Doosan D20S-3, D25S-3, D30S-3, D33S-3, G25E-3 User Manual

...

Operation & Maintenance Manual

LIFT TRUCKS D20S-3, D25S-3, D30S-3, D33S-3 G20E-3, G25E-3, G30E-3 GC20E-3, GC25E-3, GC30E-3 G20P-3, G25P-3, G30P-3, G33P-3 GC20P-3, GC25P-3, GC30P-3 D32S-3 (6,500lb@24"L.C.) G32E-3 (6,500lb@24"L.C.) G32P-3 (6,500lb@24"L.C.) GC32E-3 (6,500lb@24"L.C.) GC32P-3 (6,500lb@24"L.C.)

SB2302E06

WARNING

Do not start, operate or service this machine unless you have read and understood 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.

Table of Contents

Information Section

Foreword................................................................ 2

Literature Information............................................. 2

Safety Section

Important Safety Information ................................. 4

Safety..................................................................... 5

Warning Signs and Labels.................................. 5

Parking brake...................................................... 9

General Hazard Information ............................. 10

Operation Information....................................... 11

Maintenance Information.................................. 14

Operator Restraint System(If Equipped) ..........17

Avoiding Lift Truck Tipover ............................... 21

Safety Rules ..................................................... 23

How to Survive in a Tipover.............................. 28

General Section

Specifications....................................................... 30

Noise and Vibration ............................................. 50

Capacity Chart ..................................................... 51

Serial Number...................................................... 61

Operator's Warning and Identification Plate........ 64

Operation Section

Operator's Station and Monitoring Systems ........ 65

Lift Truck Controls................................................ 69

Refueling.............................................................. 72

Before Starting the Engine................................... 75

Starting the Engine .............................................. 78

Dual Fuel System (If G424 Dual Fuel Engine

Equipped) ............................................................ 81

Dual Fuel System (G424E Engine Only)............. 83

Lift Truck Operation ............................................. 86

G424E/G430E Electronic Controlled LP Engines

(If Equipped) ........................................................ 89

Advanced Diagnostics ....................................... 104

Table a. MI-04 Diagnostic Fault Codes (Flash

Codes) ...............................................................106

Auto Shift Controller ASC-100 (If Equipped) ..... 112

Operating Techniques........................................ 115

Parking the Lift Truck......................................... 119

Lift Fork Adjustment........................................... 120

Storage Information ........................................... 121

Transportation Hints........................................... 122

Towing Information............................................. 123

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck

Forks ..................................................................124

Tire Inflation Information.....................................128

Torque Specifications .........................................129

Cooling System Specifications...........................131

Fuel Specifications .............................................133

Lubricant Information .........................................135

Lubricant Viscosities and Refill Capacities.........137

Maintenance Intervals ........................................138

When Required ..................................................142

Every 10 Service Hours or Daily ........................152

First 50 - 100 Service Hours or a Week.............157

First 250 Service Hours or a Month ...................162

Every 250 Service Hours or Monthly..................163

Every 500 Service Hours or 3 Months ...............170

Every 1000 Service Hours or 6 Months .............179

Every 1500 Service Hours or 9 Months .............185

Every 2000 Service Hours or Yearly ..................188

Every 2500 Service Hours or 15 Months ...........195

Every 3000 Service Hours or 18 Months ...........198

Every 4500 Service Hours or two Years ............199

Index Section

Index...................................................................200

-1-

Information Section

Foreword

Literature Information

This manual should be stored in the operator’s compartment in the literature holder or seat back

literature storage area.

This manual contains safety, operation, transportation, lubrication and maintenance information.

Some photographs or illustrations in this publication show details or attachments that can be different from your lift truck. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your lift truck which are not included in this publication. Read, study and keep this manual with the lift truck.

Whenever a question arises regarding your lift truck, or this publication, please consult your DAEWOO dealer for the latest available information.

Safety

The Safety Section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs and labels used on the lift truck. Read and understand the basic precautions listed in the Safety Section before operating or performing lubrication, maintenance and repair on this lift truck.

Operator Restraint System (If Equipped)

This manual contains safety, operation and maintenance information for the DAEWOO operator restraint system. Read, study and keep it handy.

WARNING

Your DAEWOO truck comes equipped with an operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DAEWOO operator restraint system.

Photographs or illustrations guide the operator through correct procedures of checking, operation and maintenance of the DAEWOO operator restraint system.

SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness on the part of the operator. To develop this skill the operator should read and understand the Safe Driving Practices contained in this manual.

Forklift trucks seldom tipover, but in the rare event they do, the operator may be pinned to the ground by the lift truck or the overhead guard. This could result in serious injury or death.

Operator training and safety awareness is an effective way to prevent accidents, but accidents can still happen. The DAEWOO operator restraint system can minimize injuries. The DAEWOO operator restraint system keeps the operator substantially within the confines of the operator’s compartment and the overhead guard.

This manual contains information necessary for Safe Operation. Before operating a lift truck, make sure that the necessary instructions are available and understood.

Operation

The Operation Section is a reference for the new operator and a refresher for the experienced one. This section includes a discussion of gauges, switches, lift truck controls, attachment controls, transportation and towing information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the lift truck. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the lift truck and its capabilities.

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Information Section

Maintenance

The Maintenance Section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by servicing intervals. Items without specific intervals are listed under “When Required” topics. Items in the “Maintenance Intervals” chart are referenced to detailed instructions that follow.

Maintenance Intervals

Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.

Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the “Maintenance Intervals” chart might be necessary.

Perform service on items at multiples of the original requirement. For example, at “Every 500 Service Hours or 3 Months”, also service those items listed under “Every 250 Service Hours or Monthly” and “Every 10 Service Hours or Daily”.

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

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, 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.

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.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as shown below.

WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.

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

The safety rules and regulations in this section are representative of some, but not all rules and regulations noted under the Occupational Safety and Health Act (OSHA) and are paraphrased without representation that the OSHA rules and regulations have been reproduced verbatim.

Please refer to 1910. 178 in Federal Register Vol. 37, No. 202, the National Fire Protection Association No. 505 (NFPA), American National Standard, ANSI B56. 1 Safety Standard for Low lift and High Lift Trucks and subsequent revisions for a complete list of OSHA rules and regulations as to the safe operation of powered industrial lift trucks. Since regulations vary from country to country outside in U.S.A., operate this lift truck in accordance with local regulations.

DAEWOO lift trucks are manufactured according to the regulations and standards laid down in EU Machinery Directive 98/37/EC and EMC directive 89/336/EC. Please refer to the Directives 89/655/EC and 89/391/EC and its amendments for the safe use of DAEWOO lift trucks.

The most effective method of preventing serious injury or death to the lift truck operator or others is for the lift truck operator to be familiar with the proper operation of the lift truck, to be alert and to avoid actions or conditions which can result in an accident.

Do not operate a lift truck if in need of repair, defective or in any way unsafe. Report all defects and unsafe conditions immediately. Do not attempt any adjustments or repairs unless trained and authorized to do so.

Safety Section

Warning Signs and Labels

There are several specific safety signs on your lift truck. Their exact location and description of the hazard are reviewed in this section. Please take the time to familiarize yourself with these safety signs. Make sure that you can read all warning and instruction labels. Clean or replace these labels if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, gasoline, etc. You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part. See your dealer for new labels.

Traing Required To Operate or Service Warning

Located on the right side of the steering wheel.

WARNING

Improper operation or maintenance could result in injury or death. Do not operate or work on the lift truck unless you are properly trained. Read and understand the Operation and Maintenance Manual. Additional manuals are available from DAEWOO Lift Truck dealers.

This label also provides allowable lift truck capacity information

-5-

Safety Section

General Warning to Operator

Located on the right side of the operator's seat (STD).

Located on the overhead guard (If Convenience Package Equipped).

WARNING

Only trained and authorized personnel may operate this machine. For safe operation, read and follow the operation and maintenance Manual furnished with this lift truck and observe the following warnings:

1. Before starting machine. Check all controls and

warning devices for proper operation.

2. Refer to machine identification plate for

allowable machine capacity. Do not overload. Operate machines equipped with attachments as partially loaded machines when not handling a load.

3. Put directional control or shift lever in neutral

before “ON - OFF” switch is turned on.

4. Start, turn and brake smoothly. Slow down for

turns, slippery or uneven surfaces. Extremely poor surfaces should be repaired. Avoid running over loose objects or holes in the roadway surfaces. Use extreme caution when turning on inclines.

5. Travel with load as low as possible and tilted

back. If load interferes with visibility, travel with load trailing.

6. On grade operations travel with load up grade.

7. Watch out for pedestrians and obstructions.

Check overhead clearances.

8. Do not permit riders on forks or machine at any

time.

9. Do not allow anyone to stand or pass under the

elevated portion of any machine.

10. Be sure operating surface can safely support

machine.

11. Operate machine and attachments only from

operator's position.

12. Do not handle unstable or loosely stacked

loads.

13. Use minimum tilt when picking up or depositing

a load.

14. Use extreme care when handling long, high, or

wide loads.

15. Forks should be completely under load and

spread apart as far as load permits.

16. Machine should be equipped with overhead

guard or equivalent protection. Where load requires it, use a load backrest extension. Use extreme caution if operating without these devices.

17. Parking - Lower lifting mechanism to floor. Put

directional control or shift lever in neutral. Set parking/secondary brake. Turn “ON - OFF” switch off. Chock wheels if machine is on incline. Disconnect battery when storing electric machines.

18. Observe safety rules when handling fuel for

engine powered machine and when changing batteries for electric machines.

-6-

Safety Section

Pressure Warning

WARNING

Contents under pressure may be hot. Allow to cool before opening.

Located on the radiator top tank by the radiator cap.

Hand Placement Warning

WARNING

No Standing On Fork Warning No Standing Under Fork Warning

WARNING

Do not stand or ride on the forks. Do not stand or ride on a load or pallet on the forks. Do not stand or walk under the forks.

Located on the lift cylinder.

Load Backrest Must Be In Place Warning

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.

Located on the mast.

WARNING

Operation without this device in place may be hazardous.

Located on the load backrest.

-7-

Safety Section

Overhead Guard Must Be In Place Warning

WARNING

Operation without this device in place may be hazardous. This guard conforms to A.N.S.I.B56.1 and F.E.M.Section IV. This design has been tested with an impact of appropriate valve.

Located on the Overhead Guard.

No Riders Warning

Moving Fan Warning

WARNING

To avoid personal injury, stay clear of moving fan.

Located inside the engine compartment cover.

WARNING

To avoid personal injury, allow no riders. A lift truck is designed for only one operator and no riders.

Located beside the operator's station (STD) or on front of the hood (Convenience Package).

-8-

Safety Section

Parking brake

Pull the lever BACK to engage the parking brake.

Push the lever FORWARD to release the parking brake.

Applying the parking brake puts the transmission in NEUTRAL. The parking brake must be applied when leaving the lift truck and when starting the engine. If the operator leaves the seat without applying the parking brake, an audible alarm will sound.

WARNING

When leaving machine apply parking brake! Parking brake is not automatically applied. Alarm will sound if parking brake is not applied.

WARNING

Correct adjustment is necessary to provide adequate braking. See the MAINTENANCE section for adjustment procedures. The lift truck may creep at engine idle and can cause damage, injury or death. Always apply the parking brake when leaving the lift truck. The parking brake is NOT automatically applied.

-9-

Safety Section

General Hazard Information

Attach a “Do Not Operate” or similar warning tag to start switch or controls before servicing or repairing the lift truck.

Do not start or service the lift truck when a “DO NOT OPERATE” or similar warning tag is attached to the start switch or controls.

Wear a hard hat, protective glasses and other protective equipment as required by job conditions.

Know the width of your attachments so proper clearance can be maintained when operating near fences, boundary obstacles, etc.

Do not wear loose clothing or jewelry that can catch on controls or other parts of the lift truck.

Keep the lift truck, especially the deck and steps, free of foreign material such as debris, oil tools and other items which are not part of the lift truck.

Secure all loose items such as lunch boxes, tools and other items which are not part of the lift truck.

Know the appropriate work-site hand signals and who gives them. Accept signals from one person only.

Always use the overhead guard. The overhead guard is intended to protect the lift truck operator from overhead obstructions and from falling objects.

A truck that is used for handing small objects or uneven loads must be fitted with a load backrest.

If the lift truck must be operated without the overhead guard in place due to low overhead clearance, use extreme care. Make sure there is no possibility of falling objects from any adjacent storage or work area. Make sure the load is stable and fully supported by the carriage and the load backrest extension (if equipped).

Do not raise loads any higher than necessary and never raise a load higher than 1830 mm (72 in) with the overhead guard removed.

Always use load backrest extension when the carriage or attachment does not fully support the load. The load backrest extension is intended to prevent the load or any part of the load from falling backwards into the operator's station.

When operating the lift truck, do not depend only on flashing lights or back-up alarm (if equipped) to warn pedestrians.

Always be aware of pedestrians and do not proceed until the pedestrians are aware of your presence and intended actions and have moved clear of the lift truck and/or load.

Do not drive lift truck up to anyone standing in front of an object.

Obey all traffic rules and warning signs.

Keep hands, feet and head inside the operator 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.

Do not allow unauthorized personnel to ride on the forks or any other part of the lift truck, at any time.

When working in a building or dock, observe floor load limits and overhead clearances.

-10-

Safety Section

Inhaling Freon gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting Freon can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever Freon gas may be present.

Never put maintenance fluids into glass containers. Use all cleaning solutions with care.

Do not use steam, solvent, or high pressure to clean electrical components.

Report all needed repairs.

Inspect the part of the chain that is normally operated over the crosshead roller. When the chain bends over the roller, the movement of the parts against each other causes wears.

Inspect to be sure that chain link pins do not extend outside of the bore hole.

If any single link pin is extended beyond its connecting corresponding link, it should be suspected of being broken inside of its bore hole.

Inspect the chain anchor and the anchor links for wear.

Do not change any factory set adjustment values (including engine rpm setting) unless you have both authorization and training. Especially Safety equipment and switches may not be removed or adjusted incorrectly. Repairs, adjustments and maintenances that are not correct can make a dangerous operating condition.

For any checkup, repair, adjustments, maintenance and all other work concerning your forklift truck, please contact your DAEWOO dealer. We would like to draw your attention to the fact that any secondary damages due to improper handling, insufficient maintenance, wrong repairs or the use of other than original DAEWOO spare parts waive any liability by DAEWOO.

Operation Information

Mounting and Dismounting

Mount and dismount the lift truck carefully.

Clean your shoes and wipe your hands before mounting.

Use both hands and face the lift truck when mounting and dismounting.

Use the handgrips for mounting and dismounting.

Do not try to climb on or off the lift truck when carrying tools or supplies.

Do not use any controls as handholds when entering or leaving the operator's station.

Never get on or off a moving lift truck. Never jump off the lift truck.

Keep hands and steering wheel free of slippery material.

Before Starting the Lift Truck

Perform a walk-around inspection daily and at the start of each shift. Refer to the topic “Walk-around Inspection” in “Every 10 Service Hours or Daily” section of this manual.

