Daewoo G20E-3 Operation & Maintenance Manual Download Page 200 | Manualshive

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Maintenance Section

-198-

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” for the procedure and
specification.

Timing Belt for Counterbalance
Shaft [G424(E) LP-Gas, Gasoline
& Dual Fuel Engine Only]
- Change

See the “Service manual” for the procedure and
specification.

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Summary of Contents for G20E-3

Page 1: ...S 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 50...

Page 2: ...by the machine operator and by all personnel who will come into contact with it The following warning is provided pursuant to California Health Safety Code Sections 25247 5 et seq WARNING California...

Page 3: ...ed 89 Advanced Diagnostics 104 Table a MI 04 Diagnostic Fault Codes Flash Codes 106 Auto Shift Controller ASC 100 If Equipped 112 Operating Techniques 115 Parking the Lift Truck 119 Lift Fork Adjustme...

Page 4: ...be replaced with another DAEWOO operator restraint system Photographs or illustrations guide the operator through correct procedures of checking operation and maintenance of the DAEWOO operator restr...

Page 5: ...vice on items at multiples of the original requirement For example at Every 500 Service Hours or 3 Months also service those items listed under Every 250 Service Hours or Monthly and Every 10 Service...

Page 6: ...this safety alert symbol is as follows Attention Become Alert Your Safety is involved The message that appears under the warning explaining the hazard can be either written or pictorially presented O...

Page 7: ...of the lift truck to be alert and to avoid actions or conditions which can result in an accident Do not operate a lift truck if in need of repair defective or in any way unsafe Report all defects and...

Page 8: ...load interferes with visibility travel with load trailing 6 On grade operations travel with load up grade 7 Watch out for pedestrians and obstructions Check overhead clearances 8 Do not permit riders...

Page 9: ...touch lean on or reach through the mast or permit others to do so Located on the mast No Standing On Fork Warning No Standing Under Fork Warning WARNING Do not stand or ride on the forks Do not stand...

Page 10: ...ed with an impact of appropriate valve Located on the Overhead Guard No Riders Warning WARNING To avoid personal injury allow no riders A lift truck is designed for only one operator and no riders Loc...

Page 11: ...at without applying the parking brake an audible alarm will sound WARNING When leaving machine apply parking brake Parking brake is not automatically applied Alarm will sound if parking brake is not a...

Page 12: ...erated without the overhead guard in place due to low overhead clearance use extreme care Make sure there is no possibility of falling objects from any adjacent storage or work area Make sure the load...

Page 13: ...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...

Page 14: ...lift truck operates Know its safety devices Know how the attachments work Before moving the lift truck look around Start turn and brake smoothly An operator must constantly observe his lift truck for...

Page 15: ...on and overhead guard Refer to the topic Operation Techniques in the Operation Section of this manual Loading or Unloading Trucks Trailers Do not operate lift trucks on trucks or trailers which are no...

Page 16: ...moving fan blades They will throw or cut any object or tool that falls or is pushed into them Do not use a kinked or frayed wire rope cable Wear gloves when handling the wire rope cable Retainer pins...

Page 17: ...n All fuels most lubricants and some coolant mixtures are flammable Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling ar...

Page 18: ...ur bare hand to check for leaks Use a board or cardboard to check for leaks See Fluid Penetration in the Safety Section for more details Tighten all connections to the recommended torque Replace if an...

Page 19: ...the assemblies could burst with explosive force and cause serious personal injury or death Follow carefully the specific information provided by your tire or rim servicing personnel or dealer Operator...

Page 20: ...adjusting set the seat to make sure it is properly locked DO NOT adjust the seat while the truck is in motion WARNING Do NOT place your hand or fingers under the seat Injury may occur as the seat susp...

Page 21: ...e belt cannot be inserted into the buckle properly replace the seat belt assembly 2 Belt Maintenance Every 500 service hours Check that the belt fastening works properly and that winding device is fre...

Page 22: ...asten the Seat Belt 1 Grip the plate connector of the belt and pull the belt from the retractor Then insert the plate into the slot of the buckle until a snap is heard Pull on the belt to confirm it i...

Page 23: ...e of the object When the lift truck picks up a load the truck and load have a new combined CG Stability and Center of Gravity The stability of the lift truck is determined by the location of its CG or...

Page 24: ...d face of an attachment to the CG of the load The location of the CG in the vertical direction is the same as the horizontal dimension Remember that unless otherwise indicated the capacity load shown...

Page 25: ...and think safety Do not compromise safety Follow all safety rules and read all warning signs Do not operate a lift truck unless you are in the operator s seat Keep arms legs and head inside the confin...

Page 26: ...oss both forks Always use the proper size pallet Position the forks as wide as possible under the load Position loads evenly on the forks for proper balance Do not lift a load with one fork Do not ove...

Page 27: ...r falling loads when stacking Travel with the load tilted back and the forks as low as possible This will increase stability to the truck and load and permit better visibility for you Do not elevate t...

Page 28: ...for other persons or obstructions in your path of travel An operator must be in full control of his lift truck at all times Do not drive in forward direction when loads restrict your visibility Operat...

Page 29: ...ueling Smoking and handling of naked flames during refueling are strictly prohibited This prohibition also applies during the changing of the LPG liquefied propane gas tank Mop up spilt fuel and do no...

Page 30: ...over the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided Always use operator restraint system DON T jump Ho...

Page 31: ...Safety Section 29 Lean away from the direction of fall Lean forward...

