust” in “First
50-100 Service Hours or a Week”.
7. Install the dip stick/filter cap.
-173-
Maintenance Section
Inching & Braking Control Shaft - Engine Oil & Filter (B3.3 Diesel
Lubricate Engine Only) - Change
B3.3 Diesel Engine crankcase
engine oil recommendations. If the fuel has over
0.5% sulfur content, the CD engine oil must have a
TBN of 20 times the percentage of fuel sulfur (TBN
as measured by the ASTM D-2896 method). Your
oil supplier should be able to furnish the correct
oils.
1. Operate lift truck a few minutes to warm oil.

engine stopped.
1. Lubricate two fittings for the inching and brake
pedal control shaft. 2. Raise rear of lift truck off ground and block
securely.
Horn and Lights (If Equipped) - WARNING

Check
contact skin.
1. Press horn button, to determine if horn is

operational.
2. Check and replace all defective gauges. 3. Remove the crankcase drain plug and allow oil
3. Check all lights such as warning, directional, install drain plug.
backup, driving and flood lights for correct
operation. Replace all burned out bulbs.
Have repairs made if needed.
-174-
Maintenance Section
Typical Example
4. Raise the hood and seat assembly. Maintain the oil level between the MAX. and
MIN marks on dip stick.
5. Remove and discard oil filter element.
6. Wipe sealing surface of oil filter element
mounting base. Make sure the entire old gasket
is removed. NOTICE
Servicing of the engine oil and oil filter element
7. Before installing a new filter element, apply a will largely affect the engine performance as
small amount of clean engine oil to the filter well as the engine life.
element gasket. Engine oil and filter element must be changed
after the first 50 hours.

Typical Example
11. Start the engine and allow the oil to fill the filter
and passages.
12. Check for oil leaks.
-175-
Maintenance Section
Fuel Strainer (B3.3 Diesel Engine

Only) – Clean
At every Engine oil exchange, clean the strainer of
fuel feed pump.
3. Soak the mesh strainer in diesel oil and wipe

the outside with a non-metallic brush.
4. Soak the mesh strainer again in new diesel oil

and take it out.
Fuel passes through fuel strainer from fuel tank to 5. Blowing the compressed air inside the mesh
fuel filter. strainer.
The first filtering device uses the mesh strainer and 6. Repeat items 3 through 5, 4-5 times.
the second one uses the paper element.
7. Assemble in the reverse order of disassembly.
Periodically the mesh strainer must be cleaned and

the paper element must be replaced.
Disassembly and cleaning of fuel filter.

1. Loosen the bolts and separate the mesh
strainer.
2. Pull out the mesh strainer.
-176-
Maintenance Section
Inspect Vacuum Lines and Inspect Electrical System

Fittings (G424E/G430 Engine (G424E/G430E Engine Only)
Only)
1. Check for loose, dirty or damaged connectors
1. Visually inspect vacuum lines and fittings for and wires on the harness including: Fuel
physical damage such as bittleness, cracks and lock-off, TMAP sensor, O2 sensor, Electronic
kinks. Repair/replace as required. throttle, Control Relays, Fuel Trim Valve, Foot
Pedal, and Distributor sensor.
2. Slovent or oil damage may cause vacuum lines
to become soft resulting in a collapsed line 2. Repair and/or replace as necessary.
while the engine is running.
3. If abnormally soft lines are detected, replace as Inspect VR Sensor – Clean

necessary. (G424E engine only)
1. Steer the tires fully so that VR sensor around

2
engine crankshaft pulley can be seen.
2. Stop engine and disconnect battry cables.
3. Inspect VR sensor and tooth wheel. If they are

soiled, clean them with air.
1
1
(1) Fuel Trim Valve(FTV)
(2) Vacuum lines
2
Fuel Trim Valve(FTV) Inspection
(G424E/G430E Engine Only)
1. Visually inspect the Fuel trim valve for
abrasions or cracking. Replace as necessary.
(1) VR sensor
2. To ensure the valve is not leaking a blow-by (2) Tooth Wheel
test can be performed.
3. With the engine off, disconnect the electrical

connector to the FTV.
4. Disconnect the vacuum lines form the FTV to

the pressure regulator/converter, at the
converter’s tee connection.
5. Lightly blow through the vacuum line connected

to the FTV. Air should not pass through the FTV
when de-energized. If air leaks past the FTV
when de-energized replace replace the FTV.
-177-
Maintenance Section
Fuel Filter (B3.3 Diesel Engine

Only) - Change
Diesel Engine
B3.3 Diesel Engine
1. Remove fuel filter cartridge assembly.
2. Remove sensor assembly from cartridge

assembly.
3. Before installing a new cartridge assembly,

assemble existing sensor assembly and apply a
small amount of clean fuel to the filter cartridge
gasket.
NOTICE
Do not fill fuel filters with fuel before installing
them. Contaminated fuel will cause accelerated
wear to fuel system parts.
4. Install the new fuel filter cartridge assembly.
5. Turn the new fuel filter cartridge assembly until

the filter gasket is fitted against the sealing
face.
6. Turn the fuel filter cartridge assembly an

additional 2/3 of turn.
-178-
Maintenance Section

Hydraulic Return Filter, Breather

& Strainer - Check, Change
WARNING
contact skin.
Park the lift truck level with the forks lowered,

and the engine stopped.
Typical Example
7. Remove and discard the air breather.
8. Install a new air breather.

controls, and the steering system, through a
few cycles to fill the lines. Look for oil leaks.
10. Stop the engine and check the oil level. With all
FULL mark on the dipstick/filter cap assembly.
1. Loosen the bolts of the hydraulic tank top plate

assembly.
2. Remove the return filter from tank top plate

assembly.
3. Install new return filter by hand.
4. Remove the suction strainer from the tank.
5. Install the new strainer by hand.
6. Install the tank top plate assembly and fasten

the bolts.
-179-
Maintenance Section
Transmission Oil, Oil Filter & Check for Equal Tension

Strainer - Check, Clean, Change
See topic, “Transmission Oil, Oil Filter & Strainer-
Check, Clean, Change” in “First 50 - 100 Service
Hours”
Lift Chains - Test, Check, Adjust