Adjust the seat so that full brake pedal travel can be obtained with the operator's back against the seat back.

Make sure the lift truck is equipped with a lighting system as required by conditions.

Make sure all hydraulic controls are in the HOLD position.

Make sure the direction control lever is in the NEUTRAL position.

Make sure the parking brake is engaged.

Make sure no one is standing and/or working on, underneath or close to the lift truck before operating the lift truck.

Operate the lift truck and controls only from the operator's station.

-11-

Safety Section

Make sure the lift truck horn, lights, backup alarm (if equipped) and all other devices are working properly.

Check for proper operation of mast and attachments. Pay particular attention to unusual noises or erratic movement which might indicate a problem.

Make sure service and parking brakes, steering, and directional controls are operational.

Make sure all personnel are clear of lift truck and travel path.

Refer to the topic “Lift Truck Operation” in the “Operation Section” of this manual for specific starting instructions.

Starting the Lift truck

Operating the Lift Truck

Always keep the lift truck under control.

Obey all traffic rules and warning signs.

Never leave the lift truck with the engine operating, or with the parking brake disengaged.

Operate the engine only in a well ventilated area.

Lower a mast, with or without load, before turning or traveling. Tip over could result. Watch out for overhead obstructions.

Always observe floor load limits and overhead clearance.

Start, turn, and brake smoothly. Slow down for turns, grades, slippery or uneven surfaces.

Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” or similar warning tag attached to the start switch or controls.

Before Operating the Lift Truck

Test brakes, steering controls, horn and other devices for proper operation. Report any faulty performance. Do not operate lift truck until repaired.

Learn how your lift truck operates. Know its safety devices. Know how the attachments work. Before moving the lift truck, look around. Start, turn and brake smoothly.

An operator must constantly observe his lift truck for proper operation.

Use special care when operating on grades. Do not angle across or turn on grades. Do not use lift truck on slippery grades. Travel with forks downgrade when unloaded. Travel with load upgrade.

Do not overload, or handle offset, unstable, or loosely stacked loads. Refer to load capacity plate on the lift truck. Use extreme caution when handling suspended, long, high or wide load.

-12-

Tilt the elevated load forward only when directly over unloading area and with load as low as possible.

Do not stunt ride or indulge in horseplay.

Always look and keep a clear view of the path of travel.

Travel in reverse if load or attachment obstructs visibility. Use extreme caution if visibility is obstructed.

Stay in designated travel path, clear of dock edges, ditches, other drop-offs and surfaces which cannot safely support the lift truck.

Slow down and use extra care through doorways, intersections and other location where visibility is reduced.

Slow down for cross aisles, turns, ramps, dips, uneven or slippery surfaces and in congested areas, avoid pedestrians, other vehicles, obstruction, pot holes and other hazards or objects in the path of travel.

Always use overhead guards except where operation conditions do not permit. Do not operate lift truck in high stacking areas without overhead guards.

When stacking, watch for falling objects. Use load backrest extension and overhead guard.

Refer to the topic “Operation Techniques” in the “Operation Section” of this manual.

Safety Section

Loading or Unloading Trucks/Trailers

Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose. Be certain truck or trailer brakes are applied and wheel chocks in place (or be certain unit is locked to the loading dock) before entering onto trucks or trailers.

If trailer is not coupled to tractor, make sure the trailer landing gear is properly secured in place. On some trailers, extra supports may be needed to prevent upending or corner dipping.

Be certain dock plates are in good condition and properly placed and secured. Do not exceed the rated capacity of dock boards or bridge plates.

Lift Truck Parking

When leaving the operator station, park the lift truck in authorized areas only. Do not block traffic.

z Park the lift truck level, with the forks lowered and

the mast tilted forward until the fork tips touch the floor.

z Move the direction control lever to NEUTRAL.

z Engage the parking brake.

z Turn the key switch off and remove the key.

z Turn the disconnect switch to OFF (if equipped).

z Block the drive wheels when parking on an

incline.

-13-

Safety Section

Maintenance Information

Perform all maintenance unless otherwise specified as follows:

z Park the lift truck in authorized areas only. z Park the lift truck level, with the forks lowered and

the mast tilted forward until the fork tips touch the floor.

z Place the transmission controls in neutral. z Engage the parking brake. z Stop the engine. z Remove the start switch key and turn the

disconnect switch OFF (if equipped).

z Block the drive wheels when parking on an

incline.

Pressure Air

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.

The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

Fluid Penetration

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury immediately.

Crushing or Cutting Prevention

Support equipment and attachments properly when working beneath them. Do not depend on hydraulic cylinders to hold it up. Any attachment can fall if a control is moved, or if a hydraulic line breaks.

Never attempt adjustments while the lift truck is moving or the engine is running unless otherwise specified.

Where there are attachment linkages, the clearance in the linkage area will increase or decrease with movement of the attachment.

Stay clear of all rotating and moving parts.

Keep objects away from moving fan blades.

They will throw or cut any object or tool that falls or is pushed into them.

Do not use a kinked or frayed wire rope cable. Wear gloves when handling the wire rope cable.

Retainer pins, when struck with force, can fly out and injure nearby persons. Make sure the area is clear of people when driving retainer pins.

Wear protective glasses when striking a retainer pin to avoid injury to your eyes.

Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying debris before striking any object.

Falling Objects Protective Structure (FOPS)

This is an attached guard located above the operator's compartment and secured to the lift truck.

To avoid possible weakening of the Falling Objects Protective Structure (FOPS), consult a DAEWOO dealer before altering, by adding weight to, welding on, or cutting or drilling holes into the structure.

The overhead guard is not intended to protect against every possible impact. The overhead guard may not protect against some objects penetrating into the operator's station from the sides or ends of the lift truck.

The lift truck is equipped with an overhead guard and FOPS as standard. If there is a possibility of overhead objects falling through the guard, the guard must be equipped with smaller holes or a Plexiglas cover.

Any altering done that is not specifically authorized by DAEWOO invalidates DAEWOO's FOPS certification. The protection offered by this FOPS will be impaired if it has been subjected to structural damage. Structural damage can be caused by an overturn accident, by falling objects, etc.

Do not mount any item such as fire extinguishers, first aid kits and lights by welding brackets to or drilling holes in any FOPS structure. See your DAEWOO dealer for mounting guidelines.

-14-

Safety Section

Burn Prevention

Coolant

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns.

Steam can cause personal injury.

Check the coolant level only after engine has been stopped and the filter cap is cool enough to remove with your bare hand.

Remove the cooling system filter cap slowly to relieve pressure.

Cooling system additive contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink.

Allow cooling system components to cool before draining.

Oils

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.

At operation temperature, the hydraulic tank is hot and can be under pressure.

Remove the hydraulic tank filter cap only after the engine has been stopped and the filter cap is cool enough to remove with your bare hand.

Remove the hydraulic tank filter cap slowly to relieve pressure.

Relieve all pressure in air, oil fuel or cooling systems before any lines, fittings or related items are disconnected or removed.

Batteries

Batteries give off flammable fumes which can explode.

Do not smoke when observing the battery electrolyte levels.

Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.

Always wear protective glasses when working with batteries.

Fire or Explosion Prevention

All fuels, most lubricants and some coolant mixtures are flammable.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Do not smoke while refueling or in a refueling area.

Do not smoke in areas where batteries are charged, or where flammable materials are stored.

Batteries in series can be located in separate compartments. When using jumper cables always connect positive(+) cable to positive(+) terminal of battery connected to starter solenoid and negative(-) cable from external source to starter negative(-) terminal. (If not equipped with starter negative(-) terminal, connect to engine block.)

See the Operation Section of this manual for specific starting instructions.

Clean and tighten all electrical connections. Check daily for loose or frayed electrical wires. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the lift truck.

Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.

Store all oily rags or other flammable material in a protective container, in a safe place.

Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.

Remove all flammable materials such as fuel, oil and other debris before they accumulate on the lift truck.

Do not expose the lift truck to flames, burning brush, etc., if at all possible.

Shields, which protect hot exhaust components from oil or fuel spray in the event of a line, tube or seal failure, must be installed correctly.

Do not operate in areas where explosive gases exist or are suspected.

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Safety Section

Fire Extinguisher

Have a fire extinguisher-type BC and 1.5KG minimum capacity-on rear overhead guard leg with latch and know how to use it. Inspect and have it serviced as recommended on its instruction plate.

Ether

Ether is poisonous and flammable.

Breathing ether vapors or repeated contact of ether with skin can cause personal injury.

Use ether only in well-ventilated areas. Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in living areas or in the operator's compartment.

Do not store ether cylinders in direct sunlight or at temperatures above 39°C (102°F).

Discard cylinders in a safe place. Do not puncture or burn cylinders.

Keep ether cylinders out of the reach of unauthorized personnel.

Lines, Tubes and Hoses

z End fittings damaged or leaking. z Outer covering chafed or cut and wire reinforcing

exposed.

z Outer covering ballooning locally. z Evidence of kinking or crushing of the flexible

part of hose.

z Armoring embedded in the outer cover. z End fittings displaced.

Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration, rubbing against other parts, and excessive heat during

operation.

Tire Information

Explosions of air-inflated tires have resulted from heat-induced gas combustion inside the tires. The heat, generated by welding or heating rim components, external fire, or excessive use of brakes can cause gaseous combustion.

A tire explosion is much more violent than a blowout. The explosion can propel the tire, rim and axle components as far as 500 m (1500 ft) or more from the lift truck. Both the force of the explosion and the flying debris can cause personal injury or death, and property damage.

Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses.

Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your DAEWOO dealer for repair or replacement.

Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. See Fluid Penetration in the Safety Section for more details. Tighten all connections to the recommended torque. Replace if any of the following conditions are found.

Do not approach a warm tire closer than the outside of the area represented by the shaded area in the above drawing.

-16-

Safety Section

Dry nitrogen (N2) gas is recommended for inflation of tires. If the tires were originally inflated with air, nitrogen is still preferred for adjusting the pressure. Nitrogen mixes properly with air.

Nitrogen inflated tires reduce the potential of a tire explosion, because nitrogen does not support combustion. Also, nitrogen helps prevent oxidation and the resulting deterioration of rubber and corrosion of rim components.

Proper nitrogen inflation equipment and training in its use are necessary to avoid over-inflation. A tire blowout or rim failure can result from improper or misused equipment.

Stand behind the tread and use a self-attaching chuck when inflation a tire.

Servicing, changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious personal injury or death. Follow carefully the specific information provided by your tire or rim servicing personnel or dealer.

Operator Restraint System(If Equipped)

Warning Signs and Labels

Your DAEWOO lift truck has the following tipover warning decals.

Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, gasoline, etc. You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part. See you DAEWOO Lift Truck dealer for new labels. The most effective method of preventing serious injury or death to yourself or others is to familiarize yourself with the proper operation of the lift truck, to be alert, and to avoid actions or conditions which can result in an accident.

WARNING

Tipover can occur if the truck is improperly operated. In the event of tipover, injury or death could result.

-17-

Safety Section

The “Survive in tipover” warning is located on the overhead guard. It shows the proper use of the operator restraint system.

Seat Adjustment

WARNING

Do NOT place your hand or fingers under the seat. Injury may occur as the seat suspension mechanism moves up and down.

NOTICE

Before getting on the truck, adjust the level of the suspension using the grip in the rear of the seat.

Move the lever, slide the seat to the desired position, and release the lever. Adjust the seat before operating the lift truck. After adjusting, set the seat to make sure it is properly locked. DO NOT adjust the seat while the truck is in motion.

WARNING

When raising and lowering the seat backrest, avoid placing hand or fingers in the hinge area indicated by the circle. Injury may occur.

-18-

Safety Section

If Optional Suspension Seat (weight adjusting type) Equipped

Seat Belt

The Operator Restraint System, Prevents the operator from jumping from the operator’s compartment in the event of a forward or side tipover. The system is designed to keep the operator on the seat and in the operator’s compartment in the event of a tipover.

Inspection

1. If the seat belt is torn, if pulling motion is

interrupted during extension of the belt, or if the belt cannot be inserted into the buckle properly, replace the seat belt assembly.

2. Belt Maintenance - Every 500 service hours.

Check that the belt fastening works properly and that winding device is free from run lock when jerked. Check that the belt is suitably fastened to the seat. Check that the seat is correctly secured to the hood and the chassis. On visual inspection, fastenings must be intact, otherwise, contact the safety manager.

WARNING

Your DAEWOO truck comes equipped with a DAEWOO operator restraint system. Should it become necessary to replace the seat for any reason, it should only be replaced with another DAEWOO operator restraint system.

-19-

Safety Section

3. In the event of a tipover, the seat and restraint

system should be inspected for damage and replaced, if necessary.

NOTE: Operator restraints shall be examined at

the regular truck service intervals. It is recommended that they be replaced if any of the following conditions are found:

Cut or frayed strap Worn or damaged hardware including anchor points Buckle or retractor malfunction

z Loosen stitching

WARNING

The seat belt may cause the operator to bend at the waist. If you are pregnant or have suffered from some abdominal disease, consult a doctor before you use the seat belt.

Fasten the Seat Belt

4. Be sure to fasten the belt across your hips, not

across your abdomen.

NOTE: The belt is designed to automatically adjust

to your size and movement. A quick pull on the belt will confirm that the automatic adjuster will hold the belt position in the event of an accident.

Release the Seat Belt

Push the button of the buckle to release the belt. The belt will automatically retract when released. Hold the plate of the belt and allow the belt to slowly retract.

1. Grip the plate (connector) of the belt and pull the

belt from the retractor. Then insert the plate into the slot of the buckle until a snap is heard. Pull on the belt to confirm it is latched.

2. Make sure the belt is not twisted.

WARNING

If you fasten the belt across your abdomen, the belt may injure your abdomen in an accident.

-20-

Safety Section

Avoiding Lift Truck Tipover

Lift Truck Stability

Counterbalanced lift truck design is based on the balance of two weights on opposite sides of a fulcrum (the front axle). The load on the forks must be balanced by the weight of the lift truck. The location of the center of gravity of both the truck and the load is also a factor. This basic principle is used for picking up a load. The ability of the lift truck to handle a load is discussed in terms of center of gravity and both forward and sideways stability.

Center of Gravity (CG)

Stability and Center of Gravity

The stability of the lift truck is determined by the location of its CG; or, if the truck is loaded, the combined CG of the truck and load. The lift truck has moving parts and, therefore, has a CG that moves. The CG moves forward or backward as the mast is tilted forward or backward. The CG moves up or down as the mast moves up or down. The CG and, therefore, the stability of the loaded lift truck, are affected by a number of factors such as:

z the size, weight, shape and position of the load

z the height to which the load is lifted

z the amount of forward or backward tilt

z tire pressure

z dynamic forces created when the lift truck is

accelerated, braked or turned

z condition and grade of surfaces on which the lift

truck is operated

The point within an object, at which the whole weight of the object may be regarded as being concentrated, is called the center of gravity or CG. If the object is uniform, its geometric center will coincide with its CG. If it is not uniform, the CG could be at a point outside of the object. When the lift truck picks up a load, the truck and load have a new combined CG.