Page 32: ...ecting aisle mm 1970 2000 PERFORMANCE 24 travel loaded unloaded km h 19 5 20 19 4 19 9 25 lift loaded unloaded mm s 550 600 530 600 26 Speeds lowering loaded unloaded mm s 510 460 510 460 28 Drawbar p...

Page 33: ...14 21 485 485 22 2849 2899 23 2050 2100 23a 19 2 19 7 19 0 19 5 24 520 600 520 600 25 510 460 510 460 26 1705 1705 28 23 0 23 30 31 4715 5070 32 6705 1010 6810 1260 33 1890 2825 1810 3260 34 2 2 2 2 3...

Page 34: ...ersecting aisle mm 1970 2000 PERFORMANCE 24 travel loaded unloaded km hr 19 5 20 19 5 20 25 lift loaded unloaded mm s 550 600 530 600 26 Speeds lowering loaded unloaded mm s 510 460 510 460 28 Drawbar...

Page 35: ...2100 23a 19 0 19 5 19 0 19 5 19 0 19 5 24 520 600 520 600 500 600 25 510 460 510 460 510 460 26 1890 1890 1900 28 25 25 23 5 30 31 4715 5070 5070 32 6705 1010 6810 1260 7030 1290 33 1890 2825 1810 32...

Page 36: ...ersecting aisle mm 1970 2000 PERFORMANCE 24 travel loaded unloaded km hr 18 2 19 3 18 0 19 3 25 lift loaded unloaded mm s 530 600 510 600 26 Speeds lowering loaded unloaded mm s 510 460 510 460 28 Dra...

Page 37: ...4 21 485 485 22 2849 2899 23 2050 2100 23a 17 0 18 4 17 0 18 0 24 500 600 500 600 25 510 460 510 460 26 1550 1550 28 20 8 20 8 30 31 4530 4830 32 6605 925 6690 1140 33 1790 2740 1680 3150 34 2 2 2 2 3...

Page 38: ...23a 90 intersecting aisle mm 1798 1822 PERFORMANCE 24 travel loaded unloaded km h 17 5 17 9 17 4 17 8 25 lift loaded unloaded mm s 530 600 510 600 26 Speeds lowering loaded unloaded mm s 510 460 510...

Page 39: ...8 20 2105 2135 21 374 374 22 2479 2509 23 1872 1907 23a 17 3 17 7 17 3 17 7 24 500 600 500 600 25 510 460 510 460 26 1540 1540 28 24 24 30 31 4140 4310 32 6290 850 6450 860 33 1430 2710 1380 2930 34 2...

Page 40: ...intersecting aisle mm 1970 2000 PERFORMANCE 24 travel loaded unloaded km h 20 1 21 4 19 8 21 3 25 lift loaded unloaded mm s 530 600 510 600 26 Speeds lowering loaded unloaded mm s 510 460 510 460 28...

Page 41: ...364 2414 21 485 485 22 2849 2899 23 2050 2100 23a 18 8 20 5 18 8 20 5 24 500 600 500 600 25 510 460 510 460 26 1705 1705 28 23 1 23 1 30 31 4530 4830 32 6605 925 6690 1140 33 1790 2740 1680 3150 34 2...

Page 42: ...19 23a 90 intersecting aisle mm 1798 1822 PERFORMANCE 24 travel loaded unloaded km h 17 4 18 0 17 3 18 0 25 lift loaded unloaded mm s 530 600 510 600 26 Speeds lowering loaded unloaded mm s 510 460 51...

Page 43: ...38 1038 20 2105 2135 21 374 374 22 2479 2509 23 1872 1907 23a 17 1 18 0 17 1 18 0 24 500 600 500 600 25 510 460 510 460 26 2000 2000 28 28 8 28 8 30 31 4140 4310 32 6290 850 6450 860 33 1430 2710 1380...

Page 44: ...stacking aisle mm 2374 2419 22a 90 intersecting aisle mm 1798 1822 PERFORMANCE 23 travel loaded unloaded km h 18 0 18 0 18 0 18 0 24 lift loaded unloaded mm s 530 600 510 600 25 Speeds lowering loaded...

Page 45: ...0 19 1038 1038 20 2105 2135 21 374 374 22 2479 2509 23 1872 1907 23a 18 0 18 0 18 0 18 0 24 500 600 500 600 25 510 460 510 460 26 1540 1540 28 24 24 30 31 4140 4310 32 6290 850 6450 860 33 1430 2710 1...

Page 46: ...stacking aisle mm 2374 2419 22a 90 intersecting aisle mm 1798 1822 PERFORMANCE 23 travel loaded unloaded km h 17 5 17 5 17 5 17 5 24 lift loaded unloaded mm s 530 600 510 600 25 Speeds lowering loaded...

Page 47: ...19 1038 1038 20 2105 2135 21 374 374 22 2479 2509 23 1872 1907 23a 17 5 17 5 17 5 17 5 24 500 600 500 600 25 510 460 510 460 26 2000 2000 28 29 29 30 31 4170 4340 32 6240 890 6370 1050 33 1430 2740 1...

Page 48: ...cking aisle mm 2705 2750 22a 90 intersecting aisle mm 1970 2000 PERFORMANCE 23 travel loaded unloaded km h 19 5 20 0 19 5 20 0 24 lift loaded unloaded mm s 530 600 510 600 25 Speeds lowering loaded un...

