Daewoo D25S-3 Service Manual

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.)
SB2302E06

Daewoo D25S-3 Specifications

General

Brand	Daewoo
Model	D25S-3
Category	Trucks
Language	English

Summary

Safety Section

Important Safety Information

Essential safety precautions and hazard identification.

Warning Signs and Labels

Explanation of safety signs and labels on the lift truck.

Traing Required To Operate or Service

Requirement for training before operating or servicing the lift truck.

General Warning to Operator

Key operational warnings and safety advice for the operator.

Parking brake

Procedure for engaging and releasing the parking brake.

General Hazard Information

General safety guidelines to avoid hazards during operation.

Operator Restraint System (If Equipped)

Safety and operational guidance for the operator restraint system.

Avoiding Lift Truck Tipover

Information on lift truck stability and prevention of tipovers.

Safety Rules

Fundamental safety rules for operating forklift trucks.

How to Survive in a Tipover

Guidelines for operator safety during a tipover event.

Operation Section

Operator's Station and Monitoring Systems

Description of the instrument panel and monitoring indicators.

Lift Truck Controls

Overview of various lift truck control levers and switches.

Refueling

Procedure for safely refueling gasoline or diesel lift trucks.

Changing LP - Gas Tanks

Steps for safely exchanging LP-Gas tanks.

Before Starting the Engine

Detailed walk-around inspection checklist before starting the engine.

Towing Information

Recommendations and warnings for towing a disabled lift truck.

Starting the Engine

Procedures for starting gasoline, LP-Gas, and diesel engines.

Dual Fuel System (If G424 Dual Fuel Engine Equipped)

Instructions for switching between gasoline and LP-Gas fuel.

Lift Truck Operation

Guidance on operating the lift truck with power shift transmission.

G424E/G430E Electronic Controlled LP and Dual Fuel Engines (If Equipped)

Basic Troubleshooting(LPG)

Troubleshooting guide for common LPG engine issues.

Advanced Diagnostics

Information on the MI-04 system's fault diagnostics and MIL.

Reading Diagnostic Fault Codes

How to interpret diagnostic fault codes displayed by the MIL.

Displaying Fault Codes (DFC) From SECM Memory

Procedure to enter code display mode and view fault codes.

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

List of MI-04 diagnostic fault codes and their corrective actions.

Auto Shift Controller ASC-100 (If Equipped)

Diagnostics Features

Operation

Automatic mode (Direction Inhibit mode)

Manual Mode (Fail-Safe mode)

Operating Techniques

Lifting the Load

Traveling With the Load

Unloading

Parking the Lift Truck

Step-by-step instructions for parking the lift truck safely.

Lift Fork Adjustment

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

Guidelines for inspecting, maintaining, and repairing lift truck forks.

Causes of Fork Failure

Fork Inspection

Tire Inflation Information

Torque Specifications

Torque values for metric and standard hardware and hose clamps.

Cooling System Specifications

Fuel Specifications

Lubricant Information

Lubricant Viscosities and Refill Capacities

Maintenance Intervals

Schedule for routine maintenance tasks based on service hours or time.

When Required

Every 10 Service Hours or Daily

Walk-Around Inspection - Inspect

Thorough walk-around inspection checklist for maximum service life.

Parking Brake - Inspect

Inspection procedures for the parking brake, with engine off and on.

First 250 Service Hours or a Month

Every 250 Service Hours or Monthly

Air Intake System - Check, Clean

Every 500 Service Hours or 3 Months

Belts - Check, Adjust

Transmission Oil Filter – Change

Drive Axle Oil & Strainer - Change, Clean

Parking Brake - Test, Adjust

Referral to parking brake testing and adjustment procedures.

Every 1000 Service Hours or 6 Months

Hydraulic Return Filter, Breather & Strainer - Check, Change

Transmission Oil, Oil Filter & Strainer - Check, Clean, Change

Lift Chains - Test, Check, Adjust

Carriage Chain Adjustment

Mast Chain Adjustment - FF, FFT Mast

Every 1500 Service Hours or 9 Months

Inspect Ignition System (LP-Gas, Gasoline & Dual Fuel Engines Only)

Replace Spark Plugs (LP-Gas, Gasoline & Dual Fuel Engines Only)

Replace Gasoline Primary Fuel Filter(G424E/G430E Dual Fuel Only)

Replace LP Fuel Filter Element (LP-Gas, Dual Fuel Engine Only)

Every 2000 Service Hours or Yearly

Fuel Filter (G424 Gasoline & Dual Fuel Engine Only) - Change

Steer Wheel Bearings - Reassemble

Every 2500 Service Hours or 15 Months

Hydraulic Oil - Check, Clean, Change

Checking the TMAP Sensor (G424E/G430E Engine Only)

Replace PCV Valve and breather element - Change (LP-Gas, Gasoline and Dual Fuel Engines)

Every 3000 Service Hours or 18 Months

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

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

Every 4500 Service Hours or two Years

Replace Oxygen Sensor (G424E/G430E Engine Only)