These same factors are also important for unloaded lift trucks. They tip over sideways easier than a loaded lift truck carrying its load in the lowered position.

-21-

Safety Section

Lift Truck Stability Base

For the lift truck to be stable (not tip over forward or to the side), the CG must stay within the area of the lift truck stability base – a triangular area between the front wheels and the pivot of the steer wheels. If the CG moves forward of the front axle, the lift truck will tip forward. If the CG moves outside of the line on either side of the stability base, the lift truck will tip to the side.

WARNING

Dynamic forces (braking, acceleration, turning) also affect stability and can produce tipover even when the CG is within the stability triangle.

mast, and having no special-purpose attachment. In addition, the capacity load assumes that the load center is no further from the top of the forks than it is from the face of the backrest. If these conditions do not exist, the operator may have to reduce the safe operating load because the truck stability may be reduced. The lift truck should not be operated if its capacity/nameplate does not indicate capacity load.

NOTE: If the load is not uniform, the heaviest

portion should be placed closer to the backrest and centered on the forks.

NOTICE

1. Capacity/Nameplates originally attached to

forklifts sold by DAEWOO shall not be removed, altered or replaced without DAEWOO’s approval.

2. DAEWOO assumes no responsibility for lift

trucks placed in service without a valid DAEWOO Nameplate.

3. If necessary to change your specification, contact

your DAEWOO lift truck dealer.

Capacity Load (Weight and Load Center)

The capacity load of the lift truck is shown on the capacity/nameplate riveted to the truck. It is determined by the weight and load center. The load center is determined by the location of the CG of the load.

The load center shown on the nameplate is the 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. Remember that, unless otherwise indicated, the capacity load shown on the nameplate is for a standard lift truck with standard backrest, forks and

-22-

Safety Rules

Only properly trained and authorized personnel should operate forklift trucks. Wear a hard hat and safety shoes when operating a lift truck. Do not wear loose clothing.

Safety Section

Do not operate a lift truck unless you are in the operator's seat. Keep arms, legs and head inside the confines of the operator's area. Keep hands and feet out of the mast assembly.

Inspect and check the condition of your forklift truck using the operator's check list before starting work. Immediately report to your supervisor any obvious defects or required repairs.

Do not operate your truck in unauthorized areas. Know your forklift truck and think safety. Do not compromise safety. Follow all safety rules and read all warning signs.

Do not start, stop, turn or change direction suddenly or at high speed. Sudden movement can cause the lift truck to tip over. Slow the speed of your truck and use the horn near corners, exits, entrances, and near people.

Never operate a lift truck with wet hands or shoes. Never hold any controls with grease on your hands. Your hands or feet will slide off of the controls and cause an accident.

-23-

Safety Section

Do not raise anyone on the forks of your lift truck unless using an approved safety cage. Do not let other people ride on the truck. Lift trucks are designed to carry loads, not people.

Do not operate your truck without the load backrest extension and overhead guard. Keep the load against the backrest with the mast tilted backward

Do not overload. Always handle loads within the rated capacity shown on the capacity plate. Do not add extra counterweight to the truck. An overload can cause the truck to roll over and cause injury to personnel and damage to the lift truck.

Do not drive on soft ground. Observe all signs, especially those on maximum permitted floor loadings, elevator capacities and clearance heights. Handle loads carefully and check them closely for stability and balance.

Do not lift or move loads that are not safe. Do not pick up an off center load. Such a load increases the possibility of a tipover to the side. Make sure loads are correctly stacked and positioned across both forks. Always use the proper size pallet. Position the forks as wide as possible under the load. Position loads evenly on the forks for proper balance. Do not lift a load with one fork.

Do not drive on slippery surfaces. Sand, gravel, ice or mud can cause a tipover. If unavoidable, slow down.

-24-

Safety Section

Do not permit anyone to stand or walk under the load or lifting mechanism. The load can fall and cause injury or death to anyone standing below.

Look out for overhead obstructions when raising or stacking loads. Do not travel with a raised load. Do not travel with the mast raised. The lift truck can roll over and cause injury or death to you or other personnel.

Do not elevate the load with the mast tilted forward. Do not tilt the elevated loads forwards. This will cause the lift truck to tip over forward.

Do not jump off if your truck starts to tip over. Stay in your seat to survive.

Do not move loose loads that are higher than the load backrest. Be alert for falling loads when stacking. Travel with the load tilted back and the forks as low as possible. This will increase stability to the truck and load and permit better visibility for you.

Go up ramps in forward direction and down ramps in reverse direction when moving loads. Never elevate a load with the forklift truck on an incline. Go straight off and straight down. Use an assistant when going up or down a ramp with a bulky load.

-25-

Safety Section

Do not stack or turn on ramps. Do not attempt to pick-up or deposit a load unless the lift truck is level. Do not turn on or drive across an incline.

Do not go over rough terrain. If unavoidable, slow down. Cross railroad tracks slowly and diagonally whenever possible. A railroad crossing can give a loaded forklift truck a real jolt. For smoother crossing, cross the railroad diagonally so one wheel crosses at a time.

Do not drive in forward direction when loads restrict your visibility. Operate your lift truck in reverse to improve visibility except when moving up a ramp.

Be careful when operating a lift truck near the edge of a loading dock or ramp. Maintain a safe distance from the edge of docks, ramps and platforms. Always watch tail swing. The truck can fall over the edge and cause injury or death.

Avoid running over loose objects. Look in the direction of travel. Look out for other persons or obstructions in your path of travel. An operator must be in full control of his lift truck at all times.

Do not operate on bridge plates unless they can support the weight of the truck and load. Make sure that they are correctly positioned. Put blocks on the vehicle you enter to keep it from moving.

-26-

Safety Section

Do not operate your truck close to another truck. Always keep a safe distance from other trucks and make sure there is enough distance to stop safely. Never overtake other vehicles.

Do not use your lift truck to push or tow another truck. Do not let another push or tow your truck. If a truck will not move, call a service technician.

Park your lift truck in authorized areas only. Fully lower the forks to the floor, put direction lever in NEUTRAL position, engage the parking brake, and turn the key to the OFF position. Remove the key and put blocks behind the wheels to prevent the truck from rolling. Shut off your forklift truck when leaving it unattended. Check the condition of your forklift truck after the day's work.

Forklift trucks may only be refueled at specially reserved locations. Switch off the engine when refueling. Smoking and handling of naked flames during refueling are strictly prohibited. This prohibition also applies during the changing of the LPG (liquefied propane gas) tank. Mop up spilt fuel and do not forget to close the fuel tank before restarting the engine.

-27-

Safety Section

How to Survive in a Tipover

WARNING

In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided.

Always use operator restraint system.

DON’T jump.

Hold on tight.

Brace your feet and keep them within the operator’s compartment.

-28-

Safety Section

Lean away from the direction of fall.

Lean forward.

-29-

General Section

Specifications

CHARACTERISTICS

Manufacturer

Model

Capacity at rated load center

Load center distance

Power type electric, diesel, gasoline, LPG

Operator type stand-on, rider seated

Tires* c = cushion, p = pneumatic

Wheels (x = driven) number, front/rear

DIMENSIONS

Lift with STD

two - stage mast

Fork carriage

Forks

Tilt of mast

14 15 16 17

Overall dimensions

18 19 20

Outside turning radius

Load moment constant (from center of front wheel to fork face)

90° stacking aisle (add load length and clearance)

90° intersecting aisle

23a

maximum fork height with rated load free lift special free lift ISO class thickness X width X length fork spacing (minimum X maximum) forward/backward length without forks width mast lowered height mast extended height overhead guard height seat height

PERFORMANCE

Speeds

25 26

Drawbar pull

Gradeability

Acceleration time

travel, loaded/unloaded lift, loaded/unloaded lowering, loaded/unloaded at 1.6 km/h, loaded/unloaded at 1.6 km/h, loaded/unloaded traveling loaded/unloaded

WEIGHT

Total weight at unloaded

32 33 34

Axle load

with load front/rear without load front/rear

CHASSIS

Tires

36 37

Wheelbase

Tread front/rear

39 40

Ground clearance

Service brake

Parking brake

number of front/rear front size rear size

at the lowest point at the center of wheelbase

DRIVE

Battery voltage/capacity

45 49 50 51 52 53 55 56

Engine

Transmission

manufacturer/model rated output (at rpm) gas/LPG max. torque (at rpm) gas/LPG cycle/cylinders/displacement fuel consumption type

number of speeds forward/reverse 1/1 1/1

* Solid soft rider tires are available instead of pneumatic as an option.

DHI&M DHI&M D20S-3 D25S-3

kg 2000 2500

mm 500 500

mm 3230 3230 mm 152 152 mm

ll ll mm 45 X 100 X 1050 45 X 100 X 1050 13 mm 275 X 1035 275 X 1035 deg 6/10 6/10 mm 2505 2573 mm 1170 1170 mm 2170 2170 mm 4470 4470 mm 2183 2183 mm 1026 1026 mm 2220 2265 mm 485 485 mm 2705 2750 mm 1970 2000

km/h 19.5/20 19.4/19.9 mm/s 550/600 530/600 mm/s 510/460 510/460

kg 1610/ 1620/

% 28.6/ 24.9/

kg 3910 4280 kg 5180/730 5925/855 kg 1970/1940 1910/2370

mm 1625 1625 mm 975/1000 975/1000 mm 115 115 mm 153 153

V/AH 12/85 12/85

kW 44.1(2300) 44.1(2300)

kg - m 20(1600) 20(1600)

cc 4/4/3268 4/4/3268

l/hr

diesel diesel

rider - seated rider - seated

p p

X2/2 X2/2

2/2 2/2

7.00 X 15 - 12PR 7.00 X 15 - 12PR

6.50 X 10 - 10PR 6.50 X 10 - 10PR

foot/hydraulic foot/hydraulic

hand/mechanical hand/mechanical

DHI&M/DB33A DHI&M/DB33A

Powershift Powershift

-30-

DHI&M DHI&M 1 D30S-3 D32S-3 2

3000 3000(6500lb) 3

500 600(24in) 4

diesel diesel 5

rider - seated rider-seated 6

p p 7

X2/2 X2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45X125X1050

286 X 1044 286X1044 13

6/10 6/10 14 2636 2690 15 1197 1197 16 2160 2160 17 4470 4470 18 2183 2183 19 1026 1026 20 2364 2414 21

485 485 22 2849 2899 23 2050 2100 23a

19.2/19.7 19.0/19.5 24 520/600 520/600 25 510/460 510/460 26

1705/ 1705/ 28

23.0/ 23/ 30 31

4715 5070 32 6705/1010 6810/1260 33 1890/2825 1810/3260 34

2/2 2/2 35

28 X 9 X 15 - 12PR 28X9X15-12PR 36

6.50 X 10 - 10PR 6.50X10-10PR 37 1625 1625 38

982/1000 982/1000 39

105 105 40 153 153 41

foot/hydraulic foot/hydraulic 42

hand/mechanical hand/mechanical 43

12/85 12/85 45

DHI&M/DB33A DHI&M/DB33A 49

44.1(2300) 44(2300) 50 20(1600) 20/1600 51

4/4/3268 4/4/3268 52

Powershift Powershift 55

1/1 1/1 56

General Section

-31-

General Section

Specifications

CHARACTERISTICS TIER - II

Manufacturer

Model

Capacity at rated load center

Load center distance

Power type electric, diesel, gasoline, LPG

Operator type stand-on, rider seated

Tires* c = cushion, p = pneumatic

Wheels (x = driven) number, front/rear

kg 2000 2500

mm 500 500

DIMENSIONS

Lift with STD

two - stage mast

Fork carriage

Forks

Tilt of mast

14 15 16 17

Overall dimensions

18 19 20

Outside turning radius

Load moment constant (from center of front wheel to fork face)

90° stacking aisle (add load length and clearance)

90° intersecting aisle

23a

mm 3230 3230 mm 152 152 mm

ll ll mm 45 X 100 X 1050 45 X 100 X 1050 mm 275 X 1035 275 X 1035 deg 6/10 6/10 mm 2505 2573 mm 1170 1170 mm 2170 2170 mm 4470 4470 mm 2183 2183 mm 1026 1026 mm 2220 2265 mm 485 485 mm 2705 2750 mm 1970 2000

PERFORMANCE

Speeds

25 26

Drawbar pull

Gradeability

Acceleration time

travel, loaded/unloaded lift, loaded/unloaded lowering, loaded/unloaded at 1.6 km/h, loaded/unloaded at 1.6 km/h, loaded/unloaded traveling loaded/unloaded

km/hr 19.5/20 19.5/20 mm/s 550/600 530/600 mm/s 510/460 510/460

kg 1850 1860 % 32 28

WEIGHT

32 33 34

Total weight

Axle load

at unloaded with load front/rear without load front/rear

kg 3910 4280 kg 5180/730 5925/855 kg 1970/1940 1910/2370

CHASSIS

Tires

36 37

Wheelbase

Tread

39 40

Ground clearance

Service brake

Parking brake

number of front/rear front size rear size

front/rear at the lowest point at the center of wheelbase

mm 1625 1625 mm 975/1000 975/1000 mm 115 115 mm 153 153

DRIVE

45 49 50 51 52 53 55 56

Battery

Engine

Transmission

voltage/capacity manufacturer/model rated output (at rpm) gas/LPG max. torque (at rpm) gas/LPG cycle/cylinders/displacement fuel consumption type number of speeds forward/reverse

V/AH 12/85 12/85

kW 43.4(2200) 43.4(2200)

kg - m 20.5(1600) 20.5(1600)

cc 4/4/3260 4/4/3260

l/hr

* Solid soft rider tires are available instead of pneumatic as an option.