Page 49: ...183 19 20 2364 2414 21 485 485 22 2849 2899 23 2050 2100 23a 19 0 19 5 19 0 19 5 24 500 600 500 600 25 510 460 510 460 26 1550 1550 28 21 20 30 31 4530 4830 32 6605 925 6690 1140 33 1790 2740 1680 315...

Page 50: ...king aisle mm 2705 2750 22a 90 intersecting aisle mm 1970 2000 PERFORMANCE 23 travel loaded unloaded km h 20 0 21 5 20 0 21 5 24 lift loaded unloaded mm s 530 600 510 600 25 Speeds lowering loaded unl...

Page 51: ...99 2899 23 2050 2100 2100 23a 19 0 20 5 19 0 20 0 19 0 20 0 24 500 600 500 600 500 600 25 510 460 510 460 510 460 26 1705 1705 1700 28 23 5 23 5 23 5 30 31 4530 4830 4830 32 6605 925 6690 1140 6900 11...

Page 52: ...Cabin 77 2 79 3 76 76 104 G20E 3 G25E 3 G30E 3 G32E 3 W O Cabin 78 3 81 5 80 82 106 G20P 3 G25P 3 G30P 3 G32P 3 W O Cabin 78 0 81 0 81 84 NA GC20E 3 GC25E 3 GC30E 3 GC32E 3 W O Cabin 78 0 81 0 81 84...

Page 53: ...S 3 G25E 3 G25P 3 A 2030 4350mm MFH MAST B 4960mm MFH MAST A 3900 4290mm MFH MAST B 4730mm MFH MAST C 5560mm MFH MAST D 6010mm MFH MAST D30S 3 G30E 3 G30P 3 A 2030 4350mm MFH MAST B 4960mm MFH MAST A...

Page 54: ...10mm MFH MAST D25S 3 G25E 3 G25P 3 A 2030 4350mm MFH MAST B 4960mm MFH MAST A 3900 4290mm MFH MAST B 4730mm MFH MAST C 5560mm MFH MAST D 6010mm MFH MAST D30S 3 G30E 3 G30P 3 A 2030 4350mm MFH MAST B 4...

Page 55: ...4730mm MFH MAST C 5560mm MFH MAST D 6010mm MFH MAST GC25E 3 GC25P 3 A 2030 4350mm MFH MAST B 4960mm MFH MAST A 3900 4290mm MFH MAST B 4730mm MFH MAST C 5560mm MFH MAST D 6010mm MFH MAST GC30E 3 GC30P...

Page 56: ...MFH MAST C 5560mm MFH MAST D 6010mm MFH MAST GC25E 3 GC25P 3 A 2030 4350mm MFH MAST B 4960mm MFH MAST A 3900 4290mm MFH MAST B 4730mm MFH MAST C 5560mm MFH MAST D 6010mm MFH MAST GC30E 3 GC30P 3 STD M...

Page 57: ...FH MAST B 3500 3950mm MFH MAST C 4350mm MFH MAST D 4960mm MFH MAST A 3900mm MFH MAST B 4290mm MFH MAST C 4730mm MFH MAST D 5560mm MFH MAST E 6010mm MFH MAST D30S 3 G30E 3 G30P 3 A 2030 3230mm MFH MAST...

Page 58: ...50mm MFH MAST C 4350mm MFH MAST D 4960mm MFH MAST A 3900mm MFH MAST B 4290mm MFH MAST C 4730mm MFH MAST D 5560mm MFH MAST E 6010mm MFH MAST D30S 3 G30E 3 G30P 3 A 2030 3230mm MFH MAST B 3500 3950mm MF...

Page 59: ...0mm MFH MAST B 4290mm MFH MAST C 4730mm MFH MAST D 5560mm MFH MAST E 6010mm MFH MAST GC25E 3 GC25P 3 A 2030 3230mm MFH MAST B 3500 3950mm MFH MAST C 4350mm MFH MAST D 4960mm MFH MAST A 3900mm MFH MAST...

Page 60: ...90mm MFH MAST C 4730mm MFH MAST D 5560mm MFH MAST E 6010mm MFH MAST GC25E 3 GC25P 3 A 2030 3230mm MFH MAST B 3500 3950mm MFH MAST C 4350mm MFH MAST D 4960mm MFH MAST A 3900mm MFH MAST B 4290mm MFH MAS...

Page 61: ...m MFH MAST D 6010mm MFH MAST D32S 3 G32E 3 G32P 3 DOUBLE TIRE A 2030 4960mm MFH MAST A 3900 4730mm MFH MAST B 5560mm MFH MAST C 6010mm MFH MAST NARROW TIRE A 2030 4350mm MFH MAST B 4960mm MFH MAST A 3...

Page 62: ...IRE A 2030 3950mm MFH MAST B 4350mm MFH MAST C 4960mm MFH MAST A 3900mm MFH MAST B 4290mm MFH MAST C 4730mm MFH MAST D 5560mm MFH MAST E 6010mm MFH MAST NARROW TIRE A 2030 3950mm MFH MAST B 4350mm MFH...

Page 63: ...ft Truck Serial Number _____________________________ 3 3 liter DB33A Diesel Engine Serial Number _____________________________ 3 3 liter B3 3 Diesel Engine Serial Number _____________________________...

Page 64: ...____ 3 0 liter LP and Dual Fuel Engine G430E _____________________________ Power Shift Transmission Serial Number _____________________________ Drive Axle Serial Number _____________________________ T...

Page 65: ...type Sideshift Carriage ITA CW Counterweight SF Special Forks SWS Swing Shift Sideshift RAM Ram or Boom DBCBH Double Cube Block Handler HFP Hydraulic Fork Positioner CR Crane Arm or Crane Boom TH Tir...

