D (G) 20sc
D (G) 20sc
D (G) 20sc
form SB4047E
SB4048E00
Oct. 2000
NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers listed with mark (*) are, they are not available for the initial
release of the manual. When items are updated, or supplements added, they
will be announced in preview and should be ordered as they become available.
ENGINE
POWER TRAIN
VEHICLE SYSTEMS
WARNING
SAFETY
WARNING WARNING
The proper and safe lubrication and maintenance Do not operate this machine unless you have
for this machine, recommended by DAEWOO, are read and understand the instructions in the
outlined in the OPERATION & MAINTENANCE OPERATOR'S GUIDE. Improper machine
GUIDE for this machine. operation is dangerous and could result in
Improper performance of lubrication or injury or death.
maintenance procedures is dangerous and could
result in injury or death. Read and understand the
OPERATION & MAINTENANCE GUIDE before 5. Use steps and grab handles (if applicable) when
performing any lubrication or maintenance. mounting or dismounting a machine. Clean any mud or
debris from steps, walkways or work platforms before
using. Always face machine when using steps, ladders
The serviceman or mechanic may be unfamiliar with many and walkways. When it is not possible to use the
of the systems on this machine. This makes it important designed access system, provide ladders, scaffolds, or
to use caution when performing service work. A work platforms to perform safe repair operations.
knowledge of the system and/or components is 6. To avoid back injury, use a hoist when lifting
important before the removal or disassembly of any components which weigh 23 kg (50 lb.) or more. Make
component. sure all chains, hooks, slings, etc., are in good
Because of the size of some of the machine condition and are of the correct capacity. Be sure
components, the serviceman or mechanic should check hooks are positioned correctly. Lifting eyes are not to
the weights noted in this Manual, Use proper lifting be side loaded during a lifting operation.
procedures when removing any components. 7. To avoid burns, be alert for hot parts on machines
Following is a list of basic precautions that should always which have just been stopped and hot fluids in lines,
be observed. tubes and compartments.
1. Read and understand all Warning plates and decals on 8. Be careful when removing cover plates. Gradually
the machine before operating, lubricating or repairing back off the last two bolts or nuts located at opposite
the product. ends of the cover or device and pry cover loose to
relieve any spring or other pressure, before removing
2. Always wear protective glasses and protective shoes
the last two bolts or nuts completely.
when working around machines. In particular, wear
protective glasses when pounding on any part of the 9. Be careful when removing filler caps, breathers and
machine or its attachments with a hammer or sledge. plugs on the machine. Hold a rag over the cap or plug
Use welders gloves, hood/goggles, apron and other to prevent being sprayed or splashed by liquids under
protective clothing appropriate to the welding job pressure. The danger is even greater if the machine
being performed. Do not wear loose-fitting or torn has just been stopped because fluids can be hot.
clothing. Remove all rings from fingers when working 10. Always use tools that are in good condition and be
on machinery. sure you understand how to use them before
3. Do not work on any machine that is supported only by performing any service work.
lift jacks or a hoist. Always use blocks or jack stands 11. Reinstall all fasteners with same part number. Do not
to support the machine before performing any use a lesser quality fastener if replacements are
disassembly. necessary. Do not mix metric fasteners with
4. Lower the forks or other implements to the ground standard nuts and bolts.
before performing any work on the machine. If this 12. If possible, make all repairs with the machine parked
cannot be done, make sure the forks or other on a level, hard surface. Block machine so it does
implements are blocked correctly to prevent them not roll while working on or under machine.
from dropping unexpectedly.
1 of 2
WARNING
13. Disconnect battery and discharge any capacitors 21. Do not operate a machine if any rotating part is
(electric trucks) before starting to work on machine. damaged or contacts any other part during
Hang "Do Not Operate" tag in the Operator's operation. Any high speed rotating component that
Compartment. has been damaged or altered should be checked
for balance before reusing.
14. Repairs, which require welding, should be
performed only with the benefit of the appropriate 22. On LP equipped lift trucks, be sure to close the
reference information and by personnel adequately valve on the LP tank before service work is
trained and knowledgeable in welding procedures. performed. Always close the valve on the LP tank
Determine type of metal being welded and select when the lift truck is being stored. Do not check for
correct welding procedure and electrodes, rods or LP leaks with an open flame.
wire to provide a weld metal strength equivalent at
23. Caution should be used to avoid breathing dust that
least to that of parent metal.
may be generated when handling components
15. Do not damage wiring during removal operations. containing asbestos fibers. If this dust is inhaled, it
Reinstall the wiring so it is not damaged nor will it can be hazardous to your health. Components in
be damaged in operation by contacting sharp DAEWOO products that may contain asbestos
corners, or by rubbing against some object or hot fibers are brake pads, brake band and lining
surface. Do not connect wiring to a line containing assemblies, clutch plates and some gaskets. The
fluid. asbestos used in these components is usually
bound in a resin or sealed in some way. Normal
16. Be sure all protective devices including guards and
handling is not hazardous as long as airborne dust
shields are properly installed and functioning
which contains asbestos is not generated.
correctly before starting a repair. If a guard or shield
must be removed to perform the repair work, use If dust which may contain asbestos is present, there are
extra caution. several common sense guidelines that should be
followed.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance a. Never use compressed air for cleaning.
or repair work is performed, which requires the
b. Avoid brushing or grinding of asbestos containing
mast in the raised position.
materials.
18. Loose or damaged fuel, lubricant and hydraulic
c. For clean up, use wet methods or a vacuum
lines, tubes and hoses can cause fires. Do not
equipped with a high efficiency particulate air
bend or strike high pressure lines or install ones
(HEPA) filter.
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks d. Use exhaust ventilation on permanent machining
with your hands. Pin hole (very small) leaks can jobs.
result in a high velocity oil stream that will be e. Wear an approved respirator if there is no other way
invisible close to the hose. This oil can penetrate to control the dust.
the skin and cause personal injury. Use cardboard
or paper to locate pin hole leaks. f. Comply with applicable rules and regulations for the
work place (for example in the U.S.A., OSHA
19. Tighten connections to the correct torque. Make requirements as set forth in 29 CFR 1910. 1001).
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibration g. Follow environmental rules and regulations for
or rubbing against other parts during operation. disposal of asbestos.
Shields that protect against oil spray onto hot h. Avoid areas where asbestos particles may be in the
exhaust components in event of a line, tube or seal air.
failure must be installed correctly.
20. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting any
device from a system that utilizes pressure.
2 of 2
SB2004E00
Dec. 1998
Specifications
TORQUE
SPECIFICATIONS
STANDARD TORQUE FOR METRIC FASTENERS
NOTE : Take care to avoid mixing metric and inch dimensioned fasteners.
Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or
possible injury. Exceptions to these torques are given in the Service Manual where
needed.
NOTE : Prior to installation of any hardware, be sure components are in near new
condition. Bolt and nut threads must not be worn or damaged. Hardware must be
free of rust and corrosion. Clean hardware with a non-corrosive cleaner and apply
engine oil to threads and bearing face. If thread lock or other compounds are to be
applied, do not apply engine oil.
1 of 7
STANDARD TORQUE FOR INCH FASTENERS
2 of 7
O-RING FACE SEAL FITTINGS
3 of 7
FITTING INSTALLATION
HYDRAULIC LINE INSTALLATION 1. Put locknut (3), backup washer (4) and O-ring seal
(5) as far back on fitting body (2) as possible. Hold
these components in this position. Turn the fitting
1. For a metal tube to hose installation, install the tube into the part it is used on until backup washer (4) just
and tighten all bolts finger tight. makes contact with the face of the part it is used on.
2. Tighten the bolts at the rigid end. 2.To put the fitting assembly in its correct position, turn
3. Install the hose and tighten all bolts finger tight. the fitting body (2) out (counterclockwise) a
maximum of 359û. Tighten locknut (3) to the torque
4. Put the hose in a position so that it does not make shown in the correct chart for the fitting used.
contact with the machine or another hose.
NOTE: If the fitting is a connector (straight fitting), the
5. Tighten the bolts on both connections. hex on the body takes the place of the locknut. To
6. Start the engine. install this type fitting, tighten the hex against the face
of the part it goes into.
7. Move the implement control levers to all positions.
8. Look at the hose during movement of the
implement. Make sure hose is not in contact with TORQUES FOR FLARED AND O-RING FITTINGS
the machine or other hoses.
The torques shown in the charts that follow are to be
9. Shut off the engine.
used on the nut part of 37û Flared, 45û Flared and
10. If necessary, put the hose in a new position where it Inverted Flared fittings (when used with steel tubing),
will not make contact when the implement is moved. O-ring plugs, O-ring fittings and swivel nuts when
used in applications to 3000 psi (20 700 kPa).
2
1 IDAS003B
4 of 7
37û FLARED AND STRAIGHT THREAD O-RING FITTINGS
Hi Seal Fittings
Put nut and sleeve over the tubing with the short
heavy end of the sleeve facing the end of tubing. Put
the tube end against the counterbore in the body of
the fitting and tighten until nut is over the last thread IDAS006B
on the body. The remainder of space is used
whenever the fitting is removed and installed again.
5 of 7
45û FLARED AND 45û INVERTED FLARE FITTINGS
INVERTED
45û FLARED 45û FLARED
IDAS007B
Flex Fittings
Put nut and sleeve over the tubing and push tube in
to counterbore of fitting body as far as possible.
Tighten the nut until it is against the hex part of the
fitting body.
IDAS009B
6 of 7
AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS
IDAS010B
7 of 7
SB4008E01
May 2000
Service Manual
G420 LP/Gasoline Engine
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. 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.
1
Index
General Information
General ......................................................................8
How To Read This Manual.........................................4
Precautions Before Servce ........................................6
Sealant .....................................................................12
Tightening Torque ......................................................9
Specifications
General Specifications .............................................13
Service Specifications..............................................14
System Operation
Engine ......................................................................90
Lubricating System ..................................................95
Fuel System .............................................................96
Cooling System......................................................105
Intake and Exhaush System ..................................106
Electrical System ...................................................107
Special Tools
Special Tools ..........................................................123
¥ Reassembly steps.
Specified in case reassembly is impossible in
reverse order of disassembly steps. Omitted if
reassembly is possible in reverse order of
disassembly steps.
Symbols for Lubrication, Sealants and following the component parts page, and
Adhesives explained.
Information concerning the locations for
lubrication and for application of sealants and .... Sealant or adhesive
adhesives if provided, by using symbols, in the
diagram of component parts, or on the page .... Engine oil or gear oil
Inspection
Only the inspections to be performed by using special tools or measuring instruments are covered. General
service procedures not covered in this manual, such as visual inspections and cleaning of parts, however, should
always be performed during actual service operations.
6EN1898
Removal steps
N 1. Oil filter H 17. Oil pump case assembly
M 2. Oil pressure switch 18. Front case gasket
3. Drain plug G 19. Oil pump cover
L 4. Drain plug gasket G 20. Oil pump drive gear
A K 5. Oil pan G 21. Oil pump driven gear
6. Oil screen F 22. Crankshaft front oil seal
7. Oil screen gasket E 23. Oil pump oil seal
B J 8. Plug D 24. Counterbalance shaft oil seal
9. O-ring 25. Front case
C I 10. Flang bolt 26. Counterbalance shaft, left
11. Relief plug 27. Counterbalance shaft, right
12. Gasket D C 28. Counterbalance shaft, front bearing
13. Relief spring E B 29. Counterbalance shaft, rear bearing, left
14. Relief plunger E A 30. Counterbalance shaft, rear bearing, right
15. Oil filter bracket
16. Oil filter bracket gasket
6EN0698
This alphabetical letter corresponds to the one assigned Operating procedures, cautions, etc.
to a part in the removal, installation, disassembly or on removal, installation, disassembly
reassembly steps that are indicated in the drawing on the and reassembly are described
first page of each section.
1EN0018
Special Tool
Be sure to use Special Tools when their use is specified for
the operation.
Use of substitute tools will result in malfunction of the part
or damage it.
1EN0019
Tightening Torque
Tighten the part properly to specified torque.
1EN0020
Sealant
T
AN
1EN0021
1EN0022
Rubber Parts
Do not stain timing belt and V-belt with oil or water.
Therefore, do not clean the pulley and sprocket with
detergent.
1EN0023
1EN0024
Genuine Part
When the part is to be replaced, be sure to use genuine
part.
For selection of appropriate parts, refer to the Parts
Catalog.
1EN0025
6EN1916
Torque
Item Remarks
kg¥m lb¥ft N¥m
Water pump pulley bolt 0.9 6.5 9
Crankshaft pulley bolt 2.5 18.1 25
Ignition system
Spark plug 2.5 18.1 25
Distributor nut 1.2 8.7 12
Timing belt cover bolt 1.1 8.0 11
0.9 6.5 9
Tensioner spring spacer 4.9 35.4 48
Tensioner bolt 4.9 35.4 48
Oil pump sprocket nut 5.5 39.8 54
Tensioner belt Crankshaft bolt 12.0 86.8 118
Tensioner B bolt 1.9 13.7 19
Counterbalance shaft 4.6 33.3 45
Engine support bracket bolt 3.6 26.0 35
Camshaft sprocket bolt 9.0 65.1 88
Timing belt rear bolt 1.4 10.1 14
Fuel system Carburetor nut 1.2 8.7 12
carburetor Air horn nut 1.2 8.7 12
Stud 1.2 8.7 12
Fuel pump 1.1 8.0 11
Fuel system LPG carburetor nut 1.2 8.7 12
LPG carburetor Fuel pump cover 1.1 8.0 11
Intake manifold Water outlet bolt 1.4 10.1 14
Intake manifold bolt/nut 1.8 13.0 18
Exhaust Oil level gauge guide bolt 1.4 10.1 14
manifold Heat protector bolt 0.9 6.5 9
Exhaust manifold nut 3.5 25.3 34
Water inlet pipe bolt 1.4 10.1 14
Water pump bolt 1.4 10.1 14
Rocker cover bolt 0.6 4.3 6
Rocker arm
M8 B 25 2.4 17.4 24
and camshaft Bearing cap bolt
M6 B 65 2.0 14.5 20
Cylinder head,
8.0 kgf¥m(57.9 lb¥ft)[78 N¥m]+ 0 +
valve Cylinder head bolt 2.0 kgf¥m(14.5 lb¥ft)[20 N¥m]+
1/4 turn + 1/4 turn
Tapered Threads
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
¥Tightening method
After tightening the bolts to the specified torque, tighten them another 90¡ or 180¡ (twice 90¡). The tightening
method varies on different areas. Observe the tightening method described in the text.
The engine has several areas where the from-in- Thoroughly remove all substances deposited on the
place gasket(FIPG) is in use. To ensure that gasket gasket application surfaces, using a gasket scraper
fully serves its purpose, it is necessary to observe or wire brush.
some precautions when applying the gasket. Bead Check to ensure that the surfaces to which the FIPG
size, continuity and location are of paramount is to be applied is flat. Make sure that there are no
importance. Too thin a bead could cause leaks. Too oils, greases and foreign substances deposited on
thick a bead, on the other hand, could be squeezed the application surfaces. Do not forget to remove the
out of location, causing blocking or narrowing of the old FIPG remaining in the bolt holes.
fluid feed line. To eliminate the possibility of leaks
from a joint, therefore, it is absolutely necessary to From-in-place gasket Application
apply the gasket evenly without a break, while Applied FIPG bead should be of the specified size
observing the correct bead size. and without breaks. Also be sure to encircle the bolt
hole circumference with a completely continuous
Since the FIPG used in the engine hardens as it bead. The FIPG can be wiped away unless it is
reacts with the moisture in the atmospheric air, it is hardened. While the FIPG is still moist (in less than
normally used in the metallic flange areas. 15 minutes), mount the parts in position. When the
parts are mounted, make sure that the gasket is
Disassembly applied to the required area only.
The parts assembled with the FIPG can be easily
disassembled without use of a special method. In The FIPG application procedure may vary on
some cases, however, the sealant between the different areas. Observe the procedure described in
joined surfaces may have broken by lightly striking the text when applying the FIPG.
with a mallet or similar tool. A flat and thin gasket
scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be
taken to prevent damage to the joined surfaces. For
removal of the oil pan, the special tool ÒOil Pan
RemoverÓ (MD998727) is available. Be sure to use
the special tool to remove the oil pan.
General Specifications
Engine model
Item G420
Type Water-cooled, 4-cycle, gasoline-powered and L.P.G.-powered
No. of cylinders and arrangement 4, in-line
Combustion chamber type Semi-spherical
Valve mechanism OHC
Total displacement, cm3(cc) [cu in.] 1997 (1997) [122]
Bore x stroke, mm (in.) 85 B 88 (3.35 B 3.46)
Dry weight, kg (lb) 143 (315)
Compression ratio 8.5
Compression pressure, kPa (kgf/cm2) [psi] 1128 (11.5) [163.5]
Intake Open 12¡ BTDC
valve Close 40¡ ABDC
Valve timing
Exhaust Open 54¡ BBDC
valve Close 6¡ ATDC
Firing order 1-3-4-2
Ignition timing, BTDC/rpm 4¡/740 (gasoline), 9¡/740 (L.P.G.)
Fuel pump Gasoline Mechanical (diaphragm type)
Carburetor Down-draft type
Governor Air flow type
Lubrication system Pressure feed, full-flow filtration type
Oil pump Gear, driven by timing belt
Oil filter Filter paper, cartridge type
Cooling system Water-cooled, forced circulation
Water pump Centrifugal, driven by V-belt
Thermostat Wax type
Electrical system 12V DC, negative ground
Alternator, (12V-50A) Alternator current, built-in fan and regulator
Starter motor, (12V-1.2kW) Reduction drive
Distributor Equipped with automatic timing controller, breaker less type
Spark plug (NGK) Gasoline BPR4ES
L. P. G. BPR5ES
3
Quantity of lubricating oil, cm (liter) [U.S.gal] 4000(4.0) [1.06 ]( including 300 cm3(0.3 liter)[0.08 U.S.gal ]in oil filter
Quantity of coolant, cm3 (liter) [U.S.gal] 3100 (3.1) [0.82] (in engine proper)
IDLE RPM LOW (RPM) 750 L 25
HIGH (RPM) 2450 L 50
ring hole
rework
Cam height
Exhaust 41.62 (1.6386) 41.12 (1.6189)
Journal diameter 33.935 to 33.950 (1.33602 to 1.33661)
Oil clearance 0.05 to 0.09 (0.0020 to 0.0035)
Intake 109.8 (4.328) 109.3 (4.3031)
Overall length
Exhaust 106.6 (4.197) 106.1 (4.126)
Valve stem projection 42.05 (1.6555) 42.55 (1.6752)
Stem diameter Intake 7.960 to 7.975 (0.31339 to 0.31398)
Exhaust
Valve
length
Bend 0.05 (0.0020)
Twist 0.10 (0.0039)
Big end thrust clearance 0.10 to 0.25 (0.0039 to 0.0098)
End play 0.05 to 0.18 (0.0020 to 0.0071)
Journal outside diameter 56.982 to 57.000 (2.24338 to 2.24409)
Pin Outside diameter 44.985 to 45.000 (1.77106 to 1.77165)
Crankshaft
Deflection
Used belt 10 (0.39)
Throttle bore diameter 32 (1.26)
Outer venturi diameter 24 (0.94)
Inner venturi diameter 9 to 12 (0.35 to 0.47)
Carburetor
Ignition System
6EN1891
Gear mating mark (1) Turn the crankshaft so that the No.1 cylinder is at top
dead center.
Housings mating mark (2) Align the distributor housing and gear mating marks.
6EN0598
(3) Install the distributor to the engine while aligning the fine
cut (groove or projection) of the distributorÕs installation
Stud
flange with the center of the distributor installation stud.
HousingÕs
mating mark
6EN0599
Removal steps
1. Timing belt front cover upper 12. Tensioner B
2. Timing belt front cover lower E D 13. Timing belt B
A H 3. Timing belt F C 14. Counterbalance shaft sprocket
G 4. Tensioner spacer 15. Spacer
G 5. Tensioner spring G 16. Crankshaft sprocket B
G 6. Tensioner pulley 17. Crankshaft key
B F 7. Oil pump sprocket B 18. Engine support bracket
C E 8. Crankshaft bolt 19. Camshaft sprocket bolt
9. Crankshaft washer H A 20. Camshaft sprocket
D 10. Crankshaft sprocket 21. Timing belt rear cover
11. Flang
6EN0884
6EN0663
6EN0868
6EN0642
6EN0636
MD998778
(1) If it is difficult to remove the sprocket, use the special
tool.
6EN0637
MD998719
6EN0668
Inspection
1. Timing Belt
Replace belt if any of the following conditions exist.
8EN0066
Peeling Cracks
Cracks 8EN0044
Rounded edge NOTE: The sides are normal if they are sharp as if cut by a
knife.
Abuormal wear
(Flutty strand)
8EN0067
8EN0068
6EN0669
6EN0739
6EN0636
Timing (1) Align timing mark on the crankshaft sprocket ÒBÓ and
marks timing counterbalance shaft sprocket with the marks on the
(on fron marks front case respectively.
case)
(2) Install the timing belt ÒBÓ on the crankshaft sprocket ÒBÓ
and counterbalance shaft sprocket. There should be no
slack on the tension side.
DEN0602
Center of
tensioner
Center of bolt
paller 6EN0571
6EN0572
timing
marks
6EN0573
MD998781
6EN0634
Screw driver
6EN0564
Bolt
6EN0670
Timing mask
6EN0671
(3) Align the timing mark on the oil pump sprocket with its
Timing mark mating mark.
6EN0672
Timing
mark
Timing
belt
6EN0562
Tensioner
6EN0017
Tensioner 6EN0015
(11) Hold the center of the tension side span of the timing
belt (between the camshaft and oil pump sprockets)
14mm between your thumb and index finger as shown. Then,
(0.55in)
make sure that the clearance between the belt back
surface and cover meets the standard value.
Standard value: 14 mm (0.55 in.)
6EN0616
6EN1893
Removal steps
1. Return set hose assembly 8. Fuel pipe
2. Oil seal 9. Fuel hose
3. Air horn 10. Fuel pipe
4. Gasket B A 11. Fuel pump
A 5. Carburetor 12. Gasket
6. Air governor 13. Insulator
7. Gasket 14. Push rod
6EN1890
Removal steps
1. Throttle return spring 6. Throttle body
2. Accel wire assembly 7. Carburetor gasket
3. Return spring support 8. Air governor
4. LPG carburetor 9. Air governor gasket
5. Throttle chamber gasket 10. Fuel pump cover
6EN1894
Removal steps
1. Water outlet 4. Engine hanger
2. Gasket 5. Intake manifold
3. Thermostat 6. Gasket
6EN1895
Removal steps
1. Oil level gauge 7. Exhaust manifold
2. Oil level gauge guide 8. Gasket
3. O-ring A 9. Water inlet pipe
4. Heat protector A A 10.O-ring
5. Heat protector B 11. Water hose
6. Engine hanger 12. Water pump
13. Gasket
Caution:
1) Never apply engine oil or any other oil or grease to the
O-ring.
2) Fasten the water pipe after the thermostat housing has
been installed.
6EN1896
Removal steps
1. Breather hose D 12. Bearing cap No. 4
2. P.C.V. hose 13. Rocker arm C
3. P.C.V. valve D 14. Bearing cap No. 3
4. Oil filler cap D 15. Bearing cap No. 2
5. Rocker cover C 16. Wave washer
6. Gasket B 17. Right rocker shaft
G 7. Semi-circular packing B 18. Left rocker shaft
A 8. Rocker arms and rocker shafts 19. Front bearing cap
9. Rear bearing cap E 20. Lash adjuster
10. Rear arm D F 21. Oil seal
11. Spring A 22. Camshaft
Caution:
If the lash adjuster is re-used, clean the lash adjuster.
(1) Fit the lash adjuster onto the rocker arm without allowing
diesel fuel to spill out. Fit. Special tool MD998443 to
prevent the lash adjuster coming free and falling to the
6EN0569
floor.
Inspection
1. Camshaft
Measure the cam height and if the limit is exceeded,
replace.
Standard value: 41.62 mm (1.6386 in.)
Limit: 41.12 mm (1.6189 in.)
2. Lash Adjuster
9EN0058
Caution:
¥The lash adjusters are precision-engineered mechanisms.
Do not allow them to become contaminated by dirt or other
foreign substances.
¥Do not attempt to disassemble the lash adjusters.
¥Use only fresh diesel fuel to clean the lash adjusters
A B C
6EN1698
Diesel
fuel
6EN1699
(3) While gently pushing down the internal steel ball using
special tool MD998442, move the plunger through five to
ten strokes until it slides smoothly. In addition to
eliminating stiffness in the plunger, this operation will
remove dirty oil.
MD998442
MD998442
Diesel fuel
6EN1809
6EN1810
(8) Stand the lash adjuster with its plunger at the top, then
MD998442 push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure
chamber to fill with diesel fuel.
Diesel fuel
6EN1811
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top.
Push the plunger firmly and check that it does not move.
6EN0576
D Bearing cap
Rocker cover Mounting bolt hole (1) No.3 bearing cap looks very similar to No.2 and No.4
bearing caps.
(2) Install the bearing caps with their front marks pointing to
the camshaft sprocket side.
Front mark Indentification Mark
No.2 No.3 No.4
6EN0024
6EN0569
MD998713 (1) Apply engine oil to the lip area of the oil seal and the
camshaft front end outer diameter.
(2) Using special tool, install the camshaft oil seal.
6EN0650
DEN0053
6EN1897
Removal steps
A D 1. Cylinder head bolt 11. Exhaust valve
2. Cylinder head assembly C A 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
B C 4. Retainer lock C A 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
B 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
B C 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
B 10. Valve spring 20. Cylinder head
6EN0717
6EN0652
Inspection
1. Cylinder Head
6EN0718 (1) Check the cylinder head for water leaks, gas leaks,
damage or cracks before cleaning.
(2) Thoroughly remove oil, water scale, sealant, carbon
deposit, etc. After the oil passages have been cleaned,
blow air to make sure that they are clean.
(3) Check the cylinder head gasket surface for flatness by
using straightedge and thickness gauge.
If the service limit is exceeded, correct to meet the
specification.
Standard valve: 0.03 mm (0.0012 in.) or less.
Limit: 0.2 mm (0.008 in.)
Grinding limit: 0.2 mm (0.008 in.)
