Doosan G20E-5 - User Manual

Other manuals for Doosan G20E-5

Service Manual4 pages

Questions and Answers

D
Dr. Denise Cooper DDSAug 4, 2025
How to troubleshoot engine cranking but not starting in Doosan Lifting Systems (Gas)?
- D
  Daniel BooneAug 4, 2025
  If your Doosan Lifting Systems engine cranks but won't start, several issues could be the cause. First, ensure the fuel tank isn't empty and is at least ¼ full. Other potential causes include a clogged fuel filter (repair or replace as needed), a faulty vapor connection (check for holes, loose clamps, or kinks), an electric fuel pump malfunction (check electrical connections, relay, and fuse), a malfunctioning fuel pressure regulator (test its operation), a malfunctioning fuel injector (test its operation), incorrect air/fuel or ignition/spark control (see Advanced Diagnostics), or no VR Sensor signal (verify the VR signal is present).
K
kristayuAug 8, 2025
Why is my Doosan Lifting Systems difficult to start (Gas)?
- H
  harrisjacobAug 8, 2025
  If your Doosan Lifting Systems experiences difficulty starting, it might be due to several reasons. Check if the fuel tank is almost empty, as this can cause fuel pump cavitations; ensure the tank is at least ¼ full. Other potential causes include a clogged fuel filter (repair or replace), an electric fuel pump malfunction (check connections, relay, and fuse, and verify the pump is operating), a malfunctioning pressure regulator (test its operation), a malfunctioning fuel injector (test its operation), or a clogged air filter (clean or replace as required). Also, incorrect air/fuel or ignition control could be the issue (see Advanced Diagnostics). For engine mechanical issues, consult the Engine Service Manual.
A
Amy SnyderAug 16, 2025
Why does my Doosan Lifting Systems not accelerate or hesitate during acceleration (Gas)?
- C
  Crystal BondAug 17, 2025
  If your Doosan Lifting Systems will not accelerate, hesitates during acceleration, or the engine stalls, first isolate the gasoline system by running the lift truck on LPG. Verify the LPG cylinder is full and the valve is open. If the problem does not exist in LPG mode, proceed with the corrective action steps below; if the problem also exists in LPG mode, the root cause is most likely something other than the fuel system. Other potential causes include a fuel tank that's nearly empty (ensure it's at least ¼ full), a clogged fuel filter (repair or replace), a pressure regulator malfunction (test its operation), or a fuel injector malfunction (test its operation).
H
hatkinsAug 21, 2025
How to fix rough idle on Doosan Lifting Systems (Gas)?
- G
  gericksonAug 21, 2025
  If your Doosan Lifting Systems has a rough idle, isolate the gasoline system by running the lift truck on LPG. Verify the LPG cylinder is full and the valve is open. If the problem does not exist in LPG mode, proceed with the corrective action steps below; if the problem also exists in LPG mode, the root cause is most likely something other than the fuel system. Other potential causes include a pressure regulator malfunction (test its operation), a clogged fuel filter (repair or replace), or a vacuum leak (check between mixer and throttle body, throttle body and intake manifold, and intake manifold and cylinder head).
S
sandrabenitezAug 26, 2025
What causes poor high speed performance in Doosan Lifting Systems (Gas)?
- M
  Michael ClarkAug 26, 2025
  To address poor high-speed performance in your Doosan Lifting Systems, start by isolating the gasoline system by running the lift truck on LPG. Verify the LPG cylinder is full and the valve is open. If the problem does not exist in LPG mode, proceed with the corrective action steps below; if the problem also exists in LPG mode, the root cause is most likely something other than the fuel system. Also check for a clogged fuel filter (repair or replace), a plugged fuel line (remove obstruction), a clogged air filter (clean or replace), a faulty vapor connection (check for holes, tight clamps, and kinks), a pressure regulator malfunction (test its operation). For incorrect ignition control, see Advanced Diagnostics & Engine Service Manual.
E
Erin FloresAug 29, 2025
How to decrease high idle speed on Doosan Lifting Systems (Gas)?
- H
  hansenjadeAug 29, 2025
  To troubleshoot high idle speed in your Doosan Lifting Systems, check the pedal return spring travel for binding. For incorrect idle speed control, see Advanced Diagnostics & Engine Service Manual.
N
Nancy NguyenNov 11, 2025
What to do if Doosan Lifting Systems will not run continuously (Gas)?
- D
  Deborah MartinNov 11, 2025
  If your Doosan Lifting Systems will not run continuously, begin by isolating the gasoline system by running the lift truck on LPG. Verify the LPG cylinder is full and the valve is open. If the problem does not exist in LPG mode, proceed with the corrective action steps below; if the problem also exists in LPG mode, the root cause is most likely something other than the fuel system. Other potential causes include a nearly empty fuel tank (ensure it's at least ¼ full), a clogged fuel filter (repair or replace), an electric fuel pump malfunction (check connections, relay, and fuse), a pressure regulator malfunction (test its operation), or a fuel injector malfunction (test its operation). For incorrect idle speed or ignition problems, see Advanced Diagnostics. For engine mechanical issues, co...