Page 66: ...Attachment Plate Located on the cowl to the right side of the steering column Below are abbreviations that may appear on the IDENTIFICATION LIFT CAPACITY and ATTACHMENT PLATES and their meanings Mast...

Page 67: ...rrounding air temperature When the light goes OFF the maximum pre combustion chamber temperature has been reached and the key can be turned to the START position to start the engine 4 Diesel Engine Wa...

Page 68: ...the engine control module ECM Once a fault occurs the MIL will illuminate and remain ON This signals the operator that a faults has been detected by the SECM 9 Seat Belt Warning Light If Equipment In...

Page 69: ...tment 1 The engine compartment is accessible by pulling the latch GC Series or pushing down the lever located at cowl G D Series and raising the hood and seat assembly Note Unlock latch before pulling...

Page 70: ...Only NOTE The switch is located in the engine compartment 1 LPG This position supplies electrical power to the LP fuelock solenoid when the ignition switch is in the ON or the START position With the...

Page 71: ...ever 1 Forward Push the lever forward for FORWARD direction travel 2 Neutral Move the lever to center position for NEUTRAL 3 Reverse Pull the lever back for REVERSE direction travel Plate for Function...

Page 72: ...e Lever Pull the lever BACK to engage the parking brake Push the lever FORWARD to release the parking brake Lift Control NOTE To prevent a sudden change of position of the load operate all lift tilt a...

Page 73: ...Tilting action will stop 3 Mast Tilt Back Pull the lever BACK smoothly to tilt the mast backward Sideshift Attachment If Equipped 1 Sideshift Left Push the lever FORWARD to shift the carriage to the l...

Page 74: ...oisture laden air and to prevent condensation In the cold weather the moisture condensation can cause rust in the fuel system and hard starting due to its freezing Do not fill the tank to the top Fuel...

Page 75: ...resent during refueling Do not smoke in refueling areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to indoor locations Stop the engine and ge...

Page 76: ...vel gauge 10 Inspect the quick disconnect couplings for deterioration damage or missing flexible seals 11 Position the replacement tank so that the locating pin dowel is in place CAUTION The LP Gas ta...

Page 77: ...ights or gauges 3 Test the horn and other safety devices for proper operation 4 Inspect the mast and lift chains for wear broken links pins and loose rollers 5 Inspect the carriage forks or attachment...

Page 78: ...nd MIN or FULL and ADD notches on the dip stick DB33A Diesel Engine B3 3 Diesel Engine 12 Observe the engine coolant level in the coolant recovery bottle With the engine cold maintain the level to the...

Page 79: ...djustment Always adjust the operator s seat before starting the lift truck engine Seat adjustment must be done at the beginning of each shift and when operators change 14 To position the seat PUSH the...

Page 80: ...l disconnect switches the engine will not start unless the disconnect switch is in the ON closed position 2 4 Liter Gasoline Engine G424 NOTICE Do not leave the key in ON position when engine is not r...

Page 81: ...Engine 1 Turn the key to the ON position The start pre heat light will come ON The preheat light will stay ON approximately seven seconds depending on the surrounding air temperature NOTICE Do not eng...

Page 82: ...and below the battery and well clear of fuel system components NOTICE Do not reverse battery cables It can cause damage to the alternator Always connect the external power source cables in parallel wi...

Page 83: ...o the OFF 2 position Leave lever 1 in this position until the gasoline in the carburetor is used and the engine stops 4 Move lever 1 to the LPG 3 position 5 Lower the hood and seat assembly 6 Open the...

Page 84: ...ood 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 7 Turn the i...

Page 85: ...sion in NEUTRAL and the engine running 2 Raise the hood and seat assembly Make certain the air lift cylinder securely holds the hood open 3 Open the fuel valve on the LP Gas tank by slowly turning the...

Page 86: ...e engine stops 5 Lower the hood and seat assembly When Stop the Engine G424E Dual Fuel Only Engine wiring harness includes timer relay The purpose of it is to prevent backire to exhaust when stop engi...

Page 87: ...light comes ON Refer G424E G430E Engines of this section 4 The diesel engine water in fuel filter indicator light 4 will not come ON with the engine running unless water in fuel filter exceeds 100cc...

Page 88: ...ission control lever in the NEUTRAL center position and apply the parking brake before dismounting the lift truck 5 Release the service brake 6 Push down on the accelerator pedal to obtain the desired...

Page 89: ...to the desired direction of travel Slowly push down on the accelerator pedal as the lift truck changes direction 10 When the direction change is completed continue to push down on the accelerator peda...

Page 90: ...ither direction slowly push down on the inching pedal This will start to apply the service brakes and allow the transmission clutch discs to slip 2 Vary the position of the inching pedal and the accel...

Page 91: ...tion about the engines performance Engine speed is monitored by the SECM through a variable reluctance VR sensor Intake manifold air temperature and absolute pressure is monitored with a TMAP sensor T...

Page 92: ...Fuel Trim Valve Mixer Distributor Engine VR Sensor Oil Pressure Switch Coolant Temp Sensor Catalytic Muffler Oxygen Sensor TMAP DBW Throttle Fault Light Air Cleaner LP Fuel Line Coolant Line TPS APP M...

Page 93: ...et excess flow valve z Close liquid valve z Wait for a click sound z Slowly open liquid valve Plugged fuel line Remove obstruction from the fuel line z Close liquid fuel valve z Using caution disconne...