Lift Chain Wear Test
Inspect the part of the chain that is normally
operated over the cross head roller. When the
Typical example
chain bends over the roller, the movement of the
parts against each other causes wears.
Inspect to be sure that chain link pins do not extend Lift the carriage and the mast high enough for
outside of the link hole. If any single link pin is getting tension on lift chains. Check the chains, and
extended beyond its connecting corresponding link, make sure the tension is the same. Lift chains are
it should be suspected of being broken inside of its required to check for equal tension about every
link hole. Lift chains are required to check for wear 1,000 service hours or 6 months.
about every 1,000 service hours or 6 months.
WARNING
Chain wear test is a measurement of wear of the
chain links and pins. Take the following steps to Personal injury can be caused by sudden
movement of the mast and carriage. Keep
check chain wear. hands and feet clear of any parts that can move.
1. Lift the mast and carriage enough for getting
tension on lift chains.
Lift Chain Adjustment
Typical example
2. Measure precisely ten links of chain distance at Typical example for carriage equal tension
the center of pins in millimeter.
If the tension is not the same on both chains, take
3. Calculate chain wear rate*. the procedure as follows.
4. If the chain wears rate is 2% or more, replace NOTE: If carriage height is not correct, make
the lift chain. adjustments by following procedures.
*Chain wear rate (%)
= Actual measurement - Pitch** X 10 X 100

Pitch** X 10
**Chain Pitch = 19.05mm (0.75in)
-180-
Maintenance Section
Carriage Chain Adjustment Mast Chain Adjustment - FF, FFT Mast

Make sure that carriage height is correct. If correct,
adjust the chain for equal tension. If not, adjust the
chain for correct carriage height by adjusting
anchor nuts (1), (2).
NOTE: See the previous section, “Carriage Roller

Extrusion” in “When Required” for proper
height of carriage.
1. Fully lower the carriage and tilt mast forward or

lift the carriage and put blocks under the carriage
to release the tension from the lift chains.
Typical example for FF mast
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 FFT mast
Make sure that mast height is correct. If correct,

Typical example for carriage chain of STD mast adjust chain for equal tension. If not, adjust mast
chain for correct mast height by adjusting anchor
nuts (3), (4).
NOTE: See the previous section, “Carriage Roller

Extrusion” in “When Required” for proper
inner mast height.
1. Lift the inner mast and put blocks under the inner
mast to release the tension from the lift chains.
Typical example for carriage chain of FF, FFT mast
3. Make adjustment anchor nut (1), (2) for equal

chain tension.
4. Set the mast vertical and raise the carriage and

check equal chain tension. If not equal, repeat
the same procedure as step 1 through step 3.
5. Put LOCTITE No. 242 Tread lock on the threads

of the anchor nuts (1), (2) after the adjustment is
completed.
-181-
Maintenance Section
2. Loosen nut (3) and adjust nut (4) to make inner Universal Joint – Inspect
mast rail flush with outer mast rail bottom.
3. Make adjustment anchor nuts (3), (4) for equal

chain tension.
4. Raise the inner mast and check equal chain

tension. If not equal, repeat the same procedure
as step 1 through step 3.
5. Put LOCTITE No. 242 tread lock on the threads

of the anchor nuts (3), (4) after the adjustment is
completed.
Check for worn or damaged bearings. Have worn

or damaged bearings replaced. Check for loose
retaining bolts and nuts. Tighten the bolts and nuts,
if necessary.
Carburetor (LP-Gas, Gasoline &

Dual Fuel Engine Only) - Adjust,
Clean
G424 Engine: Gasoline, LP - Gas, Dual
Fuel
G430 Engine: LP - Gas
If the engine is hard to start or the exhaust is
smoking, he carburetor may need cleaning and
adjusting.
Before adjusting the carburetor, make sure the

engine is at normal operating temperature. Park the
lift truck with the forks lowered, parking brake
applied, transmission in neutral and the engine
stopped.
Inspect and Iubricate throttle cable linkage every

500service hours.
For the complete procedure and specifications for

your specific engine, see the “Service Manual”.
-182-
Maintenance Section
Air Intake System - Change Inspect Coolant Hoses

Changing Primary Element (LP Engine Only)
See topic, “Air Intake System - Check, Clean” in 1. Visually inspect coolant hoses and clamps.
“Every 250 Service Hours or Monthly” Remember to check the two coolant lines that
Changing Secondary Element
2. Replace any hoses that shows signs of swelling,
1. Remove the primary air cleaner element. See cracking, abrasion or deterioration.
topic “Servicing Filter Element.” Clean the
inside of the air cleaner housing and cover.
2
1
(1) LP Regulator/Converter
(2) Coolant hoses
2. Remove the secondary element. Inspect the
gasket between the air cleaner housing and the
engine inlet. Replace the gasket if it is LP Regulator/Converter
damaged.
Inspection (LP Engine Only)
NOTICE
1. Visually inspect the pressure
Always replace the secondary element. Do not regulator/converter housing for coolant leaks.
attempt to reuse it by cleaning. Refer to the pressure regulator/converter
section of the service manual if maintenance is
3. Install a new secondary element. Install a new required.
or cleaned primary element. Install the cover.
Tighten the latches. NOTE: For pressure testing and internal inspection
of the pressure regulator/converter, refer to
4. Start the engine and observe the air cleaner the pressure regulator/converter section of
service indicator. If the indicator shows RED the service manual.
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.
-183-
Maintenance Section
Fuel Lines & Fittings - Check Fuel Filter (DB33A Diesel Engine
Visually inspect fuel lines and fittings for physical Only) - Change
damage. Replace as required.
Diesel Engine
DB33A Diesel Engine