DHI&M DHI&M

D20S-3 D25S-3

diesel diesel

rider - seated rider - seated

p p

X2/2 X2/2

2/2 2/2

7.00 X 15 - 12PR 7.00 X 15 - 12PR

6.50 X 10 - 10PR 6.50 X 10 - 10PR

foot/hydraulic foot/hydraulic

hand/mechanical hand/mechanical

CUMMINS/B3.3 CUMMINS/B3.3

Powershift Powershift

1/1 1/1

-32-

TIER - II

DHI&M DHI&M DHI&M 1 D30S-3 D32S-3 D33S-3 2

3000 3000(6500lb) 3250 3

500 600(24in) 500 4

diesel diesel diesel 5

rider - seated rider-seated rider-seated 6

p p p 7

X2/2 X2/2 X2/2 8

3230 3230 3230 9

152 152 152 10

lll lll lll 12

45 X 125 X 1050 45X125X1050 45X125X1050

286 X 1044 286X1044 286X1044

6/10 6/10 6/10 14 2636 2690 2690 15 1197 1197 1197 16 2160 2160 2160 17 4470 4470 4470 18 2183 2183 2183 19 1026 1026 1026 20 2364 2414 2414 21

485 485 485 22 2849 2899 2899 23 2050 2100 2100 23a

19.0/19.5 19.0/19.5 19.0/19.5 24 520/600 520/600 500/600 25 510/460 510/460 510/460 26

1890 1890 1900 28

25 25 23.5 30

4715 5070 5070 32 6705/1010 6810/1260 7030/1290 33 1890/2825 1810/3260 1810/3260 34

2/2 2/2 2/2 35

28 X 9 X 15 - 12PR 28X9X15-12PR 28X9X15-12PR 36

6.50 X 10 - 10PR 6.50X10-10PR 6.50X10-10PR 37 1625 1625 1625 38

982/1000 982/1000 982/1000 39

105 105 105 40 153 153 153 41

foot/hydraulic foot/hydraulic foot/hydraulic 42

hand/mechanical hand/mechanical hand/mechanical 43

12/85 12/85 12/85 45

CUMMINS/B3.3 CUMMINS/B3.3 CUMMINS/B3.3 49

43.4(2200) 43.4(2200) 43.4(2200) 50

20.5(1600) 20.5(1600) 20.5(1600) 51 4/4/3260 4/4/3260 4/4/3260 52

Powershift Powershift Powershift 55

1/1 1/1 1/1 56

General Section

-33-

General Section

Specifications

CHARACTERISTICS

1 Manufacturer DHI&M DHI&M 2 Model G20E-3 G25E-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gasoline, LPG gasoline / LPG gasoline / LPG 6 Operator type stand-on, rider seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic p p 8 Wheels (x = driven) number, front/rear X2/2 X2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD two - stage mast

10 free lift mm 152 152 11 12 Fork carriage ISO class ll ll

13 Forks

14 Tilt of mast forward/backward deg 6/10 6/10 15 length without forks mm 2505 2573 16 Overall width mm 1170 1170 17 dimensions mast lowered height mm 2170 2170 18 mast extended height mm 4470 4470 19 overhead guard height mm 2183 2183 20 seat height mm 1026 1026 21 Outside turning radius mm 2220 2265 22 Load moment constant (from center of front wheel to fork face) mm 485 485 23 90° stacking aisle (add load length and clearance) mm 2705 2750

23a 90° intersecting aisle mm 1970 2000

PERFORMANCE

24 travel, loaded/unloaded km/hr 18.2/19.3 18.0/19.3

Speeds

25 lift, loaded/unloaded mm/s 530/600 510/600 26 28 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1500/ 1480/ 30 Gradeability at 1.6 km/h, loaded/unloaded % 26.7/ 22.7/ 31 Acceleration time traveling loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3750 4120 33 with load front/rear kg 5095/655 5820/800

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 7.00 X 15 - 12PR 7.00 X 15 - 12PR 37 38 Wheelbase mm 1625 1625 39 Tread front/rear mm 975/1000 975/1000 40 at the lowest point mm 115 115

Ground clearance

41 42 Service brake foot/hydraulic foot/hydraulic 43 Parking brake hand/mechanical hand/mechanical

DRIVE

45 Battery voltage/capacity V/AH 12/45 12/45 49 manufacturer/model DHI&M/G424 DHI&M/G424 50 rated output (at rpm) gas/LPG kW 34.5(2300) 34.5(2300)

Engine

51 max. torque (at rpm) gas/LPG kg - m 16.3(1600) 16.3(1600) 52 cycle/cylinders/displacement cc 4/4/2350 4/4/2350 53 55 type Powershift Powershift

Transmission

* Solid soft rider tires are available instead of pneumatic as an option.

special free lift mm

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum) mm 275 X 1035 275 X 1035

lowering, loaded/unloaded mm/s 510/460 510/460

without load front/rear

rear size 6.50 X 10 - 10PR 6.50 X 10 - 10PR

at the center of wheelbase mm 153 153

fuel consumption l/hr

number of speeds forward/reverse 1/1 1/1

kg 1880/1870 1810/2310

-34-

DHI&M DHI&M 1 G30E-3 G32E-3 2

3000 3000(6500lb) 3

500 600(24in) 4

gasoline / LPG LPG 5

rider - seated rider-seated 6

p p 7

X 2/2 X2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45X125X1050

286 X 1044 286X1044

6/10 6/10 14 2636 2690 15 1197 1197 16 2160 2160 17 4470 4470 18 2183 2183 19 1026 1026 20 2364 2414 21

485 485 22 2849 2899 23 2050 2100 23a

17.0/18.4 17.0/18.0 24 500/600 500/600 25 510/460 510/460 26

1550/ 1550/ 28

20.8/ 20.8/ 30 31

4530 4830 32

6605/925 6690/1140 33

1790/2740 1680/3150 34

2/2 2/2 35

28 X 9 X 15 - 12PR 28X9X15-12PR 36

6.50 X 10 - 10PR 6.50X10-10PR 37 1625 1625 38

982/1000 982/1000 39

105 105 40 153 153 41

foot/hydraulic foot/hydraulic 42

hand/mechanical hand/mechanical 43

12/45 12/45 45

DHI&M/G424 DHI&M/G424 49

34.5(2300) 34.5(2300) 50

16.3(1600) 16.3(1600) 51 4/4/2350 4/4/2350 52

Powershift Powershift 55

1/1 1/1 56

General Section

-35-

General Section

Specifications

CHARACTERISTICS

1 Manufacturer DHI&M DHI&M 2 Model GC20E-3 GC25E-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gasoline, LPG gasoline / LPG gasoline / LPG 6 Operator type stand-on, rider seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic c c 8 Wheels (x = driven) number, front/rear X 2/2 X 2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD

10 free lift mm 152 152

two - stage mast

11 12 Fork carriage ISO class ll ll

13 Forks

14 Tilt of mast forward/backward deg 6/8 6/8 15 length without forks mm 2218 2268 16 width mm 1110 1110

Overall

17 mast lowered height mm 2125 2125

dimensions

18 mast extended height mm 4470 4470 19 overhead guard height mm 2150 2150 20 21 Outside turning radius mm 2000 2045 22 Load moment constant (from center of front wheel to fork face) mm 374 374 23 90° stacking aisle (add load length and clearance) mm 2374 2419

23a 90° intersecting aisle mm 1798 1822

PERFORMANCE

24 travel, loaded/unloaded km/h 17.5/17.9 17.4/17.8

Speeds

25 lift, loaded/unloaded mm/s 530/600 510/600 26 28 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1630/ 1590/ 30 Gradeability at 1.6 km/h, loaded/unloaded % 31.2/ 26.2/ 31 Acceleration time traveling loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3380 3680 33

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 21 X 7 - 15 21 X 7 - 15 37 38 Wheelbase mm 1410 1410 39 Tread front/rear mm 932/983 932/983 40 at the lowest point mm 90 90

Ground clearance

41 42 Service brake foot/hydraulic foot/hydraulic 43 Parking brake hand/mechanical hand/mechanical

DRIVE

45 Battery voltage/capacity V/AH 12/45 12/45 49 manufacturer/model DHI&M/G424 DHI&M/G424 50 rated output (at rpm) gas/LPG kW 34.5(2300) 34.5(2300)

Engine

51 max. torque (at rpm) gas/LPG kg - m 16.3(1600) 16.3(1600) 52 cycle/cylinders/displacement cc 4/4/2350 4/4/2350 53 55 type Powershift Powershift

Transmission

* Solid soft rider tires are available instead of pneumatic as an option.

special free lift mm

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum) mm 297 X 905 297 X 905

seat height mm 1038 1038

lowering, loaded/unloaded mm/s 510/460 510/460

with load front/rear kg 4730/650 5470/710 without load front/rear

rear size 16 X 5 - 10.5 16 X 5 - 10.5

at the center of wheelbase mm 135 135

fuel consumption l/hr

number of speeds forward/reverse 1/1 1/1

kg 1490/1890 1420/2260

-36-

DHI&M DHI&M 1

GC30E-3 GC32E-3 2

3000 3000(6500lb) 3

500 600(24in) 4

gasoline / LPG LPG 5

rider - seated rider - seated 6

c c 7

X2/2 X2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45 X 125 X 1050

282 X 954 282 X 954

6/8 6/8 14 2333 2368 15 1110 1100 16 2125 2125 17 4470 4470 18 2150 2150 19 1038 1038 20 2105 2135 21

374 374 22 2479 2509 23 1872 1907 23a

17.3/17.7 17.3/17.7 24 500/600 500/600 25 510/460 510/460 26

1540/ 1540 28

24/ 24/ 30

4140 4310 32

6290/850 6450/860 33

1430/2710 1380/2930 34

2/2 2/2 35

21 X 8 - 15 21 X 8 -15 36

16 X 5 - 10.5 16 X 6 -10.5 37

1410 1410 38

907/956 907/956 39

90 90 40

135 135 41

foot/hydraulic foot/hydraulic 42

hand/mechanical hand/mechanical 43

12/45 12/45 45

DHI&M/G424 DHI&M/G424 49

34.5(2300) 34.5(2300) 50

16.3(1600) 16.3(1600) 51 4/4/2350 4/4/2350 52

Powershift Powershift 55

1/1 1/1 56

General Section

-37-

General Section

Specifications

CHARACTERISTICS

1 Manufacturer DHI&M DHI&M 2 Model G20P-3 G25P-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gasoline, LPG LPG LPG 6 Operator type stand-on, rider seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic P P 8 Wheels (x = driven) number, front/rear X2/2 X2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD

two - stage mast

11 12 Fork carriage ISO class ll ll

13 Forks

14 Tilt of mast forward/backward deg 6/10 6/10 15 length without forks mm 2505 2573 16 width mm 1170 1170

Overall

17 mast lowered height mm 2170 2170

dimensions

18 mast extended height mm 4470 4470 19 overhead guard height mm 2183 2183 20 21 Outside turning radius mm 2220 2265 22 Load moment constant (from center of front wheel to fork face) mm 485 485 23 90° stacking aisle (add load length and clearance) mm 2705 2750

23a 90° intersecting aisle mm 1970 2000

PERFORMANCE

24 travel, loaded/unloaded km/h 20.1/21.4 19.8/21.3

Speeds

25 lift, loaded/unloaded mm/s 530/600 510/600 26 28 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1660 1655 30 Gradeability at 1.6 km/h, loaded/unloaded % 30.0 25.7 31 Acceleration time traveling loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3750 4120 33 with load front/rear kg 5095/655 5820/800

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 7.00 X 15 - 12PR 7.00 X 15 - 12PR 37 38 Wheelbase mm 1625 1625 39 Tread front/rear mm 975/1000 975/1000 40 at the lowest point mm 115 115

Ground clearance

41 42 Service brake foot/hyd foot/hyd 43 Parking brake hand/mech hand/mech

DRIVE

45 Battery voltage/capacity V/AH 12/65 12/65 49 manufacturer/model DHI&M/G430 DHI&M/G430 50

Engine

51 max. torque (at rpm) gas/LPG kg - m 20.5(1800) 20.5(1800) 52 cycle/cylinders/displacement cc 4/4/2967 4/4/2967 53 55 type Powershift Powershift

Transmission

* Solid soft rider tires are available instead of pneumatic as an option.

free lift mm 152 152 special free lift mm

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum) mm 275 X 1035 275 X 1035

seat height mm 1026 1026

lowering, loaded/unloaded mm/s 510/460 510/460

without load front/rear

rear size 6.50 X 10 - 10PR 6.50 X 10 - 10PR

at the center of wheelbase mm 153 153

rated output (at rpm) gas/LPG kW 43.4(2200) 43.4(2200)

fuel consumption l/hr

number of speeds forward/reverse 1/1 1/1

kg 1880/1870 1810/2310

-38-

DHI&M DHI&M 1

G30P-3 G32P-3 2

3000 3000(6500lb) 3

500 600(24in) 4

LPG LPG 5

rider - seated rider - seated 6

P p 7

X2/2 X2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45 X 125 X 1050

286 X 1044 286 X 1044

6/10 6/10 14 2636 2690 15 1197 1197 16 2160 2160 17 4470 4470 18 2183 2183 19 1026 1026 20 2364 2414 21

485 485 22 2849 2899 23 2050 2100 23a

18.8/20.5 18.8/20.5 24 500/600 500/600 25 510/460 510/460 26

1705 1705 28

23.1 23.1 30 31

4530 4830 32

6605/925 6690/1140 33

1790/2740 1680/3150 34

2/2 2/2 35

28 X 9 X 15 - 12PR 28 X 9 X 15 -12PR 36

6.50 X 10 - 10PR 6.50 X 10 - 10PR 37 1625 1625 38

982/1000 982/1000 39

105 105 40 153 153 41

foot/hyd foot/hyd 42

hand/mech hand/mech 43

12/65 12/65 45

DHI&M/G430 DHI&M/G430 49

43.4(2200) 43.4(2200) 50

20.5(1800) 20.5(1800) 51 4/4/2967 4/4/2967 52

Powershift Powershift 55

1/1 1/1 56

General Section

-39-

General Section

Specifications

CHARACTERISTICS

1 Manufacturer DHI&M DHI&M 2 Model GC20P-3 GC25P-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gasoline, LPG LPG LPG 6 Operator type stand-on, rider seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic C C 8 Wheels (x = driven) number, front/rear X2/2 X2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD two - stage mast

10 free lift mm 152 152 11 12 Fork carriage ISO class ll ll

13 Forks

14 Tilt of mast forward/backward deg 6/8 6/8 15 length without forks mm 2218 2268 16 width mm 1110 1110 17 mast lowered height mm 2125 2125

Overall dimensions

23a 90° intersecting aisle mm 1798 1822

PERFORMANCE

24 travel, loaded/unloaded km/h 17.4/18.0 17.3/18.0

Speeds

25 lift, loaded/unloaded mm/s 530/600 510/600 26 28 Drawbar pull at 1.6 km/h, loaded/unloaded kg 2045 2025 30 Gradeability at 1.6 km/h, loaded/unloaded % 40.2 34.1 31 Acceleration time traveling loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3380 3680 33 with load front/rear kg 4730/650 5470/710

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 21 X 7 - 15 21 X 7 - 15 37 38 Wheelbase mm 1410 1410 39 Tread front/rear mm 932/983 932/983 40 at the lowest point mm 90 90

Ground clearance

41 42 Service brake foot/hyd foot/hyd 43 Parking brake hand/mech hand/mech

DRIVE

45 Battery voltage/capacity V/AH 12/65 12/65 49 manufacturer/model DHI&M/G430 DHI&M/G430 50 rated output (at rpm) gas/LPG kW 43.4(2200) 43.4(2200)

Engine

51 max. torque (at rpm) gas/LPG kg - m 20.5(1800) 20.5(1800) 52 cycle/cylinders/displacement cc 4/4/2967 4/4/2967 53 55 type Powershift Powershift

Transmission

* Solid soft rider tires are available instead of pneumatic as an option.