Page 94: ...escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Faulty vapor connection between the pressure regulator converter and the mixer Check c...

Page 95: ...nnect fuel line z Slowly open liquid fuel valve Leak test Pressure regulator freezes Check level in cooling system z Must be full check coolant strength z 35F minimum Check coolant hoses z Watch for k...

Page 96: ...nostics Will Not Accelerate Hesita tion During Acceleration Engine Mechanical See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet z Fill fuel container z Do not exceed 8...

Page 97: ...ce Manual Vacuum leak Check for vacuum leaks z Between mixer and throttle body z Between throttle body and intake manifold z Between intake manifold and cylinder head Air Fuel Mixer malfunction Check...

Page 98: ...e z Using caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve Leak test Air filter clogged Check air...

Page 99: ...ator malfunction fuel pressure too high Test pressure regulator operation z See G424E G430E Engine Service Manual Faulty FTV Check FTV for housing cracks or obstructions z See Advanced Diagnostics FTV...

Page 100: ...nnection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and or collapsed hose Electric Fuel Pump malfunction GAS Check electrical connection z Check Relay and fuse Turn key...

Page 101: ...r operation z See G424E G430E Dual Fuel Engine Service Manual Air filter clogged Check air filter z Clean replace as required Incorrect air fuel or ignition control See Advanced Diagnostics Difficult...

Page 102: ...m by running the lift truck on LPG Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in...

Page 103: ...then the root cause is most likely to be something other than the fuel system z See Advanced Diagnostics G424E G430E Dual Fuel Engine Service Manual Pressure regulator malfunction Test pressure regul...

Page 104: ...24E G430E Dual Fuel Engine Service Manual Rough Idle Gas Engine Mechanical See Engine Service Manual Incorrect Idle speed control Throttle sticking See Advanced Diagnostics G424E G430E Dual Fuel Engin...

Page 105: ...Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve Leak test Air filter clogged Check air filter z Clean replace as required Faulty vapor connection between...

Page 106: ...des are two digit codes When the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 5 seconds between digits and a long pause 1 2 seconds between fault codes A co...

Page 107: ...the foot pedal three 3 times within five 5 seconds to enable the display codes feature of the SECM Simply turn the key OFF to exit display mode The code list will continue to repeat until the key is t...

Page 108: ...d for leaks in the system Possible ECT short to GND check ECT signal wiring z Check regulator for coolant leaks 22 ThrottleSensorInputLo TPS1 signal disconnected or open circuit Expected faults when E...

Page 109: ...l shut down 28 ETCSpringTestFailed Upon initial key up the internal throttle return spring has become weak Power Limit Perform throttle spring test by cycling the ignition key and re check for fault 2...

Page 110: ...intenance check on electrical connections to the battery and chassis ground z Check battery voltage during starting and with the engine running to verify charging system and alternator function Measur...

Page 111: ...dditional ETC faults z Check for ETC Sticking or other ETC faults z Verify if the lift truck was motored down a steep grade 61 Pedal1SensorInputLo APP1 signal disconnected open circuit or sensor malfu...

Page 112: ...d Fault Code MIL Only Check foot pedal connector 69 Pedal1ToPedal2Difference Measured APP2 pedal position signal is different than APP1 signal MIN power Limit Check foot pedal connector 71 AFRTrimValv...

Page 113: ...p and operation see mixer section z Check N2001 secondary for operation see N2001 Regulator section 74 O2SensorSwitching O2 sensor is not switching across the reference AFR voltage Stored Fault Code M...

Page 114: ...e the system to change gears smoothly the shift points for offset speed are adjustable The Autoshift controller prevents strain and abuse to the transmission It also prevents damage to the half shaft...

Page 115: ...Direction Inhibit mode Selected as factory setting z Manual mode Fail Safe mode manual operation in emergency Automatic mode Direction Inhibit mode z Start the engine See topic Starting the engine z...

Page 116: ...mally The sudden reversal of a loaded lift truck traveling forward can cause the load to fall or the lift truck to tip If the controller fails An operator can operate the truck manually by selecting t...

Page 117: ...art as load permits Typical Example 2 Move the lift truck FORWARD until the load touches the carriage Lifting the Load 1 Lift the load carefully and tilt the mast back a short distance Typical Example...

Page 118: ...ill on upgrades and downgrades Typical Example 2 For better vision travel in reverse with bulky loads Unloading Typical Example 1 Move the lift truck into the unloading position Typical Example 2 Tilt...

Page 119: ...le 4 Lower the carriage and forks to the travel position or to the park position Turning 1 When turning sharp corners keep close to the inside corner Begin the turn when the inside drive wheel meets t...

Page 120: ...n 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 a...

Page 121: ...parking brake 4 Tilt the mast forward and lower the fork to the ground WARNING Blocking the wheels will prevent unexpected lift truck movement which could cause personal injury 5 Turn the key in the...

Page 122: ...position 2 Raise the hook pin in each fork to side the fork on the carriage bar 3 Adjust the forks in the position most appropriate for the load and as wide as possible for load stability 4 When adjus...

Page 123: ...mmer z Dismount the battery from the machine Even though the machine is parked indoors if the place is hot or humid the battery should be kept in a dry cool place Charge the battery once a month z App...

Page 124: ...ck on the truck bed or the rail car Apply the parking brake and place the transmission control in NEUTRAL Tilt the mast forward and lower forks to the floor Turn the ignition switch to the OFF positio...