Cylinder head height (when new): 89.9 to 90.1 mm
(3.539 to 3.547 in.)
3. Valve Spring
Out of squareness
(1) Measure the free height of spring and, if it is smaller
than the limit, replace.
Standard value: 48.0 mm (1.89 in.)
Limit: 47.0 mm (1.85 in.)
Free height
(2) Measure the squareness of the spring and, if the limit is
exceeded, replace.
Standard value: 2 degrees or less
Limit: 4 degrees
1EN0264
4. Valve Guide
Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide or
valve, or both.
Valve
guide
Stem I.D.
Guide I.D. 1EN0279
DEN0212
1EN0105
Cut away
0.5 to 1.0
(0.020 to 0.030)
1EN0274
Press Press (3) Press in the valve guide to the position shown in the
illustration.
Standard value: 11.5 mm (0.453 in.)
Caution:
1) Do not reuse removed valve stem seal.
6EN0743 2) The special tool must be used to install the valve stem
seal. Improper installation could result in oil leaking past
the valve guide.
Stem seal
Spring seat
6EN0437
6EN0652
6EN0782
Caution:
10 4 2 5 7 1) If the bolt is turned less than 90¡, proper fastening
performance may not be expected. When tightening the
6EN0694 bolt, therefore, be careful to give a sufficient turn to it.
2) If the bolt is over tightened, loosen the bolt completely
and then retighten it by repeating the tightening
procedure from step (1).
6EN1898
Removal steps
N 1. Oil filter H 17. Oil pump case assembly
M 2. Oil pressure switch 18. Front case gasket
3. Drain plug G 19. Oil pump cover
L 4. Drain plug gasket G 20. Oil pump drive gear
A K 5. Oil pan G 21. Oil pump driven gear
6. Oil screen F 22. Crankshaft front oil seal
7. Oil screen gasket E 23. Oil pump oil seal
B J 8. Plug D 24. Counterbalance shaft oil seal
9. O-ring 25. Front case
C I 10. Flange bolt 26. Counterbalance shaft, left
11. Relief plug 27. Counterbalance shaft, right
12. Gasket D C 28. Counterbalance shaft, front bearing
13. Relief spring E B 29. Counterbalance shaft, rear bearing,left
14. Relief plunger E A 30. Counterbalance shaft, rear bearing, right
15. Oil filter bracket
16. Oil filter bracket gasket
6EN0698
B Plug removal
MD998162 (1) Fit special tool MD998162 on the plug, then hold it in
position with special tool MD998783.
(2) Loose the plug.
MD998783
6EN0909
Screw driver
Plug
6EN1026
6EN0565
Front
bearing
MD998371 3EN0166
MD998372
6EM0207
Inspection
1. Front Case
(1) Check oil holes for clogging and clean if necessary.
(2) Check the left counterbalance shaft front bearing section
for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
(3) Check the front case for cracks and other damage.
Replace cracked or damaged front case.
2. Oil Seal
(1) Check the oil seal lip for wear and Replace oil seal if
necessary.
(2) Check the oil seal lip for deterioration. Replace oil seal if
necessary.
3. Counterbalance Shaft
(1) Check oil hole for clogging.
(2) Check journals for seizure, damaged and contact with
bearing. If there is anything wrong with the journal
assembly.
DEN0711
MD998705
MD998705
Cylinder block
6EN1034
MD998705
6EN0208
Rear bearing
MB991603
MD998705
6EN0557
MD998705
MD998705
Bearing
Cylinder block
6EN1035
Front case
Oil seal
6EN0580
Socket (1) Using a suitable socket wrench, install the oil pump oil
seal into the front case.
Oil seal
Front case
6EN0494
Oil seal
Front case
6EN0579
Alignment (1) Apply engine oil amply to the gears and line up the
mark alignment marks.
6LU0015
MD998285
6EN0746
(2) Install the front case assembly through a new front case
gasket and temporarily tighten the flange bolts(other
than those for tightening the filter bracket).
MD998285
6EN0747
Screw driver
6EN0564
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
6EN0565
MD998783
6EN0909
8mm bolts
Drain plug
L Drain plug gasket installation
(1) Install the drain plug gasket in the direction shown.
7EN0179
9EN0094
6EN0591
6EN1899
Removal steps
G 1. Nut C 7. Piston ring No. 2
A F 2. Connecting rod cap B 8. Oil ring
E 3. Connecting rod bearing B A 9. Piston pin
D 4. Piston and connecting rod assembly 10. Piston
E 5. Connecting rod bearing 11. Connecting rod
C 6. Piston ring No. 1 12. Bolt
DEN0050
Guide A
Guide C 18.9(0.744)
Base Guide A
20.9(0.823)
Guide A
21.9(0.862)
7EN0431
(1) Insert the special tool, Push Rod, into the piston from
the side on which the front mark is stamped in the piston
Push rod head, and attach the guide C to the push rod end.
(2) Place the piston and connecting rod assembly on the
special tool, Piston Pin Setting Base, with the front mark
facing upward.
Front mark (3) Using a press, remove the piston pin.
Front
mark NOTE: Keep the disassembled piston, piston pins and
connecting rods in order according to the cylinder number.
Guide C
Base
7EN0390
Guide B Guide A
7EN0433
Push rod
Piston pin
Front mark
Front mark
(8) Place the piston onto the piston setting base with the
front marks directed upward.
(9) Press-fit the piston pin using a press.
If the press-fitting force required is less than the
Guide A standard value, replace the piston and piston pin set
or/and the connecting rod.
Base
Standard value: 750 to 1750 kgf
(1654 to 3859 lbf)
[7350 to 17160 N]
Guide B
7EN0391
Side (1) Fit the oil ring spacer into the piston ring groove. First,
rail install the upper side rail, and then install the lower side
rail.
Spacer
NOTE:
1) The side rails and spacer may be installed in either
direction.
2) The new spacers and side rails are painted in the
6EN0585 following colors to identify their sizes.
(2) To install the side rail, first fit one end of the rail into the
Side rail gap
piston groove, then press the remaining portion into
position by finger. See illustration.
(3) Make sure that the side rails move smoothly in either
direction.
7EN0451
9EN0524
Size Size mark
STD Paint red
0.50 mm (0.020 in.) O.S. 50
1.00 mm (0.040 in.) O.S. 100
7EN0452
(4) Insert the piston and connecting rod assembly with the
piston rings held firmly with a ring band. Forcing it by
pounding should be avoided because damage to the
piston rings or crank pin could result.
9EN0072
Notches
DEN0051
(2) Make sure that connecting rod big end side clearance
meets the specification.
Standard value: 0.10 to 0.25 mm (0.0039 to 0.0098 in.)
Limit: 0.4 mm (0.016 in.)
6EN0621
Caution:
1) If the nut is turned less than 90¡, proper fastening
performance may not be expected. When tightening the
nut, therefore, be careful to give a sufficient turn to it.
2) If the nut is over tightened (exceeding 100¡), loosen the
nut completely and then retighten it by repeating the
tightening procedure from step (1).
6EN1900
Removal steps
1. Flywheel bolt C 8. Crankshaft bearing cap
2. Flywheel B 9. Crankshaft bearing lower
F 3. Rear plate 10. Crankshaft
4. Rear plate cover B 11. Crankshaft bearing upper
E 5. Oil seal case B 12. Thrust bearing
D 6. Oil seal 13. Cylinder block
C 7. Crankshaft bearing cap bolt
6EN0623
2. Cylinder Block
(1) Visually check for scratches, rust, and corrosion. Use
also a flaw detecting agent for the check. If defects are
evident, correct, or replace.
(2) Using a straightedge and feeler gauge, check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matter.
Standard value: 0.05 mm (0.0020 in.)
Limit: 0.1 mm (0.004 in.)
9EN0074
6EN0705
Cylinder
inner
diameter
size mark
6EN1632
Identification mark of
color
6EN1096
for upper
for lower
6EN1558
Caution:
1) If the bolt is turned less than 90¡, proper fastening
performance may not be expected. When tightening the
bolt, therefore, be careful to give a sufficient turn to it.
2) If the bolt is over tightened (exceeding 100¡), loosen the
bolt completely and then retighten it by repeating the
tightening procedure from step (1).
(4) After installing the bearing caps, make sure that the end
play is correct. If the end play exceeds the limit, replace
the crankshaft bearings.
Standard value: 0.05 to 0.25 mm (0.0020 to 0.0098 in.)
Limit: 0.4 mm (.016 in.)
6EN0625
MD998776
6EN0709
NOTE:
1) Be sure to install the case quickly while the sealant is
wet(within 15 minutes).
2) After installation, keep the sealant area away front the oil
and coolant for approx. one hour.
6EN0626
Special washer
6EN1919
Disassembly steps
A 1. Throttle return spring
2. Damper spring
A 3. Choke rod
4. Screw
B 5. Float chamber cover
6. Float chamber cover gasket
7. Cover
8. Packing
9. Bimetal
10. O-ring
11. Accelerator wire bracket
C 12. Float pin
C 13. Float
14. Needle valve assembly
15. Packing
16. Filter
C B 17. Weight
C B 18. Ball
D A 19. Main jet
20. Screw
21. Screw
22. Accelerator pump cover
23. Diaphragm
24. Spring
25. Fuel cut solenoid
26. O-ring
27. Enrichment
28. Enrichment jet
29. Speed adjust screw
30. Pilot jet 6En0850
31. Choke lever
32. Spring
33. Main body
34. Insulator gasket
35. Throttle lever
36. Throttle control lever
37. Mixture adjusting screw
38. Throttle body
6EN0851
C Pump weight/ball
Turn the main body upside down to remove the weight and
ball.
6EN0852
6EN0854
6EN1888
6EN0855
6EN0852
130
Size symbol
6EN0869
6EN0856
6EN0858
6EN0859
Clearance ÒAÓ
(drill bit diameter)
6EN1889
6EN0861
6EN0862
Disassembly steps
1. Ventilation hose
2. Gasket
3. Sealing cap
4. Cover plate assembly
5. Gasket
6. Adjusting nut
7. Adjusting screw
A 8. Plate assembly Disassembly Service Points
A 9. Valve assembly
10. Valve shaft assembly Caution: Since the air governor has been adjusted and sealed
11. Piston cover
in the manufacturerÕs factory to conform to the specifications, it
12. Gasket
13. Stabilizer piston should not be disassembled in general cases. Like any other
A 14. Piston shaft sealed components, the air governor should not be
B 15. Governor body disassembled anywhere except the locations where a warranty
claim decision is authorized. In addition, the cam on the throttle
valve shaft should never be removed.
Valve
Shaft
Screw
Adjusting nut
Removal steps
1. Bolt 6EN0867
2. Starter
Inspection
1EN0301
Disconnect (3) If pinion moves out, then pull-in coil is good. If it doesnÕt.
connector replace magnetic switch.
6EN0871
Disconnect (3) Pull pinion out and release. If pinion quickly returns to its
connector original position, everything is in order. If it doesnÕt,
6EN0873 replace magnetic switch.
Caution: Be careful not to get your fingers caught when
pulling out the pinion.
6EN1917
Disassembly steps
1. Screw 12. Packing A
A 2. Magnetic switch 13. Packing B
3. Screw 14. Plate
4. Screw 15. Planetary gear
5. Rear bracket 16. Lever
6. Brush holder C A 17. Snap ring
7. Brush C A 18. Stop ring
8. Rear bearing 19. Overrunning clutch
B 9. Armature 20. Internal gear
10. Yoke assembly 21. Planetary gear holder
B 11. Ball 22. Front bracket
Stop ring
Pinion gear
Overrunning
clutch
Armature
6EN0611
(2) Remove snap ring with snap ring pliers and then remove
Snap ring stop ring and overrunning clutch.
Snap ring
Pinion pliersa
gear
Overrunning
clutch
Armature
6EN0612
1EN0298
1EN0302
Mica
1EN0296
1EN0292
6EN0600
6EN0601
1EN0299
Disassembly steps
1. Distributor cap 8. Breaker assembly
2. Rotor 9. Snap ring
3. Cover 10. Vacuum control
4. Signal rotor 11. Connector assembly
A 5. Pickup coil assembly 12. O-ring
6. Ignitor 13. Distributor housing
7. Heat sink
1EL0052
1EL0053
Signal rotor
Reassembly Procedure
A Pickup coil assembly installation
Check the air gap between the signal rotor and pickup
assembly.
Standard value: 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
Engine
The cylinder blocks are made of the special cast iron The camshaft is located on the top of the cylinder
and employ 5-bearing, deep skirt system. heads and driven by cog type timing belt.
The cylinder heads have hemisphere combustion Dual type exhaust manifold is employed in order to
chambers, are of cross flow type arranged with V- reduce output loss by exhaust interference.
type valves and high efficient combustion is intended.
Timing belt
The timing belt is the cogged type, using rubber as its basic
material, and it employs a high-strength glass fiber core
which does not expand or contract.
The features of the cogged-type belt compared to a chin are
no expansion/contraction, low noise level, no necessity for
lubrication, light weight, etc.
The silent shaft mechanism function mainly to figure below. The right silent shaft rotates in the
eliminate, by the action of the silent shafts same direction as the crankshaft, and the left silent
incorporated at both sides of the cylinder block, the shaft rotates in the opposites direction. Both of these
vertical vibromotive force of the engine as well as the silent shafts rotate at speed twice that of the
vibromotive moment in the rolling direction, thus crankshaft.
making possible quieter operation of the vehicle. Right silent shaft is driven by timing belt B, and the
The two silent shafts are arranged as shown in the left silent shaft is driven by drive gear.
Construction
Fuel System
Gasolin
2. Float system
The float maintains a constant fuel level in the float
chamber. Fuel from the fuel tank is pumped out by the
fuel pump and filtered by the strainer. Then, fuel enters
the float chamber through a needle valve.
With entrance of fuel in the float chamber, the float
moves up gradually. At last, the float pushes the needle
valve to shut off the fuel inlet.
When the fuel level lowers, the float moves down and
releases the needle so that the fuel inlet is opened. With
repetition of up-and-down movement of the float, fuel in
Float System the float chamber is kept at an almost constant level
during engine operation.
This system provides adequate air-fuel-mixture The mixture adjusting screw is used for adjusting the
richness for smooth engine running ranging from richness of air-fuel-mixture necessary for good idling.
slow-idle to light-load operation. The bypass screw is for the purpose of adjusting the
Fuel from the float chamber is sent through the main flow of primary air-fuel-mixture to the bypass hole so
jet to the pilot jet where metering of fuel is made. as to provide sufficient mixture richness mainly for
On the other hand, air entering the venturi air leak engine operation ranging from Òoff idlingÓ to a part of
and that entering the pilot air jet No.2 join at the pilot medium-load operation.
air jet No.1 where metering of air is made. As a result The fuel cutoff solenoid in the idle system functions
of metering, fuel mixes with air and flows through the as follows : When the key switch is turned to ON, the
air-fuel-mixture passage to the pilot outlet. The flow solenoid attracts the needle valve to open the fuel
of air-fuel-mixture is adjusted properly by the bypass feed line. When the key switch is turned to OFF, the
screw and enters the air horn through the bypass needle valve protrudes to cut off the fuel feed line,
hole or the pilot outlet. It mixes with the small amount thus preventing spontaneous running of the engine
of air that gets past the closed or slightly opened which is overheated.
throttle valve. The final mixture flows into the engine
cylinders.
The idle compensator uses a bimetal. When the Fuel metered by the main jet is bled by air from
carbretor ambient temperature rises during idle or the main air jet and enters the bleed pipe through
Òoff idleÓ running, the bimetal bends enough to its holes. The fuel is discharged from the main
open the compensator valve. Now additional air nozzle and sucked by engine cylinders.
from the choke bore can flow through the auxiliary If percolation of fuel arises along the main well,
air passage to the intake manifold directly. It leans gasoline vapor can escape from the main air jet
out the mixture enough to make up for the proper through the relatively wide outside of the bleed
richness. pipe. This prevents liquid fuel from spurting from
the main nozzle, thus assuring stable engine
operation and easy restarting.
4. Main metering system
To prevent percolation due to conduction of heat
The wider the throttle valve opens, the faster the
from the engine, sufficient cooling of the float
air flow in the venturi and the greater the vacuum
chamber periphery is taken into consideration in
in the inner venturi will be. As the vacuum
design of the carburetor.
becomes greater, additional fuel is discharged
from the main nozzle.
The main metering system is provided with the
bleed valve press-fitted to the inner venturi and the
main air jet.
The enrichment system provides additional fuel When the engine is accelerated quickly, the
feed to the main metering system during high- membrane is pushed by the pump lever linked to
speed large-torque operation. the throttle valve and forces fuel to flow under
This system use the membrane (diaphragm) which pressure. When the engine is decelerated, the
is actuated by the intake manifold vacuum and membrane is pushed back by the spring and the
membrane spring to open or close the fuel feed pump chamber is refilled with fuel.
line. Pump delivery decreases with engine speed from
During partial-throttle operation, a large manifold which acceleration is starred. It does not deliver
vacuum is applied to the vacuum chamber through fuel at all when the angle of throttle valve from the
the vacuum line and acts on the membrane to idling position exceeds the preset angle.
close the valve against the membrane spring
force. 7. Stating system
When the throttle is opened wide, manifold The starting system consists of the choke valve,
vacuum decreases. lever assembly, choke connecting rod, and choke
This allows the membrane spring to open the operating lever. This system is provided for
valve. Now, more fuel from the float chamber is feeding a very rich air-fuel mixture to the engine
metered by the enrichment jet and can flow when the engine is started (until the engine warms
through the valve into the primary main line up) or when a temporary increase of output is
leading to the main metering system. needed during engine operation. When the engine
is cold, some throttle opening must be maintained
6. Accelerator-pump system so that the engine idles faster then it would when
Rapid opening of the throttle for acceleration warm. This is done with Òfast idle.Ó With the fast
allows a sudden inrush of air. Thus there is a idle, the choke valve is closed while the throttle
sudden demand for additional fuel. To provide this valve is held at a partially opened position most
extra fuel, the accelerator-pump system can feed suitable to warming-up run.
fuel immediately under pressure.
Fuel from the inlet check valve is sent to the pump
nozzle through the outlet check valve by
reciprocating movement of the membrane. The
fuel is then injected into the main bore.
The carburetor for LPG engines is a combination of 3. Gas metering valve 4, provided in the air-gas
the carburetor upper body and adapter. Like the valve, varies its opening with movement of air-gas
carburetor on gasoline engines, this carburetor is valve diaphragm so that adequate gas flow passes
mounted on the throttle body on the air governor. through it and mixes with air.
The carburetor consists of a converter (vaporizer)
and a mixer (carburetor). The converter which 4. Idle screw 7 serves to meter the air-gas mixture
serves only to vaporize liquefied petroleum does not necessary for maintaining slow-idle run of the
require external adjustment. engine.
1. When the cylinder piston is in down stoke, vacuum 5. Gas regulating valve 8 serves to keep the air-gas
created over the top of piston connects through air ratio suited to the maximum engine output when
passage 5 in air-gas valve 2 to the cavity over the engine runs under load. This valve is effective
diaphragm 6. Accordingly, atmospheric pressure only in nearly full-load condition of the engine.
pushes the diaphragm up against the force of
spring 3.
Thermostat
The thermostat is the wax pellet type. A jiggle valve (which
improves air bleeding during water supply) is provided on
the flange part. When the thermostat is closed, the
circulation of coolant is stopped, thereby making warm-up
faster.
Operation
When the temperature of the coolant is low, the valve is
closed by the spring, with the result that the coolant
circulates within the engine, without passing through the
radiator.
When the temperature of the coolant rises and reaches a
certain specified temperature, the valve opens and the
coolant also circulates through the radiator.
When the temperature increases further and reaches a
certain specified temperature, the valve opens fully, allowing
even more coolant to circulate through the radiator.
Thus, in this way the degree of valve opening is varied
according to the temperature of the coolant, and the
temperature of the coolant is adjusted by varying the
amount of coolant caused to circulate through the radiator.
Wiring Diagram
Operation
Distributor
In the figure below, pin A rotates together with the the spring. Because pin B of the weight is fit into the
shaft. A governor weight is installed to this pin A. oblong hole In the cam base, the movement of pin B
There is a pin B on the governor weight which fits becomes rotation of the cam in the direction of
into the oblong hole in the cam base. The governor rotation. In other words, the cam advances in
spring is attached to the spring hook of the governor relation to the shaft.
weight, pulling the governor weight to the fully closed When the rotation speed becomes sufficiently high,
position. pin B contacts the outer side of the oblong hole in the
When the rotation speed increases, the governor cam base, and the weight opens no further. This
weight is subjected to centrifugal force which causes position is the fully advanced condition.
it to open outward. When the centrifugal force When the rotation speed decreases, the centrifugal
becomes stronger than the tensile force of the spring, force of the weight becomes weaker and the weight
the weight opens, as shown by (b) in the figure is closed by the force of the spring, thus returning to
below, thus maintaining a balance with the force of the original condition.
There is a diaphragm within the vacuum controller, is drawn out by the air/fuel mixture flowing near the
with a spring at the negative-pressure (vacuum) side vacuum port, thus resulting in a negative-pressure
which pressure against the diaphragm. A link is (vacuum) condition. Because the tube is connected
attached to the diaphragm and is connected to the to the negative-pressure (vacuum) port of the
pickup plate. The pickup assy is installed on the vacuum controller, the diaphragm pressure against
pickup plate, and can rotate together with the pickup the spring, and it moves in the direction of the arrow.
plate. Then the link rotates the pickup plate and, because
The negative pressure (vacuum) side of the vacuum the position of the pickup changes, the timing also
controller is connected to the vacuum port of the changes. The direction is the direction opposite to
carburetor by a tube. the direction of signal rotor rotation, so that the
When the throttle valve of the carburetor is closed, projection of signal rotor will pass the pickup quickly.
the engine is in the idling condition, and there is no In this way, then, the ignition timing advances.
vacuum inside the tube at this time. When the
throttle valve is partially open, the air within the tube
Engine Adjustment
Adjustment
The following is the method of adjustment of the carburetor and pneumatic governor on a reassembled engine.
Caution:
(1) The pneumatic governor has been properly adjusted and sealed in the factory before shipping. Never break
the seal unless it is necessary during engine overhaul.
(2) If the pneumatic governor is readjusted, seal it again and advise your user that he should not break the seal.
5. Anti-Hunting Adjustment
Governor Characteristics
Larger spring (1) Place all the hydraulic levers or power train in the
rigidity
neutral position.
Smaller spring
(2) Depress the accelerator pedal all the way. (The
Out put (PS)
rigidity
carburetor throttle valve will open fully.)
(3) Slowly rotate the adjusting screw clockwise until hunting
disappears.
Adjusting screw:
Clockwise rotation
Engine Speed (rpm) Increases spring tension (reduces the number of
6EN0836
active turns of spring).
Counterclockwise rotation
Reduces spring tension (increases the number of
active turns of spring).
Increasing the spring tension will eliminate hunting, but
an excessively high tension will change the governor
characteristics and produce some effects on the output
characteristics of the engine. It is, therefore, imperative
to limit the movement of the adjusting screw to less than
two turns from the standard position.
(4) Clockwise rotation of the adjusting screw raises the
engine maximum speed. Rotate the push nut
counterclockwise to reduce the speed.
(5) Repeat anti-hunting adjustment two or three times by
alternately adjusting the push nut and the adjusting
screw until the best result is obtained.
(6) The number of active turns of spring should not be less
than 11 when the adjustment is finished.
Entry of air from carburetor or intake manifold ÐRetighten set bolts or replace heat
insulator and/or intake manifold gasket.
Valves and related
Defective valves and related components ÐAdjust or repair valves and related
components
components.
Insufficient Ignition system out Incorrect ignition timing ÐAdjust ignition timing.
output of adjustment
Defective spark plug ÐReplace spark plug.
Overheating Insufficient coolant ÐAdd coolant and check for leaky points.
Coolant leaks from cylinder head gasket ÐRetighten cylinder head bolts or replace
gasket.
Overcooling
(Coolant
Defective thermostat ÐReplace thermostat.
temperature does
not rise.) Extremely low atmospheric temperature ÐPlace cover or anything proper on the
front of radiator.
Valves and Poor idling Incorrect valve clearance ÐCleaned or replace auto-lash adjuster.
related Valve not in close contact with valve seat ÐReface seat surface.
components
Excessive clearance between valve stem ÐReplace valve and valve guide.
and valve guide
Excessive fuel
Pressure leaks from cylinder head gasket ÐRetighten cylinder head bolts and
consumption replace gasket.
Piston ring binding or worn ÐReplace ring.
Insufficient output Piston ring or ring worn ÐDisassemble and repair engine.
Oil leaks
Loose timing gear cover or damaged gasket ÐRetighten set bolts or replace gasket.
Loose oil filter set bolt. ÐRetighten set bolts or replace oil filter
gasket.
Engine Excessive oil Piston ring gaps in improper positions ÐAdjust ring gap positions.
consumption
Piston rings or ring grooves worn or rings ÐReplace piston or rings.
seized in grooves
Worn piston and cylinder ÐRebore and hone cylinder and install
oversize piston.
Excessive quantity of oil in oil pan ÐOil quantity: 4.0 liter (1.1 U.S. gal).
Worn valve stem and valve guide ÐReplace valve and guide.
Excessive clearance due to worn cylinder ÐRebore and hone cylinder and install
oversize piston.
Worn float level pin and related components ÐReplace level pin and its related parts
Distributor Poor engine starting Cracked distributor cap and burnt or ÐClean or replace.
contaminated cord insertion hole
Insufficient engine
output
Excessive fuel
consumption
Spark plug Poor engine starting Improper spark plug gap ÐAdjust or replace.
Poor engine
acceleration
Insufficient engine
output
Ignition coil Poor engine staring Defective ignition coil ÐReplace ignition coil.
Poor engine
acceleration
Poor sliding of splined section ÐRub surfaces smooth, clean and repair.
Alternator
Brush and slip ring not properly connected ÐReplace brush if worn. (Clean holder.)
(Brush does not properly come down) ÐPolish slip ring.
Battery
Wiring
MD998375 Crankshaft front oil seal Installation of crankshaft front oil seal
installer
MD998285 Crankshaft front oil seal Guide for installation of crankshaft front
guide oil seal
MD998780 Piston pin setting tool Removal and installation of piston pin
MD998776 Crankshaft rear oil seal Installation of crankshaft rear oil seal
installer
Service Manual
Diesel Engine
DC24 (2.4 Liter)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
In this manual, the following symbols are used to indicate the type of service operations to be performed.
