Daewoo Forkilt Operation & Maintenance Manual
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Daewoo Forkilt Operation & Maintenance Manual

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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.)

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  • Page 1 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.)
  • Page 2 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.

  • Page 3: Table Of Contents

    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 Torque Specifications .........129 Safety Section Cooling System Specifications ......131 Fuel Specifications ..........133 Important Safety Information ......... 4 Lubricant Information .........135 Safety..............

  • Page 4: Information Section

    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,...
  • Page 5 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 14001 certified which...

  • Page 6: Safety Section

    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.

  • Page 7: Safety

    U.S.A., operate this lift truck in Traing Required To Operate or Service accordance with local regulations. 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.
  • Page 8 Safety Section 5. Travel with load as low as possible and tilted General Warning to Operator 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.
  • Page 9 Safety Section Pressure Warning No Standing On Fork Warning No Standing Under Fork Warning WARNING WARNING Contents under pressure may be hot. Allow to 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.
  • Page 10 Safety Section Moving Fan Warning Overhead Guard Must Be In Place Warning WARNING WARNING To avoid personal injury, stay clear of moving fan. Operation without this device in place may be hazardous. This guard conforms A.N.S.I.B56.1 and F.E.M.Section IV. This design has been tested with an impact of appropriate valve.

  • Page 11: Parking Brake

    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.

  • Page 12: General Hazard Information

    Safety Section Always use the overhead guard. The overhead General Hazard Information guard is intended to protect the lift truck operator from overhead obstructions and from falling objects. A truck that is used for handing small objects or uneven loads must be fitted with a load backrest. If the lift truck must be operated without the overhead guard in place due to low overhead clearance, use extreme care.

  • Page 13: Operation Information

    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-...
  • Page 14 Safety Section Make sure the lift truck horn, lights, backup alarm (if Operating the Lift Truck equipped) and all other devices are working Always keep the lift truck under control. properly. Obey all traffic rules and warning signs. Check proper operation mast attachments.
  • Page 15 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.

  • Page 16: Maintenance Information

    The maximum air pressure must be below 205 kPa To avoid possible weakening of the Falling Objects Protective Structure (FOPS), consult a DAEWOO (30 psi) for cleaning purposes. dealer before altering, by adding weight to, welding on, or cutting or drilling holes into the structure.
  • Page 17 Safety Section Burn Prevention Fire or Explosion Prevention All fuels, most lubricants and some coolant 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.

  • Page 18: Fire Extinguisher

    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.

  • Page 19: Operator Restraint System(If Equipped)

    See you DAEWOO Lift Truck dealer for new labels. Stand behind the tread and use a self-attaching The most effective method of preventing serious chuck when inflation a tire.
  • Page 20 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”...
  • Page 21 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.
  • Page 22 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.

  • Page 23: Avoiding Lift Truck Tipover

    Safety Section Stability and Center of Gravity Avoiding Lift Truck Tipover 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.
  • Page 24 – 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.

  • Page 25: Safety Rules

    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.
  • Page 26 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.
  • Page 27 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.
  • Page 28 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.
  • Page 29 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.

  • Page 30: How To Survive In A Tipover

    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 follows instructions provided. Hold on tight. Always use operator restraint system.
  • Page 31 Safety Section Lean away from the direction of fall. Lean forward. -29-...

