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Daewoo GC25E-3 - User Manual

Daewoo GC25E-3
205 pages
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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

Table of Contents

Other manuals for Daewoo GC25E-3

Questions and Answers

Summary

Foreword

Literature Information

Manual storage, content, and design information.

Safety

Important Safety Information

Basic safety precautions, hazard identification, and general safety advice.

Warning Signs and Labels

Explanation of safety signs and labels on the lift truck.

General Warning to Operator

Key operational warnings and safety rules for the operator.

Operation Information

Mounting and Dismounting

Steps for safely getting on and off the lift truck.

Before Starting the Lift Truck

Pre-operation checks and adjustments before starting the engine.

Operators Station and Monitoring Systems

Instrument Panel

Details about the instrument panel and indicators for Diesel and LPG/Gas engines.

Lift Truck Controls

Direction Control Lever

Explanation of directional control lever for forward, neutral, and reverse.

Refueling

Gasoline or Diesel Engine Equipped

Procedures for refueling gasoline or diesel engines.

Changing LP - Gas Tanks

Before Starting the Engine

Walk - Around Inspection

Thorough walk-around inspection steps before starting the engine.

Starting the Engine

Diesel Engine

Procedures for starting cold and warm diesel engines.

Dual Fuel System

Changing From Gasoline to LP - Gas

Instructions for switching from gasoline to LP-Gas fuel.

Lift Truck Operation

Power Shift Transmission; Drive axle

Guidance on operating the lift truck with power shift transmission.

Basic Troubleshooting(LPG)

Advanced Diagnostics

Reading Diagnostic Fault Codes

Information on retrieving and interpreting diagnostic fault codes.

Inspection, Maintenance and Repair of Lift Truck Forks

Causes of Fork Failure

Discusses improper repair, bending, fatigue, and overloading as causes.

Fork Inspection

Guidelines for daily and 12-month inspection of forks.

Torque Specifications

Torque for Standard Bolts, Nuts, and Taperlock Studs

General torque specifications for SAE Grade 5 or better bolts and nuts.

Cooling System Specifications

Coolant Information

Information on engine operating temperatures and coolant importance.

Fuel Specifications

Diesel Specifications

Preferred and permissible fuel types for DAEWOO Diesel Engines.

Lubricant Information

Engine Oil (DEO and EO)

Oil specifications for Gasoline/LP-Gas and Diesel engines.

Hydraulic Oil (HYDO)

Commercial classifications and viscosity for hydraulic systems.

Lubricant Viscosities and Refill Capacities

Refill Capacities

Approximate capacities for various compartments and systems.

Drive Axle Oil

Drive Axle Oil

Recommendations for API and MIL specifications for drive axle oil.

Transmission Oil

Transmission Oil

Recommendations and cautions for transmission oil.

Maintenance Intervals

Every 10 Service Hours or Daily

Daily maintenance checks and inspections.

First 50 - 100 Service Hours or a Week

Initial maintenance tasks after 50-100 service hours or one week.

First 250 Service Hours or a Month

Maintenance tasks for the first 250 service hours or month.

Every 500 Service Hours or 3 Months

Maintenance tasks every 500 service hours or 3 months.

Every 2000 Service Hours or Yearly

Yearly maintenance tasks.

Every 3000 Service Hours or 18 Months

Maintenance tasks every 3000 service hours or 18 months.

Quick Reference to Maintenance Schedule

10 Service Hours or Daily

Maintenance tasks scheduled for every 10 service hours or daily.

250 Service Hours or a Month

Maintenance tasks scheduled for 250 service hours or monthly.

1000 Service Hours or 6 Months

Maintenance tasks scheduled for 1000 service hours or semi-annually.

When Required

Fuel Tank Filter Cap and Screen (If Equipped) - Clean

Procedure for cleaning the fuel tank filter cap and screen.

Seat, Hood Latch & Support Cylinder - Check, Lubricate

Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset

Circuit Breaker

Information on locating, resetting, and checking circuit breakers.

Priming the Fuel System (Diesel Engine Only)

Bleeding the Fuel System

Procedure for removing air from the fuel system after service.