(1) Fuel lines
(2) LP mixer 1. Remove fuel filter cartridge assembly.
(3) Throttle Assembly
2. Remove sensor assembly from cartridge
assembly.
Inspect Mixer Assembly
(G424E/G430E Engine Only) 3. Before installing a new cartridge assembly,
assemble existing sensor assembly and apply a
Refer to the LP mixer section of the engine service small amount of clean fuel to the filter cartridge
manual for procedures. gasket.
NOTICE
Inspect Throttle Assembly
(G424E/G430E Engine Only) Do not fill fuel filters with fuel before installing
them. Contaminated fuel will cause accelerated
wear to fuel system parts.
1. Visually inspect the throttle assembly motor
housing for coking, cracks and missing 4. Install the new fuel filter cartridge assembly.
cover-retaining clips. Repair and/or replace as
necessary. 5. Turn the new fuel filter cartridge assembly until
the filter gasket is fitted against the sealing
NOTE: Refer to the LP mixer and throttle section of face.
the service manual for procedures on
removing the mixer and inspecting the 6. Turn the fuel filter cartridge assembly an
throttle plate. additional 2/3 of turn.
-184-
Maintenance Section
Inspect Ignition System (LP-Gas, Replace Spark Plugs (LP-Gas,

Gasoline & Dual Fuel Engines Gasoline & Dual Fuel Engines
Only) Only)
1. Disconnect Battery Cables. 1. Disconnect Battery Cables.
2. Remove and inspect the spark plugs. Replace 2. Using a gentle twisting motion remove the high
as required. voltage cables from the spark plugs. Replace
any damaged cables.
3. Test secondary cables with an Ohmmeter.If
maximum resistance is higher than 25 kOhms, 3. Remove the spark plugs.
4. Gap the new spark plugs to the proper
4. Remove distributor cap and perform visual specifications.
inspection. Replace cap and rotor if corrosion is G424(E) Engine : 0.7 - 0.8 mm
found on the contacts. G430(E) Engine : 0.9 mm
5. Inspect the ignition coil for cracks and heat
deterioration. Visually inspect the coil heat sink 5. Apply anti-seize compound to the spark plug
fins. If any fins are broken replace as required. threads and install.
G424(E) Engine : 25 N•m (18 lb•ft)
G430(E) Engine : 30 N•m (22 lb•ft)
G424(E) Engine
CAUTION
DO NOT OVERTIGHTEN THE SPARK PLUGS.
6. Re-install the high voltage cables.
G430(E) Engine
(1) Spark Plug Cables

(2) Distributor Cap
-185-
Maintenance Section
Replace Gasoline Primary Fuel G430E Dual Fuel

Filter(G424E/G430E Dual Fuel Only)
Park the lift truck in an authorized refueling area

with the forks lowered, parking brake applied and
the transmission in Neutral.
1. Place the fuel select switch in the Gasoline

position. Remove the fuse for the electric fuel
pump.
1
2. Start and run the engine until the fuel in the 2
system runs out of fuel and the engine stops. 3
Turn off the ignition switch.
3. Replace the fuel filter taking care to install the (1) Primary fuel filter. (2) Fuel pump. (3) Secondary fuel filter.
new filter with flow in the proper direction.
When replacing the Primary fuel filter use a
hose clamp between the tank and the filter to Inspect the Fuel Pump Insulated
prevent fuel from spilling during replacement. Mounting Clamps(G424E/G430E
4. Re-install the fuse for the pump and crank the Dual Fuel Only)
engine several times before attempting a start
to prime the fuel pump.
1. Check the rubber insulation on the electric fuel
pump mounting clamps.
NOTE: Replacement interval of Secondary fuel
filter is 2,500 hrs or 15 months
2. If the housing of the pump makes contact with
the engine chassis a ground path can be
G424E Dual Fuel created causing the pump to run anytime the
ignition key is in the ON position and the fuel
select switch is in GAS position.
3. If the clamp insulation is damaged replace the

clamp with a new insulated clamp.
1
WARNING
When assembling the filters, check the arrow
mark on the filter surface.
The arrow mark position is same as fuel flow
2 direction.
.(1) Primary fuel filter. (2) Fuel pump. (3) Secondary fuel filter.
-186-
Maintenance Section
Replace LP Fuel Filter Element 3. Check bottom cover O-ring seal (6) for damage.
Replace if necessary.
(LP-Gas, Dual Fuel Engine Only)
4. Re-assemble the filter assembly aligning the
Park the lift truck in an authorized refueling area scribe lines on the top and bottom covers.
the transmission in Neutral. 5. Install the cover retaining screws, tightening the
screws in an opposite sequence across the
1. Close the fuel shutoff valve on the LP-Fuel tank. cover.
out and the engine stops. 6. Open the fuel valve by slowly turning the valve
counterclockwise.
7. Crank the engine several revolutions to open
3. Scribe a line across the filter housing covers, the fuel lock-off. DO NOT START THE ENGINE.
which will be used for alignment purposes when Turn the ignition key switch to the off position.
re-installing the filter cover.
8. Check the filter housing, fuel lines and fittings
for leaks. Repair as necessary.
1
Filter
Housing Testing Fuel Lock-off Operation
Scribe (LP-Gas Engine Only)
Point
1. Start engine.
2. Locate the electrical connector for the fuel lock
3. Disconnect the electrical connector.

(1) screws
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
Fuel Filter (LP - Gas Engine Only)
NOTE: The length of time the engine runs on
Disassembly trapped fuel vapor increases with any
2 regulator/converter.
4
1
5 1
3
3
6
2
7
1. Remove top cover (2), magnet (3), spring (4),

and filter element (7) from bottom cover (5).
2. Replace the filter element (7). (1) LP fuel lock-off

(2) Regulator/Converter
(3) Fuel Trim valve (FTV)
-187-
Maintenance Section
Every 2000 Service Hours or Yearly

Fuel Filter (G424 Gasoline & Dual Engine Valve Lash (B3.3 Diesel
Fuel Engine Only) - Change Engine Only) – Check, Adjust
NOTE: Engine must be stopped and cool. See topic “Engine valve Lash (B3.3 Engine Only) –
Check, Adjust”. In First 250 Service hours.
with the forks lowered, parking brake applied,
transmission in NEUTRAL and the engine stopped.
WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
Turn the disconnect switch OFF if fitted or
disconnect the battery when changing fuel
filters
1. Raise the hood and seat assembly.
2. Loosen Bolt (1) and clamps (2), (3).
3. Replace old fuel filter with new filter.
4. Fasten Bolt (1) and clamps (2), (3).
-188-
Maintenance Section
Steer Wheel Bearings - 3. Straighten the lock washer tangs.