special free lift mm

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum)

seat height mm 1038 1038

lowering, loaded/unloaded mm/s 510/460 510/460

without load front/rear kg 1490/1890 1420/2260

rear size 16 X 5 - 10.5 16 X 5 - 10.5

at the center of wheelbase mm 135 135

fuel consumption l/hr

number of speeds forward/reverse 1/1 1/1

mm 297 X 905 297 X 905

-40-

DHI&M DHI&M 1

GC30P-3 GC32P-3 2

3000 3000(6500lb) 3

500 600(24in) 4

LPG LPG 5

rider - seated rider - seated 6

C C 7

X2/2 X 2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45 X 125 X 1050

282 X 954 282 X 954

6/8 6/8 14 2333 2368 15 1110 1100 16 2125 2125 17 4470 4470 18 2150 2150 19 1038 1038 20 2105 2135 21

374 374 22 2479 2509 23 1872 1907 23a

17.1/18.0 17.1/18.0 24 500/600 500/600 25 510/460 510/460 26

2000 2000 28

28.8 28.8 30 31

4140 4310 32

6290/850 6450/860 33

1430/2710 1380/2930 34

2/2 2/2 35

21 X 8 - 15 21 X 8 -15 36

16 X 5 - 10.5 16 X 6 -10.5 37

1410 1410 38

907/956 907/956 39

90 90 40

135 135 41

foot/hyd foot/hyd 42

hand/mech hand/mech 43

12/65 12/65 45

DHI&M/G430 DHI&M/G430 49

43.4(2200) 43.4(2200) 50

20.5(1800) 20.5(1800) 51 4/4/2967 4/4/2967 52

Powershift Powershift 55

1/1 1/1 56

General Section

-41-

General Section

Specifications

CHARACTERISTICS Tier-2

1 Manufacturer DHI DHI 2 Model GC20E-3 GC25E-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gas, LPG-gas LPG LPG 6 Operator type stand-on, ride- seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic C C 8 Wheels (x = driven) number of front/rear X2/2 X2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD two - stage mast

10 11 Fork carriage ISO class ll ll

12 Forks

13 Tilt of mast forward/backward deg 6/8 6/8 14 length without forks mm 2218 2268 15 width mm 1110 1110

Overall

16 mast lowered height mm 2125 2125

dimensions

17 mast extended height mm 4470 4470 18 overhead guard height mm 2150 2150 19 20 Outside turning radius mm 2000 2045 21 Load moment constant (from center of front wheel to fork face) mm 374 374 22 90° stacking aisle mm 2374 2419

22a 90° intersecting aisle mm 1798 1822

PERFORMANCE

23 travel, loaded/unloaded km/h 18.0/18.0 18.0/18.0

Speeds

24 lift, loaded/unloaded mm/s 530/600 510/600 25 26 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1630 1590 30 Gradeability at 1.6 km/h, loaded/unloaded % 31.5 26.5 31 Acceleration time time reached at max speed, loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3380 3680 33 at loaded, fornt/rear kg 4730/650 5470/710

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 21 X 7 - 15 21 X 7 - 15 37 38 Wheelbase mm 1410 1410 39 Tread front/rear mm 932/983 932/983 40 at loaded, the lowest point mm 90 90

Ground clearance

41 42 Service brake foot/hyd foot/hyd 43 Parking brake hand/mech hand/mech

DRIVE

45 Battery voltage/capacity V/AH 12/45 12/45 49 manufacturer/model DHI/G424E DHI/G424E 50 rated output / rpm ps(kw) 52/2600 52/2600

Engine

51 max. torque / rpm kg - m 17(1600 17/1600 52 55 type Powershift Powershift

Transmission

free lift mm 152 152

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum) mm 297 X 905 297 X 905

seat height mm 1038 1038

lowering, loaded/unloaded mm/s 510/460 510/460

at unloaded, fornt/rear kg 1490/1890 1420/2260

rear size

at loaded, center of wheelbase mm 135 135

cycle/cylinders/displacement cc 4/4/2350 4/4/2350

number of speeds forward/reverse 1/1 1/1

16 X 5 - 10.5 16 X 5 - 10.5

-42-

Tier-2

DHI DHI 1

GC30E-3 GC32E-3 2

3000 3000(6500lbs) 3

500 600 4

LPG LPG 5

rider - seated rider - seated 6

C C 7

X2/2 X 2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45 X 125 X 1050

282 X 954 282 X 954

6/8 6/8 14 2333 2368 15 1110 1110 16 2125 2125 17 4470 4470 18 2150 2150 19 1038 1038 20 2105 2135 21

374 374 22 2479 2509 23 1872 1907 23a

18.0/18.0 18.0/18.0 24 500/600 500/600 25 510/460 510/460 26

1540 1540 28

24 24 30

4140 4310 32

6290/850 6450/860 33

1430/2710 1380/2930 34

2/2 2/2 35

21 X 8 - 15 21 X 8 -15 36

16 X 5 - 10.5 16 X 6 -10.5 37

1410 1410 38

907/956 907/956 39

90 90 40

135 135 41

foot/hyd foot/hyd 42

hand/mech hand/mech 43

12/45 12/45 45

DHI/G424E DHI/G424E 49

52/2600 52/2600 50 17/1600 17/1600 51

4/4/2350 4/4/2350 52

Powershift Powershift 55

1/1 1/1 56

General Section

-43-

General Section

Specifications

CHARACTERISTICS Tier-2

1 Manufacturer DHI DHI 2 Model GC20P-3 GC25P-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gas, LPG-gas LPG LPG 6 Operator type stand-on, ride- seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic C C 8 Wheels (x = driven) number of front/rear X2/2 X2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD two - stage mast

10 11 Fork carriage ISO class ll ll

12 Forks

13 Tilt of mast forward/backward deg 6/8 6/8 14 length without forks mm 2218 2268 15 width mm 1110 1110

Overall

16 mast lowered height mm 2125 2125

dimensions

22a 90° intersecting aisle mm 1798 1822

PERFORMANCE

23 travel, loaded/unloaded km/h 17.5/17.5 17.5/17.5

Speeds

24 lift, loaded/unloaded mm/s 530/600 510/600 25 26 Drawbar pull at 1.6 km/h, loaded/unloaded kg 2045 2025 30 Gradeability at 1.6 km/h, loaded/unloaded % 40.5 34.5 31 Acceleration time time reached at max speed, loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3400 3700 33 at loaded, fornt/rear kg 4735/675 5455/755

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 21 X 7 - 15 21 X 7 - 15 37 38 Wheelbase mm 1410 1410 39 Tread front/rear mm 932/983 932/983 40 at loaded, the lowest point mm 90 90

Ground clearance

41 42 Service brake foot/hyd foot/hyd 43 Parking brake hand/mech hand/mech

DRIVE

45 Battery voltage/capacity V/AH 12/65 12/65 49 manufacturer/model DHI/G430E DHI/G430E 50 rated output / rpm ps(kw) 61/2500 61/2500

Engine

51 max. torque / rpm kg - m 19/1800 19/1800 52 55 type Powershift Powershift

Transmission

free lift mm 152 152

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum) mm 297 X 905 297 X 905

seat height mm 1038 1038

lowering, loaded/unloaded mm/s 510/460 510/460

at unloaded, fornt/rear kg 1490/1910 1410/2290

rear size

at loaded, center of wheelbase mm 135 135

cycle/cylinders/displacement cc 4/4/2967 4/4/2967

number of speeds forward/reverse 1/1 1/1

16 X 5 - 10.5 16 X 5 - 10.5

-44-

Tier-2

DHI DHI 1

GC30P-3 GC32P-3 2

3000 3000(6500lbs) 3

500 600 4

LPG LPG 5

rider - seated rider - seated 6

C C 7

X2/2 X 2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45 X 125 X 1050

282 X 954 282 X 954

6/8 6/8 14 2333 2368 15 1110 1100 16 2125 2125 17 4470 4470 18 2150 2150 19 1038 1038 20 2105 2135 21

374 374 22 2479 2509 23 1872 1907 23a

17.5/17.5 17.5/17.5 24 500/600 500/600 25 510/460 510/460 26

2000 2000 28

29 29 30

4170 4340 32

6240/890 6370/1050 33

1430/2740 1380/2960 34

2/2 2/2 35

21 X 8 - 15 21 X 8 -15 36

16 X 5 - 10.5 16 X 6 -10.5 37

1410 1410 38

907/956 907/956 39

90 90 40

135 135 41

foot/hyd foot/hyd 42

hand/mech hand/mech 43

12/65 12/65 45

DHI/G430E DHI/G430E 49

61/2500 61/2500 50 19/1800 19/1800 51

4/4/2967 4/4/2967 52

Powershift Powershift 55

1/1 1/1 56

General Section

-45-

General Section

Specifications

CHARACTERISTICS 2004 YEAR (Tier-2)

1 Manufacturer DHI DHI 2 Model G20E-3 G25E-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gas, LPG-gas LPG LPG 6 Operator type stand-on, ride- seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic P P 8 Wheels (x = driven) number of front/rear X2/2 X2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD two - stage mast

10 11 Fork carriage ISO class ll ll

12 Forks

13 Tilt of mast forward/backward deg 6/10 6/10 14 length without forks mm 2505 2573 15 width mm 1170 1170

Overall

16 mast lowered height mm 2170 2170

dimensions

17 mast extended height mm 4470 4470 18 overhead guard height mm 2183 2183 19 20 Outside turning radius mm 2220 2265 21 Load moment constant (from center of front wheel to fork face) mm 485 485 22 90° stacking aisle mm 2705 2750

22a 90° intersecting aisle mm 1970 2000

PERFORMANCE

23 travel, loaded/unloaded km/h 19.5/20.0 19.5/20.0

Speeds

24 lift, loaded/unloaded mm/s 530/600 510/600 25 26 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1500 1480 30 Gradeability at 1.6 km/h, loaded/unloaded % 27 23 31 Acceleration time time reached at max speed, loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3750 4120 33 at loaded, fornt/rear kg 5095/655 5820/800

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 7.00 X 15 - 12 7.00 X 15 - 12 37 38 Wheelbase mm 1625 1625 39 Tread front/rear mm 975/1000 975/1000 40 at loaded, the lowest point mm 115 115

Ground clearance

41 42 Service brake foot/hyd foot/hyd 43 Parking brake hand/mech hand/mech

DRIVE

45 Battery voltage/capacity V/AH 12/45 12/45 49 manufacturer/model DHI/G424E DHI/G424E 50 rated output / rpm ps(kw) 52/2600 52/2600

Engine

51 max. torque / rpm kg - m 17/1600 17/1600 52 55 type Powershift Powershift

Transmission

free lift mm 152 152

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum) mm 275 X 1035 275 X 1035

seat height mm

lowering, loaded/unloaded mm/s 510/460 510/460

at unloaded, fornt/rear kg 1880/1870 1810/2310

rear size

at loaded, center of wheelbase mm 153 153

cycle/cylinders/displacement cc 4/4/2350 4/4/2350

number of speeds forward/reverse 1/1 1/1

6.50 X 10 - 10 6.50 X 10 - 10

-46-

2004 YEAR (Tier-2)

DHI DHI 1

G30E-3 G32E-3 2

3000 3000(6500lbs) 3

500 600 4

LPG LPG 5

rider - seated rider - seated 6

P P 7

X2/2 X 2/2 8

3230 3230 9

152 152 10

lll lll 12

45 X 125 X 1050 45 X 125 X 1050

286 X 1044 286 X 1044

6/10 6/10 14 2636 2690 15 1197 1197 16 2160 2160 17 4470 4470 18 2183 2183 19

2364 2414 21

485 485 22 2849 2899 23 2050 2100 23a

19.0/19.5 19.0/19.5 24 500/600 500/600 25 510/460 510/460 26

1550 1550 28

21 20 30

4530 4830 32

6605/925 6690/1140 33

1790/2740 1680/3150 34

2/2 2/2 35

28 X 9 X 15 - 12 28 X 9 X 15 - 12 36

6.50 X 10 - 10 6.50 X 10 - 10 37 1625 1625 38

982/1000 982/1000 39

105 105 40 153 153 41

foot/hyd foot/hyd 42

hand/mech hand/mech 43

12/45 12/45 45

DHI/G424E DHI/G424E 49

52/2600 52/2600 50 17/1600 17/1600 51

4/4/2350 4/4/2350 52

Powershift Powershift 55

1/1 1/1 56

General Section

-47-

General Section

Specifications

CHARACTERISTICS 2004 YEAR (Tier-2)

1 Manufacturer DHI DHI 2 Model G20P-3 G25P-3 3 Capacity at rated load center kg 2000 2500 4 Load center distance mm 500 500 5 Power type electric, diesel, gas, LPG-gas LP LP 6 Operator type stand-on, ride- seated rider - seated rider - seated 7 Tires* c = cushion, p = pneumatic P P 8 Wheels (x = driven) number of front/rear X2/2 X2/2

DIMENSIONS

9 maximum fork height with rated load mm 3230 3230

Lift with STD two - stage mast

10 11 Fork carriage ISO class ll ll

12 Forks

13 Tilt of mast forward/backward deg 6/10 6/10 14 length without forks mm 2505 2573 15 width mm 1170 1170

Overall

16 mast lowered height mm 2170 2170

dimensions

22a 90° intersecting aisle mm 1970 2000

PERFORMANCE

23 travel, loaded/unloaded km/h 20.0/21.5 20.0/21.5

Speeds

24 lift, loaded/unloaded mm/s 530/600 510/600 25 26 Drawbar pull at 1.6 km/h, loaded/unloaded kg 1660 1655 30 Gradeability at 1.6 km/h, loaded/unloaded % 30 26 31 Acceleration time time reached at max speed, loaded/unloaded s

WEIGHT

32 Total weight at unloaded kg 3750 4120 33 at loaded, fornt/rear kg 5095/655 5820/800

Axle load

CHASSIS

35 number of front/rear 2/2 2/2

Tires

36 front size 7.00 X 15 - 12 7.00 X 15 - 12 37 38 Wheelbase mm 1625 1625 39 Tread front/rear mm 975/1000 975/1000 40 at loaded, the lowest point mm 115 115

Ground clearance

41 42 Service brake foot/hyd foot/hyd 43 Parking brake hand/mech hand/mech

DRIVE

45 Battery voltage/capacity V/AH 12/65 12/65 49 manufacturer/model DHI/G430E DHI/G430E 50 rated output / rpm ps(kw) 61/2500) 61/2500

Engine

51 max. torque / rpm kg - m 19/1800 19/1800 52 55 type Powershift Powershift

Transmission

free lift mm 152 152

thickness X width X length mm 45 X 100 X 1050 45 X 100 X 1050 fork spacing (minimum X maximum) mm 275 X 1035 275 X 1035

seat height mm

lowering, loaded/unloaded mm/s 510/460 510/460

at unloaded, fornt/rear kg 1880/1870 1810/2310

rear size

at loaded, center of wheelbase mm 153 153

cycle/cylinders/displacement cc 4/4/2967 4/4/2967

number of speeds forward/reverse 1/1 1/1

6.50 X 10 - 10 6.50 X 10 - 10

-48-

2004 YEAR (Tier-2)

DHI DHI DHI 1

G30P-3 G32P-3 G33P-3 2

3000 3000(6500lbs) 3250 3

500 600 500 4

LP LP LP 5

rider - seated rider - seated rider - seated 6

P P P 7

X2/2 X 2/2 X 2/2 8

3230 3230 3230 9

152 152 152 10

lll lll lll 12

45 X 125 X 1050 45 X 125 X 1050 45 X 125 X 1050

286 X 1044 286 X 1044 286 X 1044

6/10 6/10 6/10 14 2636 2690 2690 15 1197 1197 1197 16 2160 2160 2160 17 4470 4470 4470 18 2183 2183 2183 19

2364 2414 2414 21

485 485 485 22 2849 2899 2899 23 2050 2100 2100 23a

19.0/20.5 19.0/20.0 19.0/20.0 24 500/600 500/600 500/600 25 510/460 510/460 510/460 26

1705 1705 1700 28

23.5 23.5 23.5 30 31

4530 4830 4830 32

6605/925 6690/1140 6900/1180 33

1790/2740 1680/3150 1680/3150 34

2/2 2/2 2/2 35

28 X 9 X 15 - 12 28 X 9 X 15 - 12 28 X 9 X 15 - 12 36

6.50 X 10 - 10 6.50 X 10 - 10 6.50 X 10 - 10 37 1625 1625 1625 38

982/1000 982/1000 982/1000 39

105 105 105 40 153 153 153 41

foot/hyd foot/hyd foot/hyd 42

hand/mech hand/mech hand/mech 43

12/65 12/65 12/65 45

DHI/G430E DHI/G430E DHI/G430E 49

61/2500 61/2500 61/2500 50 19/1800 19/1800 19/1800 51 4/4/2967 4/4/2967 4/4/2967 52

Powershift Powershift Powershift 55

1/1 1/1 1/1 56

General Section

-49-

General Section

Noise and Vibration

Noise

Model

Sound Pressure Level

at Operator’s ear (Leq.)