Summary

FORKLIFTS

Diesel Forklift Models

Lists Diesel forklift models with Yanmar engines and Tier-3 compliance.

Gasoline Forklift Models (HMC)

Lists Gasoline forklift models with HMC engines and Tier-3 compliance.

Gasoline Forklift Models (MMC)

Lists Gasoline forklift models with MMC engines and Tier-3 compliance.

Gasoline Forklift Models (GM)

Lists Gasoline forklift models with GM engines and Tier-3 compliance.

Information Section

Foreword

Provides an overview of the manual's contents and importance of reading it.

Safety Section

Safety Precautions

Details essential safety rules and regulations for lift truck operation.

Warning Signs and Labels

Identifies and describes various safety signs and labels on the lift truck.

General Warning to Operator

Provides critical warnings and general safety advice for lift truck operators.

Parking Brake

Explains the operation, engagement, and release of the parking brake.

General Hazard Information

Details potential hazards during operation and maintenance, including warnings and notices.

Operation Information

Covers essential information for operating the lift truck, including mounting and dismounting.

Maintenance Information

Provides guidelines for equipment care and maintenance procedures.

Burn Prevention

Details precautions related to hot engine components, coolant, oils, and batteries.

Fire or Explosion Prevention

Outlines measures to prevent fires and explosions related to fuel, lubricants, and batteries.

Operator Restraint System (If Equipped)

Explains the function and inspection of the operator restraint system.

Avoiding Lift Truck Tipover

Discusses lift truck stability factors and how to prevent tipover incidents.

Safety Rules

Presents a series of essential safety rules for operating forklift trucks.

How to Survive in a Tipover

Provides instructions on how operators should react during a tipover event.

General Section

Declaration of Conformity

States the equipment's compliance with relevant EU directives and standards.

Specifications

Details technical specifications for various lift truck models.

Noise and Vibration

Provides data on sound pressure levels and whole-body vibration.

Capacity Chart (Without Sideshifter Pneumatic)

Charts showing load capacities for various models without sideshifter.

Capacity Chart (With Sideshifter Pneumatic)

Charts showing load capacities for various models with sideshifter.

Capacity Chart (Without Sideshifter cushion)

Charts showing load capacities for various models without sideshifter.

Serial Number

Locations for identifying the lift truck and engine serial numbers.

Attachment Abbreviations

Lists abbreviations for various attachments, including special forks.

Operators Warning and Identification Plate

Details the operator's warning plate and identification, lift capacity, and attachment plates.

Operation Section

Operator’s Station and Monitoring Systems

Describes the instrument panel, indicators, and gauges for monitoring lift truck status.

Electrical Disconnect Switch

Explains the function and operation of the electrical disconnect switch.

Engine Compartment

Provides access instructions for the engine compartment and hood.

Audio System

Details the controls and functions of the AM/FM tuner with USB/AUX player.

Getting started

Instructions on turning the unit on/off and adjusting volume.

Setting the sound

Guide to adjusting bass, mid, treble, fader, balance, loudness, and EQ settings.

Radio

Instructions on tuning stations, saving stations manually and automatically.

USB player

Information on playing MP3/WMA files from a USB device.

Playing a USB device

Steps for connecting and playing files from a USB device.

Controlling the playback

Details on navigating tracks and folders, and controlling playback functions.

Change the playback mode

Explains how to change playback modes like intro scan, repeat, and random.

AUX player

Instructions for connecting and listening to auxiliary audio equipment.

Seat Switch System (If Equipped)

Explains the function of the seat switch system and its role in operation.