Removal Adjustment
Installation Cleaning
Measurement
If you have any question or recommendation in connection with this manual, please do not hesitate to contact our
head office, dealers or authorized service shops.
3. Major Maintenance.............................................................................................................................................16
3.1. Major Parts Fixing Bolts 3.2. Engine Repair Kit
3.3. Repair
5. Lubricating System............................................................................................................................................59
5.1. General description 5.2. OIl Pump
5.3. Oil Filter 5.4. Oil Cooler
Appendix
- Engine Assembly (ELFFO)
2. Before performing service operation, disconnect the grounding cable form the battery for reduce the chance of
cable damage and burning due to short-circuliting.
3. Before performing service operation release the air pressure in the machine air line machine air line system for
safty. To not do so in extremely dangerous.
5. Brake oil and anti-freeze solution must be handled with reasonable to efficient and reliable service operation.
6. The use of proper tools and special tools where specificed is important to efficient and reliable service operation.
8. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones
should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.
9. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing
bolts and nut separate is very improtant as they vary in hardness and design depending on position of installation.
10. Clean the parts before inspection or reassembly. Also clean oil ports, etc. usig compressed air to make certain
they are free form restrictions.
11. Lubricate rotation and sliding faces of parts with oil or grease before installation.
13. Carefully observe all specifications for bolts and nuts torques.
14. When service operation is completed, make a final check to be sure service has been done propery.
DC24 O 00001 FO
Suffix (ELFFO)
Serial No.
Production Year(2000)
Engine Model
1.3.1. Specification
Performance KS-R1004
Power (max.) 44 PS/2,250 rpm
Maximum torque 14.5 kg.m/1,800 rpm
Fuel consumption rating (min.) 200 g/PS.h
Performance KS-R1004
Power (max.) 45 PS / 2,400 rpm
Maximum torque 14.5 kg.m / 2,000 rpm
Fuel consumption rating (min.) 200 g / PS.h
4 5 6 7 8 21
3 20
2
1
12 11 10
13 14 15 16 17
22 23 24
18 19
NOTE : The proper density control of antifreezing solution and rust preventing additive will be
able to prevent the rusting effectively and maintain the stable quality of engine.
=Since DC24 diesel engine cylinder liner is dry type, particularly the cooling water control should be
applied thoroughly.
=The density of antifreezing solution and additive for rust prevention is able to be confirmed by the
cooling water test kit. (Fleetguard CC260M or DAEWOO 60.99901-0038)
=How to use the cooling water test kit
(1) When the cooling water temp of engine is in the range of 10 ~ 55 ûC, loosen the plug for cooling
water discharge and fill the plastic cup about a half.
NOTE : In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to
measure the accurate density. Take the cooling water sample necessarily loosening the cooling
water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper out through water
agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
NOTE : However, it should not elapse longer than 75 sec, and if it did, the hue would change.
(4) Make the numerical value by comparing the test paper which hue has changed with the color list of
label on storage bottle.
(5) By comparing thehue changed into yellowish green or so with the green color indication of test paper
storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to
50%).
(6) The brown at the middle of test paper and the lower pink color indication represent the additive state
for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and
pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storqge bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than
0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh
water.
Ambient
Cooling water (%) Anti-freeze (%)
Temperature (¡C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
¥ Testing conditions : coolant temperature 20¡C, Engine rpm 200rpm (10 turns)
2.1.11. Battery
= Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case
of poor condition.
= Inspect for amount of electrolytic solution, and replenish if insufficient.
= Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish.
The torque values given in the following table should be applied where a particular torque is not specified.
Bolt identification
4T 7T 9T
Bolt diameter x pitch Low carbon steel High carbon steel Alloy steel
EA0O4014
Timing 13¡ ± 1¡
T 13° 18°
D
C
EA0O4011
2) VE Injection Pump
=Turn the crank pulley until No. 1 piston is placed in
the ÒTDCÓ position of notch marks on the crank
pulley, and then turn again the crank pulley
clockwise until showing the notch mark of the right
figure corresponding to the injection timing is
aligned with the pointer ( ) on the crank pulley. T 13° 18°
D
C
DC24
EA0O4011
Fuel injection timing
(B.T.D.C static) 13¡
(kg/cm2, 200rpm)
Standard Limit
28 22.0 - 23.0
EA0O4015
EA0M3002
Adjustment
Adjust the injection starting pressure with the adjusting
screw using a nozzle tester
EA0M3003
Priming pump
EA0O4010
2) VE Injection Pump
After the cleaning of the fuel filter or after the engine
stop by the lack of fuel, the bleeding of the fuel
system must be executed by all means.
Bleed the system by manually operating the priming
pump with fuel injection pipe nut and filter bleeder
screw loosened.
¥ Press the priming pump cap repetitively until the
fuel without bubbles comes out from the bleeding
screw
¥ After the whole air is pulled out, close the screw of
the fuel filter and fuel injection pipe nut.
EA0O4008
EA3M1031
EA0M3005
Removal steps
Disconnect water separator sensor wiring at the
connector.
EA3M1031
Installation steps
Install the water separator sensor in the new filter. Apply
diesel fuel to o-ring.
Remove the filter cartridge using filter wrench Oil filter head
EA0M3006
Fan pulley
Adjust belt tension by moving generator pulley. about 10mm
EA0M3010
Thermo Switch
Operating temperature
EA0M3011
EA0M3012
4
5
EA0M4003
EA0M4003
<Disassembly steps>
1. Pulley. 3. Injection pump gear.
2. Timing gear case cover. 4. Idle gear.
Important Operations
Standard Limit
0.10-0.17 mm 0.3 mm EA0M4004
Standard Limit
0.07 mm 0.2 mm
EA0M4004
<Disassembly steps>
▲ 1. Spring seat and valve cotter
2. Valve spring
3. Valve
Important Operation
EA0M4008
<Disassembly steps>
▲ 1. Piston ring 4. Piston
2. Snap ring 5. Connecting-rod
▲ 3. Piston pin
EA0M4009
<Disassembly steps>
1. Rocker arm (A) 4. Rocker arm shaft bracket
2. Rocker arm shaft bracket 5. Rocker arm shaft
3. Rocker arm (B)
Standard Limit
Overall length 0.05 mm 0.2 mm
Thickness (H) 247.97-248.03 mm 247.7 mm
EA0M4012
Grade datermination
Take an average of 3 values obtained by measuring the
diameters shown in the right.
90
Measunng point : Approx. 90 mm from the upper face.
The mark on the upper face should be neglected in
case of Engine overhaul.
Grade tolerance
Standard
1 2
¯90.010 ¯90.020
Cylinder
¯90 ~ ~
bore dia
¯90.001 ¯90.011
¯89.984 ¯89.995
Liner
¯90 ~ ~
outer dia
¯89.995 ¯90.006
Standard
Steel liner -0.015~0.115 mm
Cast liner 0.008~0.070 mm
Tightness 0 - 0.02 mm
EA0M4016
Journal Pin
U/S 0.25 ¯ 69.67-¯ 69.68 mm ¯ 52.67-¯ 52.68 mm
U/S 0.50 ¯ 69.42-¯ 69.43 mm ¯ 52.42-¯ 52.43 mm
U/S 0.75 ¯ 69.17-¯ 69.18 mm ¯ 52.17-¯ 52.18 mm
U/S 1.00 ¯ 68.92-¯ 68.93 mm ¯ 51.92-¯ 51.93 mm
Fillet section
Standard Limit
Journal 0.001 mm 0.05 mm
Pin 0.001 mm 0.05 mm
Wear
Standard Limit
Clearance 0.018-0.065 mm 0.12 mm
Torque(kg¥m) 18.5
Standard Limit
0.029-0.082 mm 0.12 mm
EA0M4021
Limit
Crankshaft bearing 74.5 mm
Connecting-rod bearing 56.5 mm
EA0M4022
Run-out
Standard Limit
0.03 mm 0.06
EA0M4023
EA0M4024
Installation
: Installer
Installer EA0M4025
EA0M4026
EA0M4027
EA0M4028
EA0M4029
= Cylinder block
a) Marking number ; 1 or 2
(Size grade for of cylinder bore diameter)
b) Marking position ; Middle of the cylinder block side surface.
Piston grade of Cylinder block grade
cylinder No.4
lPistion
a) Marking number ; A or B Marking EA4M2021
(Size grade for piston outer diameter)
b) Marking position ; Center of the piston upper surface
4.3.5. Piston
Piston clearance
Grade A B
Cylinder ¯86.020 ¯86.031
inside Cast liner ~ ¯86.031 ~ ¯86.042
diameter
Steel liner ¯86.020~¯86.060
Piston clearance 0.035~0.062
Standard Limit
¯26.995-¯27.0 mm ¯26.96 mm
Standard Limit
1st compression ring 0.085 - 0.115mm 0.2mm
2nd compression ring 0.05 - 0.085mm 0.15mm
Oil ring 0.03 - 0.065mm 0.15mm
EA0M4032
Standard Limit
1st compression ring 0.20 - 0.40mm 1.5mm Feeler Gouge
2nd compression ring 0.20 - 0.40mm 1.5mm
Oil ring 0.10 - 0.30mm 1.5mm
EA0M4033
Standard Limit
Distortion 0.05 mm 0.20 mm
Parallelism 0.05 mm 0.15 mm
EA0M4034
Standard Limit
0.008 - 0.02mm 0.05mm
EA0M4035
Bushing Replacement
Removal
: Remover
Installation
: Installer
EA0M4036
Standard Limit
Overall length 0.05 mm 0.2 mm
Thickness (H) 91.95-92.05mm 91.75 mm
EA0M4038
Limit 0.02 mm
EA0M4039
EA0M4040
EA0M4041
EA0M4042
EA0M4043
EA0M4044
Standard Limit
Intake valves ¯7.946 - ¯7.961mm ¯7.88mm
Exhaust valve ¯7.921 - ¯7.936mm ¯7.85mm II III
I
EA0M4045
Depression
Standard Limit
Intake valves 0.65mm 2.5 mm
Exhaust valve 0.65mm 2.5 mm Depression
EAOM4046
Contact width
Standard Limit
1.06mm 3.6 mm
Contact width
EAOM4047
B
EA0M4048
EA0M4048
Valve thickness
Standard Limit
Intake valve 1.3 mm 1.0 mm
Exhaust valve 1.3 mm 1.0 mm
Thickness
EA0M4049
Welding
bead
EA0M4051
Standard Limit
Intake valve 0.039 - 0.071 mm 0.20 mm
Eahaust valve 0.064 - 0.096 mm 0.25 mm
EA0M4052
EA0M4053
EA0M4054
Standard Limit
Free Square
lnner 47.9mm 46.5mm
Free length Length
Outer 47.3mm 45.8mm
lnner - 1.0mm
Inclination
Outer - 1.0mm EA0M4055
EA0M40
Free lenght and inclination
EA0M4056
Limit 0.4 mm
EA0M4057
Standard Limit
¯18.98 - ¯19.00 mm ¯18.85 mm
EA0M4058
Standard Limit
0.020 - 0.070 mm 0.2 mm
EA0M4060
EA0M4061
Standard Limit
Journal diameter ¯47.945 - ¯47.975mm ¯47.6mm
Height of cam lobe 40.568mm 40.2mm
I II I II
A
C B B
D A EA0M4062
EA0M4063
Run-out
Standard Limit
0.05 mm 0.1 mm
EA0M4066
End play
Standard Limit
0.05-0.11mm 0.2 mm
EA0M4067
EA0M4068
EA0M4069
Tappet
Inspect tappet for wear, damage or other abnormal
condition.
Diameter
Standard Limit
¯12.977-¯12.990mm ¯12.95 mm
Standard Limit
0.03 mm 0.1 mm
EA0M4072
Limit 0.4 mm
Standard Limit
¯44.945 - ¯44.975mm ¯44.845 mm
EA0M4074
Standard Limit
0.025-0.085mm 0.2 mm
EA0M4075
EA0M4076
Installation
: Installer
EA0M4077
EA0M4078
<Reassembly steps>
1. Valve 3. Retainer and valve cotter
▲2. Valve spring
Important operations
Painted portion
EA0M4079
3 21 4 5 6 7 8 9 10 11 12 13 14 15 16
EA0M4080
Important operations
EA0M4081
EA M
=Rocker arm (B) (18)
=Rocker arm (D) (6, 10, 14)
Difference between rocker arm (B) and (D)
Rocker arm(C) Rocker arm(A)
EA0M4081
<Reassembly steps>
1. Piston and connecting-rod 3. Snap ring
2. Piston pin 4. Piston ring
Important operations
= Piston pin
Install the piston pin after heating the piston to about
100¡C
Snap ring
Important operations
Fit correctly
With oil hole
=Crankshaft and bearing and groove
EA0M4083
Block
Cap side
EA0M4106
No. 1
0-0.05
EA0M4084
EA0M4085
Install front and rear side thrust bearings with the oil
groove turned to the timing gear and flywheel,
respectively.
EA0M4086
Bolt lenght 89 mm
EA0M4088
Flywheel
Tighten the bolts in the numerical order as the
illustration
3 1
5 6
Torque (kg-m) 12.0 2 4
EA0M4089
120 EA0M4090
EA0M4091
Matching
number
EA0M4092
EA0M4093
Oil jet
pipe
EA0M4094
45
45
Crankshaft
EA0M4095
EA0M4096
<Reassmbly steps>
▲1. Idle gear assembly ▲3. Timing gear case cover
▲2. Injection pump gear ▲4. Crank shaft pulley
EA0M4098
EA0M4099
EA0M4107
EA0M4100
2) VE Injection pump
=Turn the crank pulley until No. 1 piston is placed in the
ÒTDCÓ position of notch marks on the crank pulley, and
then turn again the crank pulley clockwise until
showing the notch mark of the right figure
corresponding to the injection timing is aligned with
the pointer ( ) on the crank pulley.
T 13° 18°
DC24 D
C
Fuel injection timing EA0O4011
(B.T.D.C static) 13¡
<Reassembly steps>
▲ 1. Cylinder head gasket ▲ 3. Rocker arm shaft assembly
▲ 2. Cylinder head 4. Water pump
"TOP" 0048
Fan pulley
= Fan belt (6) about 10mm
Specified belt deflection
Regulation
valve
Crankshaft Camshaft
Timing gear
bear ing bear ing
Piston
Oil jet
Cylinder
Connecting-
head valve
rod bear ing
mechanism
Piston
Oil pump
EA0M5001
1 3
EA0M5002
<Disassembly steps>
1. Oil pipe 3. Pump cover
2. Strainer 4. Vane
Standard Limit
0.02 - 0.07 mm 0.15 mm
Standard Limit
0.02 - 0.13 mm 0.15 mm
Standard Limit
0.04 mm 0.2 mm
Pinion replacement
Removal
File off caulked end of the pinion stopper, then drive out
the pin toward opposite side.
Installation
Install a new stopper pin and caulked end of the pin after
installation.
EA0M5006
EA0M5008
Installation
When the pin is installed, check to make sure the end of
the pin is not projected from the end of rotor.
EA0M5009
Reassembly
To assemble, follow the disassemble procedure in
reverse order.
3
5
1
EA0M5010
<Disassembly steps>
1. Drain plug 4. Oil filter cartridge
2. Plug screw 5. Relief valve assÕy
3. Plug screw 6. Oil filter housing
Reassembly
To assemble, follow the disassembly procedure in reverse order.
EA0M5015
EA0M5016
Thermostat
Cylinder head
By-pass
Car heater
Radiator
Cylinder block
Water pump
EA0M6001
<Disassembly steps>
1. Cover ▲ 4. Impeller and mechanial seal
2. Set screw 5. Unit bearing
▲ 3. Hub
= Hub (3)
EA0M6003
EA0M6004
EA0M6005
EA0M6006
<Reassembly steps>
▲ 1. Unit bearing 4. Cover
2. Set screw ▲ 5. Hub
▲ 3. Impeller and Mechanical seal
Important operations
EA0M6008
Apply liquid
gasket here
EA0M6009
EA0M6010
Depth 1.0 mm
EA0M6011
EA0M6012
EA0M6013
Nozzle holder
Fuel filter
EA0M7001
2) VE Injection pump
7 3
2
6
<Disassembly steps>
1. Cap nut 6. Nozzle nut
2. Nut ▲7. Nozzle
3. Adjusting screw 8. Nozzle holder screw
4. Nozzle spring 9. Connector
5. Push rod
Important operations
=Nozzle (7)
After removal of nozzle assembly from the nozzle
body, keep them separate to maintain proper needle
valve to body combinations.
Reassembly
To reassemble, follow the disassembly procedure in
reverse order.
Refer to ÒFUEL SYSTEMÓ in general information for
injection of spraying condition and injection starting
pressure adjustment.
(A) Test condition for Nozzle 105000-2010 Opening pressure: 150 kg/cm2
injection pump Holder AssÕy 105780-2080 -
Injection pipe(IDxOD-L) - ¯2.0 x ¯6.0-840 mm
Test oil ISO4113 Temperature: 40 ± 5 ¡C
(B) Engine stan 65.10101-7075A
Nozzle (¯1.0)
dard parts (DOOWON)
Nozzle & holder AssÕy
65.10101-7076A
(LUCAS) Opening pressure: 120 kg/cm2
Max. various
Pump speed Average quantity Adjust
between cylinder Remark
(rpm) (mm3/stroke) Adjust
(mm3/stroke)
500 (34.5 ± 2.0)
Full load 900 35.5 ± 1.0 3.0 ✻ Full load
1200 (36.0 ± 1.0)
Governing 1320 8.5 ± 3.0 ✻ Governing
Idling 425 7.5 ± 2.0 2.0 ✻ Idling
Start (idling) 100 (60.0 ± 20)
(A) Test condition for Nozzle 105780-0000 Opening pressure: 175 kg/cm2
injection pump Nozzle & holder AssÕy 105780-8140 -
Injection pipe(IDxOD-L) - ¯6.0 x ¯2.0 - 600 mm
Test oil ISO4113 Temperature: 40 ± 5 ¡C
(B) Engine standard 65.10101-7075A
Nozzle (¯1.0)
parts Nozzle & holder AssÕy (DOOWON)
65.10101-7076A
Opening pressure: 120 kg/cm2
(LUCAS)
Injection pipe(ID x L) 65.10301-6172 ¯2.0 x 334 mm
Rack diagram and setting valve at each point
Check Rack Pump Injection Q`ty on RIG
Point position speed (mm3 / 1,000st) Press.
(mm) (rpm) (A) Test condition (B) Engine (mmHg)
18+30 for inj. pump standard parts
RACK CAP:APPROX15.0
A 12.5 750 37 ± 1.6 - -
A
12.2 B B 12.0 1200 38.5 ± 1.0 - -
12.0
0.5 +0.1
11.2
C 8.2 350 8 ± 1.1 - -
8.2 C
6.9
1:00 1200+90
-10
(1160)
Intake manifold
Check intake manifold head side for flatness.
Limit 0.4 mm
EA0M8006
Reassemble
To reassemble, follow the disassembly procedure in
reverse.
Limit 0.4 mm
Service Manual
Delce Remy CS-121
Series Alternators
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary train-
ing, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publica-
tion.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubri-
cation, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. 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 avail-
able.
1
Index
Specifications
Alternator................................................................. 5
Systems Operation
Alternator................................................................. 6
CS-121 Alternator Operation ........................... 6
Alternator Components ............................ 7
Alternator Operation Schematic ............... 9
Introduction ...................................................... 6
Troubleshooting..................................................... 10
Troubleshooting Problem List ................ 10
Troubleshooting Problems ..................... 10
Alternator
IDAS012B
ALTERNATOR SPECIFICATIONS
DAEWOO Part No. 8C5510
Delco Remy Series CS-121
Voltage Rating 12V
Polarity Neg. Gnd.
Rotation CW
2 Test Speed 6500 rpm
Rated Output (Cold) 61A
IDAS011B
Output Voltage 14.0L0.5V
CS-121 Alternator Cross-Sectional View Rotor Field Winding
Resistance [At 27C(80¡F)] -
Field Current [At 14.0V or -
27.5V and 27C(80¡F)]
Stator Winding -
Resistance
Turn On Speed (Max.) -
Slip Rings (3) : -
Maximum Runout (TIR)
Minimum Diameter -
Brush Length (Measured
On Longest Side) : -
New
Minimum
Pulley Nut (2) Torque 100 L 7 N I m
(75 L lb I ft)
Thru Bolt (1) Torque -
Terminal Torques :
Bat 3.6 L 0.8 N I m
(32 L 7 lb I in)
Gnd -
IDAS001C
3 5 6
1 2 4
10
IDAS002C
7
The major components of the alternator are stator
(4), rotor (3), rectifier (10), regulator (9), brush holder
(7) and frames (2) and (5). The CS-121 alternators
8 feature a high ampere output per pound of weight,
IDAS013B with a totally new and different regulator. A diode trio
is not used. A delta wound stator, rectifier bridge,
Alternator Components-Cross-Sectional View rotor with slip rings and brushes are electrically
(1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive similar to the SI series. alternators. The CS stands
end frame. (6) External fan. (7) Brush holder. (8) Internal for Charging System. The 121 denotes the outside
fan. diameter in millimeters of the stator laminations. This
series of alternators has two fans for cooling the
alternator.
IDAS014B
Stator
(4) Stator.
IDAS003C 8
Rotor
(1) Slip rings. (3) Rotor. (8) Internal fan.
7
IDAS015B
Brush Holder
(7) Brush holder. (11) Brushes.
Probable Cause:
Troubleshooting
1. Loose Drive Belt For Alternator:
Adjust the alternator drive belt.
Troubleshooting can be difficult. On the page that 2. Loose Alternator Drive Pulley:
follows is a list of possible problems. To make a repair Check the pulley for wear. If it is worn, install a
to a problem, make reference to the probable cause. new pulley. Tighten the pulley nut to the correct
torque shown in Specifications.
This list of problems and probable causes will only
give an indication of where a possible problem can 3. Charging Or Ground Return Circuit Or Battery
be and what repairs are needed. Sometimes more or Connections Defective:
other repair work is needed beyond the Inspect all cables and connections. Clean and
recommendations in the list. Remember that a tighten all connections. Replace defective parts.
problem is not normally caused by one part, but by
4. Regulator Is Defective:
the relation of one part with other parts. This list
Replace the regulator.
cannot give all possible problems and probable
causes. The serviceman must find the problem and 5. Rectifier Is Defective:
its source, then make the necessary repairs. Replace the rectifier.
2. Regulator Is Defective:
Install a new regulator.
Troubleshooting Problems
Problem 4: Alternator Is Noisy
Problem 1: Alternator Does Not Charge
Probable Cause:
Probable Cause:
1. Drive Belt For Alternator Is Worn Or Defective:
1. Loose Drive Belt For Alternator : Install a new drive belt for the alternator.
Adjust the alternator drive belt.
2. Loose Alternator Drive Pulley:
2. Loose Alternator Drive Pulley : Check the pulley for wear. If it is worn, install a
Check the pulley for wear. If it is worn, install a new pulley. Tighten the pulley nut to the correct
new pulley. Tighten the pulley nut to the correct torque shown in Specifications.
torque shown in Specifications. 3. Drive Belt And Drive Pulley For Alternator Are Not
3. Charging Or Ground Return Circuit Or Battery In Alignment:
Connection Are Defective: Make an adjustment to put the drive belt and drive
Inspect all cables and connections. Clean and pulley in correct alignment.
tighten all connections. Replace defective parts. 4. Alternator Bearings Are Worn:
4. Rotor Field Winding Or Regulator Is Defective: Install new bearings in the alternator.
Install a new rotor or regulator.
Tools Needed
Digital Multimeter or Equivalent 1
AC/DC Clamp-On Ammeter 1
Machine Test
* Some models that have the CS-121 alternator do not have a resistor in the ignition of key start switch circuit, if the indicator
lamp is burned out, the alternator cannot turn on. Also, if a machine is jump started because the battery is too low, the
alternator may not have any output. This is because the battery may be too low to send current to the alternator. The
alternator needs current to start the charging process.
Service Manual
CS-105D Series
Alternator
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary train-
ing, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publica-
tion.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubri-
cation, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. 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 avail-
able.
1
Index
Specifications
Alternator................................................................. 5
Systems Operation
Alternator................................................................. 6
CS-105D Alternator Operation......................... 6
Alternator Components ............................ 7
Alternator Operation Schematic ............... 9
Introduction ...................................................... 6
Troubleshooting..................................................... 10
Troubleshooting Problem List ................ 10
Troubleshooting Problems ..................... 10
Alternator
ALTERNATOR SPECIFICATIONS
DAEWOO Part No. A274017
Series CS-105D
Voltage Rating 12V
Polarity Neg. Gnd.
Rotation CW
Test Speed 6500 rpm
Rated Output (Cold) 50A
Output Voltage 14.5 L 0.3V
Rotor Field Winding
Resistance [At 27¡C(80¡F)] 2.97 ~ 3.05 OHMS
Field Current [At 14.0V or -
CS-105D Alternator View 27.5V and 27¡C(80¡F)]
Stator Winding -
Resistance
Turn On Speed (Max.) -
Slip Rings (3) : 0.08
Maximum Runout (TIR)
Minimum Diameter -
Brush Length (Measured
On Longest Side) : 17.0 L 0.3 mm
New
Minimum
Pulley Nut (2) Torque 100 L 10 N I m
(900 L 90 lb I in)
Thru Bolt (1) Torque -
Terminal Torques : 10 L 1.0 N I m
Bat (90 L 10 lb I in)
Gnd -
CS-105D Alternator
2
9
P0004349
IDAS014B
Stator
(4) Stator.
10
1
3
P0004350 P0004349
Rotor Rectifier
(1) Slip rings. (3) Rotor. (8) Internal fan. (10) Rectifier.
Rotor (3) consists of a core, coils and slip rings (1). Rectifier (10) contains three positive (+) and three
The rotor provides the magnetic field between the negative (-) diodes to form the full wave rectifier
rotor field winding and the stator. Slip rings (1) pro- bridge which is connected to the stator. Rectifier (10)
vide the surfaces for brush contact. Internal fan (8) changes or rectifies three phase AC to DC.
pulls air through the rear frame to cool the rectifier
bridge and regulator.