Draining the Water from the Fuel Filter

Test Fuel System for Leaks(LP and Dual Fuel Engines Only)

Tires and Wheels (D, G-Series) - Inspect, Check

Carriage Roller Extrusion - Adjust

Every 10 Service Hours or Daily

Inspect Engine for Fluid Leaks

Procedure to inspect the engine for oil and coolant leaks.

Engine Oil Level - Check

Steps to check the engine oil level using the dipstick.

Coolant Level - Check

Procedure to check the engine coolant level.

Walk-Around Inspection - Inspect

Mast Channels - Lubricate

Transmission Oil Level - Check

Parking Brake - Inspect

Inspection from Operators Seat, Engine OFF

Procedure to inspect the parking brake lever when the engine is off.

First 50 - 100 Service Hours or a Week

Engine Oil & Filter (DB33 A Diesel Engine Only) - Change

Steps to change the engine oil and filter for DB33A Diesel engines.

Drive Axle Oil - Change

Parking Brake - Test, Adjust

Parking Brake Testing

Procedure to test the parking brake's ability to hold the truck on a grade.

First 250 Service Hours or a Month

Hydraulic Return Filter - Change

Procedure to change the hydraulic return filter.

Every 250 Service Hours or Monthly

Air Intake System - Check, Clean

Steps to check and clean the air intake system.

Cleaning Primary Filter Elements

Every 500 Service Hours or 3 Months

Belts - Check, Adjust

Procedure to check and adjust drive belts.

Mast Pivot Eyes-Lubricate

Cylinder Rod Extension-Adjust

Crosshead Rollers - Inspect

Transmission Oil Filter - Change

Overhead Guard - Inspect

Drive Axle Oil & Strainer - Change, Clean

Steer Suspension - Inspect

Inching & Braking Control Shaft - Lubricate

Horn and Lights (If Equipped) - Check

Engine Oil & Filter (B3.3 Diesel Engine Only) - Change

Fuel Strainer (B3.3 Diesel Engine Only) - Clean

Inspect Vacuum Lines and Fittings (G424 E;G430 Engine Only)

Inspect Electrical System (G424 E;G430 E Engine Only)

Inspect VR Sensor - Clean (G424 E engine only)

Fuel Filter (B3.3 Diesel Engine Only) - Change

Every 1000 Service Hours or 6 Months

Hydraulic Return Filter, Breather & Strainer - Check, Change

Procedure to check and change hydraulic return filter, breather, and strainer.

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

Lift Chain Wear Test

Method for measuring chain link and pin wear.

Carriage Chain Adjustment

Mast Chain Adjustment - FF, FFT Mast

Universal Joint - Inspect

Carburetor (LP-Gas, Gasoline & Dual Fuel Engine Only) - Adjust, Clean

Air Intake System - Change

Changing Primary Element

Procedure for changing the primary air cleaner element.

Changing Secondary Element

Procedure for replacing the secondary air cleaner element.

Inspect Coolant Hoses (LP Engine Only)

LP Regulator;Converter Inspection (LP Engine Only)

Every 1500 Service Hours or 9 Months

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

Steps to inspect the ignition system for LP-Gas, Gasoline, and Dual Fuel engines.

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

Procedure for replacing spark plugs on LP-Gas, Gasoline, and Dual Fuel engines.

Replace Gasoline Secondary Fuel Filter(G424 E;G430 E 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

Steps to change the fuel filter for G424 Gasoline and Dual Fuel engines.

Steer Wheel Bearings - Reassemble

Drive Wheel Bearing (Power Shaft and Drive Wheel) - Reassemble

Cooling System - Clean, Change

Forks - Inspect

Every 2500 Service Hours or 15 Months

Hydraulic Oil - Check, Clean, Change

Procedure to check, clean, and change the hydraulic oil.

Inspect Battery System

Steps to clean and inspect the battery system.

Every 3000 Service Hours or 18 Months

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

Procedure and specification for changing the timing belt.

Every 4500 Service Hours or two Years

Replace Oxygen Sensor (G424 E;G430 E Engine Only)

Procedure for replacing the oxygen sensor on G424E/G430E engines.