AS 3713 prEN 12053 Drive-By Lifting Mode

Noise Level [Unit : dB(A)]

Sound Pressure Level at By-stander position

(AS 3713)

Guaranteed Sound

Power level(L

WA )

by new Directive

2000/14/EC

(DB33A E/G)

W/O Cabin 80.5 82.7 80 81 107

D20S-3 D25S-3 D30S-3 D32S-3

With Cabin 84.4 85.8 79 82 107

With Low Noise

Cabin

79.2 81.7 78 79 107

TIER - II (B3.3 E/G)

D20S-3,D25S-3,D30S-3,D32S-3,

D33S-3

79.3 76 76 104

77.2

(W/O Cabin)

G20E-3,G25E-3,G30E-3,G32E-3

(W/O Cabin)

G20P-3,G25P-3,G30P-3,G32P-3

(W/O Cabin)

81.5 80 82 106

78.3

78.0

81.0 81 84 *NA

GC20E-3,GC25E-3,GC30E-3,

78.0

GC32E-3

81.0 81 84 *NA

(W/O Cabin)

GC20P-3,GC25P-3,GC30P-3,

78.0

GC32P-3

81.0 81 84 *NA

(W/O Cabin)

* NA : Not Applicable

Vibration (weighted overall value)

unit: m/sec2

Measuring Place

Model

(DB33A E/G)

D20S-3, D25S-3, D30S-3, D32S-3

TIER - II (B3.3 E/G)

D20S-3, D25S-3, D30S-3, D32S-3, D33S-3

Seat

0.48 2.28 0.41

0.8 1.2 0.4

Steering

Wheel

G20E-3, G25E-3, G30E-3, G32E-3 0.3 0.7 0.3

G20P-3, G25P-3, G30P-3, G32P-3 0.4 0.8 0.4 GC20E-3, GC25E-3, GC30E-3, GC32E-3 0.2 0.5 0.3 GC20P-3, GC25P-3, GC30P-3, GC32P-3 0.3 0.6 0.4

-50-

Floor Plate

Capacity Chart

General Section

D20S-3, G20E-3, G20P-3

D25S-3, G25E-3,G25P-3

STD, FFL FFT

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

A. 2030 - 4350mm MFH MAST

B. 4960mm MFH MAST

SINGLE TIRE

A. 3900 - 4290mm MFH MAST

B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

A. 3900 - 4290mm MFH MAST

B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

D30S-3, G30E-3,G30P-3

D33S-3

A. 2030 - 4350mm MFH MAST

B. 4960mm MFH MAST

A. 2030 - 4350mm MFH MAST

B. 4960mm MFH MAST

-51-

A. 3900 - 4290mm MFH MAST

B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

A. 2030 - 4290mm MFH MAST

B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

General Section

D20S-3, G20E-3,G20P-3

D25S-3, G25E-3,G25P-3

STD, FFL FFT

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

DOUBLE TIRE

A. 3900 - 4290mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

D30S-3, G30E-3,G30P-3

D33S-3

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

A. 2030 - 4960mm MFH MAST

A. 3900 - 4730mm FORK HEIGHT B. 5560mm MFH MAST C. 6010mm MFH MAST

-52-

Capacity Chart

General Section

NARROW TIRE

STD, FFL FFT

GC20E-3,GC20P-3

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

A. 3900 - 4290mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

GC25E-3,GC25P-3

GC30E-3,GC30P-3

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

STD MAST A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST FFL MAST C. 2580mm MFH MAST

A. 3900 - 4290mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

A. 3900 - 4730mm MFH MAST B. 5560mm MFH MAST C. 6010mm MFH MAST

-53-

General Section

GC20E-3,GC20P-3

STD, FFL FFT

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

WIDE TIRE

A. 3900 - 4290mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

GC25E-3,GC25P-3

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

GC30E-3,GC30P-3

STD MAST FFL MAST A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST C. 2580mm MFH MAST

A. 3900 - 4290mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

A. 3900 - 4730mm MFH MAST B. 5560mm MFH MAST C. 6010mm MFH MAST

-54-

Capacity Chart (with Side Shifter)

General Section

D20S-3, G20E-3,G20P-3

SINGLE TIRE

STD, FFL FFT

A. 2030 - 3230mm MFH MAST B. 3500 - 3950mm MFH MAST C. 4350mm MFH MAST D. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

D25S-3, G25E-3,G25P-3

D30S-3, G30E-3.G30P-3

A. 2030 - 3230mm MFH MAST B. 3500 - 3950mm MFH MAST C. 4350mm MFH MAST D. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

D33S-3

A. 2030 - 3950mm MFH MAST B. 4350mm MFH MAST C. 4960mm MFH MAST

-55-

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

General Section

D20S-3, G20E-3,G20P-3

STD, FFL FFT

A. 2030 - 3230mm MFH MAST B. 3500 - 3950mm MFH MAST C. 4350mm MFH MAST D. 4960mm MFH MAST

DOUBLE TIRE

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

D25S-3, G25E-3,G25P-3

D30S-3, G30E-3,G30P-3

A. 2030 - 3230mm MFH MAST B. 3500 - 3950mm MFH MAST C. 4350mm MFH MAST D. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

D33S-3

A. 2030 - 3950mm MFH MAST B. 4350mm MFH MAST C. 4960mm MFH MAST

-56-

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

Capacity Chart (with Side Shifter)

General Section

NARROW TIRE

STD, FFL FFT

GC20E-3,GC20P-3

A. 2030 - 3230mm MFH MAST B. 3500 - 3950mm MFH MAST C. 4350mm MFH MAST D. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

GC25E-3,GC25P-3

GC30E-3,GC30P-3

A. 2030 - 3230mm MFH MAST B. 3500 - 3950mm MFH MAST C. 4350mm MFH MAST D. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

-57-

General Section

WIDE TIRE

STD, FFL FFT

GC20E-3,GC20P-3

GC25E-3,GC25P-3

A. 2030 - 3230mm MFH MAST B. 3500 - 3950mm MFH MAST C. 4350mm MFH MAST D. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

GC30E-3,GC30P-3

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

-58-

General Section

Capacity Chart: 3,000kg@600mm L.C. (6,500lb@24”)

MODEL STD, FFL FFT

SINGLE TIRE

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

A. 3900 - 4290mm MFH MAST B. 4730mm MFH MAST C. 5560mm MFH MAST D. 6010mm MFH MAST

D32S-3, G32E-3, G32P-3

DOUBLE TIRE

A. 2030-4960mm MFH MAST

A. 3900-4730mm MFH MAST B. 5560mm MFH MAST C. 6010mm MFH MAST

NARROW TIRE

A. 2030 - 4350mm MFH MAST B. 4960mm MFH MAST

A. 3900-4730mm MFH MAST B. 5560mm MFH MAST C. 6010mm MFH MAST

GC32E-3,GC32P-3

WIDE TIRE

A. 2030 - 4960mm MFH MAST B. 4960mm MFH MAST

A. 3900-4730mm MFH MAST B. 5560mm MFH MAST C. 6010mm MFH MAST

-59-

General Section

Capacity Chart (with Side Shifter):3,000kg@600mm L.C. (6,500lb@24”)

MODEL STD, FFL FFT

SINGLE TIRE

A. 2030 - 3950mm MFH MAST B. 4350mm MFH MAST

C. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

D32S-3, G32E-3, G32P-3

DOUBLE TIRE

A. 2030 - 3950mm MFH MAST B. 4350mm MFH MAST

C. 4960mm MFH MAST

NARROW TIRE

A. 2030 - 3950mm MFH MAST B. 4350mm MFH MAST C. 4960mm MFH MAST

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

GC32E-3,GC32P-3

WIDE TIRE

A. 2030 - 3950mm MFH MAST B. 4350mm MFH MAST C. 4960mm MFH MAST

-60-

A. 3900mm MFH MAST B. 4290mm MFH MAST C. 4730mm MFH MAST D. 5560mm MFH MAST E. 6010mm MFH MAST

Serial Number

Serial Number Locations

For quick reference, record your lift truck's serial numbers in the spaces provided below the photographs.

General Section

Lift Truck Serial Number

•_____________________________

3.3 liter (DB33A) Diesel Engine Serial Number

•_____________________________

2.4 liter Gasoline, LP-Gas, Dual Fuel Engine Serial Number(G424)

•_____________________________

3.0 liter LP-Gas Engine Serial Number(G430)

•_____________________________

3.3 liter (B3.3) Diesel Engine Serial Number

•_____________________________

-61-

General Section

2.4 liter LP and Dual Fuel Engine (G424E)

•_____________________________

3.0 liter LP and Dual Fuel Engine (G430E)

•_____________________________

Power Shift Transmission Serial Number

•_____________________________

Drive Axle Serial Number

•_____________________________

Typical Example Side Shifter Serial Number (If Equipped)

•_____________________________

-62-

Attachment Abbreviations (Includes Special Forks)

SSS HSS CW SF SWS RAM DBCBH HFP CR TH CTH LPP CC RC LS PWH SS-ST

-Special Carriage-increased width, height or outreach

-Shaft-type Sideshift Carriage

-Hook-type Sideshift Carriage (ITA)

-Counterweight

-Special Forks

-Swing Shift, Sideshift

-Ram or Boom

-Double Cube Block Handler

-Hydraulic Fork Positioner

-Crane Arm or Crane Boom

-Tire Handler

-Container Handler

-Load Push-Pull Device

-Carton Clamp

-Roll Clamp

-Load Stabilizer

-Pulp Wood Handler

Sideshift-Side Tilt Carriage

General Section

-63-

General Section

Operator's Warning and Identification Plate

Familiarize yourself with the OPERATOR’S WARNING PLATE and IDENTIFICATION, LIFT APACITY and ATTACHMENT PLATES. DO NOT exceed capacity as equipped load ratings.

Operator's Warning Plate

Located on the right side of the operator's seat.

If Convenience Package Equipped

Located on the overhead guard.

Identification, Lift Capacity and Attachment Plate

Located on the cowl to the right side of the steering column.

Below are abbreviations that may appear on the IDENTIFICATION, LIFT CAPACITY and ATTACHMENT PLATES and their meanings.

Mast Abbreviations

STD - Standard Mast (single inner member,

low free lift)

FF - Full Free Lift Mast (single inner member

with high free lift duplex cylinder)

FFT - Triple Lift Mast (two inner members)

with either low or full free lift characteristics.

QUAD - Quadruple (Quad) Mast(with three inner

members)

NOTE: When only a mast-type is listed on the

identification plate, a standard carriage and forks are used.

-64-

Operator's Station and Monitoring Systems

Instrument Panel

Diesel

3 4

LPG/GAS

light should go off after the engine is started. If the light turns on while operating the lift truck, insufficient engine oil pressure is indicated. Park the lift truck and stop the engine.

The light should go off after the engine is started, indicating the alternator is producing sufficient voltage to charge the battery. If the light turns on with the engine running, check the alternator charging system for a malfunction.

1. Engine Oil Pressure Indicator Light

- Indicates insufficient engine oil pressure.

The light will come on when the ignition switch is turned to the ON position. The

2. Alternator Indicator Light - Indicates if the battery charging system is operational. The light will come on when the ignition switch is turned to the ON position.

5 6

ILOO001P

IB1O003L

the glow plugs are preheating the pre-combustion chambers for easier starting.

The amount of time needed to preheat the pre-combustion chambers is approximately seven seconds, depending on the surrounding air temperature. When the light goes OFF the maximum pre-combustion chamber temperature has been reached and the key can be turned to the START position to start the engine.

The light will come ON when the ignition switch is turned to the ON position. The light should go off after the engine is started. If the light turns on with the engine running, park the lift truck and stop the engine. Drain some fuel (and any water) until clean fuel flows from the filter which approximately takes 5 to 6 seconds.

is indicated. Park the lift truck and stop the engine.

Check the cooling system for a malfunction. The pointer will be at the end of the green band when the coolant temperature reaches approximately 106°C (223°F) on all engines.

the green band while operating the lift truck, excessive transmission oil temperature is indicated. Park the lift truck and stop the engine.

3. Diesel Engine Start Preheat Indicator Light - The light will come ON

when the key is turned to the ON position from the OFF position. This indicates that

4. Diesel Engine Water in Fuel Filter Indicator Light - Indicates when the

engine is running, there is water in the fuel filter exceeds 100cc.

5. Fuel Level Gauge - Indicates fuel level (Gas, Diesel, or Dual Fuel Trucks Only)

6. Engine Coolant Temperature Gauge

- Indicates coolant temperature. If the

pointer moves beyond the green band while operating the lift truck, overheating

7. Transmission Oil Temperature Gauge - Indicates transmission oil

temperature. If the pointer moves beyond

Operation Section

-65-

Operation Section

8. G424E/G430E Engine Malfunction Indicator Lamp (MIL)

G424E and G430E engine control

systems are equipped with built-in fault diagnostics. Deteted system faults can be displayed by the Malfunction Indicator Lamp (MIL) as Diagnostic Fault Codes (DFC) or flash codes, and viewed in detail with the use of service tool software. When the ignition key is turned ON the MIL will perform a self-test, illuminate once and then go OFF. If a detected falut condition exists, the fault or faults will be stored in the memory of the engine control module (ECM). Once a fault occurs the MIL will illuminate and remain ON. This signals the operator that a faults has been detected by the SECM.