P0004349
Regulator
(9) Regulator.
The integral charging system schematic and The field current is sufficient to cause the alternator
explanation that follow indicate the terminals and to turn on when the engine is started. At engine idle
basic circuitry for the CS-105D series alternator. speeds, voltage induced in the stator will cause the
stator to supply field current and also output voltage
and current at the Bat terminal for the vehicle
electrical system.
CS-105D Integral Charging System Schematic As alternator speed increases, less field current is
needed to generate the desired system voltage. The
duty cycle changes to reduce the average field
When the switch is closed, the indicator lamp turns current. For example, at high engine speeds, the
on and a voltage is applied to the regulator at the "L" regulator may be on only 10 percent of the time and
terminal to cause transistor to rapidly "turn on" and off 90 percent of the time. This duty cycle will change
"turn off". The transistor will be turned on about 30 as operating factors change to provide just the right
percent of the time and turned off 70 percent of the amount of voltage.
time. The battery will supply field current which will
flow into the alternator output or Bat terminal and Most regulators are temperature compensated to
then through transistor and the field coil to ground. provide the maximum voltage needed for battery
Field current does not flow through the indicator charging. As the temperature increases, the voltage
lamp. setting will decrease. Under cold weather conditions,
the regulator will operate at a higher voltage setting
to provide the higher voltage required by the battery
for charging under these conditions.
Probable Cause:
Troubleshooting
1. Loose Drive Belt For Alternator:
Adjust the alternator drive belt.
Troubleshooting can be difficult. On the page that 2. Loose Alternator Drive Pulley:
follows is a list of possible problems. To make a repair Check the pulley for wear. If it is worn, install a
to a problem, make reference to the probable cause. new pulley. Tighten the pulley nut to the correct
torque shown in Specifications.
This list of problems and probable causes will only
give an indication of where a possible problem can 3. Charging Or Ground Return Circuit Or Battery
be and what repairs are needed. Sometimes more or Connections Defective:
other repair work is needed beyond the Inspect all cables and connections. Clean and
recommendations in the list. Remember that a tighten all connections. Replace defective parts.
problem is not normally caused by one part, but by
4. Regulator Is Defective:
the relation of one part with other parts. This list
Replace the regulator.
cannot give all possible problems and probable
causes. The serviceman must find the problem and 5. Rectifier Is Defective:
its source, then make the necessary repairs. Replace the rectifier.
2. Regulator Is Defective:
Install a new regulator.
Troubleshooting Problems
Problem 4: Alternator Is Noisy
Problem 1: Alternator Does Not Charge
Probable Cause:
Probable Cause:
1. Drive Belt For Alternator Is Worn Or Defective:
1. Loose Drive Belt For Alternator : Install a new drive belt for the alternator.
Adjust the alternator drive belt.
2. Loose Alternator Drive Pulley:
2. Loose Alternator Drive Pulley : Check the pulley for wear. If it is worn, install a
Check the pulley for wear. If it is worn, install a new pulley. Tighten the pulley nut to the correct
new pulley. Tighten the pulley nut to the correct torque shown in Specifications.
torque shown in Specifications. 3. Drive Belt And Drive Pulley For Alternator Are Not
3. Charging Or Ground Return Circuit Or Battery In Alignment:
Connection Are Defective: Make an adjustment to put the drive belt and drive
Inspect all cables and connections. Clean and pulley in correct alignment.
tighten all connections. Replace defective parts. 4. Alternator Bearings Are Worn:
4. Rotor Field Winding Or Regulator Is Defective: Install new bearings in the alternator.
Install a new rotor or regulator.
Tools Needed
Digital Multimeter or Equivalent 1
AC/DC Clamp-On Ammeter 1
Machine Test
* Some models that have the CS-105D alternator do not have a resistor in the ignition of key start switch circuit, if the indicator
lamp is burned out, the alternator cannot turn on. Also, if a machine is jump started because the battery is too low, the
alternator may not have any output. This is because the battery may be too low to send current to the alternator. The
alternator needs current to start the charging process.
Specifications
Systems Operation
Testing & Adjusting
Disassembly & Assembly
Lift Trucks Power Train
D15S-2, D18S-2, D20SC-2
G15S-2, G18S-2, G20SC-2
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. 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.
1
Index
Specifications
Final Drives And Wheels .......................................... 7
Torque Converter ...................................................... 5
Transmission............................................................. 6
Wheel Bearing Adjustment ....................................... 8
Systems Operation
Differential And Drive Axles .................................... 22
General Information .................................................. 9
Torque Converter .................................................... 10
Transmission General Information.......................... 12
Transmission Hydraulic System ............................. 14
Transmission Power Flows..................................... 13
Troubleshooting ...................................................... 23
Differential.......................................................... 25
Checks During Operation .................................. 23
Visual Checks .................................................... 23
Torque Converter
4
6 3
(1) Torque for bolts sealing cap ............98 to 123 N¥m (7) Ring gear runout measured on back
(72 to 90 lb¥ft) ........................................0.1 mm (0.0039 in) T.I.R
(2) Torque for bolts that hold plate (Apply (8) Backlash of spiral bevel gear.......0.15 to 0.23 mm
Loctite No. 271).........27 to 34 N¥m (20 to 25 lb¥ft) (0.006 to 0.009 in)
(3) Torque for Lock nut .......................314 to 441 N¥m (9) Rolling torque of ring gear for complete assembly
(231 to 325 lb¥ft) ..............................31 to 57 N¥m (276 to 507 lb¥in)
(4) Torque for bolts that hold case cover (Apply See Transaxle in Testing and adjusting for the
Loctite No. 271).........25 to 39 N¥m (19 to 28 lb¥ft) complete adjustment procedure.
General Information
4
3 2 5 1
(1) Engine. (2) Torque Converter. (3) Power Shift Transmission. (4) Drive Axle. (5) Adapter Housing.
The basic components of the power train are engine Power from either clutch pack is sent through an
(1), torque converter (2), power shift transmission (3), output gear and a spiral bevel gear to the differential.
drive axle (4), adapter housing (5) and the wheels. The differential sends power out through the axles to
the final drives and wheels.
A transaxle contains a power shift transmission and a
differential. Two axle shafts connect the differential to
two final drives. The drive wheels are mounted to the
final drives.
AA
BB
CC
4
6
Torque Converter
AA. Components Turned by Engine Flywheel. BB. Components Turned by (AA). CC. Stationary components.
(1) Transmission Input Shaft. (2) Pump Stator Support. (3) Stator. (4) Turbine. (5) Housing. (6) Impeller.
The torque converter hydraulically connects the The torque converter has four main parts : housing
engine to the transaxle. There is no direct (5), impeller (6), turbine (4), and stator (3). The
mechanical connection between the engine and the housing and impeller turn with the engine. The
transaxle. When the machine works against a load, turbine turns transmission input shaft (1), and the
the torque converter can multiply the torque from the stator is held stationary.
engine and send a higher torque to the transaxle.
After the oil hits the turbine blades, it goes toward the
inside of the turbine. As the oil goes from the turbine,
it moves in a direction opposite to the direction of
impeller rotation.
6 5 4 3 11 12 13 14 1
10
(1) Toruqe Converter. (2) Input Shaft. (3) Clutch Cylinder. (4) Piston (Forward). (5) Forward Clutch Pack. (6) Gear (forward).
(7) Gear. (8) Gear. (9) Output Gear. (10) Pinion. (11) Piston (Reverse). (12) Reverse Clutch Pack. (13) Gear (Reverse).
(14) Pump.
Forward Direction
Reverse Direction
Hydraulic System
Neutral Position
7
4
PUMP PRESSURE
ACCUMULATOR PRESSURE
15
CLUTCH PRESSURE
16 17
6
10
3
16
2
12 P T 8
14
13 S 10
11
Systems Operation
9
Transmission Hydraulic System
(1) Pump. (2) Main Relief Valve. (3) Inching Valve.
(4) Modulating Valve. (5) Directional Valve.
(6) Forward Clutch. (7) Reverse Clutch. (8) Torque Convertor.
(9) TC-in Relief Valve. (10) TC-out Relief Valve.
(11) Oil Cooler. (12) Cooler Relief Valve. (13) Reservoir.
(14) Suction Filter. (15) Shuttle Valve.
(16) Solenoid Valve-Forward. (17) Solenoid Valve-Reverse.
Neutral Position
Hydraulic System
Forward Position
4 7
PUMP PRESSURE
ACCUMULATOR PRESSURE
15 CLUTCH PRESSURE
16 17
6
18
3
1
2
12 P T 8
14
13 S 10
11
Systems Operation
9
Transmission Hydraulic System
(1) Pump. (2) Main Relief Valve. (3) Inching Valve.
(4) Modulating Valve. (5) Directional Valve.
(6) Forward Clutch. (7) Reverse Clutch. (8) Torque Convertor.
(9) TC-in Relief Valve. (10) TC-out Relief Valve.
(11) Oil Cooler. (12) Cooler Relief Valve. (13) Reservoir.
(14) Suction Filter. (15) Shuttle Valve.
(16) Solenoid Valve-Forward. (17) Solenoid Valve-Reverse.
Forward Direction
Hydraulic System
Reverse Position
7
4 PUMP PRESSURE
ACCUMULATOR PRESSURE
15
CLUTCH PRESSURE
16 17 6
3
20
2
12 P T 8
14
13 S 10
11
Systems Operation
9
Transmission Hydraulic System
(1) Pump. (2) Main Relief Valve. (3) Inching Valve.
(4) Modulating Valve. (5) Directional Valve.
(6) Forward Clutch. (7) Reverse Clutch. (8) Torque Convertor.
(9) TC-in Relief Valve. (10) TC-out Relief Valve.
(11) Oil Cooler. (12) Cooler Relief Valve. (13) Reservoir.
(14) Suction Filter. (15) Shuttle Valve.
(16) Solenoid Valve-Forward. (17) Solenoid Valve-Reverse.
Reverse Direction
1
3 2 4 5 6 7 8
(1) Spider. (2) Pinion. (3) Gear. (4) Differential case. (5) Nut. (6) Tube. (7) Drum. (8) Hub. (9) Shaft.
The location of the differential is in the front of the lift During a turn, the force (traction) that is on the drive
truck. The differential is a part of the transaxle. It is a wheels is different. These different forces are also felt
single reduction unit with a differential drive gear (3) on opposite sides of the differential and cause
fastened on the differential case (4). pinions (2) to turn. The rotation of pinions (2) stops or
slows the inside wheel and lets the outside wheel go
The differential is used to send the power from the faster. This moves the machine through a turn under
transaxle to the wheels. When one wheel turns full power.
slower than the other, the differential lets the inside
wheel stop or turn slower in relation to the outside The differential gets lubrication from oil thrown about
wheel. inside the housing.
Case (4) has four differential pinion (2). The pinions The differential turns axle shaft (9). Tube (6) which is
are engaged with two side gears. The side gears are pressed into axle housing is used as a support for
splined to the axle shafts (9). hub (8). The hub (8) and bearings are turned by axle
When the lift truck moves in a forward direction and shaft (9) through a direct connection between the
there is same traction under each wheel, there is hub and axle shaft. The drive wheel is fastened to
also the same torque on each axle and pinions (2) hub (8) and turns with the hub.
are stopped. This gives the same effect as if both
wheels were on the same axle.
Troubleshooting NOTICE
Before these checks are started, fill the transmission
Troubleshooting can be difficult. A list of possible with oil to the correct level.
problems and corrections is on the pages that follow.
This list of problems and corrections will only give an
indication of where a problem can be and what
Power Shift Transmission
repairs are needed. Normally, more or other repair
work is needed beyond the recommendations on the
With the engine running and brakes on, move the
list. Remember that a problem is not necessarily
selector lever to all positions. The detents must be
caused only by one part, but by the relation of one
felt in each position.
part with other parts. This list can not give all
possible problems and corrections. The serviceman
Operate the machine in each direction. Make note of
must find the problem and its source, then make the
all noises that are not normal and find their sources.
necessary repairs.
If the operation is not correct, make reference to the
Always make visual checks first. Check the operation
CHECK LIST DURING OPERATION for ÒproblemsÓ
of the machine and then check with instruments.
and Òprobable causesÓ.
1. Restriction in cooling lines. 1. Discs and plates have too much wear in forward
direction clutch.
2. Oil level too high or too low.
2. Leakage at the seals.
3. Core of the oil cooler not completely open.
3. Forward clutch components have damage.
4. Air mixed in the oil. Air leak on intake side of
pump. 4. Control linkage has damage or wrong adjustment.
5. Low oil flow through converter because converter Problem: Low stall speed.
regulator valve is stuck.
Probable Cause:
6. Wrong application for vehicle, (loads are too heavy
for the lift truck). 1. Engine performance is not correct.
Problem: Loss of power during or after a shift. 2. The one-way clutch of the torque converter does
not hold.
Probable Cause:
Problem: High stall speed in both directions.
1. Cold oil.
Probable Cause:
2. Low converter pressure.
1. Low oil level.
Problem: Pump noise not normal.
2. Air in the oil.
Probable Cause:
3. Clutches slip(clutch plates slide in relation to one
1. A loud sound at short time periods gives an another).
indication that foreign material is in the
transmission hydraulic system. 4. Torque converter failure.
2. A constant loud noise is an indication of pump Problem: High stall speed in one direction.
failure.
Probable Cause:
Problem: Noise in the transmission which is not
normal. 1. There is a leak in that clutch circuit.
1. Parts have wear or have damage. Problem: Clutch engagement is slow and makes
rough shifts.
Problem: Transmission operates in forward only.
Probable Cause:
Probable Cause:
1. Shift linkage adjustment is not correct.
1. Discs and plates have too much wear in reverse
direction clutch. 2. Inching valve adjustment is not correct.
1. Inching valve stuck. 1. Clutch discs and plates have too much wear.
Problem: Pressure to one clutch is low. 3. Forward and reverse clutch components have
damage.
Probable Cause:
3. Transmission pump is worn. 4. Drive gear and pinion not in adjustment for correct
tooth contact.
4. Converter regulator valve stuck open.
5. Teeth of drive gear and pinion have damage or
Problem: Low main pressure. wear.
Problem: Clutch pressure and main pressure are 1. Ring gear does not run even.
high.
a. Bolts on drive gear not tightened correctly.
Probable Cause: b. Drive gear has a defect(warped).
Probable Cause:
a. Lubricant above specification level. Raise the front of the lift truck off the floor. Put wood
b. Wrong kind of lubricant. blocks or jack stands of the correct capacity under it
c. Restriction of axle housing breather. to hold it in this position while pressure tests are
d. Pinion oil seal worn or not installed correctly. performed.
2. Install a tachometer on the engine to show engine The test checks the maximum RPM that the engine,
speed during the test. at full throttle, can turn the converter with the turbine
held stationary. To hold the converter turbine, engage
3. Put a thermistor probe in place of the dipstick in the brakes with the transmission in either FORWARD
the transaxle oil reservoir. or REVERSE.
4. Remove each of the following pressure tap plugs The drive wheels must not turn during the stall test.
in the order shown and install the pressure gauge. Put a heavy load on the forks and put the truck in
After the pressure check is done, remove the position against a solid object that will not move
gauge and install the plug again. (such as a loading dock). Engage the parking brake.
When the tests are made, the wheel brakes must be
engaged with the left foot ; the accelerator pedal can
be operated with the right foot. Make sure that the
transmission oil is at the correct temperature for
operation before tests are made.
Check the high idle setting before the stall test is
made. The high idles on G420 engine and DC24
engine are as follows.
WARNING
1
2 4
3 Make tests in a clear level area only. There must be
one operator. Keep all other personnel away from
the lift truck. Check the operation of the brakes
before the tests are made.
5
3 7 510 B
9
2 5
X
1
4
1 2 4 8 6 11
A
(1) Pinion Gear. (2) Shim Pack. (3) Bearing Cone. Pinion Bearing Preload Adjustment.
(4) Bearing Cup. (5) Bearing Cone. (6) Bearing Cup. (1) Bearing. (2) Bearing. (3) Race B. (4) Race A. (5) Shim Pack.
(7) Race B. (8) Race A. (9) Shim Pack. (10) Race. (11) Nut.
EXAMPLE: If the old pinion has a mark of (128.15) 4. The theoretical dimension of X is 55.95. If the
and the new pinion has a mark of (128.00) add 0.15 measured distance of X is 55.85, then the
mm (.006 in) shims to the original shim thickness. deviation (D) of the bearing is
(D) = 55.95 - 55.85 = 0.1 mm
2. Install bearing cone (3) on pinion shaft (1) with
new shim pack (2) behind bearing cone (3). 5. Install the shim behind the bearing cone (1).
3. Put the taper roller bearing assembly (3~9) and 6. Tighten the Jig B to torque of 15 to 20 N¥m (11 to
race (10) into the pinion shaft. Tighten nut (11) to a 15 lb¥ft) again.
torque of 32 to 45 N¥m (23 to 33 lb¥ft) while
rotating the pinion. 7. Check the rolling torque of the taper roller bearing.
It must be 2 to 5 N¥m (1.5 to 3.7 lb¥ft).
4. If the taper roller bearing and/or housing is If the torque is not correct, add or remove shim (5)
changed, then see pinion Depth check and pinion until it is correct.
bearing adjustment.
Tools Needed:
D
Dial Indicator Group (A)
Z
X
5
C
H
Y
4
3
1 2
3. Read the mark of the pinion shaft. If the mark is Backlash Adjustment
(1) Bearing Cone. (2) Spiral Bevel Gear. (3) Bolt.
128.00 mm, then the deviation of the mounting (4) Bearing Cup. (5) Bearing Cap. (6) Locknut. (7) Plate.
distance (M) is
deviation (M) = 128.25 - 128.00 = 0.25 mm.
1. Install bearing cones (1) on the differential case.
4. Required shim of the pinion is as follows.
Required shim (S) = gap (X) + deviation (D) 2. Put spiral bevel gear (2) on the differential case
+ deviation (M) and tighten eight bolts (3) to a torque of 110 L 5
N¥m (82 L 5 lb¥ft). Put bearing cups (4) on bearing
cones (1).
IBPS012B
Torque Converter 3
Disassembly
1. Drain the transmission oil and disconnect the
torque converter assembly
(housing + torgue converter) from the IBPD103P
transmission.
IBPD101P IBPD104P
2. Drain oil in the torque converter. 4. Remove the flexible plate(2) , pilot boss (3), and
O-ring (4).
5
2
6
1
IBPD102P
IBPD105P
IBPD106P IBPD109P
6. Remove the torque converter 9. Install 2 jackbolts (9) and remove the oil pump
(10).
ATTENTION : Canting the torque converter can
cause damage of pump oil seal.
11 12
IBPD110P
IBPD107P
10. Install 2 jackbolts (11) and remove the stator
shaft (12).
7. Check sealing ring (7) and replace if necessary.
IBPD108P
IBPD111P
IBPD114P
IBPD115S
12. Remove the two plugs and then the springs and
pistons.
Label the two sets (the springs especially -so that
they do not get confused).
IBPD116P IBPD119P
3. Install bearing on the turbine shaft. Install snap 6. Lightly grease the pump casing with lithium grease
ring. and Install pump (6).
2 1
7
3
IBPD112P IBPD108P
4. Make sure that the sealing ring (1) is completely 7. Tighten the bolts (7) to a torque of 19 to 24 N¥m
inside before inserting the shaft. Install terbine (14 to 18 lb¥ft).
shaft (2) on the housing (3).
IBPD121P
IBPD118P
IBPD107P IBPD105P
11
12
IBPD106P IBPD104P
10. Install torque converter. 13. Assemble O-ring (11) on the pilot boss (12) and
then install pilot boss on the torque converter.
13
14
IBPD122P
IBPD108P
IBPD101P IBPD124P
Transmission
Disassembly
1. Drain the transmission oil.
IBPD125P
IBPD123P
IBPD127P IBPD130P
5 6
IBPD131P
IBPD128P
9. Loosen bolts and remove the plate (8). Tap pinion
shaft from the opposite side of pinion head and
7. Loosen the bolts (5) and remove side cover (6) remove pinion shaft.
and then remove gasket.
IBPD132P
IBPD129P
13
IBPD133P IBPD136P
11. Remove the sealing cap (9) by using tool. 14. Loosen the bolts (12) and remove the plate (13).
10
IBPD137P
11
IBPD138P
Disassembly-Forward
5
4
IBPD142P
IBPD139P
IBPD143P
IBPD140P
7
2. Remove spring (2).
IBPD144P
IBPD141P
IBPD145P IBPD148P
7. Remove the needle bearing (8). 10. Remove the snap ring (12) while pressing the
return spring on the spring retainer with a
hydraulic press.
9
Disassembly-Reverse.
10
IBPD146P
11 IBPD149P
IBPD147P
2
9. Remove plates (11) and discs.
IBPD150P
IBPD151P IBPD154P
3. Remove the spacer (3), ball (4) and washer (5). 6. Remove the snap ring (8), plates and discs.
IBPD152P
IBPD139P
IBPD138P
2
3
IBPD157P
IBPD136P
IBPD138P
5. Place the plate (5) on the shaft. Tighten bolts (6) to
2. Fit bearing (2) on the idle shaft (3). Install the idle a torque of 27.5 to 34.0 N¥m (20.3 to 25.3 lb¥ft)
shaft into the transmission housing.
10
IBPD159P IBPD162P
6. Install bearing.
IBPD132P
IBPD135P
9. Install O-ring (9) on the sealing cap (10).
Coat O-ring with rransmission oil and then insert
7. Install clutch pack assembly (7) into the sealing cap. Tighten the bolt.
transmission housing.
IBPD163P
IBPD134P
13
IBPD165P
IBPD166P
IBPD130P
Disassembly
5
2
1 6
7
IBPD169P
IBPD167P
IBPD170P
4 2
IBPD126P
IBPD168P
IBPD127P
IBPD173P
IBPD175P
6 Heel
FORWARD side
%
-75
40
IBPD176P
Toe
IBPD174P
b. Reduce the shim thickness at the pinion shaft to
move the pinion in direction A. Then move the
¥ Tooth contact should be checked with no load on bevel gear closer to the pinion gear in direction B.
the bevel pinion. The tooth contact pattern should
Adjust the backlash again.
cover about 40-75% of the lenght of the tooth, with
weak contact at both ends.
Disassembly/ Assembly
IBPD178P
IBPD167P
P0003062
P0003058 P0003054
P0003057 P0003053
Disassembly
4
1. Drain the drive axle oil.
1 IBPD186P
Typical Example
IBPD183P 5
Typical Example
IBPD187P
Typical Example
IBPD184P 6
Typical Example
IBPD188P
Typical Example
7. Remove the hub and drum (6) from the drive axle.
IBPD185P
Typical Example
IBPD189P IBPD194P
Typical Example
11. Loosen the bolts (12) and remove the drive axle
8. Remove bearing cone and cup from the hub and housing by using lifting device.
drum.
Assembly
The assembly procedure is the reverse order of
removal, but requires additional care as noted below.
IBPD190P
8
IBPD195P
9
IBPD191P
IBPD196P
Typical Example
3. Install brake assembly. 5. Coat rib of oil seal with lithium grease.
Tighten the bolts to a torque of 147 to 205 N¥m Install the hub and drum.
(109 to 151 lb¥ft).
NOTE : Remove dirt or oil in the inside surface of the
brake drum completely.
IBPD190P
1
IBPD200P
Typical Example
IBPD199P
Typical Example
IBPD184P
Typical Example
IBPD203P
Typical Example
* Locally Manufactured
* Locally Manufactured
* Locally Manufactured
* Locally Manufactured
45
40 5 8
C1
15
1 Differential
92
Screw Installer
* Locally Manufactured
Drive Axle
109 -0.5
55 -0.4
-0.2
0
2
Hub Nut Installer
0
30 -0.8
90 +0.8
+0.4
* Locally Manufactured
Specifications
Systems Operation
Testing & Adjusting
Lift Trucks Vehicle Systems
D15S-2, D18S-2, D20SC-2
G15S-2, G18S-2, G20SC-2
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.
SpeciÞc safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify speciÞc hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identiÞed by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identiÞed by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not speciÞcally recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, speciÞcations, and illustrations in this publication are on the basis of information available at the
time it was written. The speciÞcations, 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.
1
Index
SpeciÞcations
Brakes......................................................................12
Forward And Reverse Control Group ......................12
Hydraulic Control Valve .............................................5
Hydraulic Pump .........................................................6
Lift Cylinders ..............................................................7
Priority Valve............................................................10
Sideshift Cylinder.......................................................6
Steer Wheel Axles ...................................................12
Steering Unit ............................................................11
Steering Wheel ........................................................10
Systems Operation
Brakes System.........................................................25
Control Valve ...........................................................15
Hydraulic System.....................................................13
Steering System ......................................................22
Steering Unit ............................................................23
Hydraulic System.....................................................32
Lift Cylinders Air Removal ..................................34
Relief Valve Pressure Check ..............................32
Troubleshooting .......................................................27
Brake System .....................................................31
Hydraulic System And Mast ...............................28
Performance Tests..............................................27
Steering System .................................................31
Visual Checks .....................................................27
Control Valve
Auxiliary Relief Valve
Main Relief Valve Pressure
Model Mast Pressure
+ 500 + 70 + 500 + 70
psi psi
- 0 kPa -0 - 0 kPa -0
D/G15S-2 STD 17600 2550
D/G18S-2 FFL 19860 2880 13790 2000
D/G20SC-2 FFT 21550 3125
1 2
1
1
EHCS004B EHCS005B
(1) Put Pipe Sealant on the last three threads of (1) Put Pipe Sealant on the last three threads of
bleed screw and tighten to a torque of bearing.
.......................................6 L 1 N¥m (53 L 9 lb¥in)
Put Pipe Sealant of the last three threads of bleed
NOTE : All seals to be lubricated with hydraulic oil. screw(not shown) and tighten to a torque of
.............................................6 L 1 N¥m (53 L 9 lb¥in)
1 2
1 2
EHCS006B EHCS007B
(1) Put Pipe Sealant on the last three threads of (1) Put Pipe Sealant on the last three thread of
bearing. bearing.
(2) Put Pipe Sealant on the last three threads of (2) Put Pipe Sealant on the last three thread of bleed
bleed screw and tighten to a torque of screw and tighten to a torque of
.......................................6 L 1 N¥m (53 L 9 lb¥in) .......................................6 L 1 N¥m (53 L 9 lb¥in)
NOTE : All seals to be lubricated with hydraulic oil. NOTE : All seals to be lubricated with hydraulic oil.