  • Page 32: General Section

    General Section Specifications CHARACTERISTICS Manufacturer DHI&M DHI&M D20S-3 D25S-3 Model Capacity at rated load center 2000 2500 Load center distance Power type electric, diesel, gasoline, LPG diesel diesel rider - seated rider - seated Operator type stand-on, rider seated Tires* c = cushion, p = pneumatic Wheels (x = driven) number, front/rear...
  • Page 33 General Section DHI&M DHI&M D30S-3 D32S-3 3000 3000(6500lb) 600(24in) diesel diesel rider - seated rider-seated X2/2 X2/2 3230 3230 45 X 125 X 1050 45X125X1050 286 X 1044 286X1044 6/10 6/10 2636 2690 1197 1197 2160 2160 4470 4470 2183 2183 1026 1026...
  • Page 34 General Section Specifications CHARACTERISTICS TIER - II Manufacturer DHI&M DHI&M D20S-3 D25S-3 Model Capacity at rated load center 2000 2500 Load center distance diesel diesel Power type electric, diesel, gasoline, LPG Operator type stand-on, rider seated rider - seated rider - seated Tires* c = cushion, p = pneumatic X2/2...
  • Page 35 General Section TIER - II DHI&M DHI&M DHI&M D30S-3 D32S-3 D33S-3 3000 3000(6500lb) 3250 600(24in) diesel diesel diesel rider - seated rider-seated rider-seated X2/2 X2/2 X2/2 3230 3230 3230 45 X 125 X 1050 45X125X1050 45X125X1050 286 X 1044 286X1044 286X1044 6/10 6/10...
  • Page 36 General Section Specifications CHARACTERISTICS DHI&M DHI&M Manufacturer Model G20E-3 G25E-3 Capacity at rated load center 2000 2500 Load center distance gasoline / LPG gasoline / LPG Power type electric, diesel, gasoline, LPG Operator type stand-on, rider seated rider - seated rider - seated Tires* c = cushion, p = pneumatic...
  • Page 37 General Section DHI&M DHI&M G30E-3 G32E-3 3000 3000(6500lb) 600(24in) gasoline / LPG rider - seated rider-seated X 2/2 X2/2 3230 3230 45 X 125 X 1050 45X125X1050 286 X 1044 286X1044 6/10 6/10 2636 2690 1197 1197 2160 2160 4470 4470 2183 2183...
  • Page 38 General Section Specifications CHARACTERISTICS DHI&M DHI&M Manufacturer Model GC20E-3 GC25E-3 Capacity at rated load center 2000 2500 Load center distance gasoline / LPG gasoline / LPG Power type electric, diesel, gasoline, LPG Operator type stand-on, rider seated rider - seated rider - seated Tires* c = cushion, p = pneumatic...
  • Page 39 General Section DHI&M DHI&M GC30E-3 GC32E-3 3000 3000(6500lb) 600(24in) gasoline / LPG rider - seated rider - seated X2/2 X2/2 3230 3230 45 X 125 X 1050 45 X 125 X 1050 282 X 954 282 X 954 2333 2368 1110 1100 2125...
  • Page 40 General Section Specifications CHARACTERISTICS DHI&M DHI&M Manufacturer Model G20P-3 G25P-3 Capacity at rated load center 2000 2500 Load center distance Power type electric, diesel, gasoline, LPG Operator type stand-on, rider seated rider - seated rider - seated Tires* c = cushion, p = pneumatic X2/2 X2/2 Wheels (x = driven)
  • Page 41 General Section DHI&M DHI&M G30P-3 G32P-3 3000 3000(6500lb) 600(24in) rider - seated rider - seated X2/2 X2/2 3230 3230 45 X 125 X 1050 45 X 125 X 1050 286 X 1044 286 X 1044 6/10 6/10 2636 2690 1197 1197 2160 2160...
  • Page 42 General Section Specifications CHARACTERISTICS Manufacturer DHI&M DHI&M GC20P-3 GC25P-3 Model 2000 2500 Capacity at rated load center Load center distance Power type electric, diesel, gasoline, LPG rider - seated rider - seated Operator type stand-on, rider seated Tires* c = cushion, p = pneumatic X2/2 X2/2 Wheels (x = driven)
  • Page 43 General Section DHI&M DHI&M GC30P-3 GC32P-3 3000 3000(6500lb) 600(24in) rider - seated rider - seated X2/2 X 2/2 3230 3230 45 X 125 X 1050 45 X 125 X 1050 282 X 954 282 X 954 2333 2368 1110 1100 2125 2125 4470...
  • Page 44 General Section Specifications CHARACTERISTICS Tier-2 Manufacturer GC20E-3 GC25E-3 Model 2000 2500 Capacity at rated load center Load center distance Power type electric, diesel, gas, LPG-gas Operator type stand-on, ride- seated rider - seated rider - seated Tires* c = cushion, p = pneumatic Wheels (x = driven) number of front/rear X2/2...
  • Page 45 General Section Tier-2 GC30E-3 GC32E-3 3000 3000(6500lbs) rider - seated rider - seated X2/2 X 2/2 3230 3230 45 X 125 X 1050 45 X 125 X 1050 282 X 954 282 X 954 2333 2368 1110 1110 2125 2125 4470 4470 2150...
  • Page 46 General Section Specifications CHARACTERISTICS Tier-2 Manufacturer GC20P-3 GC25P-3 Model 2000 2500 Capacity at rated load center Load center distance Power type electric, diesel, gas, LPG-gas Operator type stand-on, ride- seated rider - seated rider - seated Tires* c = cushion, p = pneumatic Wheels (x = driven) number of front/rear X2/2...
  • Page 47 General Section Tier-2 GC30P-3 GC32P-3 3000 3000(6500lbs) rider - seated rider - seated X2/2 X 2/2 3230 3230 45 X 125 X 1050 45 X 125 X 1050 282 X 954 282 X 954 2333 2368 1110 1100 2125 2125 4470 4470 2150...
  • Page 48 General Section Specifications CHARACTERISTICS 2004 YEAR (Tier-2) Manufacturer G20E-3 G25E-3 Model 2000 2500 Capacity at rated load center Load center distance Power type electric, diesel, gas, LPG-gas Operator type stand-on, ride- seated rider - seated rider - seated Tires* c = cushion, p = pneumatic Wheels (x = driven) number of front/rear X2/2...
  • Page 49 General Section 2004 YEAR (Tier-2) G30E-3 G32E-3 3000 3000(6500lbs) rider - seated rider - seated X2/2 X 2/2 3230 3230 45 X 125 X 1050 45 X 125 X 1050 286 X 1044 286 X 1044 6/10 6/10 2636 2690 1197 1197 2160...
  • Page 50 General Section Specifications CHARACTERISTICS 2004 YEAR (Tier-2) Manufacturer G20P-3 G25P-3 Model 2000 2500 Capacity at rated load center Load center distance Power type electric, diesel, gas, LPG-gas Operator type stand-on, ride- seated rider - seated rider - seated Tires* c = cushion, p = pneumatic Wheels (x = driven) number of front/rear X2/2...
  • Page 51 General Section 2004 YEAR (Tier-2) G30P-3 G32P-3 G33P-3 3000 3000(6500lbs) 3250 rider - seated rider - seated rider - seated X2/2 X 2/2 X 2/2 3230 3230 3230 45 X 125 X 1050 45 X 125 X 1050 45 X 125 X 1050 286 X 1044 286 X 1044 286 X 1044...