Reassemble
NOTE: The procedure is shown on a GC-Series lift

truck. It is the same for D, G-Series lift
trucks.
4. Remove the locknut, lock washer and flat

washer.
Remove the outer wheel bearing.
Typical Example
1. Lift the steer wheels off the ground. Place

stands or blocking under the frame and steer
axle to support the lift truck.
Typical Example
2. Remove the hub cap which is pressed into the

wheel hub.
5. Remove the wheel assembly. Examine the seal
for damage and wear. Replace the seal if
necessary.
6. Remove the inner bearing. Clean and lubricate

the steering knuckle. Reassemble both the
inner and outer bearing cones.
7. Install the inner bearing. Lubricate the seal and

install the wheel assembly on the knuckle.
-189-
Maintenance Section
8. Install the outer wheel bearing and the out

washer. Install a new lock washer and fit the
locknut.
Typical Example
9. Tighten the locknut to 135 N•m (100 lb•ft), while

turning wheel hub to seat the bearing.
10. Loosen the locknut. Retorque it to 50 ± 5N•m

(37 ± 4 lb•ft). Bend the lock washer tang to
secure locknut.
11. Install the hub cap.
12. Raise the lift truck and remove the blocking.

Lower the lift truck to the ground.
-190-
Maintenance Section
Drive Wheel Bearing (Power Shaft GC-Series Lift Trucks.

and Drive Wheel) – Reassemble
Torque for wheel bolts (1) is 270 ± 25 N•m (200 ±

20 lb•ft).
Consult your DAEWOO lift truck dealer for the
proper wheel bearing reassembling procedure. Tighten wheel bearing nut (2) 135 N•m (100 lb•ft)
Packing of bearings and adjustment procedure while the wheel is turned in both directions. Loosen
must be made by a trained mechanic or dealer the nut completely and tighten nut again to 50 ±5
personnel. N•m (37 ± 4 lb•ft). Bend the lock washer tab into a
groove of the nut.
Pack power shaft bearings (1) and spindle bearings
(2). Pack ring gear (3) to the depth of the teeth. Torque for bolts (3) that hold cover to drive axle
housing is 55 ± 10 N•m (40 ± 7 lb•ft).
D, G-Series Lift Trucks
Apply Loctite No. 242 to threads of spindle bolts (4).
Torque for spindle bolts is 115 ± 14 N•m (85 ± 10
lb•ft).
Torque for single or dual wheel mounting nuts (1) is

644 ± 34 N•m (470 ± 25 lb•ft).
Torque for adapter assembly bolts (2) is 285 ± 13

N•m (210 ± 10 lb•ft).
Tighten wheel bearing nut (3) to 135 N•m (100 lb•ft)

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

housing is 55 ± 10 N•m (40 ± 7 lb•ft).
Apply Loctite No.242 to threads of spindle bolts

(5).Torque for spindle bolts is 115 ± 14 N•m (85 ±
10 lb•ft).
-191-
Maintenance Section
Cooling System - Clean, Change

WARNING
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine
has been stopped and the filter cap is cool
enough to touch with your bare hand.
Remove the filter cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Typical Example
Avoid contact with the skin and eyes to prevent
personal injury. 3. Open radiator drain valve. Allow the coolant to
Use all cleaning solutions with care. drain into a suitable container.
Drain the recovery bottle.
4. Close radiator drain valve and install block drain

plug. Fill the cooling system with 1 kilo (2 lb)
sodium bisulphate per 40 liters (10 gallons) of
water. Most commercial cooling system
cleaners can be used.
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.
The lift truck must be level, the forks lowered, the
parking brake engaged, the transmission in 8. Close the drain valve and install the block drain
NEUTRAL and the engine stopped and cool. plug. Fill the system with neutralizing solution,
250 g (1/2 lb) sodium carbonate per 40 liters
1. Turn the radiator cap slowly to relieve the (10 gallons) of water.
pressure, and then remove the cap.
9. Start and run the engine for 10 minutes.
10. Stop the engine and drain the neutralizing

solution into a suitable container.
11. Flush the system with clean water until draining

water is clear.
12. Close the drain valve and install the block drain
plug. Add coolant to the top of the filter neck.
13. Start and run the engine to stabilize the coolant

level. See topic, “Coolant Level - Check” in
“Every 10 Service hours or Daily”.
Typical Example
2. Remove the block drain plug.
-192-
Maintenance Section
Forks – Inspect
3. Check the straightness of the upper face of

Forks should be inspected, at a minimum, every 12 blade (D) and the front face of shank (E) with a
months. If the truck is being used in a multi-shift or straight edge.
heavy duty operation, they should be checked
every six months. The fork should be withdrawn from service if the
deviation from straightness exceeds 0.5 percent
1. Inspect the forks carefully for cracks. Special of the length of the blade and/or the height of
attention should be given to the heel section (A), the shank respectively 5 mm/1000 mm
all weld areas and mounting brackets (B). (0.18"/36").
Inspect the top and bottom hooks on forks used
on hook type carriages and tubes on shaft
mounted forks.
Forks with cracks should be removed from

service.
"Wet Test" magnetic particle inspection is

generally preferred due to its sensitivity and the
ease of interpreting the results. Portable
equipment is usually recommended so it can be
moved to the lift truck.
Inspectors should be trained and qualified in

accordance with The American Society for Non 4. Check the difference in height of one fork tip to
Destructive Testing, Level II Qualifications. the other when mounted on the fork carrier. A
difference in fork tip height can result in uneven
support of the load and cause problems with
entering loads.
The maximum recommended difference in fork

tip elevation (F) is 6.5 mm (0.25") for pallet
forks and 3 mm (0.125") for fully tapered forks.
The maximum allowable difference in fork tip
elevation between the two or more forks is 3
percent of blade length (L).
Replace one or both forks when the difference
in fork tip height exceeds the maximum
allowable difference. Contact your local
DAEWOO Lift Truck Dealer for further
2. Check the angle between the upper face of the information.
blade and the front face of the shank. The fork
should be withdrawn from service if angle (C)
exceeds 93 degrees or deviates by more than 3
degrees from an original angle other than 90
degrees, as may be found in some special
application forks.
-193-
Maintenance Section
When adjusting the fork spacing, the forks are

prevented from sliding off the end of the carriage by
stop blocks. These stop blocks are at both ends of
the carriage and in the path of the bottom fork hook.
The load backrest extension may be used in place
of the stop blocks in some cases.
Shaft mounted forks may use set collars or spacers

on the shaft to either side of the fork. They may
also use U bolts, pins, or similar devices which
engage the fork through the top structure of the
carriage.
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)
6. Check the fork mountings (K) for wear, crushing for Full Tapered and Polished (FTP) forks,
and other local deformation, which can cause all other forks 6.4 mm (.25 in), for their
excessive side to side wobble of the forks. complete length.
Excessive clearance on hook type forks may
allow them to fall from the carrier. Forks which c. Put one fork, one third from the tip, under a
show visible signs of such damage should be fixture that will not move. Then operate the
removed from service. tilt control with caution until the rear of the
truck lifts just off the floor. Follow the same
7. Check the positioning lock and other fork procedure with the second fork. Repeat Step
retention devices to make sure they are in place a.
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.
-194-
Maintenance Section