Lift Truck Controls

Details the operation of key lift truck controls like levers and pedals.

Refueling

Provides instructions and warnings for refueling gasoline or diesel engines.

Changing LP Tanks

Step-by-step guide for safely changing LP fuel tanks.

Before Starting the Engine

Covers the crucial walk-around inspection and pre-start checks.

Starting the Engine

Provides procedures for starting gasoline, LP, and diesel engines.

Dual Fuel System

Instructions for switching between gasoline and LP fuel modes.

Lift Truck Operation

Details how to operate the lift truck, including transmission and travel controls.

Advanced Diagnostics

Explains the system's diagnostic features and how to read fault codes.

Mono-Ped Control System (Option)

Describes the operation of the optional Mono-Ped control system for speed and direction.

Auto Shift Controller ASC-100

Details the autoshift controller's function, adjustments, and diagnostic features.

Manual Mode (Fail-Safe mode)

Instructions for operating the lift truck manually if the controller fails.

Finger Tip (Option)

Explains the function of electric knobs for lift, tilt, and sideshift attachments.

Storage Information

Provides guidelines for preparing the lift truck for short-term and long-term storage.

Transportation Hints

Offers advice on shipping the lift truck, including clearances and securing the load.

Towing Information

Details the correct procedure and safety precautions for towing a disabled lift truck.

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

Provides guidelines for inspecting, maintaining, and repairing lift truck forks.

Causes of Fork Failure

Discusses common causes of fork failure such as improper repair, wear, and overloading.

Fork Inspection

Details the routine inspection procedures for lift truck forks.

12 Months Inspection

Specifies the minimum inspection frequency for forks every 12 months.

Maintenance and Repair

Outlines recommended procedures and limitations for fork repairs and modifications.

Tire Inflation Information

Covers tire inflation pressures, safety, and adjustment procedures.

Torque Specifications

Provides torque values for metric and standard fasteners, hose clamps, and taperlock studs.

Cooling System Specifications

Details coolant information, including mixture, protection, and system checks.

Fuel Specifications

Specifies requirements for diesel, gasoline, and LP fuels, including additives.

Lubricant Information

Provides guidelines for selecting engine oil, hydraulic oil, and drive axle oil.

Lubricant Viscosities and Refill Capacities

Lists lubricant viscosities by temperature and refill capacities for various systems.

Maintenance Intervals

Outlines recommended maintenance intervals based on service hours or time periods.

When Required

Lists maintenance tasks to be performed as needed, independent of service intervals.

Every 10 Service Hours or Daily

Details daily inspection and maintenance tasks for optimal lift truck performance.

Every 250 Service Hours or Monthly

Outlines monthly or 250-hour service tasks, including engine oil and filter changes.

Every 500 Service Hours or 3 Months

Specifies maintenance tasks required every 500 service hours or 3 months.

12 Months Inspection

Specifies the minimum inspection frequency for forks every 12 months.

Replace Spark Plugs (G424 I(E) Engine Only)

Step-by-step instructions for replacing spark plugs on the G424I(E) engine.

Checking the TMAP Sensor

Procedure for checking the TMAP sensor mounting and O-ring seal.

Inspect for Intake Leaks

Instructions for inspecting the intake manifold, throttle assembly, and adapters for leaks.

Timing Belt (G424 P(E) LP, Dual Fuel Engine Only) - Change

Procedure for changing the timing belt on specific LP and Dual Fuel engines.

Environment Protection Section

Environment Protection

Guidelines for responsible handling and disposal of fluids and materials during servicing.

Index Section

Index

Alphabetical listing of topics and their corresponding page numbers for quick reference.

Summary

FORKLIFTS

Diesel Forklift Models

Lists Diesel forklift models with Yanmar engines and Tier-3 compliance.

Gasoline Forklift Models (HMC)

Lists Gasoline forklift models with HMC engines and Tier-3 compliance.

Gasoline Forklift Models (MMC)

Lists Gasoline forklift models with MMC engines and Tier-3 compliance.

Gasoline Forklift Models (GM)

Lists Gasoline forklift models with GM engines and Tier-3 compliance.

Information Section

Foreword

Provides an overview of the manual's contents and importance of reading it.

Safety Section

Safety Precautions

Details essential safety rules and regulations for lift truck operation.