  • Page 52: Noise And Vibration

    General Section Noise and Vibration Noise Noise Level [Unit : dB(A)] Sound Pressure Level Guaranteed Sound Sound Pressure Level at By-stander position Model Power level(L at Operator’s ear (Leq.) (AS 3713) by new Directive 2000/14/EC AS 3713 prEN 12053 Drive-By Lifting Mode W/O Cabin 80.5...

  • Page 53: Capacity Chart

    General Section Capacity Chart SINGLE TIRE STD, FFL A. 3900 - 4290mm MFH MAST A. 2030 - 4350mm MFH MAST B. 4730mm MFH MAST B. 4960mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST A. 2030 - 4350mm MFH MAST B.
  • Page 54 General Section DOUBLE TIRE STD, FFL A. 3900 - 4290mm MFH MAST A. 2030 - 4350mm MFH MAST B. 4730mm MFH MAST B. 4960mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST A. 2030 - 4350mm MFH MAST A.
  • Page 55 General Section Capacity Chart NARROW TIRE STD, FFL A. 2030 - 4350mm MFH MAST A. 3900 - 4290mm MFH MAST B. 4730mm MFH MAST B. 4960mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST A. 2030 - 4350mm MFH MAST B.
  • Page 56 General Section WIDE TIRE STD, FFL A. 2030 - 4350mm MFH MAST A. 3900 - 4290mm MFH MAST B. 4960mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST A. 2030 - 4350mm MFH MAST B.
  • Page 57 General Section Capacity Chart (with Side Shifter) SINGLE TIRE STD, FFL 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.
  • Page 58 General Section DOUBLE TIRE STD, FFL 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.
  • Page 59 General Section Capacity Chart (with Side Shifter) NARROW TIRE STD, FFL 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.
  • Page 60 General Section WIDE TIRE STD, FFL 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.
  • Page 61 General Section Capacity Chart: 3,000kg@600mm L.C. (6,500lb@24”) MODEL STD, FFL A. 2030 - 4350mm MFH MAST A. 3900 - 4290mm MFH MAST B. 4960mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST A. 2030-4960mm MFH MAST A.
  • Page 62 General Section Capacity Chart (with Side Shifter):3,000kg@600mm L.C. (6,500lb@24”) MODEL STD, FFL A. 2030 - 3950mm MFH MAST 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.

  • Page 63: Serial Number

    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 •_____________________________...
  • Page 64 General Section 2.4 liter LP and Dual Fuel Engine (G424E) Power Shift Transmission Serial Number •_____________________________ •_____________________________ Drive Axle Serial Number 3.0 liter LP and Dual Fuel Engine (G430E) •_____________________________ •_____________________________ Typical Example Side Shifter Serial Number (If Equipped) •_____________________________ -62-...
  • Page 65 General Section Attachment Abbreviations (Includes Special Forks) -Special Carriage-increased width, height or outreach -Shaft-type Sideshift Carriage -Hook-type Sideshift Carriage (ITA) -Counterweight -Special Forks -Swing Shift, Sideshift -Ram or Boom DBCBH -Double Cube Block Handler -Hydraulic Fork Positioner -Crane Arm or Crane Boom -Tire Handler -Container Handler -Load Push-Pull Device...

  • Page 66: Operator's Warning And Identification Plate

    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 column.

