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D25S-3
Daewoo D25S-3 Service Manual
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Maintenance Section
-146-
G20/25/30/32E-3 (Dual fuel Only)
Located 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 rela
y, main fuse, fuel fuse
Located rear side of valve mounting bracket.
Fuel select relay1, relay2
Located on the left frame.
147
149
Table of Contents
Table of Contents
3
Information Section
4
Foreword
4
Information Section
4
Literature Information
4
Safety Section
6
Important Safety Information
6
Safety
7
Warning Signs and Labels
7
Parking Brake
11
General Hazard Information
12
All Maintenance and Repair, Except Every
12
Operation Information
13
Maintenance Information
16
Fire Extinguisher
18
Operator Restraint System(if Equipped)
19
Avoiding Lift Truck Tipover
23
Safety Rules
25
How to Survive in a Tipover
30
General Section
32
Specifications
32
Noise and Vibration
52
Capacity Chart
53
Serial Number
63
Operator's Warning and Identification Plate
66
Operation Section
67
Operator's Station and Monitoring Systems
67
Lift Truck Controls
71
Parking Brake Lever
72
Accelerator Pedal
72
Refueling
74
Before Starting the Engine
77
Starting the Engine
80
Dual Fuel System (if G424 Dual Fuel Engine Equipped)
83
Dual Fuel System (G424E Engine Only)
85
Lift Truck Operation
88
(If Equipped)
91
Advanced Diagnostics
106
Displaying Fault Codes
107
Codes)
108
Table A. MI-04 Diagnostic Fault Codes (Flash Codes)
108
Auto Shift Controller ASC-100 (if Equipped)
114
Operating Techniques
117
Parking the Lift Truck
121
Lift Fork Adjustment
122
Storage Information
123
Transportation Hints
124
Towing Information
125
Maintenance Section
126
Inspection, Maintenance and Repair of Lift Truck Forks
126
Daily Inspection
128
Tire Inflation Information
130
Torque Specifications
131
Cooling System Specifications
133
Coolant Water
134
Antifreeze
134
Fuel Specifications
135
Quick Reference to Maintenance Schedule
135
Lubricant Information
137
Engine/Hydraulic Oil
137
Lubricant Viscosities and Refill Capacities
139
Maintenance Intervals
140
When Required
144
Engine Valve Lash (DB33A Diesel Engine Only) - Check, Adjust
144
Fuel Tank Filter Cap and Screen (if Equipped) - Clean
144
Seat, Hood Latch & Support Cylinder - Check, Lubricate
145
Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset
146
Fuse & Relay (G424E/G430E Only)
147
Priming the Fuel System (Diesel Engine Only)
149
Tires and Wheels (D, G-Series) - Inspect, Check
152
Carriage Roller Extrusion - Adjust
153
Every 10 Service Hours or Daily
154
Inspect Engine for Fluid Leaks
154
Engine Oil Level - Check
154
Coolant Level - Check
154
Air Cleaner Indicator-Check
155
Inspect Foot Pedal Operation (G424E/G430E Only)
155
Inspect Engine for Exhaust Leaks
155
Walk-Around Inspection - Inspect
156
Mast Channels - Lubricate
157
Transmission Oil Level - Check
157
Parking Brake - Inspect
158
First 50 - 100 Service Hours or a Week
159
Engine Oil & Filter (DB33A Diesel Engine Only) - Change
159
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
160
Drive Axle Oil - Change
161
Parking Brake - Test, Adjust
162
First 250 Service Hours or a Month
164
Hydraulic Return Filter - Change
164
Engine Valve Lash (B3.3 Diesel Engine Only) - Check, Adjust
164
Every 250 Service Hours or Monthly
165
Air Intake System - Check, Clean