1 2 3 4
X-closed, Y-open
IMCS003I
IDCS206S
1 2
VIEW B - B VIEW C - C
TIGHTENING SEQUENCE
FOR BOLTS
4
A
C
C
A SECTION A - A
5
IDCS180S
1 2
IMCS004S
(2) Torque for bolts (two) ......................2.8 to 3.4 N¥m (1) Torque for wheel cylinder bolts (not shown)
(25 to 30 lb¥in) .........................................8 to 12 N¥m (6 to 9 lb¥ft)
1 2
IMCS051S
(1) Tighten nut (1) slowly to 133 N¥m (98 lb¥ft) while
turning the wheel.
Hydraulic System
1
1
2
3
4
6 5
8
9 7
10
11
12
13 14 15 16
IHCS102I
The hydraulic system has hydraulic oil tank (10), The return hydraulic oil from the cylinders ßows
which holds the oil for gear type hydraulic pump (14). through hydraulic control valve (5), line (12), into Þlter
Hydraulic pump (14) sends pressure oil to hydraulic (9) and hydraulic tank (10). Relief valve (7) in the
and steering systems. control valve body will make the ßow control valve
Pump oil ßows from pump (14) to priority valve (11) release extra pressure to the hydraulic tank when the
where the oil ßow divides to the steering unit through pressure in the lift or tilt circuits goes higher than
line (15). Oil also ßows to hydraulic control valve (5) relief valve pressure shown in the control valve
and back to hydraulic tank (10). section of SpeciÞcations. Relief valve (8) does the
same thing for the sideshift circuit when it goes
The control valve levers move the valve spools in higher than the auxiliary relief valve pressure shown
control valve (5) to let the pump oil in the control in the control valve section of SpeciÞcations.
valve go to lift cylinders (1) and/or (18), tilt cylinders
(6) or sideshift cylinder (3).
4
5
6
8
7
9
10
11
12
13 14 15 16
IHCS103I
Basic Hydraulic Schematic With Full Free Lift Or Full Free Triple Lift
(1) Lift cylinders. (2) Excess ßow protector. (3) Sideshift cylinder(option). (4) Flow regulator.
(5) Hydraulic control valve. (6) Tilt cylinders. (7) Relief valve (lift and tilt). (8) Relief valve (sideshift).
(9) Hydraulic oil Þlter. (10) Hydraulic oil tank. (11) Priority valve. (12) Oil line. (13) Hydraulic strainer. (14) Hydraulic pump.
(15) Oil line to steering unit. (16) Oil line. (17) Excess ßow protector. (18) Lift cylinder(primary).
2 3 4 5 6
10
8 9
ICCS009S
2 3 4 5 6
10
8 9
ICCS010S
2 3 4 5 6
10
8 9
ICCS011S
2 3 4 5 6 7
13
9
10
14 16 15 12
11
ICCS012S
Oil from lift valve goes to both chamber (6) and (12).
Since spool (1) is in the NEUTRAL position, the only
path the oil can take is from chamber (12) to tank
through passage (11).
2 3 4 5 6 7
13
9
14
10 16 15 12
11
ICCS013S
When the control lever for tilt is moved to TILT As tilt spool (1) is moved to the TILT FORWARD
FORWARD position, spool (1) is moved until a path position, two paths are opened for the ßow of oil to
is opened between passage (4) and outlet (7) and oil the tilt cylinders. One is from passage (4) to outlet
ßow from chamber (12) to passage (11) is stopped. (7), which allows pressure oil to go to the head end
This causes the oil pressure to increase and open of the tilt cylinders. The other path is for return oil
load check valve (3). The pressure oil from the pump from the rod end of the tilt cylinders. As spool (1)
can now ßow from passage(4) to outlet (7). It then moves, oriÞce (15) moves into position to send
ßows to the head end of the tilt cylinders and the pressure oil to the chamber behind spool (10). Spool
mast tilts forward. Return oil from the rod end of the (10) moves against the force of spring (9) and opens
tilt cylinders ßows into the valve through outlet (2) in a path for return oil between passage (16) and
to passage (8) and then to tank. oriÞce (14). This has the effect of slowing down the
ßow of oil from the rod end of the tilt cylinders and
preventing cavitation in the head end. If pump ßow
(pressure) is lost, for any reason, spool (10) will
return to the NEUTRAL position and the path for
return oil is closed.
2 3 4 5 6 7
13
9
10
14 16 15 12
11
ICCS014S
13
14
12
11
IHCS104S
Relief Valve
(7) Passage for return oil. (11) Piston. (12) Dump valve.
(13) Spring chamber. (14) Pilot valve.
Hydraulic Operation
3 4 6 7
5
2 8
1
T L
P
LS
R
9 13 10 11 12
IBCS036B
The steering system is a load sensing closed center hose (10) than to hose (5). The priority valve
type and uses hydraulic oil for its operation. Oil ßow metering spool will shift back and forth to meet the
through the steering system is closed unless the steering ßow demand while maintaining the Load
steering wheel is turned. The ßow through the Sensing Pressure between load sense hose (13) and
steering gear is sensed by the priority valve, which the priority valve internal sensing line. At times ßow
then allows additional oil ßow to the steering system. to hose (5) will be closed completely. The
Hydraulic oil is pulled from hydraulic tank (12) combination of ßow restrictors in the lines and spring
through a strainer to hydraulic pump (11). The pump tension on the priority valve metering spool work
sends the oil through hose (4) to priority valve (3). together to maintain this balance.
When the steering gear is in NEUTRAL position, Check valve (9) is in the steering unit to prevent oil
pressure in hose (10) and the priority valve internal ßow back to priority valve (3), which could cause a
sensing line rises. When this pressure rises more sudden jerk of the steering wheel.
than load sensing signal hose (13) the priority valve
metering spool shifts to stop oil ßow to the steering Relief valve in priority valve body will open if the
unit. Oil ßows hose (5) to the hydraulic control valve. steering pressure goes above 8275 kPa (1200 psi).
When the steering unit is moved, oil starts to ßow to
steering cylinder (8). The pressure in line (10) and
the priority valve internal sensing line will drop. As
pressure drops in these lines, the priority valve
metering spool will shift to meet the ßow demand. As
the metering spool shifts, more oil ßow is diverted to
A B
2 3 4 5 6
8 9 10 11 12
IDCS113S
Steering Gear
(1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs.
(8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section.
Lift trucks use the load sensing, closed center (oil Oil from the priority valve goes through inlet (4) into
ßow to steering unit only when needed) steering unit. the control section of the steering unit. When the
steering wheel is turned, the control section sends
All lift truck hydraulic lines serve a dual purpose in the oil to and from the metering section and also to
that they serve both the steering and cylinder and from the steering cylinder.
hydraulics through the use of a priority valve. The
priority valve sends oil to the steering unit before the The metering section is a small hydraulic pump. It
needs of the cylinder hydraulics are met. controls (meters) the oil that goes to the steering
cylinder. As the steering wheel is turned faster, there
The steering unit has two main sections: control is an increase in the ßow of oil to the steering
section (A), and pump or metering section (B). These cylinder. This increased ßow causes the main valve
two sections work together to send oil to the steering spool to move farther. As the spool moves farther,
cylinder. more oil can ßow from the priority valve or power
steering pump to the steering cylinder, and a faster
turn is made.
Master Cylinder The master cylinder has a piston which pushes brake
liquid into the brake lines. The reservoir, located on
the cowl, is connected to inlet of master cylinder. The
supply lines keep master cylinder (2) Þlled so no air
enters the system. Reservoir (1) supplies brake liquid
1 to the system.
IBCS043B
Remote Reservoir
(4) Remote reservoir.
11 10 9
IBCS044B Parking Brake
Brakes With Automatic Adjustment (Right Side Shown)
(1) Upper adjustment link. (2) Cylinder assembly. (3) Piston.
(4) Secondary shoe. (5) Primary shoe. (6) Toggle lever.
(7) Support plate. (8) Lower adjustment link.
1
(9) Adjustment lever. (10) Adjustment screw.
(11) Adjustment spring.
PARKING-2
2. Remove the Þlter element and look for particles 6. High pressure oil leak in one or more circuits.
removed from the oil by the Þlter element. A
magnet will separate ferrous particles from non 7. Very dirty oil.
ferrous particles(piston rings, O-ring, etc).
8. Air in the hydraulic oil.
3. Check all oil lines and connections for damage or
leaks. NOTE : If the problem is because of air in the oil, it
must be corrected before the system will operate at
4. Check all the lift chains and mast carriage welds normal temperatures. There are two things that
for wear or damage. cause air in the oil (aeration).
During a diagnosis of the hydraulic system, 1. The mast is not in alignment with the other lifting
remember that correct oil ßow and pressure are components and does not move freely.
necessary for correct operation. The output of the
pump (oil ßow) increases with an increase in engine 2. Not enough lubricant on the parts of the mast that
speed (rpm) and decreases when engine speed move.
(rpm) is decreased. Oil pressure is caused by
resistance to the ßow of oil. Visual checks and 3. The carriage or mast rollers and bearings are worn
measurements are the Þrst step when and do not move (seized).
troubleshooting a possible problem. Then do the
operation checks and Þnally, do instrument test with Problem: Lift cylinder extends too slowly.
pressure gauges.
Probable Hydraulic Cause:
Use the Fittings Group, a stop watch, a magnet, a
thermometer, and an inch (mm) ruler for basic tests 1. Not enough oil supply to lift cylinder.
to measure:
2. Defective lift cylinder seals.
1. The pressure of the oil to open the relief valve.
Relief valve pressures that are too low will cause a Probable Mechanical Cause:
decrease in the lift and tilt characteristics of the lift
truck. Pressures that are too high will cause a 1. The mast is not in alignment with the other lifting
decrease in the life of hoses and components. components and does not slide freely.
2. Drift rates in the cylinders. Cylinder drift is caused by 2. Not enough lubricant on the parts of the mast that
a leakage past cylinder pistons, O-ring seals in the move.
control valve, check valves that do not seat correctly
or poor adjustment or Þt in the control valve spools. 3. The carriage or mast rollers and bearings are worn
and do not move (sized).
3. Cycle times in the lift and tilt circuits: Cycle times
that are too long are the result of leakage, pump Problem: Mast does not move smoothly.
wear and/or pump speed (rpm).
Probable Hydraulic Cause:
2. The relief valve opens at low oil pressure. 2. Load rollers defective or not adjusted correctly.
3. The hydraulic pump has too much wear. Problem: Mast will not lower completely or will
not lower at all.
4. The priority valve does not work correctly.
Probable Hydraulic Cause:
2. Not enough lubricant on the parts of the mast that Probable Cause:
move.
1. The valve spools do not hold their positions because
Problem: The mast does not tilt correctly or the springs for the valve spools are weak or broken.
moves too slowly.
2. Control valve leakage caused by worn valve spools.
Probable Hydraulic Cause:
3. The load check valves in the control valve are bad.
1. There is an air leak, which lets air into the
hydraulic system on the inlet side of the hydraulic 4. Leakage of the cylinder lines or piston seals.
pump.
5. There is foreign material in the control valve.
2. The relief valve opens at low oil pressure.
3. The hydraulic pump has too much wear. Hydraulic Gear Pump
4. The internal valve of the tilt spool is stuck. Problem: Noise in the pump.
6. The priority valve does not work correctly. 1. The oil level is low.
1. Damage or failure of the tilt cylinders. 3. The pump inlet line has a restriction in it.
4. The carriage or mast rollers and bearings are worn c. Restrictions in ßow regulator valve, load check
and do not move (seized). valve and in oil lines.
5. The pump has too much wear. 2. The load check valve and seat show wear.
6. Failure of the pump shaft or coupling. 3. Sudden loss of pump oil pressure.
7. The bolts of the pump do not have the correct 4. Damage to the relief valve which causes low oil
torque. pressure.
Problem: The control spools do not move freely. Problem: Leakage around the piston rod.
1. The temperature of the oil too high. 1. Cylinder head (bearing) seals are worn.
2. There is foreign material in the ßuid. 2. Piston rod is worn, scratched or bent.
3. The Þtting connections in the valve body are too Problem: There is leakage of oil inside the
tight. cylinder or loss of lift or tilt power.
6. Bent lift or tilt spools. Problem: The piston rods show wear.
8. The valve is not at normal temperature for 1. The cylinders are not in correct alignment.
operation.
2. Oil is dirty.
1. The wiper rings show wear and do not remove dirt 1. Loose steering knuckle king pins.
and foreign material.
2. Loose wheel bearings.
1. Priority valve releases pressure oil at a low setting. 3. The relief valve is set too high (priority valve).
2. Pump oil pressure is low, worn pump. 4. There is a restriction in line circuit.
3. Relief valve (priority valve) will not move from the Probable Cause:
open position.
1. Brake shoe adjustment not correct.
4. Oil leakage inside or outside of the system.
2. Brake pedal adjustment not correct.
5. Bad pump.
3. Mechanical resistance at the pedal or shoe.
1. Leakage or low ßuid level. Problem: Not braking evenly, or rough feeling of
braking (chatter).
2. Air in the brake hydraulic system.
Probable Cause:
3. Loose master cylinder mounting.
1. Lining surface looks like glass (glazed), or worn.
Problem: Hard pedal.
2. Oil or brake ßuid is on the lining.
Probable Cause:
3. Bad contact between the lining and drum.
1. Mechanical resistance on the pedal or shoe. 4. Loose lining.
3 4 5
IHCS105S
2
Relief Valve Adjustment
(2) Control valve. (3) Screw. (4) Jam nut. (5) Acorn nut.
3. With the engine at high idle, hold the tilt control lever
in the TILT BACK position and watch the gauge. The
indication of the gauge is the pressure of the oil that
opens the relief valve. For the correct pressure
setting, see the topic Control Valve in SpeciÞcations.
4. Lift the forks high enough to put a load on all 8. Fill the hydraulic tank to the full mark.
stages of the lift cylinders. (The illustrations shown
9. Lift and lower the mast and carriage again through
are of a full free triple lift mast.).
one complete cycle. If the mast does not operate
smoothly, repeat Step 3 through 9.
23
EHCS008C
NOTE : This oil will now ßow from the pump, the priority
valve and the steering gear, then back to the priority
valve, hydraulic control valve, hydraulic tank and Þnally
2 to the pump again. When no more oil can be added and
A oil is clear, do the procedure that follows :
1
3. Lift a capacity load to take the weight off of the steer
axle. Turn the steering wheel as rapidly as possible
to remove the air in the steering cylinder and lines.
NOTICE
Be sure to keep the oil level in the hydraulic tank above
the outlet to the pump. Do not hold steer wheels against
stops for an extended period of time. This will cause the
oil to get hot and damage the components.
IMCS054S
2. Loosen nuts (2). NOTE : The oil in the lines to the steering cylinder
stops at the piston. The oil in the cylinder does not ßow
3. Turn the steer wheel one direction until the in a circuit. As the piston moves backward and forward,
steering cylinder internal stop is reached. the oil moves backward and forward in the lines. Air in
these lines, and in the cylinder, may move slowly into
4. Adjust stop bolt (1). the steering control valve and then to the tank.
(6)
IDCD066P
WARNING (5)
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all
hydraulic pressure is released in the steering
system. Move the steer wheels to the left and right
and then to the straight forward direction.
(4)
4. Turn the steer wheels to the left or right against 7. If the steering unit and the priority valve are
the stops and make a note of the indication on the working properly, the steering cylinder is defective
pressure gauge. and must be repaired.
Systems With Remote Reservoir With each reverse brake application there will be an
adjustment made, until the lining-to-drum clearance
is made small enough to stop the movement of the
1 automatic adjustment linkage.
WARNING
IMCS052P
To remove air from the brake system, do the 2. Remove the plugs from wheel brake plate.
procedure that follows :
3. Put a brake adjustment tool through hole and into
1. Fill remote reservoir (1) with the correct brake ßuid a tooth on the adjustment screw (3).
to 12.7 mm (.50 in) from the Þller cap. See the
Operation and Maintenance Manual for the correct
brake ßuid.
93.5mm 2
IMCS055S
VIEW A-A
Parking Brake Test
1
WARNING 3 4
2. Half way up the incline, stop the lift truck with the
1. Put the parking brake control in the released
service brakes. Apply the parking brake.
position.
3. If the parking brake has the correct adjustment,
2. Make sure cables (1) and (2) are loosened.
the lift truck will be held in this position.
3. Loosen nut (4) and adjust the cables (1), (2) by nut
4. If the parking brake does not hold, do the steps in
(3).
parking Brake Adjustment.
4. Tighten nut (4).
2
4
3
1
1
IMCS056S
Inching Operation Test
(1) Inching pedal.
6. Loosen nut (4) and adjust bolt (3) to contact lug (2)
that rotates the brake control cross shaft. Tighten
nut (4).
Disassembly &
Assembly
Lift Trucks Vehicle Systems
D15S-2, D18S-2, D20SC-2
G15S-2, G18S-2, G20SC-2
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. 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.
1
Index
Alternator .................................................................45
Counterweight..........................................................41
Fuel Filter.................................................................46
Radiator ...................................................................43
WARNING
IMCD202P
2
IMCD201P
Overhead Guard
The hood and seat assembly can fall when nut (1) 1
is removed from the support cylinder rod. To avoid
personal injury, support the seat and hood
assembly before removing nut (1).
4. Lower the hood. 1. Support overhead guard (1) with lifting straps and
a hoist.
IMCD204P IMCD207P
IMCD205P
IMCD206P
EHCD101P
1
3. Remove rod (3) from the cylinder body.
EHCD099P
2 EHCD102P
EHCD100P
EHCD103P
8 8
EHCD104P EHCD104P
6. Remove O-ring seal (7) and backup ring (8) from 2. Install backup ring (8) and O-ring seal (7) onto the
the rod cover. rod cover.
12
10
11
EHCD105P EHCD103P
7. Remove wiper seal (9), U-packing (10), backup 3. Install the steel ball (6) and screw-bleeder (5) onto
ring (11) and two slyd rings (12) from the rod the rod cover.
cover.
12
10 EHCD101P
11
EHCD105P
EHCD100P
EHCD109P
5. Install rod cover assembly (2) on the cylinder and 3. Remove ring (3) from the cylinder rod.
tighten using wrench.
End By :
4
a. Install secondary lift cylinder.
a. Remove primary lift cylinder. 4. Remove O-ring seal (4) and backup ring (5) from
the head assembly.
2 1
6
EHCD108P
EHCD111P 9
1. Remove head assembly (1).
2. Remove rod (2) from the cylinder body.
5. Remove wiper seal (6), backup ring (7), U-packing
(8) and two slyd rings (9) from the head assembly.
EHCD108P
EHCD110P
EHCD109P
2
Remove Hydraulic Control Valve
3
WARNING
IMCD209P
IMCD208P
IMCD209P
IHCD107P
1
2
7
10 8
IHCD105P
6
IHCD106P
13
12
3. Remove O-ring (3) from inlet section assembly (2).
IHCD110P IHCD112P
9. Remove two screws (16) and seal plate (17). 13. Remove tilt section assembly (26) from the valve
body.
10. Remove lift spool (18).
28
26
24
19
23
29
20
27
25 21 IHCD113P
22
IHCD111P
31
12. Remove the spring seats (23 and 24), centering
spring (22) and seal plate (25).
IHCD114P
15. Remove two screws (30) and cap (31) from tilt
section assembly.
33
32
43
34
IHCD115P IHCD118P
16. Remove two screws (32), seal plate (33) and tilt 20. Remove side shift section assembly (43) and
spool (34). fourth section (44) from the valve body.
17. Remove valve (14) and O-ring (15). NOTE : Do step 7 through 12 to disassemble valve
spools of side shift and fourth section assembly.
45
46 47
37
36
38
IHCD116P
39 38 40
37
42 41
IHCD117P
19. Remove spring seats (39 and 40), spring (38 and
42) and piston (41).
23
NOTICE
Do not use caustic (corrosive) materials to clean any
parts in this valve group. Caustic materials will cause
20
corrosion and damage to parts.
25 21
22
IHCD111P
1. Make sure all valve parts are clean and free of dirt.
4. Install the spring seats (23 and 24), centering
spring (22) and seal plate (25) on the lift spool.
IHCD106P
IHCD110P
13
12
IHCD109P IHCD119P
8. Install cap (13) and two screws (12). 13. Install O-ring (47) and relief valve (46) to the
section assembly (45).
7
10 8
6
11
1
9 2
IHCD108P
IHCD105P
IHCD117P
Start By:
Remove & Install Hydraulic Pump
a. Remove alternator
For G15/18/20S(C)-2
2
IBCD107
3
4. Install the hydraulic pump in reverse order of
2
IBCD161P removal.
Tightening torque for bolts that hold pump is 55 ±
1. Disconnect lines (1) from hydraulic pump (2). 10 N¥m (40 ± 4 lb¥ft).
2. Remove two bolts (3) that hold hydraulic pump (2) 5. Fill the hydraulic tank to the correct level with fluid.
to the frame. Remove the pump. Refer to the operation and maintenance manual
for further information.
3. Make a replacement of the pump gasket if
necessary. End By :
4. Put hydraulic pump (2) in position on the frame, a. Install the alternator.
and install the bolts that hold it.
1
IBCD111C
3
4. Remove gears (8) from the pump body. Separate
the pump sections.
IBCD108C
9
NOTE: Identify and mark all sections of the hydraulic 12
pump for purposes of reassembly.
10
11
IBCD112C
4
IBCD109C 13 14
2. Remove seal (4) from the pump body.
15
6 IBCD113C
8
13 14
IBCD111C
15
IBCD113C 3. Install gears (8) in the pump body.
7
9 IBCD110C
12
10 5. Install bush (7) back-up ring (6) and seal (5) in the
pump body.
11
IBCD112C
4
IBCD109C
IBCD108C
End By:
WARNING 4
IMCD212P
If both tilt cylinders are to be removed at the same
time, make sure that the mast is held either by a
3. Remove bolts (4), the washes. Remove rear tilt
hoist or is securely held in place by blocks.
cylinder pin (5).
2
3
EHCD113P 2
NOTICE
2. Remove bolts (2), washes from the cylinder eye. Use extra care not to damage the highly finished
Remove pin (3). surface of the cylinder rod and the bore of the cylinder
body during disassembly and assembly of the tilt
cylinder.
10
EHCD114P
11
14
12
EHCD115P
EHCD118P
6. Remove spacer with a O-ring seal and shims from
the cylinder rod (2) if they are installed.
10. Remove wiper seal (12) and U-packing (14) from
7. Loosen the nut and bolt (6) on the rod eye. the rod cover.
Remove cylinder rod.
8
15
EHCD119P
EHCD116P
11. Remove the DU-bush (15) from the rod cover. If
8. Remove slipper seal (7) and O-ring seal (8) from the DU-bush has a large amount of wear,
the piston (9). Replace the DU-bush.
12
EHCD118P EHCD115P
12. Install wiper seal (12) in the rod cover. Position 16. Position the cylinder rod eye in a vise as shown.
the lip of the seal toward the outside of the rod
cover as shown. 17. Install cylinder rod (2) and shims. Tighten the nut
and bolt (6) on the rod eye to a torque of 95 L 15
13. Install U-packing (14) in the rod cover. N¥m (70 L 10 lb¥ft).
3 4 5
11
EHCD117P
EHCD116P
15. Install slipper seal (7) and O-ring seal (8) on the
piston (9).
5 2 1
EHCD113P 2
End By : 1. Remove the cotter pin from pin (1). Remove pin (1).
a. Install tilt cylinder. NOTE : Plug and cap all openings to avoid
contamination and debris from entering the system
after removing any tubes or lines.
1
4
IDCD063P
1 2 3
ILCD041P
1. Remove cap (1) from the steering wheel.
3 4 6 8 10 11
IDCD064P
5
2. Remove nut (2) and up (3) from the steering wheel
9
shaft. Put location marks on the steering wheel
7
and the steering wheel shaft for installation
12
purposes.
ILCD042P 13
5. Remove plate (7) and piston (8). NOTE : Use the following steps to install the steering
wheel.
6. Remove secondary cup (9) from piston.
7. Remove spacer (10) and primary cup (11). 4. Put the steering wheel on the steering wheel shaft
in its original position.
8. Remove spring (12) and check valve (13).
5. Install cup (3) and nut (2). Tighten nut (2) to a
9. Assemble the master cylinder in the reverse order torque of 80 L 7 N¥m (60 L 5 lb¥ft).
of disassembly.
6. Install cap (1).
End By :
Remove & Install Steering Unit To prevent personal injury be sure pressure in the
hydraulic system has been released before
disconnecting any hydraulic lines. Slowly loosen
Start By: the cap of the hydraulic tank to release any
pressure in the tank. Be cautious of hot hydraulic
a. Remove steering wheel. oil when any lines are disconnected in the
hydraulic system.
1 3
NOTE : Identify and mark all hydraulic hoses for
purposes of reassembly.
2
NOTICE
Steering unit (5) and column (2) can separate after
IDCD065P bolts (4) have all been removed, causing unit (5) to
fall. To avoid damaging components, support the
steering pump while removing bolts (4).
1. Open the access cover for the fuse panel.
End By :
4
a. Install steering wheel.
IDCD066P
Seal
Spacer(s)
IDCD280S
Seal Drive
IDCD283S
IDCD281S
Quad
Control End Ring
Seal
Seal
Dust Gland
Seal Bushing
IDCD284S
ILCD282S
Bearing
Race
IDCD285S IDCD287S
15. Remove two bearing races and the needle thrust 18. Push spool partially from control end of sleeve,
bearing from spool and sleeve assembly. then remove 4 centering springs from spool
carefully by hand.
Seal
Pin
Attention: Do not bind spool and sleeve in housing. 21. Remove check ball seat.
Rotate spool and sleeve assembly slowly when
removing from housing. 22. Tip housing to remove check ball.
Check Ball
Seat
Check Ball
IDCD289S
IDCD291S
IDCD292S
IDCD293S
IDCD295S
12. Place housing on clean lint free cloth. Install 47,5
mm [1.86 in.] ID seal in housing.
17. Install retaining ring in housing. After installing
13. Install 2 bearing races and the needle thrust
ring, tap on ring end or pry with screwdriver
bearing in the order shown.
around entire circumference of ring to properly
14. Install 25 mm [1 in.] ID dust seal in seal gland seat ring in groove.
bushing, flat or smooth side must face down
towards bushing.