  • Page 67: Operation Section

    Operation Section Operator's Station and Monitoring Systems Diesel Engine Start Preheat Instrument Panel 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 chambers for easier starting.
  • Page 68 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 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.
  • Page 69 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.
  • Page 70 Operation Section Fuel Selector Switch (G424 Dual CAUTION Fuel Only) When closing the engine hood, be careful not to pinch your hand. Circuit Breaker NOTE: The switch is located in the engine compartment. 1. LPG - This position supplies electrical power to the LP fuelock solenoid, when Circuit Breaker...

  • Page 71: Lift Truck Controls

    Operation Section 3. Reverse - Pull the lever back for Fuel Selector Switch 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 It shows the function of each pedal i.e.

  • Page 72: Parking Brake Lever

    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.
  • Page 73 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.

  • Page 74: Refueling

    Operation Section Refueling Gasoline or Diesel Engine Equipped WARNING Explosive fumes 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.
  • Page 75 Operation Section Changing LP - Gas Tanks WARNING Only trained, authorized personnel should fill or exchange LP-Gas tanks. Personnel engaged filling 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...
  • Page 76 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.

  • Page 77: Before Starting The Engine

    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.
  • Page 78 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.
  • Page 79 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.

  • Page 80: Starting The Engine

    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 NOTICE the NEUTRAL position. Do not leave the key in ON position when engine is not running.
  • Page 81 Operation Section LP - Gas Engine Diesel Engine Starting a Cold Diesel Engine WARNING 1. Turn the key to the ON position. The start pre LP - Gas fuel is flammable and can cause heat light will come ON. The preheat light will personal injury.
  • Page 82 : 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-...

  • Page 83: Dual Fuel System (If G424 Dual Fuel Engine Equipped)

    Operation Section Dual Fuel System (If G424 Dual Fuel Engine Equipped) Changing From Gasoline to LP – 6. Open the fuel valve, on the LP - Gas tank, by slowly turning the valve counterclockwise. 7. Turn the ignition switch key to the OFF position NOTE: The Underwriter’s Laboratory...
  • Page 84 Operation Section 4. Move lever (1) from the LPG (3) position to the GAS (4) position. 5. Lower the hood and seat assembly. 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.

  • Page 85: Dual Fuel System (G424E Engine Only)

    Operation Section Dual Fuel System (G424E/G430E Engine Only) Changing From Gasoline to LP – 3. Open the fuel valve, on the LP - Gas tank, by slowly turning the valve counterclockwise. 4. Move lever (1) from the GAS (2) position to LPG NOTE: The Underwriter’s Laboratory...
  • Page 86 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. 5. Lower the hood and seat assembly. When Stop the Engine (G424E Dual Fuel Only) Engine wiring harness includes timer relay.
  • Page 87 Operation Section 2. The alternator indicator light (2), should not After Starting the Engine come during normal operation. alternator is not charging if the light comes ON Observe all indicator lights and gauges frequently with the engine running. during operation, to make sure all systems are working properly.

  • Page 88: Lift Truck Operation

    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 This could result in personal injury. Engine”.
  • Page 89 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. 12. Push down on the service brake pedal and 8. Push down on the service brake pedal to bring the lift truck to a smooth stop.
  • Page 90 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.

  • Page 91: (If Equipped)