Hydraulic Oil - Check, Clean, Inspect Battery System

Change 1. Clean battery outer surfaces with a mixture of
baking soda and water.
WARNING
2. Inspect battery outer surfaces for damage and
injury. Do not allow hot oil or components to replace as necessary.
contact skin.
3. Remove battery cable and clean, repair and/or
1. Remove the hydraulic tank drain plug. Allow the

oil to drain into a suitable container. Clean and
install the plug.
2. Remove the dipstick/filter cap assembly.
3. Fill the hydraulic tank. See topic “Refill

Capacities”. Install the dipstick/filter cap
assembly.

controls, and the steering system, through a
few cycles to fill the lines. Look for oil leaks.
5. Stop the engine and check the oil level. With all
FULL mark on the dipstick/filter cap assembly.
-195-
Maintenance Section
Replace Gasoline Secondary Fuel G430E Dual Fuel

Filter(G424E/G430E Dual Fuel
Only)

the transmission in Neutral.
1. Place the fuel select switch in the Gasoline

position. Remove the fuse for the electric fuel
pump. 1
2
2. Start and run the engine until the fuel in the 3
system runs out of fuel and the engine stops.
Turn off the ignition switch.
(1) Primary fuel filter. (2) Fuel pump. (3) Secondary fuel filter.
3. Replace the fuel filter taking care to install the
new filter with flow in the proper direction.
WARNING
4. Re-install the fuse for the pump and crank the
engine several times before attempting a start When assembling the filters, check the arrow
to prime the fuel pump. mark on the filter surface.
The arrow mark position is same as fuel flow
G424E Dual Fuel direction.
.(1) Primary fuel filter. (2) Fuel pump. (3) Secondary fuel filter.
-196-
Maintenance Section
Checking the TMAP Sensor Inspect for Intake Leaks

(G424E/G430E Engine Only) (G424E/G430E Engine Only)
1. Verify that the TMAP sensor (F) is mounted 1. Visually inspect the intake manifold, throttle
tightly into the manifold adapter (E), with no assembly (2), and manifold adapters (3), for
leakage. looseness and leaks. Repair as necessary.
2. If the TMAP is found to be loose, remove the

TMAP retaining screw and the TMAP sensor Replace PCV Valve and breather
element - Change (LP-Gas,
3. Visually inspect the TMAP O-ring seal for Gasoline and Dual Fuel Engines)
G424 Engine
4. Apply a thin coat of an approved silicon
lubricant to the TMAP o-ring seal.
5. Re-install the TMAP sensor into the manifold

adapter and securely tighten the retaining
screw.
1
2
G430 Engine
3
(1) TMAP sensor

(2) Throttle Assembly
(3) Manifold Adapter
1. Loosen the hose clamps and remove the PCV

valve.
2. Assemble new PCV valve and hose.
3. Tighten the hose clamps
-197-
Maintenance Section

Timing Belt [G424(E) LP-Gas,

Gasoline Dual Fuel Engine Only]
- Change
See the “Service manual” for the procedure and
specification.
Timing Belt for Counterbalance

Shaft [G424(E) LP-Gas, Gasoline
& Dual Fuel Engine Only]
- Change
See the “Service manual” for the procedure and
specification.
-198-
Maintenance Section
Every 4500 Service Hours or two Years
Replace Oxygen Sensor

(G424E/G430E Engine Only)
G424E Engine
G430E Engine
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