Page 125: ...as low as possible on the lift truck that is being towed Quick lift truck movement could overload the tow line or bar and cause it to break Gradual and smooth lift truck movement will work better Norm...

Page 126: ...s equal to or greater than the Standard or rated Capacity of the lift truck The individual load rating in most cases will be stamped on the fork in a readily visible area This is generally on the top...

Page 127: ...d bearing cross section of the remaining metal is decreased in size until it becomes insufficient to support the load and complete failure occurs Fatigue failure is the most common mode of fork failur...

Page 128: ...the forks 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...

Page 129: ...ith a carbon stone to remove minor surface cracks or defects Polish the inside radius of the heel section to increase the fatigue life of the fork Always grind or polish in the direction of the blade...

Page 130: ...own in the following chart are cold inflation shipping pressures Shipping Pressure Size Ply Rating or Strength Index kPa psi 6 5X10 10 790 115 7 0X15 12 825 120 28X9 15 12 825 120 1 Standard tire ply...

Page 131: ...lb in 16 mm 625 in 7 5 0 5 65 5 13 5 mm 531 in 4 5 0 5 40 5 8 mm 312 in 0 9 0 2 8 2 Reassembly or Retightening Torque On Existing Hose Clamp Width N m1 lb in 16 mm 625 in 4 5 0 5 40 5 13 5 mm 531 in 3...

Page 132: ...esult in personal injury Original fasteners removed from the lift truck should be saved for reassembly whenever possible If new fasteners are needed they must be of the same size and grade as the ones...

Page 133: ...shipped to an area with freezing temperatures the cooling system must be protected to the lowest expected outside ambient temperature The engine cooling system is normally protected to 28 C 20 F with...

Page 134: ...use it mixed with antifreeze of different brand DAEWOO recommends that the coolant mix contain 50 commercially available automotive antifreeze or equivalent and acceptable water to maintain and adequ...

Page 135: ...duced engine service life Crude oil is used to describe oils fuels that are not refined and are in the original state as when pumped from the ground Certain types of crude oils can be burned in DAEWOO...

Page 136: ...asoline should be used for DAEWOO forklift trucks The gasoline in which methanol is contained is not recommended The gasoline in which ethanol is contained is not recommended either It is recommended...

Page 137: ...nfrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of engine oil The sulfur products formation depends on the fuel sulfur content oil formulati...

Page 138: ...rease can not be used multipurpose type grease which contains 3 to 5 molybdenum disulfide can be used NLGI No 2 grade is suitable for most temperatures Use NLGI No 1 or No 0 grade for extremely low te...

Page 139: ...should be selected according to ambient temperature Refill Capacities REFILL CAPACITIES APPROXIMATE Compartment or System Liters U S Gal Engine Crankcase w Filter G424 G424E 2 4liter Gasoline LP Gas 4...

Page 140: ...Hydraulic Return Filter Change 162 Engine Valve Lash B3 3 Diesel Engine Only Check Adjust 162 Every 250 Service Hours or Monthly Air Intake System Check Clean 163 Hydraulic Oil Level Check 165 Drive...

Page 141: ...rly Fuel Filter G424 Gasoline Dual Fuel Engine Only Change 188 Engine Valve Lash B3 3 Diesel Engine Only Check Adjust 188 Steer Wheel Bearings Reassemble 189 Drive Wheel Bearing Power Shaft and Drive...

Page 142: ...e Clean 172 O Drive Axle Oil Level Check 166 O Drive Wheel Bearing Power Shaft Drive Wheel Reassemble 191 O Engine Oil Filter DB33A Diesel LP Gas Gasoline E G Only Change 167 O Engine Oil Filter DB33A...

Page 143: ...Inspect Lubricate 166 O Overhead Guard Inspect 172 O Oxygen Senser Change 199 O Parking Brake Inspect 156 O Parking Brake Test Adjust 160 173 O O PCV Valve System Inspect Clean 168 O Priming the Fuel...

Page 144: ...lve lash with the engine stopped To obtain an accurate measurement allow at least 20 minutes to cool the engine cylinder head and block temperature Set the clearance to the nominal appropriate clearan...

Page 145: ...oil the seat slider tracks if necessary 2 Push the lever down to raise the hood and seat assembly D G Series Pull the latch to raise the hood and seat assembly GC Series Make certain the support cyli...

Page 146: ...amps 2 Head Rear Lamp 15 amps 3 Fwd Rev Solenoid lamp Relay Back up Lamp alarm 10 amps 4 Instrument Panel Fuel Shutoff 15 amps 5 Turn Signal Lamp Stop Strobe Lamp C S D DB33A Diesel only 15 amp 6 Sta...

Page 147: ...d rear side of valve mounting bracket G25P 3 G20 25 30 33P 3 Located rear side of valve mounting brackcet GC25E 3 GC20 25 30E 3 Located on the top of engine Located on the frame left side GC25P 3 GC20...

Page 148: ...ed on the right frame rail Located on the left frame Located rear side of valve mounting bracket G20 25 30 33p 3 Dual fuel Only Main power relay main fuse fuel fuse Located rear side of valve mounting...

Page 149: ...e a clamp 1 on overflow pipes to injection nozzles DB33A Diesel Engine B3 3 Diesel Engine 2 Push the priming pump on top of the fuel filter housing against the spring to allow air mixed with fuel to e...

Page 150: ...llustrated in Top View below 3 Turn the wing nut 2 counter clockwise more than six turns to open the drain valve on the bottom of the fuel filter 4 Drain some fuel and any water until the clean fuel f...