    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.
  • Page 92 Operation Section MI-04 Dual Fuel System LP Fuel Line Fault Light Key switch LP Fuel Filter Fuel Lock Main Foot Pedal Fuel Select Switch Relay Converter Vacuum Line Air Cleaner Fuel Coolant Line Fuel Trim Select Valve Relay 1&2 Mixer Fuel Pump Fuel Injector DBW Throttle...
  • Page 93 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.
  • Page 94 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Difficult to Start Fill fuel container Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for a “click”...
  • Page 95 Operation Section Problem Probable Cause Corrective Action Fuel container almost empty LPG Vapor from liquid outlet Will Not Run Fill fuel container Continuously Do not exceed 80% of liquid capacity Excess flow valve closed Reset excess flow valve Close liquid valve Wait for a “click”...
  • Page 96 Operation Section Problem Probable Cause Corrective Action Clogged fuel filter Repair/replace as required Will Not See Maintenance Accelerate/Hesita Section, LP Fuel Filter replacement tion During Faulty vapor connection between Check connection Acceleration pressure regulator/converter Verify no holes in hose and the mixer Clamps must be tight Look for kinked, pinched and/or collapsed hose...
  • Page 97 Operation Section Problem Probable Cause Corrective Action Fuel Lock-off malfunction Repair/replace Fuel Lock-off Engine Stalls See G424E/G430E Engine Service Manual Faulty vapor connection between Check connection pressure regulator/converter Verify no holes in hose and the mixer Clamps must be tight Look for kinked, pinched and/or collapsed hose Pressure regulator freezes...
  • Page 98 Operation Section Problem Probable Cause Corrective Action Incorrect Idle speed control Advanced Diagnostics & Rough Idle G424E/G430E Engine Service Manual Incorrect timing or spark control Engine Mechanical See Engine Service Manual Incorrect Idle speed control Advanced Diagnostics & High Idle Speed G424E/G430E Engine Service Manual Throttle sticking Foot pedal sticking or incorrect...
  • Page 99 Operation Section Problem Probable Cause Corrective Action Air/Fuel Mixer malfunction Check mixer Excessive Fuel See G424E/G430E Engine Service Consumption/LP Manual G Exhaust Smell Air filter clogged Check air filter Clean/replace as required Vacuum leak Check system vacuum hoses from regulator to FTV and mixer Repair/replace as necessary Pressure regulator malfunction/fuel Test pressure regulator operation...
  • Page 100 Operation Section Basic Troubleshooting (Gasoline) Problem Probable Cause Corrective Action Fuel tank empty Fill fuel container Engine Cranking The tank should be at least ¼ full to but Will Not Start properly prime the fuel pump. (Gas) Fuel select switch is not on GAS Clogged fuel filter Repair/replace as required See Maintenance section Primary...
  • Page 101 Operation Section Problem Probable Cause Corrective Action Fuel tank almost empty Fuel Pump Cavitations Difficult to Start The tank should be at least ¼ full to (Gas) properly prime the fuel pump Fuel select switch is not on GAS Clogged fuel filter Repair/replace as required See Maintenance section, Primary Secondary...
  • Page 102 Operation Section Problem Probable Cause Corrective Action Electric Fuel Pump malfunction Check electrical connection Will Not Run (GAS) Check Relay and fuse Turn key ON Continuously and verify pump is operating (Gas) G424E/G430E Dual Fuel Engine Service Manual Pressure regulator malfunction Test pressure regulator operation G424E/G430E Dual...
  • Page 103 Operation Section Problem Probable Cause Corrective Action Throttle butterfly valve not opening See Advanced Diagnostics Will Not or sticking Accelerate/Hesita Foot Pedal signal incorrect or tion During intermittent Acceleration or Incorrect air/fuel or ignition control Engine Stalls (Gas) Engine Mechanical See Engine Service Manual Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
  • Page 104 Operation Section Problem Probable Cause Corrective Action Incorrect Idle speed control Advanced Diagnostics & Rough Idle (Gas) G424E/G430E Dual Fuel Engine Service Incorrect timing or spark control Manual Engine Mechanical See Engine Service Manual Incorrect Idle speed control See Advanced Diagnostics & High Idle Speed G424E/G430E Dual Fuel Engine Service (Gas)
  • Page 105 Operation Section Problem Probable Cause Corrective Action Isolate the gasoline system by Verify LPG cylinder is full and valve is open. Poor High Speed running the lift truck on LPG If the problem does not exist in LPG mode Performance proceed with the corrective action steps (Gas) below.

  • Page 106: Advanced Diagnostics

    Operation Section Reading Diagnostic Fault Codes Advanced Diagnostics All MI-04 fault codes are two digit codes. When the 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.

  • Page 107: Displaying Fault Codes

    Operation Section Displaying Fault Codes (DFC) From SECM Memory To enter code display mode you must turn OFF the ignition key. Now turn ON the key but do not start the engine. As soon as you turn the key to the ON position you must cycle the foot pedal by depressing it to the floor and then fully releasing the pedal (pedal maneuver).

  • Page 108: Codes)

    Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check NONE None, used as a beginning and end NONE Signifies the end of one pass through of the fault list identification the fault list ECTSensorInputLow Stored Fault Code Check ECT sensor connector and...
  • Page 109 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Engine Shutdown Check for debris or obstructions ETCSticking Throttle plate sticking inside the inside the throttle body throttle body or the ETC driver signal Check throttle-plate shaft for is open bearing wear...
  • Page 110 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Stored Fault Code Check coil driver wiring EST1Low Coil driver signal (MIL Only) connector for shorts under-current Stored Fault Code Check coil driver wiring for an open EST1High (MIL Only) circuit or disconnected connector...
  • Page 111 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Engine Shutdown Measure transducer power at the XDRPSensorInputHigh +5VDC Transducer power supplied TMAP connector with a multimeter by the SECM to the sensors is above +5.20VDC Verify transducer power at the SECM with a multimeter...
  • Page 112 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check MIN power Limit Check foot pedal connector Pedal2SensorInputLo APP2 sensor failure or shorted circuit Pedal2SensorInputHi MIN power Limit Check foot pedal connector APP2 signal disconnected, open circuit or sensor malfunction (Expected faults...
  • Page 113 Operation Section Table a. MI-04 Diagnostic Fault Codes (Flash Codes) Probable Fault Action Corrective Action, First Check Stored Fault Code Engine measured Air/Fuel ratio at the AFRTrimValveUpperDC FTV duty cycle at high (rich) limit (MIL, Disable O2 sensor is excessively rich (Expected fault when FTV connector Adaptive learns) is unplugged)