5. Connect the electrical connector of oxygen

sensor
-199-
Index Section
Checking the TMAP Sensor (G424E/G430E Engine

Index Only) .................................................................. 197
Circuit Breaker............................................. 68, 144
# Cleaning Primary Filter Elements...................... 164
12 Months Inspection......................................... 127 Coolant Information ........................................... 131
2.4 Liter Gasoline Engine(G424) ......................... 78 Coolant Level – Check ...................................... 152
Coolant Water.................................................... 132
Cooling System - Clean, Change ...................... 192
A Cooling System Specifications .......................... 131
Accelerator Pedal ................................................ 70 Crosshead Rollers - Inspect .............................. 171
Adjustments ....................................................... 112 Crushing or Cutting Prevention ........................... 14
Advanced Diagnostics ....................................... 104 Cylinder Rod Extension-Adjust.......................... 171
After Starting the Engine...................................... 85
Air Cleaner Indicator-Check .............................. 153 D
Air Intake System - Change............................... 183
Air Intake System - Check, Clean...................... 163 D, G-Series Lift Trucks ...................................... 191
Antifreeze........................................................... 132 Daily Inspection ................................................. 126
Attachment Abbreviations .................................... 63 DB33A Diesel Engine crankcase............... 157, 167
Auto Shift Controller ASC-100 (If Equipped) ..... 112 Diagnostics Features..........................................113
Automatic mode (Direction Inhibit mode) .......... 113 Diesel............................................................. 65, 85
Avoiding Lift Truck Tipover................................... 21 Diesel Engine ...................................... 79, 178, 184
Diesel Engines................................................... 152
Diesel Specifications.......................................... 133
B Difficult to Start..................................................... 92
B3.3 Diesel Engine crankcase........................... 174 Difficult to Start (Gas) .......................................... 99
Basic Troubleshooting (Gasoline)........................ 98 Direction Control Lever........................................ 69
Basic Troubleshooting(LPG)................................ 91 Direction Inhibit Point..........................................112
Battery Terminal - Clean, Inspect ...................... 167 Disassembly ...................................................... 187
Before Operating the Lift Truck............................ 12 Display for Operator ...........................................113
Before Starting the Engine................................... 75 Display for Troubleshooting ................................113
Before Starting the Lift Truck ............................... 11 Displaying Fault Codes (DFC) From SECM Memory
Before Storage................................................... 121 ........................................................................... 105
Belts - Check, Adjust.......................................... 170 Draining the Water from the Fuel Filter ............. 148
Bent or Twisted Forks ........................................ 125 Drive Axle Oil ..................................................... 136
Bleeding the Fuel System.................................. 147 Drive Axle Oil - Change ..................................... 159
Bulbs.................................................................. 144 Drive Axle Oil & Strainer - Change, Clean......... 172
Burn Prevention ................................................... 15 Drive Axle Oil Level - Check .............................. 166
Drive Wheel Bearing (Power Shaft and Drive Wheel)
C – Reassemble.................................................... 191
Dual Fuel System (G424E/G430E Engine Only) 83
Capacity Chart ............................................... 51, 53 Dual Fuel System (If G424 Dual Fuel Engine
Capacity Chart (with Side Shifter) ................. 55, 57 Equipped) ............................................................ 81
Capacity Chart (with Side Shifter):3,000kg@600mm
L.C. (6,500lb@24”) .............................................. 60
Capacity Chart: 3,000kg@600mm L.C.
E
(6,500lb@24”)...................................................... 59 Electrical Disconnect Switch (If Equipped).......... 67
Carburetor (LP-Gas, Gasoline & Dual Fuel Engine Engine Compartment........................................... 67
Only) - Adjust, Clean.......................................... 182 Engine Cranking but Will Not Start ...................... 91
Carriage Roller Extrusion – Adjust..................... 151 Engine Cranking but Will Not Start (Gas) ............ 98
Causes of Fork Failure ...................................... 125 Engine Oil & Filter (B3.3 Diesel Engine Only) -
Center of Gravity (CG)......................................... 21 Change .............................................................. 174
Changing From Gasoline to LP – Gas........... 81. 83 Engine Oil & Filter (DB33A Diesel Engine Only) -
Changing From LP - Gas to Gasoline ........... 81, 83 Change .............................................................. 157
Changing LP - Gas Tanks.................................... 73 Engine Oil & Filter (DB33A Diesel, LP-Gas &
Changing Primary Element................................ 183 Gasoline Engine Only) - Change....................... 167
Changing Secondary Element........................... 183 Engine Oil (DEO and EO).................................. 135
Chassis Pivot Eyebolts-Lubricate ...................... 170 Engine Oil Level - Check ................................... 152
Check for Equal Tension.................................... 180 Engine Stalls........................................................ 94
Check Operation................................................ 171 Engine Valve Lash (B3.3 Diesel Engine Only) -
Checking Service Indicator................................ 153 Check, Adjust............................................. 162, 188
-200-
Index Section
Engine Valve Lash (DB33A Diesel Engine Only) - G424E Engine ................................................... 199
Check, Adjust..................................................... 142 G424E/G430E Electronic Controlled LP and Dual
Environment Management .................................... 3 Fuel Engines (If Equipped) .................................. 89
Environment Protection ..................................... 124 G430 Engine...................................................... 197
Every 10 Service Hours or Daily........................ 152 G430 Engine: LP - Gas ..................................... 182
Every 1000 Service Hours or 6 Months............. 179 G430 LP-Gas Engines....................................... 168
Every 1500 Service Hours or 9 Months............. 185 G430(E) Engine................................................. 185
Every 2000 Service Hours or Yearly.................. 188 G430E Engine ................................................... 199
Every 250 Service Hours or Monthly ................. 163 Gasoline and LP-Gas Engines .......................... 152
Every 2500 Service Hours or 15 Months........... 195 Gasoline or Diesel Engine Equipped................... 72
Every 3000 Service Hours or 18 Months........... 198 Gasoline Specifications ..................................... 134
Every 4500 Service Hours or two Years ............ 199 Gasoline, LP-Gas Engine Crankcase................ 167
Every 500 Service Hours or 3 Months............... 170 GC25E-3 (GC20/25/30E-3) ............................... 145
Excessive Fuel Consumption/LPG Exhaust Smell GC25P-3 (GC20/25/30/32P-3) .......................... 145
............................................................................. 97 GC-Series Lift Trucks. ....................................... 191
General Description............................................. 89
F General Fuel Information................................... 133
General Hazard Information ................................ 10
Fatigue............................................................... 125 General Warning to Operator ................................ 6
Fire or Explosion Prevention ............................... 15
First 250 Service Hours or a Month................... 162
First 50 - 100 Service Hours or a Week ............ 157
H
First Installation.................................................. 126 Hand Placement Warning...................................... 7
Fluid Penetration.................................................. 14 High Idle Speed ................................................... 96
Foreword................................................................ 2 High Idle Speed (Gas) ....................................... 102
Fork Inspection .................................................. 126 Hook-on type Fork ............................................. 120
Forks – Inspect .................................................. 193 Horn and Lights (If Equipped) - Check .............. 174
Fuel Filter (B3.3 Diesel Engine Only) – Change How to Survive in a Tipover................................. 28
........................................................................... 178 Hydraulic Oil - Check, Clean, Change............... 195
Fuel Filter (DB33A Diesel Engine Only) - Change Hydraulic Oil (HYDO) ........................................ 135
........................................................................... 184 Hydraulic Oil Level – Check .............................. 165
Fuel Filter (G424 Gasoline & Dual Fuel Engine Only) Hydraulic Return Filter – Change ...................... 162
- Change ............................................................ 188 Hydraulic Return Filter, Breather & Strainer - Check,
Fuel Filter (LP - Gas Engine Only) .................... 187 Change .............................................................. 179
Fuel Lines & Fittings - Check............................. 184
Fuel Selector Switch (G424 Dual Fuel Only)....... 68 I
Fuel Selector Switch (G424E/G430E Dual Fuel
Only) .................................................................... 69 Identification, Lift Capacity and Attachment Plate 64
Fuel Specifications............................................. 133 If Convenience Package Equipped ..................... 64
Fuel Strainer (B3.3 Diesel Engine Only) – Clean176 If Optional Suspension Seat (weight adjusting type)
Fuel Sulfur Content............................................ 133 Equipped ............................................................. 19
Fuel Tank Filter Cap and Screen (If Equipped) - If the excessive valve noise occurs (G424 and
Clean ................................................................. 142 G424E Engine Only)............................................ 85
Fuel Trim Valve(FTV) Inspection ....................... 177 Improper Modification or Repair ........................ 125
Fuel Types ......................................................... 133 Inching ................................................................. 88
Fuse & Relay (G424E/G430E Only).................. 145 Inching & Braking Control Shaft - Lubricate ...... 174
Fuses ................................................................. 144 Inching into Loads ..............................................115
Fuses, Bulbs, Circuit Breaker & Relay - Change, Index .................................................................. 200
Reset ................................................................. 144 Inspect Battery System...................................... 195
Inspect Coolant Hoses (LP Engine Only).......... 183
Inspect Electrical System (G424E/G430E Engine
G Only) .................................................................. 177
G20/25/30/32E-3 (Dual fuel Only) ..................... 146 Inspect Engine for Exhaust Leaks..................... 153
G20/25/30/33p-3 (Dual fuel Only)...................... 146 Inspect Engine for Fluid Leaks .......................... 152
G25E-3 (G20/25/30E-3) .................................... 145 Inspect Foot Pedal Operation (G424E/G430E Only)
G25P-3 (G20/25/30/33P-3) ............................... 145 ........................................................................... 153
G424 Engine...................................................... 197 Inspect for Intake Leaks (G424E/G430E Engine
G424 Engine: Gasoline, LP - Gas, Dual Fuel.... 182 Only) .................................................................. 197
G424 Gasoline, LP-Gas and Dual Fuel Engines168 Inspect Ignition System (LP-Gas, Gasoline & Dual
G424(E) Engine ................................................. 185 Fuel Engines Only) ............................................ 185
-201-
Index Section
Inspect Mixer Assembly (G424E/G430E Engine Metric Hardware ................................................ 129