Page 151: ...conds then perform a visual inspection of the fuel system Leaks will cause the solution to bubble 5 Repair any leaks before continuing 6 Crank the engine through several revolutions This will energize...

Page 152: ...flation Pressures To inflate tires always use a clip on chuck with a minimum 60 cm 24 inches length of hose to an in line valve and gauge Always stand behind the tread of the tire NOT in front of the...

Page 153: ...nd full free triple lift models the bottom of the inner mast must be flush with the bottom of the stationary mast 4 Measure the distance from the bottom of the inner upright to the bottom of carriage...

Page 154: ...mponents can cause personal injury Do not allow hot oil or components to contact skin Gasoline and LP Gas Engines 2 Maintain oil level between the MAX and MIN marks on the dipstick Diesel Engines 3 Ma...

Page 155: ...protective clothing and protective shoes Maximum air pressure must be less than 205 kPa 30 psi for cleaning purposes 6 Blow any dust and lint from the radiator fins Air Cleaner Indicator Check Checki...

Page 156: ...le leaks on the lift truck and on the ground 5 Inspect the operator s compartment for loose items and cleanliness 6 Inspect the instrument panel for broken gauges and indicator lights 7 Test the horn...

Page 157: ...perature 2 Park the lift truck level with the forks lowered parking brake applied and the transmission controls in NEUTRAL 3 With the service brake applied and the engine at low idle shift the directi...

Page 158: ...tendency to move under power with the parking brake engaged PARKING BRAKE NOTE The parking brake is required to be adjusted to hold the lift truck with capacity load on a 15 grade If there is a 15 gr...

Page 159: ...brake applied transmission in neutral and the engine stopped 2 Raise rear of lift truck off ground and block securely WARNING Hot oil and components can cause personal injury Do not allow hot oil or c...

Page 160: ...nt must be changed after the first 50 hours Transmission Oil Oil Filter Strainer Check Clean Change WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to conta...

Page 161: ...vel 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 approxima...

Page 162: ...parking brake and slowly release the service brake 4 Engage the parking brake and shift the transmission to NEUTRAL Slowly release the service brakes 5 The parking brake adjustment is proper if it ho...

Page 163: ...ke lever when the lever 1 is held against the stop pin 2 Then install the pin 3 and the cotter pin 4 and return the nut 6 to the clevis 5 7 Loosen lock nut 5 Tighten screw 6 to 6 to 7 N m 50 to 60 lb...

Page 164: ...bly Engine Valve Lash B3 3 Diesel Engine Only Check Adjust NOTICE The valve clearances are to be adjusted at the times of the following situations z When the engine is overhauled and the cylinder head...

Page 165: ...ocked in the visible position with the engine stopped 1 To service the air cleaner raise the hood and seat assembly Make certain the support cylinder securely holds the hood open Loosen the cover latc...

Page 166: ...eaning Do not use a filter with damaged pleats gaskets or seals When cleaning with pressure air use 205 kPa 30 psi maximum pressure to prevent filter element damage When cleaning with pressure water u...

Page 167: ...ter cap only when the engine is stopped and the cap is cool enough to touch with your bare hand Remove the filter cap slowly to relieve pressure 1 Operate the lift truck for a few minutes to warm the...

Page 168: ...operation and damage Have repairs made if necessary 4 Brush a film of oil on all links of the chain 5 Raise and lower the carriage a few times to allow lubricant to enter into the chain links NOTICE...

Page 169: ...Gas Gasoline Engine Only Change DB33A Diesel Engine Crankcase See topic Engine Oil Filter DB33A Diesel Engine Only Change in First 50 100 Service Hours Gasoline LP Gas Engine Crankcase 1 Operate lift...

Page 170: ...n 9 Raise the lift truck remove the blocking and lower the lift truck 10 Fill the crankcase See Refill Capacities 11 Start the engine and allow the oil to fill the filter and passages 12 Check for oil...

Page 171: ...wheel bolts in a sequence opposite each other 110 N m 75 lb ft Drive Wheels Typical Example 2 Inspect tightness of wheel nuts in a sequence opposite each other to 610 N m 450 lb ft Inspect Tightness...

Page 172: ...ill cause excessive stress and break the alternator mounting ear 2 To adjust the alternator drive belt loosen adjusting bracket bolt 1 and mounting bolt 2 Move the alternator in or out as required Tig...

Page 173: ...ter the other cylinder has stopped in full forward or backward tilt an adjustment must be made to one cylinder Typical Example 3 To adjust the cylinder rod extension move the spacer to the rear and lo...

Page 174: ...direction control lever to forward and reverse to fill the clutches 7 Shift the direction control lever into NEUTRAL Engage the parking brake 8 Remove the dip stick filter cap Observe the oil level 9...

Page 175: ...ll Capacities 5 Start the lift truck with engine at low idle place the directional control lever to the NEUTRAL 6 Maintain the oil level between lower mark and upper mark on the dip stick filter cap 7...

Page 176: ...f 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 t...

Page 177: ...t 3 4 of a turn more Do not over tighten 9 Raise the lift truck remove the blocking and lower the lift truck Typical Example 10 Fill the crankcase See Refill Capacities 11 Start the engine and allow t...

Page 178: ...riodically the mesh strainer must be cleaned and the paper element must be replaced Disassembly and cleaning of fuel filter 1 Loosen the bolts and separate the mesh strainer 2 Pull out the mesh strain...