9. Seat Belt Warning Light (If Equipment)

Indicates when the seat belt dose not fastened by operator. The light will come on when the ignition switch is turned to the on position. The light should go off after engine is started.

10. Horn Switch - Push on the horn button to sound the horn.

11. Service hour Meter - Indicates the total number of hours the engine and the

lift truck have operated. The hour meter will operate when the ignition switch is in the ON position, whether the engine is running or not. The hour meter is used to determine lubrication and maintenance intervals.

-66-

Operation Section

Electrical Disconnect Switch (If Equipped)

Engine Compartment

1. The engine compartment is accessible by pulling

1. ON - Connects the battery for electrical

power to all electrical circuits.

2. OFF - Disconnects the battery from all electrical circuits.

the latch (GC Series), or pushing down the lever located at cowl (G.D Series) and raising the hood and seat assembly (Note: Unlock latch before pulling-if key equipped)

2. The hood and seat assembly is held up by a

support cylinder. Make certain the air cylinder is operating properly and securely hold the hood up before doing anything in the engine compartment.

-67-

Operation Section

CAUTION

When closing the engine hood, be careful not to pinch your hand.

Circuit Breaker

Circuit Breaker -Protects the main

electrical circuits. To reset the circuit breaker, push the button in. Located in the engine compartment.

Seat

NOTE: Seat arrangements may vary.

Basic operation will be similar.

Seat adjustment should be checked at the beginning of each shift and when operators change.

Lock the seat into position before operating, to prevent an unexpected seat change.

Adjust seat to allow full brake pedal travel with operator’s back against seat back.

Fuel Selector Switch (G424 Dual Fuel Only)

NOTE: The switch is located in the engine

compartment.

1. LPG - This position supplies electrical power to the LP fuelock solenoid, when the ignition switch is in the ON or the

START position. With the LP-Gas fuel tank valve open and when engine oil pressure is present, LP-Gas can then flow the tank through the converter to the carburetor.

2. OFF - This position shuts off all fuel supply to the carburetor and is used when changing from Gasoline to LP-Gas or LP-Gas to Gasoline fuel.

Electrical power shuts off the gasoline fuelock valve and the LP fuelock solenoid. Before switching to the LPG position, allow the engine to run until all of the gasoline in the carburetor is consumed and the engine stops.

3. GAS - This position supplies electrical power to gasoline fuelock solenoid. This will allow gasoline fuel to flow from the tank through the fuel filter and fuel

pump to the carburetor.

NOTE: The seat can only be correctly adjusted

with the operator fully seated.

-68-

Operation Section

Fuel Selector Switch (G424E/G430E Dual Fuel Only)

1. LPG - This position supplies electrical

power to the LP fuelock solenoid, when the ignition switch is in the ON or the

START position. With the LP-Gas fuel tank valve open, LP-Gas can then flow the tank through the converter to the carburetor.

2. OFF – This position shuts off all fuel supply to the carburetor/injector.

3. GAS - This position supplies electrical power to gasoline fuel pump and injector This will allow gasoline fuel to flow from the tank through the fuel filter and fuel

pump to the injector.

3. Reverse - Pull the lever back for REVERSE direction travel.

Plate for Function of Pedals (If Equipped)

It shows the function of each pedal i.e. inching (clutch), brake and accelerator.

Transmission Inching Control Pedal

Lift Truck Controls

Direction Control Lever

1. Forward - Push the lever forward for

FORWARD direction travel.

2. Neutral - Move the lever to center position for NEUTRAL.

Inching Control Pedal - Pushing down on

the inching pedal, modulates the hydraulic pressure to the clutch packs, permitting disc slippage.

Further pushing on the pedal completely relieves clutch pack pressure and applies the service brakes to stop and hold the lift truck.

NOTE: The purpose of the inching control pedal is

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 positioning.

-69-

Operation Section

Service Brake Pedal

Push DOWN on the brake pedal to slow or stop the lift truck.

RELEASE the brake pedal to allow the lift

truck to move.

Accelerator Pedal

Parking Brake Lever

Pull the lever BACK to engage the parking brake.

Push the lever FORWARD to release the parking brake.

Lift Control

Push DOWN on the pedal to increase engine rpm (speed).

RELEASE the pedal to decrease engine rpm (speed).

NOTE: To prevent a sudden change of position of

the load, operate all lift, tilt and attachment controls smoothly.

1. Lower Position - Push the lever FORWARD smoothly to lower the load.

2. Hold Position - When the lever is released it will return to the HOLD or center position. Lifting or lowering action will stop.

3. Lift Position - Pull the lever BACK smoothly to lift the load.

-70-

Operation Section

Tilt Control

1. Mast Tilt Forward - Push the lever

FORWARD smoothly to tilt the mast forward.

2. Mast Hold - When the lever is released it will return to the HOLD or center position. Tilting action will stop.

3. Mast Tilt Back - Pull the lever BACK smoothly to tilt the mast backward.

Sideshift Attachment (If Equipped)

1. Sideshift Left - Push the lever

FORWARD to shift the carriage to the left.

2. Sideshift Hold - When the lever is released it will return to the HOLD or center position. Sideshifting action will stop.

3. Sideshift Right - Pull the lever BACK to shift the carriage to the right.

-71-

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.

Stop the engine and get off the lift truck during refueling.

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.

Fill the fuel tank at the end of each day of operation to drive out moisture laden air and to prevent condensation.

In the cold weather, the moisture condensation can cause rust in the fuel system and hard starting due to its freezing

Do not fill the tank to the top. Fuel expands when it gets warm and may overflow.

1. Park the lift truck only at a designated safe

location. Place the transmission in NEUTRAL. Lower the forks to the ground. Engage the parking brake. Stop the engine.

2. Open the filter cap.

3. Fill the fuel tank slowly. Close the filter cap.

If spillage occurs, wipe off excess fuel and was down area with water.

NOTE: Drain water and sediment from fuel tank as

required by prevailing conditions. Also, drain water and sediment from the main fuel storage tank weekly and before the tank is refilled. This will help prevent water or sediment being pumped from the storage tank into the lift truck fuel tank.

-72-

Changing LP - Gas Tanks

WARNING

Only trained, authorized personnel should fill or exchange LP-Gas tanks.

Personnel engaged in filling of LP-Gas containers should wear protective clothing such as face shield, long sleeves and gauntlet gloves.

Do not refuel or store LP-Gas powered lift trucks near any underground entrance, elevator shafts or any other place where LP-Gas could collect in a pocket causing a potentially dangerous condition.

Examine all LP-Gas containers before filling and again before reuse, for damage to various valves, liquid gauge, fittings and hand valve wheels.

All defective or damaged LP-Gas containers must be removed from service.

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 indoor locations.

Stop the engine and get off the lift truck during refueling.

The careless handling of LP-Gas containers can result in a serious accident.

Use extreme care when transporting containers to prevent damage to them.

Operation Section

2. Close the fuel shut off valve at the LP - Gas

tank. Run the engine until it stops, then turn off the ignition switch and the disconnect switch (if equipped).

3. Disconnect the fuel supply line.

If Swing out type LP-Cradle Equipped

1. Park the lift truck on level ground, with the

parking brake applied, the transmission in NEUTRAL, the forks lowered and the engine running at low idle.

4. Loosen the retaining clamps and remove the

tank.

5. Check the mounting to be sure the locating pin

(dowel) is not missing or broken.

-73-

Operation Section

NOTICE

If the location pin (dowel) is missing or broken, be sure the pin is replaced.

6. Check to be sure that the LP - Gas warning

plate is in position on the lift truck, and is legible.

7. Check to be sure the replacement tank is of the

correct type.

8. Inspect the replacement tank for damage such

as dents, scrapes or gouges and for indication of leakage at valves or threaded connections.

11. Position the replacement tank so that the

locating pin (dowel) is in place.

CAUTION

The LP-Gas tank must not extend past the counterweight

12. Clamp the tank securely.

13. Connect the fuel supply line.

14. Open the fuel valve by slowly turning it

counterclockwise. If the fuel valve is opened too quickly, a back pressure check valve will shut off the fuel supply. If this happens, close the fuel valve completely. Wait five seconds and then open the fuel valve very slowly.

15. Inspect the LP - Gas fuel lines and fittings with

a soap solution after filling the tank or when

looking for leaks.

9. Check for debris in the relief valve, for damage

to various valves and liquid level gauge.

10. Inspect the quick - disconnect couplings for

deterioration, damage or missing flexible seals.

-74-

Before Starting the Engine

Walk - Around Inspection

Make a thorough walk - around inspection before mounting the lift truck or starting the engine. Look for such items as loose bolts, debris buildup, oil or coolant leaks. Check condition of tires, mast, carriage, forks or attachments. Have repairs made as needed and all debris removed.

1. Inspect the operator’s compartment for loose

items and cleanliness.

2. Inspect the instrument panel for broken or

damaged indicator lights or gauges.

3. Test the horn and other safety devices for

proper operation.

4. Inspect the mast and lift chains for wear, broken

links, pins and loose rollers.

Operation Section

7. Inspect the overhead guard for damage and

loose or missing mounting bolts.

8. Inspect the hydraulic system for leaks, worn

hoses or damaged lines.

9. Look for transmission and drive axle leaks on

the truck and on the ground.

DB33A Diesel Engine

5. Inspect the carriage, forks or attachments for

wear, damage and loose or missing bolts.

6. Inspect the tires and wheels for cuts, gouges,

foreign objects, inflation pressure and loose or missing bolts.

B3.3 Diesel Engine

10. Inspect the engine compartment for oil, coolant

and fuel leaks.

-75-

Operation Section

DB33A Diesel Engine

B3.3 Diesel Engine

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.

DB33A Diesel Engine

B3.3 Diesel Engine

12. Observe the engine coolant level in the coolant

recovery bottle. With the engine cold, maintain the level to the COLD mark. If the recovery bottle is empty, also fill the radiator at the top tank.

13. Observe the fuel level gauge after starting the

truck. Add fuel if necessary.

-76-

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.

Operation Section

14. To position the seat, PUSH the lever away from

the seat track and move the seat forward or backward to a comfortable position.

-77-

Operation Section

Starting the Engine

Prestart Conditions

2.4 Liter Gasoline Engine(G424)

NOTE: The engine will not start unless the

transmission directional control lever is in the NEUTRAL position.

1. Engage the parking brake, if not already

engaged. Place the transmission directional control lever in the NEUTRAL position.

NOTICE

Do not leave the key in ON position when engine is not running. Do not engage the starter more than 10 seconds at any one time.

1. Depress the accelerator pedal completely and

then release it.

2. Then, depress the accelerator pedal more than

1/2 of its stroke and hold in this position.

3. Turn the ignition switch to the START position

to crank the engine.

4. Release it when the engine starts.

2. Lift trucks equipped with electrical disconnect

switches; the engine will not start unless the disconnect switch is in the ON (closed) position.

-78-

Operation Section

LP - Gas Engine

WARNING

LP - Gas fuel is flammable and can cause personal injury.

Inspect LP - Gas fuel lines and fitting for leaks. Inspect tank for secure mounting.

1. Turn the tank fuel valve ON by slowly turning

the valve counterclockwise. Observe the LP Gas gauge (if equipped).

2. Turn the ignition switch to the START position.

Release it when the engine starts.

3. If the engine does not start, do not press on the

accelerator pedal. Turn the starter switch to OFF position, then repeat step 2 and depress the accelerator pedal slightly during cranking.

4. Allow the engine to warm up slowly.

Diesel Engine

Starting a Cold Diesel Engine

1. Turn the key to the ON position. The start pre

heat light will come ON. The preheat light will stay ON approximately seven seconds, depending on the surrounding air temperature.

NOTICE

Do not engage the starter for more than 10 seconds.

2. When the preheat light goes OFF, turn the key

to the START position, with the accelerator pedal fully depressed.

3. Release the key when the engine starts and

release the accelerator pedal to a low idle position.

4. If the engine stalls or does not start, turn the

key to the OFF position, then repeat steps 1 thru 3.

Starting a Warm Diesel Engine

1. Turn the key to the ON position and then to

START position, without waiting for the preheat light to go OFF. At the same time fully depress the accelerator.

2. Release the key when the engine starts and

release the accelerator pedal to a low idle position.

-79-

Operation Section

Starting From a 12 Volt External Source

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.

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.

-80-

Operation Section

Dual Fuel System (If G424 Dual Fuel Engine Equipped)

Changing From Gasoline to LP – Gas

NOTE: The Underwriter’s Laboratory (U.L.)

requires that the gasoline tank must be at least one - quarter full when operating on LP - Gas. This will allow the lift truck to be restarted on gasoline and moved to an approved refueling area, when operating in a hazardous area.

1. Park the lift truck level in an authorized refueling

area with the forks lowered, the parking brake applied, the transmission in NEUTRAL and the engine running.

2. Raise the hood and seat assembly. Make certain

the air lift cylinder securely holds the hood open.

6. Open the fuel valve, on the LP - Gas tank, by

slowly turning the valve counterclockwise.

7. Turn the ignition switch key to the OFF position

and then to the START position to start the engine. Release it when the engine starts.

Changing From LP - Gas to Gasoline

1. Park the lift truck level in an authorized

refueling area with the forks lowered, the parking brake applied, the transmission in NEUTRAL and the engine running.

3. Move lever (1), on the fuel selector switch to the

OFF (2) position. Leave lever (1) in this position until the gasoline in the carburetor is used and the engine stops.

4. Move lever (1) to the LPG (3) position.

5. Lower the hood and seat assembly.

2. Close the fuel valve on the LP - Gas tank. Allow

the engine to run until the fuel in the line runs out and the engine stops. Turn the ignition switch to the OFF position.

3. Raise the hood and seat assembly. Make

certain the air lift cylinder securely holds the hood open.

-81-

Operation Section

4. Move lever (1) from the LPG (3) position to the

GAS (4) position.

5. Lower the hood and seat assembly.

6. Turn the ignition switch key to the ON position. NOTE: On trucks equipped with electric fuel pumps

wait approximately 15 seconds to fill the carburetor with gasoline.

7. Turn the ignition switch key to the START

position and start the engine. Release it when the engine starts.

-82-

Dual Fuel System (G424E/G430E Engine Only)

Changing From Gasoline to LP – Gas

Operation Section

NOTE: The Underwriter’s Laboratory (U.L.)

2 3

1. Park the lift truck level in an authorized refueling

area with the forks lowered, the parking brake applied, the transmission in NEUTRAL and the engine running.

2. Raise the hood and seat assembly. Make certain

the air lift cylinder securely holds the hood open.

3. Open the fuel valve, on the LP - Gas tank, by

slowly turning the valve counterclockwise.

4. Move lever (1) from the GAS (2) position to LPG

(3) position.

5. Lower the hood and seat assembly.

Changing From LP - Gas to Gasoline

1. Park the lift truck level in an authorized

refueling area with the forks lowered, the parking brake applied, the transmission in NEUTRAL and the engine running.