  • Page 114: Auto Shift Controller Asc-100 (If Equipped)

    Operation Section Auto Shift Controller ASC-100 (If Equipped) Product Description Adjustments The Autoshift controller is an electrical control system, specially designed for use on forklift trucks (Direction Inhibit Point) with internal combustion engines. NOTCH Vehicle Speed Its primary purpose is to prevent the operator from 3.3 km/h ( 2.05 mph ) driving the truck outside of the design parameters, 3.6 km/h ( 2.24 mph )
  • Page 115 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. Automatic mode (Direction Inhibit mode): Selected as factory-setting.
  • Page 116 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 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.

  • Page 117: Operating Techniques

    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...
  • Page 118 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.
  • Page 119 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.
  • Page 120 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.

  • Page 121: Parking The Lift Truck

    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.

  • Page 122: Lift Fork Adjustment

    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.

  • Page 123: Storage Information

    Operation Section Storage Information Before Storage To Operate the Lift Truck after a Long Time Storage Before storing your lift truck, clean and inspect as the following procedures. Remove covers and antirust from each of the components and exposed parts. Wipe away grease, oil, etc.

  • Page 124: Transportation Hints

    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.

  • Page 125: Towing Information

    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.

  • Page 126: Maintenance Section

    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.
  • Page 127 Maintenance Section Repetitive Overloading Causes of Fork Failure 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...

  • Page 128: Daily Inspection

    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”.
  • Page 129 Maintenance Section With the fork restrained in the same manner as 12 Months Inspection 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.

  • Page 130: Tire Inflation Information

    Maintenance Section Tire Inflation Information Tire Inflation Tire Shipping Pressure The tire inflation pressures shown in the following chart are cold inflation shipping pressures. Shipping Pressure Ply Rating or Size Strength Index 6.5X10 7.0X15 28X9-15 Standard tire, ply rating and inflation pressures. The operating inflation pressure is based on the weight of a ready - to - work machine without WARNING...

  • Page 131: Torque Specifications

    Maintenance Section Torque Specifications Metric Hardware Torque for Standard Bolts, Nuts, and Taperlock Studs Most of the nuts, bolts, studs, and threaded holes in your lift truck are metric. In this manual we provide specifications in both metric and U.S. customary measurement.
  • Page 132 Maintenance Section Torques for Taperlock Studs Torque for Metric Fasteners Thread Size Standard Taperlock Stud Torque NOTICE Inch N•m lb•ft Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or 8 ± 3 6 ± 2 incorrect fasteners will cause lift truck damage or 5/16 17 ±...

  • Page 133: Cooling System Specifications

    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.

  • Page 134: Coolant Water

    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.

  • Page 135: Fuel Specifications

    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 Fuel Sulfur Content two general groups, preferred and permissible. The percentage of sulfur in the fuel will affect the engine recommendations.
  • Page 136 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.

  • Page 137: Lubricant Information

    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.
  • Page 138 Shortened engine life will result. wear. NOTE: Multi-grade oils blended 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 viscosity index...

  • Page 139: Lubricant Viscosities And Refill Capacities

    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 °C °F Engine Crankcase w/Filter or System Viscosities G424 & G424E 2.4liter 1.06 G424(E) Gasoline &...

  • Page 140: Maintenance Intervals

    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 Every 250 Service Hours or Monthly only.
  • Page 141 Maintenance Section Inspect Coolant Hoses (LP Engine Only) ..183 Every 3000 Service Hours or 18 Months LP Regulator/Converter Inspection (LP Engine Timing Belt [G424(E) LP-Gas, Gasoline Dual Fuel Only) ..............183 Engine Only] - Change ........198 Fuel Lines & Fittings - Check......184 Timing Belt for Counterbalance Shaft [G424(E) Inspect Mixer Assembly (G424E/G430E Engine LP-Gas, Gasoline &...
  • Page 142 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Air Cleaner Indicator Check Air Intake System Check, Clean Air Intake System Change Battery Terminal Clean, Inspect Belts Check, Adjust Carburetor Adjust, Clean (LP-Gas, Gasoline & Dual Fuel E/G Only) Carriage Roller Extrusion Adjust Coolant Level...
  • Page 143 Maintenance Section Quick Reference to Maintenance Schedule FIRST EVERY ITEMS SERVICES PAGE Inspect VR Sensor(G424E/G430E Engine Only) Clean Inching & Braking Control Shaft Lubricate Lift Chains Test, Check, Adjust Mast Channels Lubricate Mast Hinge Pins Lubricate Mast, Carriage, Lift Chains & Attachments Inspect, Lubricate Overhead Guard Inspect...