Page 179: ...connector to the FTV 4 Disconnect the vacuum lines form the FTV to the pressure regulator converter at the converter s tee connection 5 Lightly blow through the vacuum line connected to the FTV Air sh...

Page 180: ...sting sensor assembly and apply a small amount of clean fuel to the filter cartridge gasket NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated we...

Page 181: ...L and the engine stopped 1 Loosen the bolts of the hydraulic tank top plate assembly 2 Remove the return filter from tank top plate assembly 3 Install new return filter by hand 4 Remove the suction st...

Page 182: ...eps to check chain wear 1 Lift the mast and carriage enough for getting tension on lift chains Typical example 2 Measure precisely ten links of chain distance at the center of pins in millimeter 3 Cal...

Page 183: ...in of STD mast Typical example for carriage chain of FF FFT mast 3 Make adjustment anchor nut 1 2 for equal chain tension 4 Set the mast vertical and raise the carriage and check equal chain tension I...

Page 184: ...ngs replaced Check for loose retaining bolts and nuts Tighten the bolts and nuts if necessary Carburetor LP Gas Gasoline Dual Fuel Engine Only Adjust Clean G424 Engine Gasoline LP Gas Dual Fuel G430 E...

Page 185: ...ndicator If the indicator shows RED after installing a new secondary element and a cleaned primary outer element replace the cleaned primary filter with a new element 5 Stop the engine Close the hood...

Page 186: ...anual for procedures on removing the mixer and inspecting the throttle plate Fuel Filter DB33A Diesel Engine Only Change Diesel Engine DB33A Diesel Engine 1 Remove fuel filter cartridge assembly 2 Rem...

Page 187: ...tion Visually inspect the coil heat sink fins If any fins are broken replace as required G424 E Engine G430 E Engine 1 Spark Plug Cables 2 Distributor Cap Replace Spark Plugs LP Gas Gasoline Dual Fuel...

Page 188: ...pump and crank the engine several times before attempting a start to prime the fuel pump NOTE Replacement interval of Secondary fuel filter is 2 500 hrs or 15 months G424E Dual Fuel 1 Primary fuel fi...

Page 189: ...ribe lines on the top and bottom covers 5 Install the cover retaining screws tightening the screws in an opposite sequence across the cover 6 Open the fuel valve by slowly turning the valve counterclo...

Page 190: ...area with the forks lowered parking brake applied transmission in NEUTRAL and the engine stopped WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Turn the di...

Page 191: ...under the frame and steer axle to support the lift truck Typical Example 2 Remove the hub cap which is pressed into the wheel hub 3 Straighten the lock washer tangs 4 Remove the locknut lock washer an...

Page 192: ...ocknut Typical Example 9 Tighten the locknut to 135 N m 100 lb ft while turning wheel hub to seat the bearing 10 Loosen the locknut Retorque it to 50 5N m 37 4 lb ft Bend the lock washer tang to secur...

Page 193: ...urned in both directions Loosen the nut completely and tighten nut again to 50 5 N m 37 4 lb ft Bend the lock washer tab into a groove of the nut Torque for bolts 4 that hold cover to drive axle housi...

Page 194: ...o a suitable container Drain the recovery bottle 4 Close radiator drain valve and install block drain plug Fill the cooling system with 1 kilo 2 lb sodium bisulphate per 40 liters 10 gallons of water...

Page 195: ...fork should be withdrawn from service if angle C exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees as may be found in some special application forks 3...

Page 196: ...revented 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 p...

Page 197: ...llow the oil to drain into a suitable container Clean and install the plug 2 Remove the dipstick filter cap assembly 3 Fill the hydraulic tank See topic Refill Capacities Install the dipstick filter c...

Page 198: ...ns out of fuel and the engine stops Turn off the ignition switch 3 Replace the fuel filter taking care to install the new filter with flow in the proper direction 4 Re install the fuse for the pump an...

Page 199: ...ilicon lubricant to the TMAP o ring seal 5 Re install the TMAP sensor into the manifold adapter and securely tighten the retaining screw 1 TMAP sensor 2 Throttle Assembly 3 Manifold Adapter Inspect fo...

Page 200: ...tion 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 for the procedure and specification...

Page 201: ...e Only G424E Engine G430E Engine 1 Stop engine and wait until the exhaust pipe and exhaust pipe is cooled 2 Disconnect the electrical connector of oxygen sensor 3 Remove oxygen sensor 4 Assemble new o...

Page 202: ...cking Service Indicator 153 Checking the TMAP Sensor G424E G430E Engine Only 197 Circuit Breaker 68 144 Cleaning Primary Filter Elements 164 Coolant Information 131 Coolant Level Check 152 Coolant Wat...

Page 203: ...424 Engine 197 G424 Engine Gasoline LP Gas Dual Fuel 182 G424 Gasoline LP Gas and Dual Fuel Engines168 G424 E Engine 185 G424E Engine 199 G424E G430E Electronic Controlled LP and Dual Fuel Engines If...

Page 204: ...ditions 132 Manual Mode Fail Safe mode 114 Mast Abbreviations 64 Mast Channels Lubricate 155 Mast Hinge Pin Lubricate 170 Mast Pivot Eyes Lubricate 171 Mast Carriage Lift Chains Attachments Inspect Lu...

Page 205: ...8 Timing Belt for Counterbalance Shaft G424 E LP Gas Gasoline Dual Fuel Engine Only Change 198 Tire Inflation 128 Tire Inflation Information 128 Tire Inflation Pressures Adjustment 128 Tire Shipping P...

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