Warning Signs and Labels

Identifies and describes various safety signs and labels on the lift truck.

General Warning to Operator

Provides critical warnings and general safety advice for lift truck operators.

Parking Brake

Explains the operation, engagement, and release of the parking brake.

General Hazard Information

Details potential hazards during operation and maintenance, including warnings and notices.

Operation Information

Covers essential information for operating the lift truck, including mounting and dismounting.

Maintenance Information

Provides guidelines for equipment care and maintenance procedures.

Burn Prevention

Details precautions related to hot engine components, coolant, oils, and batteries.

Fire or Explosion Prevention

Outlines measures to prevent fires and explosions related to fuel, lubricants, and batteries.

Operator Restraint System (If Equipped)

Explains the function and inspection of the operator restraint system.

Avoiding Lift Truck Tipover

Discusses lift truck stability factors and how to prevent tipover incidents.

Safety Rules

Presents a series of essential safety rules for operating forklift trucks.

How to Survive in a Tipover

Provides instructions on how operators should react during a tipover event.

General Section

Declaration of Conformity

States the equipment's compliance with relevant EU directives and standards.

Specifications

Details technical specifications for various lift truck models.

Noise and Vibration

Provides data on sound pressure levels and whole-body vibration.

Capacity Chart (Without Sideshifter Pneumatic)

Charts showing load capacities for various models without sideshifter.

Capacity Chart (With Sideshifter Pneumatic)

Charts showing load capacities for various models with sideshifter.

Capacity Chart (Without Sideshifter cushion)

Charts showing load capacities for various models without sideshifter.

Serial Number

Locations for identifying the lift truck and engine serial numbers.

Attachment Abbreviations

Lists abbreviations for various attachments, including special forks.

Operators Warning and Identification Plate

Details the operator's warning plate and identification, lift capacity, and attachment plates.

Operation Section

Operator’s Station and Monitoring Systems

Describes the instrument panel, indicators, and gauges for monitoring lift truck status.

Electrical Disconnect Switch

Explains the function and operation of the electrical disconnect switch.

Engine Compartment

Provides access instructions for the engine compartment and hood.

Audio System

Details the controls and functions of the AM/FM tuner with USB/AUX player.

Getting started

Instructions on turning the unit on/off and adjusting volume.

Setting the sound

Guide to adjusting bass, mid, treble, fader, balance, loudness, and EQ settings.

Radio

Instructions on tuning stations, saving stations manually and automatically.

USB player

Information on playing MP3/WMA files from a USB device.

Playing a USB device

Steps for connecting and playing files from a USB device.

Controlling the playback

Details on navigating tracks and folders, and controlling playback functions.

Change the playback mode

Explains how to change playback modes like intro scan, repeat, and random.

AUX player

Instructions for connecting and listening to auxiliary audio equipment.

Seat Switch System (If Equipped)

Explains the function of the seat switch system and its role in operation.

Lift Truck Controls

Details the operation of key lift truck controls like levers and pedals.

Refueling

Provides instructions and warnings for refueling gasoline or diesel engines.

Changing LP Tanks

Step-by-step guide for safely changing LP fuel tanks.

Before Starting the Engine

Covers the crucial walk-around inspection and pre-start checks.

Starting the Engine

Provides procedures for starting gasoline, LP, and diesel engines.

Dual Fuel System

Instructions for switching between gasoline and LP fuel modes.

Lift Truck Operation

Details how to operate the lift truck, including transmission and travel controls.

Advanced Diagnostics

Explains the system's diagnostic features and how to read fault codes.

Mono-Ped Control System (Option)

Describes the operation of the optional Mono-Ped control system for speed and direction.

Auto Shift Controller ASC-100

Details the autoshift controller's function, adjustments, and diagnostic features.

Manual Mode (Fail-Safe mode)

Instructions for operating the lift truck manually if the controller fails.

Finger Tip (Option)

Explains the function of electric knobs for lift, tilt, and sideshift attachments.

Storage Information

Provides guidelines for preparing the lift truck for short-term and long-term storage.

Transportation Hints

Offers advice on shipping the lift truck, including clearances and securing the load.

Towing Information

Details the correct procedure and safety precautions for towing a disabled lift truck.

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

Provides guidelines for inspecting, maintaining, and repairing lift truck forks.