Summary

Foreword

Literature Information

Manual storage, content, and design information.

Safety

Important Safety Information

Basic safety precautions, hazard identification, and general safety advice.

Warning Signs and Labels

Explanation of safety signs and labels on the lift truck.

General Warning to Operator

Key operational warnings and safety rules for the operator.

Operation Information

Mounting and Dismounting

Steps for safely getting on and off the lift truck.

Before Starting the Lift Truck

Pre-operation checks and adjustments before starting the engine.

Operators Station and Monitoring Systems

Instrument Panel

Details about the instrument panel and indicators for Diesel and LPG/Gas engines.

Lift Truck Controls

Direction Control Lever

Explanation of directional control lever for forward, neutral, and reverse.

Refueling

Gasoline or Diesel Engine Equipped

Procedures for refueling gasoline or diesel engines.

Changing LP - Gas Tanks

Before Starting the Engine

Walk - Around Inspection

Thorough walk-around inspection steps before starting the engine.

Starting the Engine

Diesel Engine

Procedures for starting cold and warm diesel engines.

Dual Fuel System

Changing From Gasoline to LP - Gas

Instructions for switching from gasoline to LP-Gas fuel.

Lift Truck Operation

Power Shift Transmission; Drive axle

Guidance on operating the lift truck with power shift transmission.

Basic Troubleshooting(LPG)

Advanced Diagnostics

Reading Diagnostic Fault Codes

Information on retrieving and interpreting diagnostic fault codes.

Inspection, Maintenance and Repair of Lift Truck Forks

Causes of Fork Failure

Discusses improper repair, bending, fatigue, and overloading as causes.

Fork Inspection

Guidelines for daily and 12-month inspection of forks.

Torque Specifications

Torque for Standard Bolts, Nuts, and Taperlock Studs

General torque specifications for SAE Grade 5 or better bolts and nuts.

Cooling System Specifications

Coolant Information

Information on engine operating temperatures and coolant importance.

Fuel Specifications

Diesel Specifications

Preferred and permissible fuel types for DAEWOO Diesel Engines.

Lubricant Information

Engine Oil (DEO and EO)

Oil specifications for Gasoline/LP-Gas and Diesel engines.

Hydraulic Oil (HYDO)

Commercial classifications and viscosity for hydraulic systems.

Lubricant Viscosities and Refill Capacities

Refill Capacities

Approximate capacities for various compartments and systems.

Drive Axle Oil

Drive Axle Oil

Recommendations for API and MIL specifications for drive axle oil.

Transmission Oil

Transmission Oil

Recommendations and cautions for transmission oil.

Maintenance Intervals

Every 10 Service Hours or Daily

Daily maintenance checks and inspections.

First 50 - 100 Service Hours or a Week

Initial maintenance tasks after 50-100 service hours or one week.

First 250 Service Hours or a Month

Maintenance tasks for the first 250 service hours or month.

Every 500 Service Hours or 3 Months

Maintenance tasks every 500 service hours or 3 months.

Every 2000 Service Hours or Yearly

Yearly maintenance tasks.

Every 3000 Service Hours or 18 Months

Maintenance tasks every 3000 service hours or 18 months.

Quick Reference to Maintenance Schedule

10 Service Hours or Daily

Maintenance tasks scheduled for every 10 service hours or daily.

250 Service Hours or a Month

Maintenance tasks scheduled for 250 service hours or monthly.

1000 Service Hours or 6 Months

Maintenance tasks scheduled for 1000 service hours or semi-annually.

When Required

Fuel Tank Filter Cap and Screen (If Equipped) - Clean

Procedure for cleaning the fuel tank filter cap and screen.

Seat, Hood Latch & Support Cylinder - Check, Lubricate

Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset

Circuit Breaker

Information on locating, resetting, and checking circuit breakers.

Priming the Fuel System (Diesel Engine Only)

Bleeding the Fuel System

Procedure for removing air from the fuel system after service.

Draining the Water from the Fuel Filter

Test Fuel System for Leaks(LP and Dual Fuel Engines Only)

Tires and Wheels (D, G-Series) - Inspect, Check

Carriage Roller Extrusion - Adjust

Every 10 Service Hours or Daily

Inspect Engine for Fluid Leaks

Procedure to inspect the engine for oil and coolant leaks.