  • Page 144: When Required

    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...

  • Page 145: Seat, Hood Latch & Support Cylinder - Check, Lubricate

    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.

  • Page 146: Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset

    Maintenance Section Fuses are identified as follows: Fuses, Bulbs, Circuit Breaker & 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.

  • Page 147: Fuse & Relay (G424E/G430E Only)

    Maintenance Section Fuse & Relay (G424E/G430E Only) G25E-3 (G20/25/30E-3) Located on the frame left side. GC25P-3 (GC20/25/30/32P-3) Located rear side of valve mounting bracket. 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.
  • Page 148 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.

  • Page 149: Priming The Fuel System (Diesel Engine Only)

    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...
  • Page 150 Maintenance Section B3.3 Diesel Engine Draining the Water from the Fuel Filter 1. Check "Diesel Engine Water in fuel filter DB33A Diesel Engine indicator light" in instrument panel. Refer to, 1. Check "Diesel Engine Water in fuel filter "Diesel Engine Water in Fuel Filter Indicator indicator light"...
  • Page 151 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.

  • Page 152: Tires And Wheels (D, G-Series) - Inspect, Check

    Maintenance Section When tires are changed, be sure to clean all rim Tires and Wheels (D, G-Series) - parts and, if necessary, repaint to stop detrimental Inspect, Check effects of corrosion. Sand blasting is recommended for removal of rust. WARNING Check all components carefully and replace any Servicing and changing tires and rims can be cracked, badly worn, damaged and severely rusted...

  • Page 153: Carriage Roller Extrusion - Adjust

    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.

  • Page 154: Every 10 Service Hours Or Daily

    Maintenance Section Every 10 Service Hours or Daily You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Inspect Engine for Fluid Leaks Coolant Level – Check 1.

  • Page 155: Air Cleaner Indicator-Check

    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.

  • Page 156: Walk-Around Inspection - Inspect

    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.

  • Page 157: Mast Channels - Lubricate

    Maintenance Section Mast Channels – Lubricate Transmission Oil Level – Check WARNING Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Start and operate the lift truck until the engine reaches normal operating temperature.

  • Page 158: Parking Brake - Inspect

    Maintenance Section PARKING BRAKE Parking Brake - Inspect Inspection from Operator's Seat, Engine NOTE: The parking brake is required to be adjusted to hold the lift truck with capacity load on a 15% grade. If there is a 15% grade in your workplace, engage a capacity load and drive over to the grade.

  • Page 159: First 50 - 100 Service Hours Or A Week

    Maintenance Section First 50 - 100 Service Hours or a Week You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Oil & Filter (DB33A Diesel Engine Only) - Change DB33A Diesel Engine crankcase The percentage of sulfur in the fuel will affect the...

  • Page 160: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

    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 Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

  • Page 161: Drive Axle Oil - Change

    Maintenance Section 12. Maintain the oil level between the Min and Max marks on the dip stick/filter cap. When the oil temperature is 40°C approximately, the cold side mark on the dipstick is applicable. When the oil temperature is 80°C approximately, the hot side mark on the dipstick is applicable.

  • Page 162: Parking Brake - Test, Adjust

    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.
  • Page 163 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).

  • Page 164: First 250 Service Hours Or A Month

    Maintenance Section First 250 Service Hours or a Month You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Return Filter – Change Engine Valve Lash (B3.3 Diesel Engine Only) - Check, Adjust WARNING Hot oil and components can cause personal...

  • Page 165: Every 250 Service Hours Or Monthly

    Maintenance Section Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Service the air cleaner when the red target in the Air Intake System - Check, Clean service indicator stays locked in the visible position Precleaner (If Equipped)
  • Page 166 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.

  • Page 167: Hydraulic Oil Level - Check

    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.

  • Page 168: Drive Axle Oil Level - Check

    Maintenance Section 5. Raise and lower the carriage a few times to Drive Axle Oil Level - Check 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 NOTICE directional control lever in NEUTRAL.

  • Page 169: Battery Terminal - Clean, Inspect

    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 DB33A Diesel Engine Crankcase explode. Do not smoke when observing the battery See topic, “Engine Oil &...

  • Page 170: Pcv Valve System - Inspect, Clean

    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.

  • Page 171: Wheel Bolts & Nuts - Inspect

    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).

  • Page 172: Every 500 Service Hours Or 3 Months

    Maintenance Section Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Belts - Check, Adjust Mast Hinge Pin – Lubricate Typical Example Typical Example 1.

  • Page 173: Crosshead Rollers - Inspect

    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.

  • Page 174: Transmission Oil Filter - Change

    Maintenance Section 9. Maintain the oil level between the Min and Max Transmission Oil Filter – Change 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.