Causes of Fork Failure

Discusses common causes of fork failure such as improper repair, wear, and overloading.

Fork Inspection

Details the routine inspection procedures for lift truck forks.

12 Months Inspection

Specifies the minimum inspection frequency for forks every 12 months.

Maintenance and Repair

Outlines recommended procedures and limitations for fork repairs and modifications.

Tire Inflation Information

Covers tire inflation pressures, safety, and adjustment procedures.

Torque Specifications

Provides torque values for metric and standard fasteners, hose clamps, and taperlock studs.

Cooling System Specifications

Details coolant information, including mixture, protection, and system checks.

Fuel Specifications

Specifies requirements for diesel, gasoline, and LP fuels, including additives.

Lubricant Information

Provides guidelines for selecting engine oil, hydraulic oil, and drive axle oil.

Lubricant Viscosities and Refill Capacities

Lists lubricant viscosities by temperature and refill capacities for various systems.

Maintenance Intervals

Outlines recommended maintenance intervals based on service hours or time periods.

When Required

Lists maintenance tasks to be performed as needed, independent of service intervals.

Every 10 Service Hours or Daily

Details daily inspection and maintenance tasks for optimal lift truck performance.

Every 250 Service Hours or Monthly

Outlines monthly or 250-hour service tasks, including engine oil and filter changes.

Every 500 Service Hours or 3 Months

Specifies maintenance tasks required every 500 service hours or 3 months.

12 Months Inspection

Specifies the minimum inspection frequency for forks every 12 months.

Replace Spark Plugs (G424 I(E) Engine Only)

Step-by-step instructions for replacing spark plugs on the G424I(E) engine.

Checking the TMAP Sensor

Procedure for checking the TMAP sensor mounting and O-ring seal.

Inspect for Intake Leaks

Instructions for inspecting the intake manifold, throttle assembly, and adapters for leaks.

Timing Belt (G424 P(E) LP, Dual Fuel Engine Only) - Change

Procedure for changing the timing belt on specific LP and Dual Fuel engines.

Environment Protection Section

Environment Protection

Guidelines for responsible handling and disposal of fluids and materials during servicing.

Index Section

Index

Alphabetical listing of topics and their corresponding page numbers for quick reference.

Doosan G20E-5 Specifications

General

Brand	Doosan
Model	G20E-5
Category	Forklifts
Language	English

Related product manuals

Doosan G20E-5 - User Manual

Table of Contents

Other manuals for Doosan G20E-5

Questions and Answers

Summary

FORKLIFTS

Diesel Forklift Models

Gasoline Forklift Models (HMC)

Gasoline Forklift Models (MMC)

Gasoline Forklift Models (GM)

Information Section

Foreword

Safety Section

Safety Precautions

Warning Signs and Labels

General Warning to Operator

Parking Brake

General Hazard Information

Operation Information

Maintenance Information

Burn Prevention

Fire or Explosion Prevention

Operator Restraint System (If Equipped)

Avoiding Lift Truck Tipover

Safety Rules

How to Survive in a Tipover

General Section

Declaration of Conformity

Specifications

Noise and Vibration

Capacity Chart (Without Sideshifter Pneumatic)

Capacity Chart (With Sideshifter Pneumatic)

Capacity Chart (Without Sideshifter cushion)

Serial Number

Attachment Abbreviations

Operators Warning and Identification Plate

Operation Section

Operator’s Station and Monitoring Systems

Electrical Disconnect Switch

Engine Compartment

Audio System

Getting started

Setting the sound

Radio

USB player

Playing a USB device

Controlling the playback

Change the playback mode

AUX player

Seat Switch System (If Equipped)

Lift Truck Controls

Refueling

Changing LP Tanks

Before Starting the Engine

Starting the Engine

Dual Fuel System

Lift Truck Operation

Advanced Diagnostics

Mono-Ped Control System (Option)

Auto Shift Controller ASC-100

Manual Mode (Fail-Safe mode)

Finger Tip (Option)

Storage Information

Transportation Hints

Towing Information

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

Causes of Fork Failure

Fork Inspection

12 Months Inspection

Maintenance and Repair

Tire Inflation Information

Torque Specifications

Cooling System Specifications

Fuel Specifications

Lubricant Information

Lubricant Viscosities and Refill Capacities

Maintenance Intervals

When Required

Every 10 Service Hours or Daily