Engine Oil Level - Check

Steps to check the engine oil level using the dipstick.

Coolant Level - Check

Procedure to check the engine coolant level.

Walk-Around Inspection - Inspect

Mast Channels - Lubricate

Transmission Oil Level - Check

Parking Brake - Inspect

Inspection from Operators Seat, Engine OFF

Procedure to inspect the parking brake lever when the engine is off.

First 50 - 100 Service Hours or a Week

Engine Oil & Filter (DB33 A Diesel Engine Only) - Change

Steps to change the engine oil and filter for DB33A Diesel engines.

Drive Axle Oil - Change

Parking Brake - Test, Adjust

Parking Brake Testing

Procedure to test the parking brake's ability to hold the truck on a grade.

First 250 Service Hours or a Month

Hydraulic Return Filter - Change

Procedure to change the hydraulic return filter.

Every 250 Service Hours or Monthly

Air Intake System - Check, Clean

Steps to check and clean the air intake system.

Cleaning Primary Filter Elements

Every 500 Service Hours or 3 Months

Belts - Check, Adjust

Procedure to check and adjust drive belts.

Mast Pivot Eyes-Lubricate

Cylinder Rod Extension-Adjust

Crosshead Rollers - Inspect

Transmission Oil Filter - Change

Overhead Guard - Inspect

Drive Axle Oil & Strainer - Change, Clean

Steer Suspension - Inspect

Inching & Braking Control Shaft - Lubricate

Horn and Lights (If Equipped) - Check

Engine Oil & Filter (B3.3 Diesel Engine Only) - Change

Fuel Strainer (B3.3 Diesel Engine Only) - Clean

Inspect Vacuum Lines and Fittings (G424 E;G430 Engine Only)

Inspect Electrical System (G424 E;G430 E Engine Only)

Inspect VR Sensor - Clean (G424 E engine only)

Fuel Filter (B3.3 Diesel Engine Only) - Change

Every 1000 Service Hours or 6 Months

Hydraulic Return Filter, Breather & Strainer - Check, Change

Procedure to check and change hydraulic return filter, breather, and strainer.

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

Lift Chain Wear Test

Method for measuring chain link and pin wear.

Carriage Chain Adjustment

Mast Chain Adjustment - FF, FFT Mast

Universal Joint - Inspect

Carburetor (LP-Gas, Gasoline & Dual Fuel Engine Only) - Adjust, Clean

Air Intake System - Change

Changing Primary Element

Procedure for changing the primary air cleaner element.

Changing Secondary Element

Procedure for replacing the secondary air cleaner element.

Inspect Coolant Hoses (LP Engine Only)

LP Regulator;Converter Inspection (LP Engine Only)

Every 1500 Service Hours or 9 Months

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

Steps to inspect the ignition system for LP-Gas, Gasoline, and Dual Fuel engines.

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

Procedure for replacing spark plugs on LP-Gas, Gasoline, and Dual Fuel engines.

Replace Gasoline Secondary Fuel Filter(G424 E;G430 E 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

Steps to change the fuel filter for G424 Gasoline and Dual Fuel engines.

Steer Wheel Bearings - Reassemble

Drive Wheel Bearing (Power Shaft and Drive Wheel) - Reassemble

Cooling System - Clean, Change

Forks - Inspect

Every 2500 Service Hours or 15 Months

Hydraulic Oil - Check, Clean, Change

Procedure to check, clean, and change the hydraulic oil.

Inspect Battery System

Steps to clean and inspect the battery system.

Every 3000 Service Hours or 18 Months

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

Procedure and specification for changing the timing belt.

Every 4500 Service Hours or two Years

Replace Oxygen Sensor (G424 E;G430 E Engine Only)

Procedure for replacing the oxygen sensor on G424E/G430E engines.

Daewoo GC25E-3 Specifications

General IconGeneral
Displacement246 cc
Number of Cylinders1
Fuel SystemCarburetor
Engine typeGasoline
Starting SystemRecoil starter
Cooling SystemAir-cooled

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