Pin
IDCD296S IDCD298S
18. Clamp housing in vise. Clamp lightly on edges of 21. Rotate spool and sleeve assembly until pin is
mounting area. Do not over tighten jaws. parallel with port face. Install drive, make sure
you engage drive with pin. To assure proper
Note: Check to insure that the spool and sleeve are alignment, mark drive as shown. Note
flush or slightly below the 14 hole surface of the relationship between slotted end of drive to
housing. splined end of drive when marking.
Seal
IDCD299S
IDCD297S
Pin Port Face 25. Install 73.5 mm [2.89 in.] ID seal in gerotor
(meter) or end cap, see notes.
IDCD300S
26. Install end cap on gerotor, align holes.
Seal
Drive Spacer(s)
IDCD302S
IDCD301S
IBCD049C
5
IBCD050C
2
IBCD048C
7
IBCD051C
12
IBCD052C IBCD055C
9. Remove hub (7) from steering knuckle (8). 12. Remove bearing cone (12) from knuckle.
9
13. Pack bearing cones (6) and (12), and lubricate
the contact surfaces of the bearing cups with
Multipurpose Grease.
7
14. Reverse the procedures and steps 1 through 12
to install the steer wheels and bearings.
IBCD054C
WARNING
5. Lower the steer axle onto the bolt heads with the
floor jack.
IBCD061C
2. Disconnect hose (1) and tube (2). Plug and cap all 6 5
openings to prevent contamination and debris from
IBCD061C
entering the system.
IBCD177C IBCD062C
Typical Example
NOTE: Use bolts (3) and cap to align steer axle (4)
7. Remove steer axle (4). with the mounting bosses while raising steer axle (4)
into position with the floor jack.
NOTE: Use the following steps to install the steer
axle. 9. Seat steer axle (4) as follows:
IBCD177C
Typical Example
2 1
IBCD063C
Start By:
IBCD062C
1
4. Remove retaining rings (3) from the cylinder rod.
IBCD064C
IBCD161C
IBCD164C
3. Remove cylinder tube (2) from the rod assembly.
8
9
6
IBCD165C
7
IBCD166C
9
6
7
IBCD166C
IBCD165C
7. Disassemble each rod cover as follows:
IBCD164C
IBCD163C IBCD064C
3. Install piston (4) on the cylinder rod. 6. Install rod cover (1) on cylinder tube (2).
End By:
3
a. Install the steering cylinder.
IBCD062C
IBCD161C
4 1
3
2 5
IMCD214P
2
1
1 1. Disconnect fuel line (1).-for G15/18/20S(C)-2
3
4
IMCD223P
8 7
IMCD052P
6
5. Remove the bearings (6), king pin (7) and seals (8).
IMCD216P
6 6
IMCD217P IMCD217P
4. Remove bolts (5) from the rear of the 3. Install bolts (5) at the rear of the counterweight.
counterweight. Tighten bolt to a torque of 400 L 50N¥m (300 L
37 lb¥ft).
5. Remove counterweight (6) from the frame of the
lift truck.
Install Counterweight
3 2
IMCD215P
IMCD214P
Start By :
5
a. Remove counterweight.
End by :
a. Install counterweight.
IMCD218P
IMCD219P
For G15/18/20S(C)-2
1 3
1
IBCD162P
IMCD221P
5 4
IBCD163P
IMCD061P 1
1 2
IMCD063P
3
1. Disconnect the battery positive cable.
IMCD062P
<G15/18/20S(C)-2>
4 2
4 3
IMCD064P
<D15/18/20S(C)-2>
2. Loosen top bolts (2) and then remove belt (3) from
the pulley.
1
IBCD166P
<G15/18/20S(C)-2>
2 3 1
IBCD165P 2. Remove fuel filter (3).
Remove & Install Oil Filter Remove & Install Air Cleaner
Housing Assembly
1
1
IBCD167P
<D15/18/20S(C)-2> IBCD169P
IBCD168P 3
<G15/18/20S(C)-2>
IBCD170P
1. Remove the oil filter housing (1) from the base.
2. Install a new oil filter housing (1) on the oil filter 2. Remove cover assembly (3) from the housing.
base.
5 4
IBCD171P
IBCD173P
9 6
3
IBCD174P
7 4 5
IBCD175P
6. Remove two bolts (8) that hold air cleaner
housing. 2. Remove nut (2) and pin (3) from the inching cable
(6). Remove nut (4) and pin (5) from the accel
7. Remove air cleaner housing from the frame. cable (7). Remove both cables.
NOTICE
Plug and cap all openings to avoid contamination and
debris from entering the system after removing any
tubes or lines.
14
11 10
9
IBCD176P IBCD178P
13
12
IBCD179P
IBCD177P
15
IBCD180P
18
16
IBCD181P IBCD184P
20 20
16
IBCD182P
23
17
IBCD174P
24
IBCD186P
25
IBCD187P IBCD145C
28
IBCD146C
27
14. Support lift truck with wooden blocks on three
IBCD188P places.
IBCD147C
30
IBCD148C IBCD191P
16. Remove nut (29) and washers (30) from the 19. Remove transaxle and engine assemblies from
engine mount, located on each side of the the frame.
engine. Put the transaxle and engine assemblies on the
For the reassembly purpose, the torque for nut wooden block.
(29) is 200 ± 20 N¥m (150 ± 15 lb¥ft).
31
IBCD192P
18. Remove four bolts (31) from the frame. c. Install seat and hood.
NOTE: At this point, make a final check to be sure all d. Install overhead guard.
removals and disconnections have been made from
the transaxle and engine. e. Install mast.
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
IImproper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made unsafe by the operation,
lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. 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.
1
Index
Forks.........................................................................5
Backrest....................................................................5
Carriage....................................................................6
Mast..........................................................................9
Carriage Adjustment...............................................22
Chain Adjustments .................................................23
Chain Wear Test.....................................................23
Carriage and Mast Height Adjustment ........................24
Forks Parallel Check ..............................................24
Tilt Cylinder Alignment............................................25
Drift Test .................................................................25
Tilt Cylinder Adjustment..........................................26
Lift & Tilt Mounting Group Adjustment....................27
Mast mounting Group Adjustment..........................28
3 2
IBCD501P
2
1. Fasten a hoist to the backrest. Remove bolts(2)
IDCD001P that fasten the backrest to the carriage.
IDCD002P
Start By:
a. Remove forks.
b. Remove backrest. 7 6
IBCD504P
4 9
IBCD502P
1. Remove two bolts (1) and hose guard (2) from the
cross head (3).
IBCD510P
3. Remove hoses (5). NOTE: Use the following steps to install the carriage.
a. Install backrest.
b. Install forks.
Disassemble Carriage
Start By:
7 6
IBCD504P
a. Remove carriage.
IBCD571P 2
IBCD503P
3
IBCD572P
1
2. Remove lower roller bearings(3) and the shims
4
from the carriage.
IBCD502P
Assemble Carriage
NOTE : The standard, Full Free Lift and Full Free
Triple Lift carriage load bearings are all adjusted the
same way. The Full Free Triple Lift carriage is shown
in the following illustrations.
Use the procedure that follows to adjust carriage 2. Find narrowest point by ruler on the inner mast in
load bearings. the area where the bearings make contact.
A A 4 1
B 5(STD)
A 3 D
A C
C
C
5 (FF, FFT) 6
B B
VIEW A-A
C 8
C 7
2
10 9 IBCD574P
A
VIEW C-C
VIEW B-B 3. Install enough shims (1) that have been divided
IBCD581I
into two equal groups behind bearings (2). At
Carriage Adjustment installation, there is to be contact [zero clearance
(3) Upper bearings. (4) Shims. (5) Bolt. (6) Screw. (A)] between the bearings and the narrowest point
(7) Side-roller bearings. (8) Lower bearings. (9) Pin-adjust. of inner mast.
(10) Bolt. (A) Zero clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) clearance.
(C) Minimum clearance. (D) 4.5 L 0.5 mm
4. Do step 2 through 3 for other sets of bearings.
a. Remove forks.
Move the truck to the place where pit is set up.
3
IDCD016P
IBCD511P
IBCD571P 5
End By:
NOTICE
Place identification marks on all hydraulic connectors
and hoses to assure proper installation. Plug and cap
all hydraulic connectors and hoses to avoid debris and
contamination from entering the system.
2. Disconnect hose(3).
WARNING 8
IBCD502S
7
103
IBCD582I
IBCD514P
7. B16/18/20X
Tilt forward mast assembly with the hoist. Remove
5. D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S bolts (8) from each side.
Tilt forward mast assembly about 8¡ with the hoist.
Remove four bolts (7) from pit each side of the WARNING
base of mast assembly.
Loosen the tension of straps to be connected with
hoist when mast assembly is tilted forward.
If straps are too tight, mast assembly could slide
off when bolts (7), (8), (10) are removed.
End By:
a. Install forks.
7
6
IBCD518P
2
4
10
IBCD519P
IBCD504S
IBCD523P 11
16
17
7. Remove top cylinder retainer bolts (11) from each
side of the mast. D,G15/18/20S(C)-2, GC15/18/20S(C)-2, B15/18S
12
IBCD524P 16 15
IBCD527P 13
14 B16/18/20X
IBCD584I
23
19
IBCD528P IBCD534P
13. Move inner mast channel (21) downward. 18. Move intermediate mast channel (24) downward.
14. Remove bearings (18) and shims from the 19. Remove bearings (22) and the shims from the
intermediate mast channel (24). stationary mast channel.
15. Remove nylon pads (19) and shims. 20. Remove nylon pads (23) and the shims.
20
24
25
IBCD529P IBCD533P
16. Remove bearings (20) and shims from the inner 21. Remove bearings (25) and the shims from the
mast channel (21). intermediate mast channel (24).
21 24
IBCD530P IBCD535P
17. Fasten nylon straps and hoist to inner channel 22. Fasten nylon straps and a hoist to the intermediate
(21). Remove inner channel. The weight of the mast channel (24). Remove intermediate mast
inner channel is 110 kg (243 lb). channel. The intermediate mast channel weighs
112kg (247 lb).
1. Make sure all parts are clean and free of dirt and
foreign material.
NOTICE
4 5 6 When the correct amount of shim has been installed
3 behind bearings (1) there will be contact (zero clearance)
between the bearings and the inner mast at most narrow
point of mast.
B C
IBCD505S
IBCD534P IBCD533P
6. Install 1mm shim and bearing (1) of stationary 9. Install 1mm shim and bearing (4) of intermediate
upper basically. lower basically.
2 1
4 5 6
3
IBCD538P
A
10. Make sure intermediate mast lower bearings are 13. Install 1 mm shim to each bearing of stationary
properly shimmed in the stationary mast by mast upper basically. Bearing should be selected
rolling up and down and moving intermediate D580006 undersize bearing.
mast to right and left. If clearance between both
masts can be detected, pull out the intermediate
mast from the stationary mast with crane and
add shim 0.5 mm or 1 mm to both intermediate
lower bearings.
4
11. In case of standard and full free mast, inner
lower bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If intermediate mast is stuck and
cannot move by rolling up and down, there might
be excessive shim. Pull out the intermediate
mast from the stationary mast and remove shim
IBCD533P
0.5 mm to both intermediate lower bearings.
Repeat same procedure of above until properly
shimmed. There is to be contact zero clearance
(C) between intermediate lower bearings and 14. Install 1mm shim and bearing (4) of intermediate
stationary channel at approximately 420 mm lower basically.
(16.5 in) channel lap.
IBCD535P
E
F
7 7
9 8
10 E 8 F
IBCD506S 7
Mast Adjustment Upper Bearings 9
(D) Zero clearance. (E) 0.80 mm (.031 in) Clearance maximum.
(F) Zero clearance. (7) Pads. (8) Shims. (9) Shims. (10) Shims.
8
10 E
IBCD506S
17. Install shims (8) behind each pad (7) until there
is 0.80 mm (.031 in) maximum clearance (E)
IBCD532P between the pads and the inner and intermediate
masts with the masts at full extension. Lift by
crane, and pull out intermediate mast from
15. Make sure stationary mast upper bearings are stationary mast and insert the shims behind each
properly shimmed by rolling up and down and pad. In case of standard and full free mast, the
moving intermediate mast to right and left. If pads of stationary upper can be easily extruded
clearance between both masts can be detected, by pulling down the inner mast from the bottom
pull out the intermediate mast from the stationary of stationary mast.
mast with crane and add shim 0.5 mm or 1 mm
to both stationary upper bearings.
4 5 6
3
IBCD542P
B C
12 11
IBCD505S
18. Select lower bearings (3) and (4) from the chart IBCD530P
to obtain minimum clearance (B) between
bearing and channel leg for full channel length.
Use same bearing on left and right side. 20. Lifting by crane, insert inner mast (11) into
intermediate mast (12) from the upper side.
IBCD528P
4 5 6
3
15
IBCD526P
B C
IBCD505S
17
9 23
IBCD524P 22
10
18
IBCD523P
IBCD520P
20
19 32. Connect chains (25) at the bottom of the mast.
21
27
IBCD521P
IBCD518P
End by :
NOTE: The standard, Full Free Lift and Full Free D580007 Standard 99.0 mm (3.898 in)
Triple Lift carriage load bearings are all adjusted the D580008 Oversize 99.5 mm (3.917 in)
same way. The Full Free Triple Lift carriage is shown
in the following illustrations. * Permissible tolerance of L 0.08mm (.003in)
C
8
C 7
10 9
A
VIEW C-C
VIEW B-B
IBCD581I
Carriage Adjustment
(3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Side-roller Bearings. (8) Lower Bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero Clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) Clearance.
(C) Minimum Clearance. (D) 4.5 L 0.5 mm
IBCD505P
2
Lift the carriage and mast high enough to put their IBCD508P
full weight on the carriage and mast chains. Check Outer Lift Chains
(2) Chain Anchor Bolts.
the chains, and make sure the tension is the same.
Chain Adjustment
Chain Wear Test
If the tension is not the same on both chains, do the
procedure that follows: Chain wear test is a measurement of wear of the
chain links and pins. Do the steps that follow to
check chain wear.
WARNING
1. Lift the mast and carriage enough to put tension
Personal injury can be caused by sudden on the lift chains.
movement of the mast and carriage. Blocks must
2. Measure precisely ten links of chain distance at
be used to prevent the mast and carriage from any
the center of pins in millimeter.
movement while the adjustments are made. Keep
A chain wear gauge can also be used.
hands and feet clear of any parts that can move.
3. Calculate chain wear rate.
WARNING
IDCS130S
IBCD585I Forks Parallel Check
(Typical Example)
<STD>
D,G15/18/20S(C)-2.......................22 mm(0.866 in)
B15/18S .........................................7 mm (0.276 in)
B16/18/20X, GC15/18/20S(C)-2,
B13/15/18T-2, BC15/18/20T ........- 6 mm(-0.236 in)
IDCD009P
Drift Test
The tilt angle of the mast must be checked in the full
tilt back and full tilt forward positions. A tilt indicator Drift is movement of the mast or carriage that is the
or a protractor can be used to measure the angle. result of hydraulic leakage in the cylinders or control
Both sides of the mast must be checked to make valve. Before testing the drift:
sure that the mast is not twisted.
16mm
To correct the tilt angle or tilt cylinder length, an
adjustment must be made to the tilt cylinder as
follows : EHCS046S
3
VIEW A-A
B B
2
(F)
VIEW B-B 4
IBCD508S
3
2
1
IBCD502S
1 3
IBCD509S
IBCD582I
For B16/18/20X
1
3 1. Tighten screw (1) that holds bearing (3) to hinge
bracket of stationary mast to a torque of 34 L7 NIm
(25 L 5 lbIft).
IBCD510S
2. Install roll pin (2) to a depth 2 ~ 3 mm (0.079 ~
0.118 in) from surface of bearing.
For B15/18S
3. Apply the crean grease to a surface of bearing.
Schematic
Lift Trucks Hydraulic System
D15S-2, D18S-2, D20SC-2
G15S-2, G18S-2, G20SC-2
11 9 8 9
6
MODEL : D15S-2, D18S-2, D20SC-2
G15S-2, G18S-2, G20SC-2
7
12 5
10
CF
EF
LS
13
P
Item Components
1 Hydraulic Pump
1 2 Suction Strainer
4 3 Hydraulic Filter
4 Control Valve
5 Flow Regulator
3 6 Flow Protector - Primary
2 7 Flow Protector - Secondary
8 Lift Cylinder - Primary
9 Lift Cylinder - Secondary
10 Tilt Cylinder
11 Steering Cylinder
12 Steering Unit
13 Priority Valve
SB4049E00
Oct. 2000
Schematic
Lift Trucks Electric System
D15S-2, D18S-2, D20SC-2
SB4022E00
May 2000
Schematic
Lift Trucks Electric Systems
G15S-2, G18S-2, G20SC-2
SB2309E01
Operation &
Maintenance Manual
LIFT TRUCKS
G15S-2, G18S-2, G20SC-2
D15S-2, D18S-2, D20SC-2
WARNING
Do not start, operate or service this machine unless you have read and
understand 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.
This manual should be kept with the machine for reference and periodically
reviewed 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 Proposition 65
Engine Exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm.
WASH HANDS AFTER HANDLING.
Information Section
Table of Contents
Information Section
-1-
Information Section
Foreword
Literature Information Photographs or illustrations guide the operator
through correct procedures of checking, operation
This manual should be stored in the operator's and maintenance of the DAEWOO operator
compartment in the literature holder or seat back restraint system.
literature storage area.
SAFE and EFFICIENT OPERATION of a lift truck
This manual contains safety, operation, depends to a great extent on the skill and alertness
transportation, lubrication and maintenance on the part of the operator. To develop this skill the
information. operator should read and understand the Safe
Driving Practices contained in this manual.
Some photographs or illustrations in this publication
show details or attachments that can be different Forklift trucks seldom tipover, but in the rare event
they do, the operator may be pinned to the ground
from your lift truck. Guards and covers might have
by the lift truck or the overhead guard. This could
been removed for illustrative purposes. result in serious injury or death.
Continuing improvement and advancement of Operator training and safety awareness is an
product design might have caused changes to your effective way to prevent accidents, but accidents
lift truck which are not included in this publication. can still happen. The DAEWOO operator restraint
Read, study and keep this manual with the lift truck. system can minimize injuries. The DAEWOO
operator restraint system keeps the operator
Whenever a question arises regarding your lift substantially within the confines of the operatorÕs
truck, or this publication, please consult your compartment and the overhead guard.
DAEWOO dealer for the latest available
information. This manual contains information necessary for
Safe Operation. Before operating a lift truck make
sure that the necessary instructions are available
Safety and understood.
-2-
Information Section
Maintenance Intervals
Environment Management
Note that DAEWOO INDUSTRIAL VEHICLE DIVISION
is ISO 14001 certified which is harmonized with ISO
9001. Periodic ENVIRONMENTAL AUDITS &
ENVIRONMENTAL PERFORMANCE EVALUATIONS
have been made by internal and external inspection
entities. LIFE-CYCLE ANALYSIS has also been made
through out the total product life. ENVIRONMENT
MANAGEMENT SYSTEM includes DESIGN FOR
ENVIRONMENT from the initial stage of the design.
ENVIRONMENT MANAGEMENT SYSTEM considers
environmental laws & regulations, reduction or
elimination of resource consumption as well as
environmental emission or pollution from industrial
activities, energy saving, environment-friendly product
design(lower noise, vibration, emission, smoke, heavy
metal free, ozone depleting substance free, etc.),
recycling, material cost reduction, and even
environmentally oriented education for the employee.
-3-
Safety Section
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons
must also have the necessary training, skills and tools before attempting to perform these functions.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Safey precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the ÒSafety Alert SymbolÓ and followed by a ÒSignal WordÓ such as ÒWARNINGÓ
as shown below.
WARNING
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DAEWOO
is used, you must be sure that it is safe for you and others. You should also ensure that the product will not
be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. 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.
-4-
Safety Section
Safety
The safety rules and regulations in this section are Warning Signs and Labels
representative of some, but not all rules and
regulations noted under the Occupational Safety There are several specific safety signs on your lift
and Health Act (OSHA) and are paraphrased truck. Their exact location and description of the
without representation that the OSHA rules and hazard are reviewed in this section. Please take the
regulations have been reproduced verbatim. time to familiarize yourself with these safety signs.
Please refer to 1910. 178 in Federal Register Vol. Make sure that you can read all safety signs. Clean
37, No. 202, the National Fire Protection or replace these if you cannot read the words or see
Association No. 505 (NFPA), American National the pictures. When cleaning the labels use a cloth,
Standard, ANSI B56. 1 Safety Standard for Low lift water and soap. Do not use solvent, gasoline, etc.
and High Lift Trucks and subsequent revisions for a
complete list of OSHA rules and regulations as to You must replace a label if it is damaged, missing or
the safe operation of powered industrial lift trucks. cannot be read. If a label is on a part that is
Since regulations vary from country to country replaced, make sure a new label is installed on the
outside in U.S.A., operate this lift truck in replaced part. See your dealer for new labels.
accordance with local regulations.
-5-
Safety Section
-6-
Safety Section
WARNING WARNING
Contents under pressure may be hot. Allow to Do not stand or ride on the forks. Do not stand
cool before opening. or ride on a load or pallet on the forks. Do not
stand or walk under the forks.
IA3M1003
WARNING
WARNING
Operation without this device in place may be
hazardous.
No hands. Do not place hands in this area.Do
not touch, lean on, or reach through the mast or
permit others to do so.
IB6OO03P
-7-
Safety Section
WARNING WARNING
Operation without this device in place may be To avoid personal injury, stay clear of moving
hazardous. This guard conforms to A.N.S.I. fan.
B56.1 and F.E.M.Section 4.
This design has been tested with an impact of
appropriate value.
IAOY009I
IB6OS02P
Located on the Overhead Guard. WARNING
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
IC3O001P
ILOS002P
Located beside the operator's station.
-8-
Safety Section
IN
G A truck that is used for handing small objects or
N
A
R uneven loads must be fitted with a load backrest.
W
t
no ate If the lift truck must be operated without the
do per overhead guard in place due to low overhead
o clearance, use extreme care. Make sure there is no
possibility of falling objects from any adjacent
IAOY010I storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
Attach a ÒDo Not OperateÓ or similar warning tag to backrest extension (if equipped).
start switch or controls before servicing or repairing
the lift truck. Do not raise loads any higher than necessary and
never raise a load higher than 1830 mm (72 in) with
Do not start or service the lift truck when a ÒDO the overhead guard removed.
NOT OPERATEÓ or similar warning tag is attached
to the start switch or controls. Always use load backrest extension when the
carriage or attachment does not fully support the
Wear a hard hat, protective glasses and other load. The load backrest extension is intended to
protective equipment as required by job conditions. prevent the load or any part of the load from falling
backwards into the operator's station.
Know the width of your attachments so proper
clearance can be maintained when operating near When operation the lift truck, do not depend only on
fences, boundary obstacles, etc. flashing lights or back-up alarm (if equipped) to
warn pedestrians.
Do not wear loose clothing or jewelry that can catch
on controls or other parts of the lift truck. Always be aware of pedestrians and do not proceed
until the pedestrians are aware of your presence
Keep the lift truck, especially the deck and steps, and intended actions and have moved clear of the
free of foreign material such as debris, oil tools and lift truck and/or load.
other items which are not part of the lift truck.
Do not drive lift truck up to anyone standing in front
Secure all loose items such as lunch boxes, tools of an object.
and other items which are not part of the lift truck.
Obey all traffic rules and warning signs.
Know the appropriate work-site hand signals and
who gives them. Accept signals from one person Keep hands, feet and head inside the operator
only. station. Do not hold onto the overhead guard
while operating the lift truck. Do not climb on any
part of the mast or overhead guard or permit
others to do so.
-9-
Safety Section
Do not use steam, solvent, or high pressure to Face the lift truck when mounting and dismounting.
clean electrical components.
Use both hands face the lift truck when mounting
Report all needed repairs. and dismounting.
Inspect the part of the chain that is normally Keep hands and steering wheel free of slippery
operated over the crosshead roller. When the chain material.
bends over the roller, the movement of the parts
against each other causes wear. Before Starting the Lift Truck
Inspect to be sure that chain link pins do not extend Perform a walk-around inspection daily and at the
outside of the bore hole. start of each shift. Refer to the topic ÒWalk-around
InspectionÓ in ÒEvery 10 Service Hours or DailyÓ
If any single link pin is extended beyond its section of this manual.
connecting corresponding link, it should be
suspected of being broken inside of its bore hole. Adjust the seat so that full brake pedal travel can be
obtained with the operator's back against the seat
Inspect the chain anchor and the anchor links for back.
wear.
Make sure the lift truck is equipped with a lighting
system as required by conditions.
- 10 -
Safety Section
underneath or close to the lift truck before operating An operator must constantly observe his lift truck
the lift truck. for proper operation.
G
IN
N
R
A
W
t
no ate
do per
o IAOY013I
- 11 -
Safety Section
Always use overhead guards except where ¥ Park the lift truck level, with the forks lowered and
operation conditions do not permit. Do not operate the mast tilted forward until the fork tips touch the
lift truck in high stacking areas without overhead floor.
guards.
¥ Move the direction control lever to NEUTRAL.
When stacking, watch for falling objects. Use load
backrest extension and overhead guard. ¥ Engage the parking brake.
Refer to the topic ÒOperation TechniquesÓ in the ¥ Turn the key switch off and remove the key.
ÒOperation SectionÓ of this manual.
¥ Turn the disconnect switch to OFF and remove the
key (if equipped).
- 12 -
Safety Section
Maintenance Information
Perform all maintenance unless otherwise specified They will throw or cut any object or tool that falls or
as follows : is pushed into them.
¥ Park the lift truck in authorized areas only. Do not use a kinked or frayed wire rope cable. Wear
¥ Park the lift truck level, with the forks lowered and gloves when handling the wire rope cable.
the mast tilted forward until the fork tips touch the
floor. Retainer pins, when struck with force, can fly out
¥ Place the transmission controls in neutral. and injure nearby persons. Make sure the area is
¥ Engage the parking brake. clear of people when driving retainer pins.
¥ Stop the engine.
¥ Remove the start switch key and turn the Wear protective glasses when striking a retainer pin
disconnect switch OFF (if equipped). to avoid injury to your eyes.