Only) .................................................................. 184 MI-04 Dual Fuel System ...................................... 90
Inspect the Fuel Pump Insulated Mounting MI-04 LP System ................................................. 89
Clamps(G424E/G430E Dual Fuel Only)............ 186 Mounting and Dismounting...................................11
Inspect Throttle Assembly (G424E/G430E Engine Moving Fan Warning.............................................. 8
Only) .................................................................. 184
Inspect Tightness (D, G - Series) ...................... 169 N
Inspect Tightness (GC - Series) ........................ 169
Inspect Vacuum Lines and Fittings (G424E/G430 No Riders Warning ................................................ 8
Engine Only) ...................................................... 177 No Standing On Fork Warning............................... 7
Inspect VR Sensor – Clean (G424E engine only)177 No Standing Under Fork Warning.......................... 7
Inspection from Operator's Seat, Engine OFF .. 156 Noise.................................................................... 50
Inspection from Operator's Seat, Engine ON .... 156 Noise and Vibration ............................................. 50
Inspection, Maintenance and Repair of Lift Truck
Forks.................................................................. 124 O
Instrument Panel.................................................. 65 Operating in hot weather ....................................118
Operating Techniques.........................................115
L Operating the Lift Truck ....................................... 12
Lift Chain Adjustment......................................... 180 Operation........................................................2, 113
Lift Chain Wear Test........................................... 180 Operation Information...........................................11
Lift Chains - Test, Check, Adjust ........................ 180 Operator Restraint System (If Equipped) ........ 2, 17
Lift Control ........................................................... 70 Operator's Station and Monitoring Systems ........ 65
Lift Fork Adjustment ........................................... 120 Operator's Warning and Identification Plate ........ 64
Lift Truck Controls................................................ 69 Operator's Warning Plate .................................... 64
Lift Truck Operation ............................................. 86 Overhead Guard – Inspect ................................ 172
Lift Truck Parking ................................................. 13 Overhead Guard Must Be In Place Warning ......... 8
Lift Truck Shipping ............................................. 122 Overloading ....................................................... 125
Lift Truck Stability................................................. 21
Lift Truck Stability Base........................................ 22 P
Lifting Drums or Round Objects......................... 118 Parking brake ........................................................ 9
Lifting the Load .................................................. 115 Parking Brake - Inspect ..................................... 156
Literature Information............................................. 2 Parking Brake - Test, Adjust ...................... 160, 173
Load Backrest Must Be In Place Warning ............. 7 Parking Brake Adjusting .................................... 160
Long Time Storage............................................. 121 Parking Brake Lever ............................................ 70
LP - Gas Engine .................................................. 79 Parking Brake Testing........................................ 160
LP Regulator/Converter Inspection (LP Engine Only) Parking the Lift Truck..........................................119
........................................................................... 183 PCV Valve System - Inspect, Clean .................. 168
LPG/GAS ....................................................... 65, 85 Poor High Speed Performance............................ 96
LP-Gas Specifications ....................................... 134 Poor High Speed Performance (Gas)................ 103
Lubricant Information ......................................... 135 Power Shift Transmission/ Drive axle.................. 86
Lubricant Viscosities .......................................... 137 Precleaner (If Equipped).................................... 163
Lubricant Viscosities and Refill Capacities ........ 137 Pressure Air ......................................................... 14
Lubricating Grease (MPGM).............................. 136 Pressure Warning .................................................. 7
Prestart Conditions .............................................. 78
M Priming the Fuel System (Diesel Engine Only)
Machine Lifting and Tiedown Information .......... 122 ........................................................................... 147
Maintenance .......................................................... 3 Product Description ............................................112
Maintenance and Repair.................................... 127
Maintenance Information ..................................... 14 R
Maintenance Intervals.................................... 3, 138 Reading Diagnostic Fault Codes....................... 104
Make proper antifreeze additions. ..................... 132 Refill Capacities................................................. 137
Manual Mode (Fail-Safe mode) ......................... 114 Refueling ............................................................. 72
Mast Abbreviations .............................................. 64 Replace Gasoline Primary Fuel Filter(G424E/G430E
Mast Channels – Lubricate................................ 155 Dual Fuel Only).................................................. 186
Mast Hinge Pin – Lubricate ............................... 170 Replace Gasoline Secondary Fuel Filter (G424E/
Mast Pivot Eyes-Lubricate................................. 171 G430E Dual Fuel Only) ..................................... 196
Mast, Carriage, Lift Chains & Attachments - Inspect, Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
Lubricate ............................................................ 166 Engine Only)...................................................... 187
-202-
Index Section
Replace Oxygen Sensor (G424E/G430E Engine Torque for Standard Hose Clamps - Worm Drive
Only) .................................................................. 199 ........................................................................... 129
Replace PCV Valve and breather element - Change Torque Specifications......................................... 129
(LP-Gas, Gasoline and Dual Fuel Engines) ...... 197 Torques for Bolts and Nuts with Standard Threads
Replace Spark Plugs (LP-Gas, Gasoline & Dual Fuel ........................................................................... 129
Engines Only) .................................................... 185 Torques for Taperlock Studs .............................. 130
Rough Idle ........................................................... 95 Towing Information ............................................ 123
Rough Idle (Gas) ............................................... 101 Traing Required To Operate or Service Warning .. 5
Transmission Inching Control Pedal.................... 69
S Transmission Oil ................................................ 136
Transmission Oil Filter – Change ...................... 172
Safety................................................................. 2, 5 Transmission Oil Level – Check ........................ 155
Safety Rules ........................................................ 23 Transmission Oil, Oil Filter & Strainer - Check, Clean,
Seat ..................................................................... 68 Change ...................................................... 158, 180
Seat Adjustment................................................... 18 Transportation Hints .......................................... 122
Seat, Hood Latch & Support Cylinder - Check, Traveling With the Load......................................116
Lubricate ............................................................ 143 Turning................................................................117
Serial Number...................................................... 61
Serial Number Locations ..................................... 61
Service Brake Pedal ............................................ 70
U
Servicing Filter Element..................................... 163 Universal Joint – Inspect ................................... 182
Sideshift Attachment (If Equipped) ...................... 71 Unloading ...........................................................116
Specifications....................................................... 30
Stability and Center of Gravity ............................. 21 V
Starting a Cold Diesel Engine.............................. 79
Starting a Warm Diesel Engine............................ 79 Vibration (weighted overall value) ....................... 50
Starting From a 12 Volt External Source ............. 80
Starting the Engine .............................................. 78 W
Starting the Lift truck ............................................ 12 Walk - Around Inspection..................................... 75
Steer Suspension – Inspect............................... 173 Walk-Around Inspection - Inspect...................... 154
Steer Wheel Bearings - Reassemble................. 189 Warning Signs and Labels............................... 5, 17
Steering Mechanism - Check, Lubricate............ 166 Wheel Bolts & Nuts - Inspect............................. 169
Storage Information ........................................... 121 When Required.......................................... 138, 142
When Stop the Engine (G424E Dual Fuel Only) . 84
T Will Not Accelerate/Hesitation During Acceleration
Table a. MI-04 Diagnostic Fault Codes (Flash ............................................................................. 93
Codes) ............................................................... 106 Will Not Accelerate/Hesitation During Acceleration or
Table of Contents................................................... 1 Engine Stalls (Gas)............................................ 100
Test Fuel System for Leaks(LP and Dual Fuel Will Not Run Continuously................................... 93
Engines Only) .................................................... 149 Will Not Run Continuously (Gas)......................... 99
Testing Fuel Lock-off Operation (LP-Gas Engine
Only) .................................................................. 187
Tilt Control............................................................ 71
Tilt Cylinders - Check, Adjust, Lubricate............ 170
Timing Belt [G424(E) LP-Gas, Gasoline Dual Fuel
Engine Only] - Change ...................................... 198
Timing Belt for Counterbalance Shaft [G424(E)
LP-Gas, Gasoline & Dual Fuel Engine Only]
- Change ............................................................ 198
Tire Inflation ....................................................... 128
Tire Inflation Information .................................... 128
Tire Inflation Pressures Adjustment ................... 128
Tire Shipping Pressure ...................................... 128
Tires and Wheels (D, G-Series) - Inspect, Check150
To Operate the Lift Truck after a Long Time Storage
........................................................................... 121
Torque for Metric Fasteners............................... 130
Torque for Standard Bolts, Nuts, and Taperlock
Studs.................................................................. 129
-203-