165
Hydraulic Oil Level - Check
167
Drive Axle Oil Level - Check
168
Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate
168
Steering Mechanism - Check, Lubricate
168
Battery Terminal - Clean, Inspect
169
Engine Oil & Filter (DB33A Diesel, LP-Gas & Gasoline Engine Only) - Change
169
PCV Valve System - Inspect, Clean
170
Wheel Bolts & Nuts - Inspect
171
Every 500 Service Hours or 3 Months
172
Belts - Check, Adjust
172
Mast Hinge Pin - Lubricate
172
Tilt Cylinders - Check, Adjust, Lubricate
172
Crosshead Rollers - Inspect
173
Transmission Oil Filter - Change
174
Overhead Guard - Inspect
174
Drive Axle Oil & Strainer - Change, Clean
174
Steer Suspension - Inspect
175
Parking Brake - Test, Adjust
175
Inching & Braking Control Shaft - Lubricate
176
Horn and Lights (if Equipped) - Check
176
Engine Oil & Filter (B3.3 Diesel Engine Only) - Change
176
Fuel Strainer (B3.3 Diesel Engine Only) - Clean
178
Inspect Vacuum Lines and Fittings (G424E/G430 Engine Only)
179
Fuel Trim Valve(FTV) Inspection
179
(G424E/G430E Engine Only)
179
Inspect Electrical System (G424E/G430E Engine Only)
179
Inspect VR Sensor - Clean (G424E/G430E Engine Only)
179
Fuel Filter (B3.3 Diesel Engine Only) - Change.178
180
Every 1000 Service Hours or 6 Months
181
Hydraulic Return Filter, Breather & Strainer - Check, Change
181
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
182
Lift Chains - Test, Check, Adjust
182
Universal Joint - Inspect
184
Carburetor (LP-Gas, Gasoline & Dual Fuel Engine Only) - Adjust, Clean
184
Air Intake System - Change
185
Inspect Coolant Hoses (LP Engine Only)
185
LP Regulator/Converter Inspection (LP Engine Only)
185
Fuel Lines & Fittings - Check
186
Inspect Mixer Assembly (G424E/G430E Engine Only)
186
Inspect Throttle Assembly (G424E/G430E Engine Only)
186
Fuel Filter (DB33A Diesel Engine Only) - Change
186
Every 1500 Service Hours or 9 Months
187
Inspect Ignition System (LP-Gas, Gasoline & Dual Fuel Engines Only)
187
Replace Spark Plugs (LP-Gas, Gasoline & Dual Fuel Engines Only)
187
Replace LP Fuel Filter Element (LP-Gas, Dual Fuel Engine Only)
188
Fuel Filter(LP-Gas Engine Only)
189
Testing Fuel Lock-Off Operation
189
Only)
189
Every 2000 Service Hours or Yearly
190
Fuel Filter(G424 Gasoline & Dual Fuel Engine Only) - Change
190
Engine Valve Lash (B3.3 Diesel Engine Only) - Check, Adjust
190
Steer Wheel Bearings - Reassemble
191
Drive Wheel Bearing (Power Shaft and Drive Wheel) - Reassemble
193
Cooling System - Clean, Change
194
Forks - Inspect
195
Every 2500 Service Hours or 15 Months
197
Hydraulic Oil - Check, Clean, Change
197
Inspect Battery System
197
Checking the TMAP Sensor (G424E/G430E Engine Only)
199
Inspect for Intake Leaks
199
Only)
199
Replace PCV Valve and Breather Element - Change
199
(LP-Gas, Gasoline and Dual Fuel Engines)
199
Every 3000 Service Hours or 18 Months
200
Timing Belt [G424(E) LP-Gas, Gasoline Dual Fuel Engine Only] - Change
200
Timing Belt for Counterbalance Shaft [G424(E) LP-Gas, Gasoline & Dual Fuel Engine Only] - Change
200
Every 4500 Service Hours or Two Years
201
Replace Oxygen Sensor (G424E/G430E Engine Only)
201
Index Section
202
Index
202
4
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Daewoo D25S-3 Specifications
General
Brand
Daewoo
Model
D25S-3
Category
Trucks
Language
English
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