  • Page 175: Steer Suspension - Inspect

    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 ±...

  • Page 176: Inching & Braking Control Shaft - Lubricate

    Maintenance Section Inching & Braking Control Shaft - Engine Oil & Filter (B3.3 Diesel Lubricate Engine Only) - Change B3.3 Diesel Engine crankcase The percentage of sulfur in the fuel will affect the 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).
  • Page 177 Maintenance Section Typical Example 13. Stop the engine and measure the oil level. 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. 14.

  • Page 178: Fuel Strainer (B3.3 Diesel Engine Only) - Clean

    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.

  • Page 179: Inspect Vacuum Lines And Fittings (G424E/G430 Engine Only)

    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 and wires on the harness including: Fuel 1. Visually inspect vacuum lines and fittings for lock-off, TMAP sensor, O2 sensor, Electronic physical damage such as bittleness, cracks and throttle, Control Relays, Fuel Trim Valve, Foot kinks.

  • Page 180: Fuel Filter (B3.3 Diesel Engine Only) - Change.178

    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.

  • Page 181: Every 1000 Service Hours Or 6 Months

    Maintenance Section Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Return Filter, Breather & Strainer - Check, Change WARNING Hot oil and components can cause personal injury.

  • Page 182: Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

    Maintenance Section Check for Equal Tension Transmission Oil, Oil Filter & 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.
  • Page 183 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”...

  • Page 184: Universal Joint - Inspect

    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.

  • Page 185: Air Intake System - Change

    Maintenance Section Air Intake System - Change Inspect Coolant Hoses (LP Engine Only) Changing Primary Element 1. Visually inspect coolant hoses and clamps. See topic, “Air Intake System - Check, Clean” in Remember to check the two coolant lines that “Every 250 Service Hours or Monthly”...

  • Page 186: Fuel Lines & Fittings - Check

    Maintenance Section Fuel Lines & Fittings - Check Fuel Filter (DB33A Diesel Engine Only) - Change Visually inspect fuel lines and fittings for physical 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.

  • Page 187: Every 1500 Service Hours Or 9 Months

    Maintenance Section Every 1500 Service Hours or 9 Months 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.

  • Page 188: Replace Lp Fuel Filter Element (Lp-Gas, Dual Fuel Engine Only)

    Maintenance Section G430E Dual Fuel Replace Gasoline Primary 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.

  • Page 189: Fuel Filter(Lp-Gas Engine Only)

    Maintenance Section 3. Check bottom cover O-ring seal (6) for damage. Replace LP Fuel Filter Element 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.

  • Page 190: Every 2000 Service Hours Or Yearly

    Maintenance Section Every 2000 Service Hours or Yearly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Fuel Filter (G424 Gasoline & Dual Engine Valve Lash (B3.3 Diesel Fuel Engine Only) - Change Engine Only) –...

  • Page 191: Steer Wheel Bearings - Reassemble

    Maintenance Section 3. Straighten the lock washer tangs. Steer Wheel Bearings - Reassemble Park the lift truck level with the forks lowered, parking brake engaged, transmission in NEUTRAL and the engine stopped. NOTE: The procedure is shown on a GC-Series lift truck.
  • Page 192 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.

  • Page 193: Drive Wheel Bearing (Power Shaft And Drive Wheel) - Reassemble

    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.

  • Page 194: Cooling System - Clean, Change

    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.

  • Page 195: Forks - Inspect

    Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. Contact your local DAEWOO Lift Truck Dealer further 2. Check the angle between the upper face of the information. blade and the front face of the shank. The fork...
  • Page 196 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.

  • Page 197: Every 2500 Service Hours Or 15 Months

    Maintenance Section Every 2500 Service Hours or 15 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Oil - Check, Clean, Inspect Battery System Change 1.
  • Page 198 Maintenance Section G430E Dual Fuel Replace Gasoline Secondary 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.

  • Page 199: Checking The Tmap Sensor (G424E/G430E Engine Only)

    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.

  • Page 200: Every 3000 Service Hours Or 18 Months

    Maintenance Section Every 3000 Service Hours or 18 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Timing Belt [G424(E) LP-Gas, Gasoline Dual Fuel Engine Only] - Change See the “Service manual”...

  • Page 201: Every 4500 Service Hours Or Two Years

    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.

  • Page 202: Index

    Index Section Checking the TMAP Sensor (G424E/G430E Engine Index Only) ..............197 Circuit Breaker..........68, 144 Cleaning Primary Filter Elements...... 164 Coolant Information ........... 131 12 Months Inspection......... 127 Coolant Level – Check ........152 2.4 Liter Gasoline Engine(G424) ......78 Coolant Water............
  • Page 203 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......
  • Page 204 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..........
  • Page 205 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 &...

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