¥ Block the drive wheels when parking on an incline.
Chips or other debris can fly off objects when
struck. Make sure no one can be injured by flying
Pressure Air
debris before striking any object.
Pressure air can cause personal infury. When using
Falling Objects Protective Structure(FOPS)
pressure air for cleaning, wear a protective face
shield, protective clothing and protective shoes.
This is an attached guard located above the
operator's compartment and secured to the lift
The maximum air pressure must be below 205 kPa
truck.
(30 psi) for cleaning purposes.
To avoid possible weakening of the Falling Objects
Fluid Penetration Protective Structure (FOPS), consult a DAEWOO
dealer before altering, by adding weight to, welding
Always use a board or cardboard when checking for on, or cutting or drilling holes into the structure.
a leak. Escaping fluid under pressure, even a pin-
hole size leak, can penetrate body tissue, causing The overhead guard is not intended to protect
serious injury, and possible death. If fluid is injected against every possible impact. The overhead guard
into your skin, it must be treated by a doctor familiar may not protect against some objects penetrating
with this type of injury immediately. into the operator's station from the sides or ends of
the lift truck.
Crushing or Cutting Prevention
The lift truck is equipped with an overhead guard
and FOPS as standard. If there is a possibility of
Support equipment and attachments properly when
overhead objects falling through the guard, the
working beneath them. Do not depend on hydraulic
guard must be equipped with smaller holes or a
cylinders to hold it up. Any attachment can fall if a
plexiglass cover.
control is moved, or if a hydraulic line breaks.
Any altering done that is not specifically authorized
Never attempt adjustments while the lift truck is
by DAEWOO invalidates DAEWOO's FOPS
moving or the engine is running unless otherwise
certification. The protection offered by this FOPS
specified.
will be impaired if it has been subjected to structural
damage. Structural damage can be caused by an
Where there are attachment linkages, the clearance
overturn accident, by falling objects, etc.
in the linkage area will increase or decrease with
movement of the attachment.
Do not mount any item such as fire extinguishers,
first aid kits and lights by welding brackets to or
Stay clear of all rotating and moving parts.
drilling holes in any FOPS structure. See your
DAEWOO dealer for mounting guidelines.
Keep objects away from moving fan blades.
- 13 -
Safety Section
Check the coolant level only after engine has been Do not smoke in areas where batteries are charged,
stopped and the fill cap is cool enough to remove or where flammable materials are stored.
with your bare hand.
Batteries in series can be located in separate
Remove the cooling system fill cap slowly to relieve compartments. When using jumper cables always
pressure. connect positive(+) cable to positive(+) terminal of
battery connected to starter solenoid and negative(-)
Cooling system additive contains alkali that can cable from external source to starter negative(-)
cause personal injury. Avoid contact with the skin terminal.
and eyes and do not drink. (If not equipped with starter negative(-) terminal,
connect to engine block.)
Allow cooling system components to cool before
draining.
See the Operation Section of this manual for
Oils specific starting instructions.
Hot oil and components can cause personal injury. Clean and tighten all electrical connections. Check
Do not allow hot oil or components to contact the daily for loose or frayed electrical wires. Have all
skin. loose or frayed electrical wires tightened, repaired
or replaced before operation the lift truck.
At operation temperature, the hydraulic tank is hot
and can be under pressure. Keep all fuels and lubricants stored in properly
marked containers and away from all unauthorized
Remove the hydraulic tank fill cap only after the persons.
engine has been stopped and the fill cap is cool
enough to remove with your bare hand. Store all oily rags or other flammable material in a
protective container, in a safe place.
Remove the hydraulic tank fill cap slowly to relieve
pressure.
Do not weld or flame cut on pipes or tubes that
Relieve all pressure in air, oil fuel or cooling contain flammable fluids. Clean them thoroughly
systems before any lines, fittings or related items with nonflammable solvent before welding or flame
are disconnected or removed. cutting on them.
Always wear protective glasses when working with Do not operate in areas where explosive gases
batteries. exist or are suspected.
- 14 -
Safety Section
Ether is poisonous and flammable. Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
Breathing ether vapors or repeated contact of ether against other parts, and excessive heat during
with skin can cause personal injury. operation.
Do not store ether cylinders in direct sunlight or at A tire explosion is much more violent than a
temperatures above 39¡C (102¡F). blowout. The explosion can propel the tire, rim and
axle components as far as 500 m (1500 ft) or more
Discard cylinders in a safe place. Do not puncture from the lift truck. Both the force of the explosion
or burn cylinders. and the flying debris can cause personal injury or
death, and property damage.
Keep ether cylinders out of the reach of
unauthorized personnel.
AT LEAST 15m (50 ft)
Lines, Tubes and Hoses AT LEAST 500m (1500 ft)
- 15 -
Safety Section
- 16 -
Safety Section
WARNING
WARNING
Your DAEWOO truck comes equipped with a
The ÒSurvive in tipoverÓ warning is located on the DAEWOO operator restraint system. Should it
overhead guard. It shows the proper use of the become necessary to replace the seat for any
operator restraint system. reason, it should only be replaced with another
DAEWOO operator restraint system.
Seat Adjustment
Seat Belt
Front-to-back adjustment
Lever
- 17 -
Safety Section
Inspection
WARNING
Plate
Buckle
- 18 -
Safety Section
INSO023I
CG
INSO024I
- 19 -
Safety Section
INSO025I INSO027I
The stability of the lift truck is determined by the For the lift truck to be stable (not tip over forward or
location of its CG; or, if the truck is loaded, the to the side), the CG must stay within the area of the
combined CG of the truck and load. The lift truck lift truck stability base Ð a triangular area between
has moving parts and, therefore, has a CG that the front wheels and the pivot of the steer wheels. If
moves. The CG moves forward or backward as the the CG moves forward of the front axle, the lift truck
mast is tilted forward or backward. The CG moves will tip forward. If the CG moves outside of the line
up or down as the mast moves up or down. The CG on either side of the stability base, the lift truck will
and, therefore, the stability of the loaded lift truck, is tip to the side.
affected by a number of factors such as:
CG load
Combined CG
CG truck
INSO026I
INSO028I
These same factors are also important for unloaded
lift trucks. They tip over sideways easier than a The capacity load of the lift truck is shown on the
loaded lift truck carrying its load in the lowered capacity/nameplate riveted to the truck. It is
position. determined by the weight and load center. The load
center is determined by the location of the CG of
the load.
- 20 -
Safety Section
The load center shown on the nameplate is the Safe Driving Practices
horizontal distance from the front face of the forks,
or the load 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.
NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DAEWOO shall not be
removed, altered or replaced without
DAEWOOÕs approval. INSO031S
2. DAEWOO assumes no responsibility for lift DONÕT go over rough terrain! If unavoidable,
trucks placed in service without a valid slow down.
DAEWOO Nameplate.
3. If necessary to change your specification,
contact your DAEWOO lift truck dealer.
- 21 -
Safety Section
INSO032S INSO035S
DONÕT start, turn, or stop quickly. DONÕT turn on, or drive across an incline.
Sudden movement can cause the lift truck to
tipover.
INSO036S
INSO037S
- 22 -
Safety Section
INSO038S INSO041S
DONÕT pick up an off center load! Such a load DONÕT jump off if your truck starts to tipover!
increases the possibility of a tipover to the side. Stay in your seat to survive.
INSO039S INSO042I
DONÕT drive on slippery surfaces! Sand, gravel, DONÕT compromise safety. Wear a hard hat if
ice or mud can cause a tipover. If unavoidable, slow required on your job site.
down.
INSO043I
INSO040S
DONÕT travel with the mast raised.
DONÕT attempt to pick up or deposit a load unless
the lift truck is level.
- 23 -
Safety Section
Equipped) WARNING
IF TRUCK IS IMPROPERLY
OPERATED.
INJURY OR DEATH
COULD RESULT.
DON'T JUMP
HOLD ON TIGHT TO
STEERING WHEEL BRACE FEET
IN CASE OF TIPOVER
LEAN AWAY
FROM IMPACT
LEAN
FORWARD
WARNING
DON'T JUMP
INSO047I
DONÕT jump.
INSO045I
Hold on tight.
FASTEN SEAT BELT
- 24 -
Safety Section
LEAN AWAY
INSO050I
LEAN FORWARD
INSO051I
Lean forward.
- 25 -
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type electric, diesel, gas, LPG
6 Operator type Stand-on, rider seated
7 Tires c = cushion, p = pneumatic
8 Wheels (x = driven) number, front/rear
DIMENSIONS
9 maximum fork height with rated load mm
10 Lift with STD free lift mm
two - stage mast
11 special free lift mm
12 Fork carriage ISO class
thickness B width B length mm
13 Forks
fork spacing ( minimum B maximum ) mm
14 Tilt of mast foreward/backward deg
15 length without forks mm
16 width mm
17 Overall most lowered height mm
18 dimensions mast extened height mm
19 overhead guard height mm
20 seat height mm
21 Outside turning radius mm
22 Load moment constant ( from center of front wheel to fork face ) mm
23 90¡ stacking aisle ( add load length and clearance ) mm
23a 90¡ intersecting aisle mm
PERFORMANCE
24 travel, loaded / unloaded km / h
25 Speeds lift, loaded / unloaded mm / s
26 lowering, loaded / unloaded mm / s
28 Drawbar pull at 1.6 km / h, loaded / unloaded kg
30 Gradeability at 1.6 km / h, loaded / unloaded %
31 Acceleration time travelling loaded / unloaded s
WEIGHT
32 Total weight kg
33 with load front / rear kg
Axle load
34 without load front / rear kg
CHASSIS
35 number of front / rear
36 Tires front
size
37 rear
38 Wheelbase mm
39 Tread front/rear mm
40 at the lowest point mm
Ground clearance loaded
41 at center of wheelbase mm
42 Service brake
43 Parking brake
DRIVE
45 Battey voltage / capacity V / AH
49 manufacturer/model
50 rated output (at rpm) gas / LPG kW(rpm)
51 Engine max. torque (at rpm) gas / LPG kg - m
52 cycle / cylinders / displacement cc
53 fuel consumption l / hr
55 type
Transmission number of speeds forward / reverse
56
57 Relief pressure system / attachment kPa
58 Noise level Leq dB (A)
- 26 -
General Section
IN
p p p 7
TE AN
RS GL
X 2/ 2 X 2/ 2 X 2/ 2 8 21
EC E A
TI IS
NG LE
RI
23
G
HT
3300 3300 3300 9 MINIMUM ASLE - 90¡ STACK
130 130 130 10
11
ll ll ll 12
35 B 100 B 900 35 B 100 B 900 40 B 100 B 900 14
13
216 B 905
6/8 6/8 6/8 14 A
2155 2202 2243 15 18
12 / 45 12 / 45 12 / 45 45
MMC / G420 MMC / G420 MMC / G420 49
27.2 (2100) 27.2 (2100) 27.2 (2100) 50
14(1400)/13.3(1400) 14(1400)/13.3(1400) 14(1400)/13.3(1400) 51
4 / 4 / 1997 4 / 4 / 1997 4 / 4 / 1997 52
53
Powershift Powershift Powershift 55
1/1 1/1 1/1 56
17600 17860 21550 57
58
- 27 -
General Section
IN
p p p 7
TE AN
RS GL
X 2/ 2 X 2/ 2 X 2/ 2 8
EC E A
21
TI IS
NG LE
RI
23
G
HT
3300 3300 3300 9 MINIMUM ASLE - 90¡ STACK
130 130 130 10
11
ll ll ll 12
35 B 100 B 900 35 B 100 B 900 40 B 100 B 900 14
13
216 B 905
6/8 6/8 6/8 14 A
2155 2202 2243 15 18
12 / 60 12 / 60 12 / 60 45
DHI/DC24 DHI/DC24 DHI/DC24 49
32.4 (2250) 32.4 (2250) 32.4 (2250) 50
14.5 (1800) 14.5 (1800) 14.5 (1800) 51
4 / 4 / 2369 4 / 4 / 2369 4 / 4 / 2369 52
53
Powershift Powershift Powershift 55
1/1 1/1 1/1 56
17600 17860 21550 57
58
- 28 -
General Section
- 29 -
General Section
SINGLE TIRE
MODEL
STD, FFL FFT
A. B. C.
kg 1500 A. kg 1500
B.
1300 1300
1100 1100
900 900 D. E. F.
700 700
500 500
300 300
G15S - 2
D15S - 2 500 600 700 800 900 1000 1100 1200
mm
500 600 700 800 900 1000 1100 1200
mm
A. B. A. B. C.
kg 1700 kg 1700
1500 1500 D.
1300 C. 1300 E.
1100 1100 F.
900 900
700 700
G18S - 2 500 500
D18S - 2 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
mm mm
A. A. B. C.
kg 1300 B. kg
1500
C.
1200 1300
1100 1100
1000 900
D. E. F.
900 700
800 500
D20S C- 2 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
mm mm
- 30 -
General Section
SINGLE TIRE
MODEL
STD, FFL FFT
A. A. B. C.
kg 1300 B. kg
1500
C.
1200 1300
1100 1100
1000 900
D. E. F.
900 700
800 500
D15S - 2 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
mm
mm
A. B. C. A. B. C.
kg 1500 kg 1500
1300 1300
1100 1100 D. E.
900 900 F.
700 700
500 500
G18S - 2 300 300
D18S - 2 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
mm mm
A. B. A. B.
kg 1900 kg 1700
1700 1500
1300 C. D.
1500 E.
1300
C. D. 1100
1100 900 F.
900 700
700 500
G20S C- 2
D20S C- 2 500 600 700 800 900 1000 1100 1200
mm
500 600 700 800 900 1000 1100 1200
mm
- 31 -
General Section
Serial Number
Serial Number Locations
For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.
IB2O401P
IPGO008P
IB2O607P
IPGO006P
- 32 -
General Section
IPSO002P
Mast Abbreviations
- 33 -
General Section
Attachment Abbreviations
(Includes Special Forks)
CW - Counterweight
SF - Special Forks
TH - Tire Handler
CC - Carton Clamp
RC - Roll Clamp
LS - Load Stabilizer
- 34 -
Operation Section
- 35 -
Operation Section
IB6OO02P
ILO1048P
9. Horn Switch - Push on the horn
button to sound the horn.
ILO0003P
- 36 -
Operation Section
IB6OO03P
ILO0006P
ILO4010P
- 37 -
Operation Section
IB1O1004
2. OFF - This position shuts off all NOTE : The seat can only be correctly adjusted
fuelsupply to the carburetor and is used with the operator fully seated.
when changing from Gasoline to LP-
Gas or LP-Gas to Gasoline fuel.
- 38 -
Operation Section
ILOO009P
Plate for Function of Pedals NOTE : The purpose of the inching control pedal is
(If Equipped) to provide precise inching control at slow
travel speed, with high engine rpm. This is
used for fast hydraulic lift during load
approach, pickup or pisitioning.
ILOO010P
- 39 -
Operation Section
IB6OO04P ILOO014P
Push DOWN on the brake pedal to Pull the lever BACK to engage the
slow or stop the lift truck. parking brake.
RELEASE the brake pedal to allow the Push the lever FORWARD to release
lift truck to move. the parking brake.
IB6OO04P ILOO015P
Push DOWN on the pedal to increase NOTE : To prevent a sudden change of position of
engine rpm (speed). the load, operate all lift, tilt and
attachment controls smoothly.
RELEASE the pedal to decrease
engine rpm (speed). 1. Lower Position - Push the lever
FORWARD smoothly to lower the load.
- 40 -
Operation Section
Tilt Control
ILOO016P
ILOO024P
- 41 -
Operation Section
Refueling
Gasoline or Diesel Engine Equipped
WARNING
Explosive fumes may be 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. IB6OS02P
Stop the engine and get off the lift truck during 1. Park the lift truck only at a designated safe
refueling. location. Place the transmission in NEUTRAL.
Lower the forks to the ground. Engage the
parking brake. Stop the engine.
NOTICE
Do not allow the lift truck to become low on fuel
or completely run out of fuel. Sediment or other
impurities in the fuel tank could be drawn into
the fuel system. This could result in difficult
starting or damage to components.
- 42 -
Operation Section
IB6OO05P
IPOO020P
NOTICE
If the location pin (dowel) is missing or broken,
be sure the pin is replaced.
- 43 -
Operation Section
IPOO021P
- 44 -
Operation Section
IB6OS02P
IB6OS06P
Typical Example
- 45 -
Operation Section
IB6OO07P ILOO027P
Typical Example 13. Observe the fuel level gauge after starting the
truck. Add fuel if necessary.
11. Measure the engine crankcase oil level with the
dip stick. Maintain the oil level between the
MAX. and MIN., (or FULL and ADD) notches on
the dip stick. 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.
IB6OO08P
Typical Example
- 46 -
Operation Section
The following provides practical guidelines for Some countries have standards or regulations
inspection, maintenance and repair of lift truck which apply specifically to the inspection and repair
forks. It also provides general information on the of forks.
design and application of forks and the common
cause fo fork failures. Users countries have standards for regulations
which apply specifically to the inspection and repair
Lift truck forks can be dangerously weakened by of forks.
improper repair or modification. They can also be
damaged by the cumulative effects of age, Users may also refer to the International
abrasion, corrosion, overloading and misuse. Organization For Standardization-ISO Technical
Report 5057-Inspection and Repair of Fork Arms
A fork failure during use can cause damage to the and ISO Standard 2330-Fork Arms-Technical
equipment and the load. A fork failure can also Characteristics and Testing.
cause serious injury.
While there are no specific standards or regulations
A good fork inspection and maintenance program in the United States, users should be familiar with
along with the proper application can be very the requirements for inspection and maintenance of
effective in preventing sudden on the job failures. lift trucks as provided by the 29 Code Federal
Register Safety Standard (s) B56.1, B56.5 or B56.6
Repairs and modifications should be done only by as applicable to the type of machine (s) in use.
the fork manufacturer or a qualified technician
- 47 -
Operation Section
2. Bent or Twisted Forks. Forks can be bent out of Scratches, nicks and corrosion are points of high
shape by extreme overloading, glancing blows stress concentration where cracks can develop.
against walls or other solid objects or using the These cracks can progress under repetitive
fork tip as a pry bar. loading in a typical mode of fatigue failue.
Bent or twisted forks are much more likely to 4. Overloading. Extreme overloading can cause
break and cause damage or injury. They should permanent bending or immediate failure of the
be removed from service immediately. forks. Using forks of less capacity than the load
or lift truck when lifting loads and using forks in a
3. Fatigue. Parts which are subjected to repeated manner for which they were not designed are
or fluctuating loads can fail after a large number some common causes of overloading.
of loading cycles even though the maximum
stress was below the static strength of the part.
Fork Inspection
The first sign of a fatigue failure is usually a crack
which starts in an area of high stress
concentration. This is usually in the heel section
or on the fork mounting.
- 48 -
Operation Section
2. Make sure fork blades are level to each other ¥ Repairing cracks or other damage by welding.
within acceptable tolerances. See ÒForks, Step
4,Ó in the Ò2000 Service Hours or 1 YearÓ in ¥ Bending or resetting.
ÒMaintenance Intervals.Ó
3. The following repairs MAY be performed.
3. Make sure positioning lock is in place and
working. Lock forks in position before using ¥ Forks may be sanded or lightlyground, to remove
truck. See ÒForks, Step 7,Ó in the Ò2000 Service rust, corrosion or minor defects from the
Hours or 1 YearÓ in ÒMaintenance IntervalsÓ. surfaces.
2. Make sure positioning lock is in place and 4. A fork should be load tested before being
working. Lock the forks in position before using returned to service on completion of repairs
the truck. See Ò2000 Service Hours or 1 YearÓ in authorized and done in accordance with the
ÒMaintenance IntervalsÓ. manufacturer's recommendations.
- 49 -
Operation Section
- 50 -
Operation Section
IB6OO09P
ILOO005P
ILO7008P
- 51 -
Operation Section
1. Turn the tank fuel valve ON by slowly turning the Starting a Warm Diesel Engine
valve counterclockwise. Observe the LP -Gas
gauge(if equipped). 1. Turn the key to the ON position and then to
START position, without waiting for the preheat
2. Turn the ignition switch to the START position. light to go OFF. At the same time fully depress the
Release it when the engine starts. accelerator.
- 52 -
Operation Section
WARNING
Sparks occurring near the battery could cause
vapors to explode.
Always connect the external power source
ground cable to a point away from and below
the battery, and well clear of fuel system
components.
IB6OO10P
Typical Example
NOTICE
Do not reverse battery cables. It can cause
damage to the alternator.
Always connect the external power source
cables in parallel with the lift truck battery
cables : 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.
- 53 -
Operation Section
ILOO027P
ILOO018P
NOTE : The UnderwriterÕs Laboratory (U.L.)
requires that the gasoline tank must be at least 6. Open the fuel valve, on the LP - Gas tank, by
one - quarter full when operating on LP - Gas. slowly turning the valve counterclockwise.
This will allow the lift truck to be restarted on
gasoline and moved to an approved refueling 7. Turn the ignition switch key to the OFF position
area, when operating in a hazardous area. and then to the START position to start the engine.
Release it when the engine starts.
1. Park the lift truck level in an authorized refueling
area with the forks lowered, the parking brake Changing From LP - Gas to
applied, the transmission in NEUTRAL and the Gasoline
engine running.
1. Park the lift truk level in an authorized refueling
2. Raise the hood and seat assembly. Make area with the forks lowered, the parking brake
certain the air lift cylinder securely holds the hood applied, the transmission in NEUTRAL and the
open. engine running.
3
2
1
4
IB1O1004 ILOO018P
Typical Example 2. Close the fuel valve on the LP - Gas tank. Allow
the engine to run until the fuel in the line runs out
3. Move lever (1), on the fuel selector switch to the and the engine stops. Turn the ignition switch to
OFF(2) positoin. Leave lever (1) in this position the OFF position.
until the gasoline in the carburetor is used and the
engine stops. 3. Raise the hood and seat assembly.
Make certain the air lift cylinder securely holds the
hood open.
- 54 -
Operation Section
1
4
IB1O1005
Typical Example
- 55 -
Operation Section
1 2 5 6 7
IB6OO02P
- 56 -
Operation Section
IB6OO04P
WARNING
Sudden revesal of a loaded lift truck traveling
forward can cause the load to fall or the lift
ILOO009P truck to tip.
4. Select the direction of travel by pushing the Failure to comply could result in personal
directional lever FORWARD for forward direction injury.
or by pulling the lever BACK for reverse
direction. Stop the loaded lift truck completely, before
shifting to reverse.
- 57 -
Operation Section
IB6OO04P IB6OO04P
7. To change the lift truck direction of travel, release 11. To stop the lift truck when traveling in either
the accelerator pedal. direction, release the accelerator pedal.
8. Push down on the service brake pedal to reduce 12. Push down on the service brake pedal and
the lift truck speed as necessary. bring the lift truck to a smooth stop.
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.
ILOO009P
IB6OO04P
- 58 -
Operation Section
Operating Techniques
Inching into Loads Lifting the Load
1. Lift the load carefully and tilt the mast back a
short distance.
IAOO037I
Typical Example
IPOO033I
1. Move the lift truck slowly FORWARD into positon
and engage the load. The truck should be square Typical Example
with load, forks spaced evenly between pallet
stringers and as far apart as load permits. 2. Tilt the mast further back to cradle the load
IPOO032I IPOO034I
2. Move the lift truck FORWARD until the load 3. Operate the lift truck in reverse until the load is
touches the carriage. clear of the other material.
- 59 -
Operation Section
NOTICE
Travel with the load as low as possible, while
still maintaining ground clearance.
IAOO042I
Typicl Example
IAOO041I
Typical Example
IKOO038I
Typical Example
IAOY013I WARNING
Typical Example
Do not tilt the mast forward with the load unless
directly over the unloading area, even if the
2. For better vision, travel in reverse with bulky
power is off.
loads.
- 60 -
Operation Section
Turning
IAOO044I
Typical Example
IAOO046I
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.
IAOO045I
- 61 -
Operation Section
IAOO048I
3. Even if the engine overheats and the coolant
boils over, let the engine idle for a while with
1. Block drums or round objects. Tilt the mast opening engine hood until temperature falls
FORWARD and side the fork tips along the floor before shut off the engine.
to get under the load.
IAOO049I
- 62 -
Operation Section
IB6OS02P ILO7008P
1. Park in an authorized area only. Do not block 5. Turn the key in the ignition switch to the OFF
traffic. If LP - Gas equipped, do not park near position and remove the key.
elevator shafts or any other area where LP-Gas
could collect in a pocket (low area), causing a
potentially dangerous condition.
IPOO017P
3. Engage the parking brake. 6. Actuate each loading lever serveral times to
remove the residual pressure in the respective
4. Lower the forks to the ground. cylinders and hoses.
WARNING
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.
- 63 -
Operation Section
Storage Information
Before Storage ¥ Cover components such as the breather and air
cleaner which may be caught with humidity.
Before storing your lift truck, clean and inspect as
the following procedures. ¥ The machine should be operated at least once a
week. Fill the cooling system, if cooling water is
¥ Wipe away grease, oil, etc. adhering to the body discharged, and mount the battery. Start the
of the truck with waste cloth, and use water, if engine and warm up thoroughly. Move the
needed. machine a little forwards and backwards. Operate
the hydraulic controls several times.
¥ While cleaning the truck, check general condition
of the truck. Especially check the truck body for
recess or damge and tires for wear or nails or
To Operate the Lift Truck After a
stones in the tread. Long Time Storage
¥ Fill the fuel tank with fuel specified. ¥ Remove covers and antirust from each of the
components and exposed parts.
¥ Check for leakage of hydraulic oil, engine oil, fuel,
or coolant, etc. ¥ Drain the engine crankcase, transmission (clutch
type machine), differential and final reduction
¥ Apply grease, where needed. gear, clean the inside of them and add new oil.
¥ Check for looseness of nuts and bolts, especially ¥ Drain off foreign matter and water from the
hub nuts. hydraulic oil tank and fuel tank.
¥ Check mast rollers to see that they rotate ¥ Remove the head cover from the engine cylinder.
smoothly. Oil valves and rocker shaft and check each valve
for proper operation.
¥ Prime the oil into the lift cylinders by actuating the
lift lever all the way several times. ¥ Add cooling water to the specified level.
¥ Drain off coolant completely in water of cold ¥ Charge the battery and mount it on the machine.
weather, if antifreeze is not used. Connect the cables.