D25-30-33S-3 B3.3 MOTOR

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D25-30-33S-3 B3.3 MOTOR

Uploaded by

Copyright:

Available Formats

For use in service manual

SERVICE MANUAL CONTENTS

TITLE FORM NUMBER

Service Manual Contents SB4134E01

3.3 Liter (B3.3) Diesel Engine SB4135E00

Power Train SB2102E01

Vehicle Systems SB4138E00

OPERATION & MAINTENANCE

Operation & Maintenance Manual SB2302E06

Models ; D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3), D32S-3(B3.3), D33S-3(B3.3)

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

37û FLARED O-RING SWIVEL NUTS

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

TIGHTENING OTHER FITTINGS

45û FLARED AND 45û INVERTED FLARE FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

TIGHTENING OTHER FITTINGS

O-RING 45û FLARE

AIR CONDITIONING FITTINGS

TAPERED PIPE THREAD FITTINGS

Skid Steer Loaders

Introduction Complete Engine.................................................. 89

Diesel Engine 3 Index

How to Use the Manual

Diesel Engine 4 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.

Diesel Engine 5 Introduction

The illustrations are intended to show repair or

Diesel Engine 6 Introduction

NOTE: The engine dataplate must not be changed

Diesel Engine 7 Engine Identification

General Engine Data Naturally Aspirated

Lubrication System Naturally Aspirated

Cooling System Naturally Aspirated

Air Induction System Naturally Aspirated

Exhaust System Naturally Aspirated

Fuel System Naturally Aspirated

Electrical System Naturally Aspirated

Diesel Engine 8 Engine Identification

1. Intake Manifold 5. Fan

Diesel Engine 9 Engine Identification

1. Oil Fill Cap 4. Dipstick

Diesel Engine 10 Engine Identification

Diesel Engine 11 Engine Identification

1. Oil Strainer 8. Camshaft