- 64 -
Operation Section
Transportation Hints
Lift Truck Shipping Machine Lifting and Tiedown
Information
Check travel route for overpass clearances. Make
sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
overhead guard or cab. NOTICE
Improper lifting or tiedowns can allow load to
To prevent the lift truck from slipping while loading, shift and cause injury and/or damage.
or shifting in transit, remove ice, snow or other
slippery material from the loading dock and the
truck bed before loading.
1. Weight and instructions given herein apply to lift
trucks as manufactured by DAEWOO.
NOTICE
2. Use proper rated cables and slings for lifting.
Obey all state and local laws governing the Position the crane for level lift truck lift.
weight, width and length of a load.
Observe all regulations governing wide loads. 3. Spreader bar widths should be sufficient to
prevent contact with the lift truck
IAOO051I
- 65 -
Operation Section
Towing Information
To provide sufficient control and braking when
WARNING
moving a disabled lift truck downhill, a larger towing
lift truck or additional lift trucks connected to the
Personal injury or death could result when
rear could be required. This will prevent
towing a disabled lift truck incorrectly.
uncontrolled rolling.
Block the lift truck wheels to prevent movement The different situation requirements cannot be
before releasing the brakes. The lift truck can given, as minimal towing lift truck capacity is
roll free if it is not blocked. required on smooth level surfaces to maximum on
Follow the recommendations below, to properly inclines or poor surface conditions.
perform the towing procedure.
Consult your DAEWOO Lift Tuck dealer for towing
a disabled lift truck.
Quick lift truck movement could overload the tow 5. Fasten the tow bar to the lift truck.
line or bar and cause it to break. Gradual and
6. Remove the wheel blocks. Tow the lift truck slowly.
smooth lift truck movement will better.
Do not tow any faster than 2 km/h (1.2 mph).
Normally, the towing lift truck should be as large as
the disabled lift truck. Satisfy yourself that the
WARNING
towing lift truck has enough brake capacity, weight
and power, to control both lift trucks for the grade
Be sure all necessary repairs and adjustments
and the distance involved.
have been made before a lift truck that has been
towed to a service area is put back into
operation.
- 66 -
Maintenance Section
Typical Example
WARNING
NOTICE
Set the tire inflation equipment regulator at no more
than 140 kPa (20 psi) over the recommended tire
pressure.
- 67 -
Maintenance Section
Torque Specification
Torques for Standard Hose Torques for Standard Fasteners
Clamps-Worm Drive Band Type
NOTICE
NOTICE The following charts give general torques for
The following chart gives the torques for initial bolts, nuts and taperlock studs or SAE Grade 5
installation of hose clamps on new hose and for or better quality.
reassembly or retightening of hose clamps on
existing hose.
Torques for Bolts and Nuts
Thread Size Standard Bolt & Nut Torque
Inch N¥m lb ft
Initial Installation
Clamp Width Torque on New Hose 1/4 12L3 9L2
N¥m Ib in 5/16 25L6 18L4.5
16 mm(.625 in) 7.5L0.5 65L5 3/8 47L9 35L7
13.5 mm(.531 in) 4.5L0.5 40L5 7/16 70L15 50L11
8 mm(.312 in) 0.9L0.2 8L2 1/2 105L20 75L15
9/16 160L30 120L20
Initial Installation
Clamp Width Torque on New Hose 5/8 215L40 160L30
N¥m Ib in 3/4 370L50 275L37
16 mm(.625 in) 4.5L0.5 40L5 7/8 620L80 460L60
13.5 mm(.531 in) 3.0L0.5 25L5 1 900L100 660L100
8 mm(.312 in) 0.7L0.2 6L2 1 1/8 1300L150 950L100
1 1/4 1800L200 1325L150
1 3/8 2400L300 1800L225
1 1/2 3100L350 2300L250
- 68 -
Maintenance Section
NOTICE
Be very careful never or mix metric with U.S.
customary (standard) fasteners. Mismatched or
incorrect fasteners will cause machine damage
or malfunction and can result in personal
injury.
Original fasteners removed from the machine
should be saved for reassembly whenever pos-
sible. If new fasteners are needed, they must
be of the same size and grade as the ones that
are being replaced.
The material strength identification is usually
shown on the bolt head by numbers (8.8, 10.9,
etc). The following chart gives standard
torques for bolts and nuts with Grade 8.8.
- 69 -
Maintenance Section
- 70 -
Maintenance Section
Antifreeze
Make proper antifreeze additions
Antifreeze Concentrations
Protection Temperature Concentration
Protection to -15¡C (5¡F) 30% antifreeze and 70% water
Protection to -23¡C (-10¡F) 40% antifreeze and 60% water
Protection to -37¡C (-34¡F) 50% antifreeze and 50% water
Protection to -51¡C (-60¡F) 60% antifreeze and 40% water
- 71 -
Maintenance Section
Fuel Specifications
Fuel Information Fuel Types
Use only fuel as recommended in this section. DAEWOO Diesel Engines have the ability to burn
a wide variety of fuels. These fuels are divided into
two general groups, preferred and permissible.
NOTICE The Preferred Fuels provide maximum engine
Fill the fuel tank at the end of each day of oper- service life and performance. They are distillate
ation to drive out moist air and to prevent con- fuels. They are commonly called diesel fuel, MDO
densation. Maintain a constant level near the diesel, furnace oil, gas oil or kerosene (for cold
top of the day tank to avoid drawing moisture weather operation).
into the tank as the level decreases.
Experience has proven that distillate fuels meeting
Do not fill the tank to the top. Fuel expands as it the following basic specifications will result in opti-
gets warm and can overflow. mum engine performance and durability.
Do not fill the fuel filters with fuel before
installing them. Contaminated fuel will cause DAEWOO strongly encourages the use of fuels
accelerated wear to the fuel system parts. that meet the Preferred Fuels specification.
- 72 -
Maintenance Section
- 73 -
Maintenance Section
Lubricant Specifications
Lubricant Information Hydraulic Oil (HYDO)
Certain abbreviations follow Society of Automotive The following commercial classifications can be
Engineers (SAE) J754 nomenclature and some used in the hydraulic system.
classifications follow SAE J183 abbreviations.
¥ API CF-4/SG, CF-4/SF, CE/SG, CE/SF, CD/SG,
or CD/SF
The MIL specifications are U.S.A. Military
¥ MIL-L-2104E or D
Specifications.
Industrial premium hydraulic oils that have passed
The recommended oil viscosities can be found in the Vickers vane pump test (35VQ25) and/or have
the Lubricant Viscosities chart in this publication. a minimum of 0.09% zinc additive may also be
used. These oils should have antiwear, antifoam,
Grease is classified by the National Lubricating antirust and antioxidation additives for heavy duty
Grease Institute (NLGI) based on ASTM D217-68 use as stated by the oil supplier. ISO viscosity
Worked Penetration characteristics which are given grade of 46 would normally be selected.
a defined consistency number.
Transmission Oil (TDTO)
Engine Oil (DEO and EO)
NOTICE
The following oil specifications provide guidelines
for the selection of commercial products : This oil is formulated for transmissions and
drive trains only, and should not be used in
¥ API CF-4/SG, CF-4/SF, CE/SG, CE/SF engines. Shortened engine life will result.
¥ API SD, SE
- 74 -
Maintenance Section
- 75 -
Maintenance Section
- 76 -
Maintenance Section
Maintenance Intervals
First 250 Service Hours
NOTICE
Engine Valve Lash - Check, Adjust ...................100
All maintenance and repair, except Every 10 Hydraulic Return Filter - Change.......................100
Service Hours or Daily, on the lift truck must be
prformed by qualified and authorized personnel
only. Every 250 Service Hours or Monthly
Hydraulic Oil Level - Check ...............................101
Drive Axle Oil Level - Check..............................101
Attachment & Mast - Inspect, Lubricate ............102
NOTICE Steering Mechanism - Check, Lubricate ...........102
Careless disposal of waste oil can harm the Battery Terminal - Clean, Inspect ......................103
environment and can be dangerous to persons. Brake Oil Level - Check.....................................103
Always dispose of waste oil to an authorized Engine Oil & Filter - Change..............................103
personnel only. PCV Valve System - Inspect, Clean ..................103
Diesel Engine.....................................................104
- 77 -
Maintenance Section
When Required
You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any aperation or maintenance procedures.
Carburetor & Fuel Filter - Adjust, Fuel Filter (Gasoline Engine and Dual
Check, Clean, Change Fuel Engine) - Check, Clean, Change
NOTICE
UNDER DUSTY OR OTHER DIRTY OPERATING
CONDITIONS
Clean the fuel filter every month and replace it
every year.
IB6OM01P
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Maintenance Section
IB2O609P
6. Dry the filter element with 205 kPa (30 psi) max-
imum air pressure.
IOMO013P
7. Check bottom cover O-ring (2) for damage.
1. Close the fuel shutoff valve on the LP-Gas tank.
Replace it if necessary.
Run the engine until fuel in the line runs out and
the engine stops. Turn off the ignition switch.
8. Install the filter element (3), O-ring (2), and cover
(1) on bottom cover (4).
IB2O608P 13. Check the fuel lines and fittings with a soap
solution.
2. Scribe a line across the filter housing covers.
Make repairs if necessary.
3. Remove the cover retaining screws.
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Maintenance Section
NOTICE NOTICE
UNDER DUSTY OR OTHER DIRTY OPERATING Do not fill fuel filters with fuel before installing
CONDITIONS them. Contaminated fuel will cause accelerated
wear to fuel system parts.
Clean the fuel filter every month and replace it
every year.
Fuel Filter (Diesel Engine) - Check, 6. Turn the new fuel filter cartridge assembly until
Clean, Change the filter gasket is fitted against the sealing face.
Changing Filter Element 7. Turn the fuel filter cartridge assembly an addi-
tional 2/3 of turn.
Park lift truck with the forks lowered, parking brake
applied, transmission in neutral, engine stopped
and cool.
Priming the Fuel System
(Diesel Engine)
1. Raise the hood and seat assembly.
Bleeding the Fuel System
IC3O004P
IC3O003P
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Maintenance Section
IC3O003P
IC3O003P
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Maintenance Section
Seat, Hood Latch & Support Fuses, Bulbs and Circuit Breaker
Cylinder - Check, Lubricate - Change, Reset
Fuses
NOTICE
Always replace fuses with ones of the correct
ampere rating.
ILO6008P
IPMO002P
2. Pull the latch to raise the hood and seat assem- Fuse - Protects an eletrical circuit from an over-
bly. Make certain the support cylinder will hold load. Opens (filament separates) if an overload
the hood open. occurs.
IPMO003P
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Maintenance Section
Circuit Breaker
IPMO004P
Bulbs
*OPTIONAL LAMP OR LIGHT 2. The main circuit breaker is located on the rear of
the support for the controls.
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Maintenance Section
IPMO007P
- 84 -
Maintenance Section
1. Remove the primary air cleaner element. See Pressure air can cause personal injury.
topic ÒServicing Filter ElementÓ. Clean the inside
When using pressure air for cleaning, wear a
of the air cleaner housing and cover.
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.
NOTICE
Do not clean the elements by bumping or tap-
ping them.
Inspect filter elements after cleaning. Do not
use a filter with damaged pleats, gaskets or
IPMO008P seals.
2. Remove the secondary element. Inspect the gas- When cleaning with pressure air, use 205 kPa
ket between the air cleaner housing and the (30 psi) maximum pressure to prevent filter
engine inlet. Replace the gasket if it is damaged. element damage.
When cleaning with pressure water, use 280
kPa (40 psi) maximum pressure to prevent fil-
NOTICE ter element damage.
Always replace the secondary element. Do not
attempt to reuse it by cleaning.
Have spare elements on hand to use while cleaning
used elements.
3. Install a new secondary element. Install a new or
cleaned primary element. Install the cover. The primary element should be replaced after a
Tighten the latches. year's service or after cleaning no more than 6
times.
4. Start the engine and observe the air cleaner ser-
vice indicator. If the indicator shows RED after
installing a new secondary elemennt and a
cleaned primary (outer) element, replace the
cleaned primary filter with a new element.
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Maintenance Section
Air-205 kPa (30 psi) Maximum Pressure Distributor & Spark Plug - Check
Checking Element
IB2O608P
- 86 -
Maintenance Section
Spark Plugs (Gasoline, and LP-Gas Tires and Wheels - Inspect, Check
Engines and Dual Fuel Engine) - Check
Park the lift truck with the forks lowered, parking WARNING
brake applied, transmission in neutal and the
engine stopped. Servicing and changing tires and rims can be
dangerous and should be done only by trained
1. Raise the hood and seat assembly. personnel using proper tools and procedures.
2. Disconnect the battery cable. Deflate tire before removing wheel nuts from
the truck.
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Maintenance Section
NOTICE
IPMO022P
Be sure to check and set Dual fuel ignition tim-
Do NOT reinflate a tire that has been run while flat ing on gasoline fuel. Dual fuel engines timing
or underinflated, without first checking to make sure must be 4¡ BTDC at 800rpm. If the engine is to
the rim is not damaged and is in the correct posi- be run on LP fuel for a long period of time, the
tion. timing can be adjusted to 9¡ BTDC at 740rpm for
better performance. When the fuel is changed
When tires are changed, be sure to clean all rim back to gasoline, the timing must be 4¡ BTDC at
parts and, if necessary, repaint to stop detrimental 740rpm. If the timing is at 9¡ BTDC at 740rpm on
effects of corrosion. Sand blasting is recommended gasoline fuel for a long period or time, the pis-
for removal of rust. tons will be damaged.
IPMO023I
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Maintenance Section
Inspect Tightness
Steer Wheels
IPMO024P
Typical Example
Drive Wheels
IPMO025P
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Maintenance Section
IB1O1012
Diesel Engines
IB6OO08P
Typical Example
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Maintenance Section
IB6OM03P
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Maintenance Section
IB6OM04P
IB6OS02P
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Maintenance Section
WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.
IB6OM06P
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Maintenance Section
Engine Chankcase
( Gasoline, and LP - Gas )
11. Start the engine and allow the oil to fill the filter
and passages.
IB2O508P
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Maintenance Section
Engine Crankcase(Diesel)
IPMO040P
IC3O007P
3. Remove the crankcase drain plug and allow oil
to drain. Clean and install drain plug. 11. Start the engine and allow the oil to fill the filter
and passages.
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Maintenance Section
WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
IC3O008P contact skin.
13. Stop the engine and measure the oil level.
Maintain the oil level between the MAX. and
MIN. marks on dip stick. Park the lift truck level, with the forks lowered, park-
ing brake engaged, transmission in NEUTRAL and
14. Close hood and seat assembly. the engine stopped.
Normal
Oil gauge
Strainer
IPMO060I
- 96 -
Maintenance Section
3. Remove the filler cap. Fill the compartment with Drive Axle Oil - Change
oil. See ÒRefill CapacitiesÓ. Install the dip
stick/filler cap. Park the lift truck on a level surface. Apply the park-
ing brake. Place the directional control lever in
4. Start the engine. NEUTRAL and stop the engine.
10. Stop the engine. Install the floor plate. 2. Block the bottom of the mast with a block of wood
to hold the load backrest in the raised position.
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Maintenance Section
NOTE : Be sure area around the lift truck is clear of Park the lift truck on the level, with forks lowered,
personnel and obstructions. transmission in NEUTRAL and the engine stopped.
Test Operation
IB6OM10P
IB6OM09P
IB6OO10P
IB6OO10P
IPMO035P
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Maintenance Section
IB6OM09P
- 99 -
Maintenance Section
WARNING
Park the lift truck level with the forks lowered, park-
Hot oil and components can cause burns. Allow ing brake engaged, transmission in NEUTRAL and
additional time for the engine to cool before the engine stopped.
measuring valve clearance.
NOTICE
Measure the valve lash with the engine stopped.
To obtain an accurate measurement, allow at
least 20 minutes for the valves to cool the
engine cylinder head and block temperature.
- 100 -
Maintenance Section
IB6OM11P
- 101 -
Maintenance Section
IPMO039P
NOTICE
Lubricate chains more freequently than normal
in applications where the lift truck is operating
in a atmosphere which could cause corrosion
of components or when lift truck must work in
rapid lift cycles.
- 102 -
Maintenance Section
IB6OM17P
IB2O624P
Typical Example
1. Clean the top of the battery and terminals. Checking Ventilation Hoses
2. Check terminals for corrosion. Coat terminals 1. Check hoses and hose connections for leaks.
with heavy grease. 2. Check each hose for cracks or distortion.
3. Disconnect all hoses and blow them out with
compressed air.
Brake Oil Level - Check
IPMO047I
IB6OM13P
If any hose cannot be made free of obstructions,
replace with a new one.
- 103 -
Maintenance Section
Diesel Engines
With engine running at idle, remove ventilation
hose from P.C.V. valve ; if valve is working proper-
ly, a hissing noise will be heard as air passes
through it and a weak air pressure should be felt
immediately when a finger is placed over valve
inlet.
IPMO048I
IPMO047I
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Maintenance Section
Crank Pulley
IPMO048I
Typical Example
IB6OM18P
Typical Example
NOTICE
Failure to loosen the alternator mounting bolt(2)
will cause excessive stress and break the alter-
nator mounting ear.
IPMO053P
2. To adjust the alternator drive belt, loosen adjust- 1. Lubricate two fittings for the mast pivot eyes, one
ing bracket bolt(1) and mounting bolt(2). Move on each side of the mast.
the alternator in or out as required. Tighten
bolts(1) and (2). 2. Check the pivot eye pins for loose retainer bolts
and wear.
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Maintenance Section
IPMO051P
IPMO054P
Crosshead Roller - Inspect
1. Check to make sure the tilt cylinders extend and
retract evenly. 1. Operate the mast through a lift cycle. Watch the
chains move over the crosshead rollers. Make
2. If one cylinder continues to move after the other sure the chain is tracking over the rollers proper-
cylinder has stopped in full forward or backward ly.
tilt, an adjustment must be made to one cylinder.
Typical Example
- 106 -
Maintenance Section
1 2
IB6OM19P
- 107 -
Maintenance Section
Hydraulic Oil & Return Filter & 2. Remove the air breather from mounting brack-
Breather & Strainer - Check, et / connecting hose.
Clean, Change 3. Wash the breather in clean, nonflammable sol-
bent and dry it.
WARNING 4. Install the air breather.
Hot oil and components can cause personal
5. Loosen the bolts of the hydrulic tank top plate
injury. Do not allow hot oil or components to
assembly.
contact skin.
Park the lift truck level with the forks lowered, park-
ing brake engaged, transmission in NEUTRAL and
the engine stopped.
Filter Strainer
ILOM040P
14. Stop the engine and check the oil level. With all
cylinders retracted, maintain the oil level to the
FULL mark on the dip stick/filler cap assembly.
- 108 -
Maintenance Section
1
2
IPMO064P IPMO066P
1. Check the lift chains for wear. Complete instruc- 1. Loosen locknut(1) and turn nut(2), on the loose
tions on the use of the tool are furnished. chain to equalize tension on the lift chains.
2. Tighten locknut(1).
IPMO065P
- 109 -
Maintenance Section
- 110 -
Maintenance Section
IPMO069S
IPMO067P
IPMO070P
- 111 -
Maintenance Section
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 fill cap is cool
IPMO071P enough to touch with your bare hand.
9. Tighten the locknut to 135 N¥m (100 lb ft), while Remove the fill cap slowly to relieve pressure.
turning wheel hub to seat the bearing.
Cooling system conditioner contains alkali.
Avoid contact with the skin and eyes to prevent
10. Loosen the locknut. Retorque it to 50L5N¥m
personal injury.
(37L4 lb ft). Bend the lockwasher tang to
secure locknut. Use all cleaning solutions with care.
IB6OM16P
Typical Example
- 112 -
Maintenance Section
12. Close the drain valve and install the block drain
plug. Add coolant to the top of the filler neck.
Typical Example
IPMO074P
Typical Example
- 113 -
Maintenance Section
Forks - Inspect
B
C
A
IAOM094I IAOM095I
Forks should be inspected, at a minimum, every 12 2. Check the angle between the upper face of the
months. If the truck is being used in a muti-shift or blade and the front face of the shank. The fork
heavy duty operation, they should be checked should be withdrawn from service if angle (C)
every six months. exceeds 93 degrees or deviates by more than 3
degrees from an original angle other than 90
1. Inspect the forks carefully for carefully for cracks. degrees, as may be found in some special appli-
Special attention should be given to the heel sec- cation forks.
tion (A), all weld areas and mounting brackets
(B). Inspect the top and bottom hooks on forks
used on hook type carriages and tubes on shaft
mounted forks.
- 114 -
Maintenance Section
IAOM096I IAOM097I
3. Check the straightness of the upper face of blade 4. Check the difference in height of one fork tip to
(D) and the front face of shank (E) with a straight the other when mounted on the fork carrier. A dif-
edge. ference in fork tip height can result in uneven
support of the load and cause problems with
The fork should be withdrawn from service if the entering loads.
deviation from straightness exceeds 0.5 percent of
the length of the blade and/or the height of the The maximum recommended difference in fork tip
shank respectively 5 mm/1000 mm (0.18"/36"). elevation (F) is 6.5 mm (0.25") for pallet forks and 3
mm (0.125") for fully tapered forks. The maximum
allowable difference in fork tip elevation between
the two or more forks is 3 percent of blade length
(L).
- 115 -
Maintenance Section
IAOM098I IAOM099I
5. Check the fork blade (J) and shank (H) for wear 6. Check the fork mountings (K) for wear, crushing
with special attention to the heel (G). The fork and other local deformation, which can cause
should be withdrawn from service if the thickness excessive side to side wobble of the forks.
is reduced to 90 percent or less of the original Excessive clearance on hook type forks may
thickness. allow them to fall from the carrier. Forks which
show visible signs of such damage should be
Fork blade length may also be reduced by wear, removed from service.
especially on tapered forks and platens. Remove
the forks from service when the blade length is no 7. Check the positioning lock and other fork reten-
longer adequate for the intended loads. tion devices to make sure they are in place and
working.
- 116 -
Maintenance Section
IA3M4086
IA3M4086
IAOM100I
8. Check fork markings (N) for legibility. Renew 9. a. Lift the mast and operate the tilt control lever,
markings as required to retain legibility. until the top surface of the forks is parallel with
the floor. Place two straight bars that are the
same width as the carriage, accross the forks
as shown.
c. Put one fork, one third from the tip, under a fix-
ture that will not move. Then operate the tilt
control with caution until the rear of the truck
lifts just off the floor. Follow the same proce-
dure with the second fork. Repeat Step a.
- 117 -
Maintenance Section
IPMO072P
- 118 -
Environment Protection Section
ENVIRONMENT PROTECTION
When servicing this lift truck, use an authorized
servicing area and an approved container to col-
lect coolant, oil, fuel, grease, electrolyte and any
other potential environmental pollutant before any
lines, fittings or related items are disconnected or
removed. After servicing, dispose of those materi-
als in an authorized place and container. When
cleaning the lift truck, be sure to use an authorized
area.
- 119 -
Index Section
Index
A D
C F
- 120 -
Index Section
G M
I
O
Identification, Lift Capacity and Attachment Plate
Mast Abbreviations ........................................ 33 Operating Techniques ........................................ 59
Attachment Abbreviations ............................. 34 Operating the Lift Truck ..................................... 11
Ignition Timing (Gasoline, LP-Gas, Dual Fuel Operating in Hot Weather .................................. 62
Engine) - Check, Adjust ............................... 88 Operation ............................................................. 2
Important Safety Information ............................... 4 Operation Information......................................... 10
Inching ............................................................... 58 Operator Restraint System ( If Equipped ) ........ 16
Inching Into Loads .............................................. 59 Operator's Station and Monitoring Systems ...... 35
Inching Braking Pedal Control Shaft Operator's Warning Identification .......................33
- Lubricate .................................................... 107 Attachment Abbreviations .............................. 34
Inspection, Maintenance and Repair of Lift Truck Overhead Guard .............................................. 107
Forks .............................................................. 47 Inspect ......................................................... 107
L P
Lift Chains - Check/Adjust ................................ 109
Lift Truck Controls ........................................ 39,40 Parking Brake .................................................... 98
Lift Fork Adjustment ........................................... 47 Test, Adjust ................................................... 98
Lift Truck Operation ............................................57 Parking Brake Lever .......................................... 40
Lift Truck Parking ............................................... 12 Parking the Lift Truck ......................................... 63
Lift Truck Shipping ............................................. 65 PCV Valve System - Inspect, Clean ................. 103
Lifting Drums or Round Objects ........................ 62 Gasoline, LP-Gas Engines ..........................103
Lifting the Load .................................................. 59 Power Shift Transaxle ....................................... 57
Literature Information .......................................... 2 Plate for Function of Pedals ( If Equipped ) ....... 39
Loading or Unloading Trucks / Trailers............... 12 Pressure Air ....................................................... 13
Long Time Storage ............................................. 64 Prestart Conditions ............................................ 51
LP-Gas Engine .................................................. 52 Priming the Fuel System ( Diesel Engine ) ........ 80
Lubricant Specifications...................................... 74
Lubricant Viscosities and Refill Capacities ........ 76
- 121 -
Index Section
R U
Refill Capacities ................................................. 67 Unloading .......................................................... 60
Refueling ........................................................... 42
V
S
Vibration.............................................................. 28
Safety ............................................................... 2,5
Safety Section ..................................................... 3
Seat ................................................................... 38 W
Seat Adjustment ................................................ 17
Seat Belt ............................................................. 17 Walk-Around Inspection ............................... 45,92
Seat Hood Latch and Supply Cylinder Warning Signs and Labels ............................. 5,16
- Check, Lubricate ........................................... 82 Wheel Bolts and Nuts......................................... 89
Serial Number Locations .................................. 32 Inspect Tightness .......................................... 89
Service Brake Pedal .......................................... 40 When Required .................................................. 78
Sideshift Attachment (If Equipped) .................... 41
Spark Plugs (Gasoline, LP-Gas, Dual Fuel
Engines) - Check .......................................... 87
Specifications...................................................... 26
Starting From a 12 Volt External Source ........... 53
Starting the Lift Truck.......................................... 11
Starting the Engine ............................................ 51
Steer Wheel Bearings - Repack ....................... 111
Steering Mechanism - Check, Lubricate .......... 102
Storage Information ........................................... 64
- 122 -