2. Raise the hood and seat assembly. Make

certain the air lift cylinder securely holds the hood open.

3. Move lever (1) from the LPG (3) postion to the

GAS (2) position.

2 3

-83-

Operation Section

4. Close the fuel valve on the LP - Gas tank. Allow

the engine to run until the fuel in the line runs out and the engine stops.

5. Lower the hood and seat assembly.

When Stop the Engine (G424E Dual Fuel Only)

Engine wiring harness includes timer relay. The purpose of it is to prevent backire to exhaust when stop engine by turning key switch OFF. Because of it, engine stop time can be delayed 1 or 2 seconds when turn key switch OFF to stop engine.

-84-

Operation Section

After Starting the Engine

Observe all indicator lights and gauges frequently during operation, to make sure all systems are working properly. The entire indicator lights will come ON with the ignition switch in the ON position before the engine is started.

Diesel

3 4

LPG/GAS

1. The engine oil pressure indicator light (1), will

not come ON with the engine running, unless there is low or no oil pressure. Stop the engine immediately, if the light comes ON.

5 6

ILOO001P

IB1O003L

2. The alternator indicator light (2), should not

come ON during normal operation. The alternator is not charging if the light comes ON with the engine running.

3. The G424/430E engine MIL(Malfunction

Indicator Light) will not come ON with the engine running, unless the fault or faults are stared in the memory of the engine control module(ECM). Stop the engine and check the electric engine control system if the light comes ON. Refer G424E/G430E Engines of this section.

4. The diesel engine water in fuel filter indicator

light(4), will not come ON with the engine running, unless water in fuel filter exceeds 100cc. Stop the engine immediately and drain the water if the light comes ON.

5. Observe the fuel level gauge (5) for fuel level in

the tank.

6. The engine coolant temperature gauge pointer

(6) will be in the green band with the engine running, unless the coolant temperature is excessive.

7. The transmission oil temperature gauge pointer

(7) will be in the green band with the engine running, unless the oil temperature is excessive.

8. Observe the hour meter to make sure it is

operating properly.

If the excessive valve noise occurs (G424 and G424E Engine Only)

In normal case, the recommended engine oil for G424 engine is SAE 10W30.

But, if the excessive valve noise occurs up to five minutes after a cold start and if the maximum ambient temperature is lower than 10 C (50 F), it is recommended to change engine oil to SAE 5W30 for that application.

-85-

Operation Section

Lift Truck Operation

Power Shift Transmission/ Drive axle

1. Start the engine. See topic “Starting the

Engine”.

WARNING

A lift truck with the engine running but without an operator can move slowly (creep) if the transmission is engaged.

This could result in personal injury. Always place the transmission control lever in

the NEUTRAL (center) position and apply the parking brake before dismounting the lift truck.

2. Push down on the service brake pedal to hold

the lift truck until ready to move it.

3. Release the parking brake. NOTE: The parking brake must be released before

the directional control can be used.

4. Select the direction of travel by pushing the

directional lever FORWARD for forward direction or by pulling the lever BACK for reverse direction.

5. Release the service brake.

6. Push down on the accelerator pedal to obtain

the desired travel speed. Release the pedal to decrease travel speed.

WARNING

Sudden reversal of a loaded lift truck traveling forward can cause the load to fall or the lift truck to tip over.

Stop the loaded lift truck completely, before shifting to reverse. Failure to comply could result in personal injury.

NOTE: Where conditions permit, directional

changes can be made under full power at speeds up to 6 km/h (3.73 mph). A speed of 6 km/h (3.73 mph) is a fast walk. Directional shift changes at speeds above 6 km/h (3.73 mph) are considered abusive. Bring the lift truck to a complete stop where load stability or other factors prevent safe operation under full power shifts.

-86-

Operation Section

7. To change the lift truck direction of travel,

release the accelerator pedal.

8. Push down on the service brake pedal to

reduce the lift truck speed as necessary.

9. Move the directional lever to the desired

direction of travel. Slowly push down on the accelerator pedal as the lift truck changes direction.

10. When the direction change is completed,

continue to push down on the accelerator pedal to obtain the desired travel speed.

11. To stop the lift truck when traveling in either

direction, release the accelerator pedal.

12. Push down on the service brake pedal and

bring the lift truck to a smooth stop.

-87-

Operation Section

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.

1. To inch (creep) in either direction, slowly push

down on the inching pedal. This will start to apply the service brakes and allow the transmission clutch discs to slip.

2. Vary the position of the inching pedal and the

accelerator pedal to control the inching speed and distance.

3. Pushing down further on the inching pedal will

disengage the transmission completely and apply the service brakes fully to stop and hold the lift truck. This will provide full engine power for fast hydraulic lift.

-88-

Operation Section

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

General Description

The MI-04 is a closed loop system utilizing a catalytic muffler to reduce the emission level in the exhaust gas. In order to obtain maximum effect from the catalyst, an accurate control of the air fuel

MI-04 LP System

The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air/fuel mixer by modulating the fuel trim valve (FTV) connected to the regulator. Reducing the fuel pressure leans the air/fuel mixture and increasing the fuel pressure enriches the air/fuel mixture. To calculate any necessary corrections to the air fuel ratio, the SECM uses a number of different sensors to gain information about the engines performance. Engine speed is monitored by the SECM through a variable reluctance (VR) sensor. Intake manifold air temperature and absolute pressure is monitored with a (TMAP) sensor. The MI-04 is a drive by wire

Fault Li

APP

Air Cleaner

Oxygen

Catalytic Muffler

Key switch

Foot Pedal

Main PWR Relay

DBW Throttle

Engine

VR Sensor

Fuel Filter

VacuumLine

Coolant Line

Mixer

TMAP

Distributor

ratio is required. A small engine control module (SECM) uses a heated exhaust gas oxygen sensor (HEGO) in the exhaust system to monitor exhaust gas content.

LP Fuel Line

Fuel Lock

Smart Coil

Converter

Fuel Trim Valve

TPS

SECM

Coolant Temp Sensor

(DBW) system connecting the accelerator pedal to the electronic throttle through the electrical harness, mechanical cables are not used. A throttle position sensor (TPS) monitors throttle position in relation to the accelerator pedal position sensor (APP) feedback. Even engine coolant temperature and adequate oil pressure is monitored by the SECM. The SECM controller has full adaptive learning capabilities, allowing it to adapt control function as operating conditions change. Factors such as ambient temperature, fuel variations, ignition component wear, clogged air filter, and other operating variables are compensated.

-89-

Operation Section

MI-04 Dual Fuel System

Fault Light

APP

Air Cleaner

Fuel Pump

Oxygen Sensor

Key switch

Foot Pedal

Main PWR Relay

Fuel Injector

DBW Throttle

Engine

LP Fuel Filter

Vacuum Line

Coolant Line

Mixer

Distributor

VR Sensor Oil Pressure Switch Coolant Temp Sensor

LP Fuel Line

Fuel Lock

Converter

Fuel Trim

Valve

TPS

TMAP

Fuel Select Relay 1&2

Smart Coil

Fuel Select Switch

SECM

Catalytic Muffler

-90-

Basic Troubleshooting(LPG)

The MI-04 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) and are covered in the Advanced Diagnostics section. Items such as fuel level, plugged fuel lines, clogged fuel filters and malfunctioning pressure regulators may not set a fault code by the Small Engine Control Module (SECM). Below are

Problem Probable Cause Corrective Action

Engine Cranking

Fuel container empty Fill fuel container

but Will Not Start

Liquid valve closed Slowly open liquid valve Excess flow valve closed Reset excess flow valve

Plugged fuel line Remove obstruction from the fuel line

Broken Fuse - SECM Replace Fuse for SECM

Clogged fuel filter Repair/replace as required

Faulty vapor connection between the pressure regulator/converter and the mixer

Fuel Lock-off malfunction Repair/replace Fuel Lock-off

Pressure regulator/converter malfunction

Incorrect air/fuel or ignition/spark control No VR Sensor Signal Verify the VR signal is present

Operation Section

basic checks that should be made before referring to the Advanced Diagnostics section, if engine or drivability problems are encountered.

Locating a problem in a propane engine is done exactly the same way as with a gasoline engine. Consider all parts of the ignition and mechanical systems as well as the fuel system.

z Do not exceed 80% of liquid

capacity

z Close liquid valve z Wait for a “click” sound z Slowly open liquid valve

z Close liquid fuel valve z Using caution, disconnect the fuel

line (some propane may escape)

z Clear obstruction with compressed

air

z Re-connect fuel line z Slowly open liquid fuel valve z Leak test

z See Maintenance Section, Fuses

replacement

z See Maintenance Section, LP Fuel

Filter replacement

Check connection

z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or

collapsed hose

z See G424E/G430E Engine Service

Manual

Test pressure regulator/converter operation

z See G424E/G430E Engine Service

Manual

See Advanced Diagnostics

z See Advanced Diagnostics

-91-

Operation Section

Problem Probable Cause Corrective Action

Difficult to Start

Fuel container almost empty LPG Vapor from liquid outlet

z Fill fuel container z Do not exceed 80% of liquid

capacity

Excess flow valve closed Reset excess flow valve

z Close liquid valve z Wait for a “click” sound

Slowly open liquid valve

Clogged fuel filter Repair/replace as required

z See Maintenance Section, LP Fuel

Filter replacement

Plugged fuel line Remove obstruction from the fuel line

z Close liquid fuel valve z Using caution, disconnect the fuel

line (some propane may escape)

z Clear obstruction with compressed

air

z Re-connect fuel line z Slowly open liquid fuel valve z Leak test

Faulty vapor connection between the pressure regulator/converter and the mixer

Check connection

z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or

collapsed hose Pressure regulator/converter malfunction

Test pressure regulator/converter operation

z See G424E/G430E Engine Service

Manual

Fuel container almost empty LPG Vapor from liquid outlet

z Fill fuel container z Do not exceed 80% of liquid

capacity Air filter clogged Check air filter

z Clean/replace as required

Incorrect air/fuel or ignition control See Advanced Diagnostics Engine Mechanical See Engine Service Manual

-92-

Problem Probable Cause Corrective Action Will Not Run Continuously

Will Not Accelerate/Hesita tion During Acceleration

Operation Section

Fuel container almost empty LPG Vapor from liquid outlet

z Fill fuel container z Do not exceed 80% of liquid

capacity

Excess flow valve closed Reset excess flow valve

z Close liquid valve z Wait for a “click” sound

Slowly open liquid valve

Clogged fuel filter Repair/replace as required

z See Maintenance Section, LP Fuel

Filter replacement

Plugged fuel line Remove obstruction from the fuel line

z Close liquid fuel valve z Using caution, disconnect the fuel

line (some propane may escape)

z Clear obstruction with compressed

air

z Re-connect fuel line z Slowly open liquid fuel valve & Leak

test

Pressure regulator freezes Check level in cooling system

z Must be full, check coolant strength z -35F minimum

Check coolant hoses

z Watch for kinks and/or pinched

hoses

z Verify one pressure hose and one

return hose

Fuel Lock-off malfunction Repair/replace Fuel Lock-off

z See G424E/G430E Engine Service

Manual

Incorrect idle speed or ignition

See Advanced Diagnostics problem Engine Mechanical See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet

z Fill fuel container z Do not exceed 80% of liquid

capacity

Excess flow valve closed Reset excess flow valve

z Close liquid valve z Wait for a “click” sound

Slowly open liquid valve

-93-

Operation Section

Problem Probable Cause Corrective Action Will Not Accelerate/Hesita tion During Acceleration

Engine Stalls

Clogged fuel filter Repair/replace as required

z See Maintenance z Section, LP Fuel Filter replacement

Faulty vapor connection between the pressure regulator/converter and the mixer

Check connection

z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or

collapsed hose

Throttle butterfly valve not opening

See Advanced Diagnostics or sticking Foot Pedal signal incorrect or intermittent Incorrect air/fuel or ignition control Engine Mechanical See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet

z Fill fuel container z Do not exceed 80% of liquid

capacity

Excess flow valve closed Reset excess flow valve

z Close liquid valve z Wait for a “click” sound

Slowly open liquid valve Clogged fuel filter Repair/replace as required

z See Maintenance Section, LP Fuel

Filter replacement

Plugged fuel line Remove obstruction from the fuel line

z Close liquid fuel valve z Using caution, disconnect the fuel

line (some propane may escape)

z Clear obstruction with compressed

air

z Re-connect fuel line z Slowly open liquid fuel valve & Leak

test

-94-

Problem Probable Cause Corrective Action

Engine Stalls

Fuel Lock-off malfunction Repair/replace Fuel Lock-off

z See G424E/G430E Engine Service

Manual

Faulty vapor connection between the pressure regulator/converter and the mixer

Check connection

z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or

collapsed hose

Pressure regulator freezes Check level in cooling system

z Must be full, check coolant strength z -35F minimum z Check coolant hoses z Watch for kinks and/or pinched

hoses

z Verify one pressure hose and one

return hose

Pressure regulator malfunction Test pressure regulator operation

z See G424E/G430E Engine Service

Manual

Vacuum leak Check for vacuum leaks

z Between mixer and throttle body z Between throttle body and intake

manifold

z Between intake manifold and

cylinder head

Air/Fuel Mixer malfunction Check mixer

z See G424E/G430E Engine Service

Manual

Engine Mechanical See Engine Manufacturers Service Manual

Operation Section

Rough Idle

Faulty vapor connection between the pressure regulator/converter and the mixer

Check connection

z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or

collapsed hose

Pressure regulator malfunction Test pressure regulator operation

z See G424E/G430E Engine Service

Manual

Vacuum leak Check for vacuum leaks

z Between mixer and throttle body z Between throttle body and intake

manifold

z Between intake manifold and

cylinder head

Air/Fuel Mixer malfunction Check mixer

z See G424E/G430E Engine Service

Manual

-95-

Operation Section

Problem Probable Cause Corrective Action

Rough Idle

High Idle Speed

Poor High Speed Performance

Incorrect Idle speed control Incorrect timing or spark control

See Advanced Diagnostics & See

G424E/G430E Engine Service Manual Engine Mechanical See Engine Service Manual Incorrect Idle speed control Throttle sticking Foot pedal sticking or incorrect pedal signal

See Advanced Diagnostics & See

G424E/G430E Engine Service Manual

Check pedal return spring travel for binding

z See Advanced Diagnostics

Clogged fuel filter Repair/replace as required

z See Maintenance section, Fuel

Filter replacement

Plugged fuel line Remove obstruction from the fuel line

z Close liquid fuel valve z Using caution, disconnect the fuel

line (some propane may escape)

z Clear obstruction with compressed

air

z Re-connect fuel line z Slowly open liquid fuel valve & Leak

test

Air filter clogged Check air filter

z Clean/replace as required

Faulty vapor connection between the pressure regulator/converter and the mixer

Check connection

z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or

collapsed hose

Pressure regulator malfunction Test pressure regulator operation

z See G424E/G430E Engine Service

Manual

Air/Fuel Mixer malfunction Check mixer

z See G424E/G430E Engine Service

Manual

Restricted exhaust system Check exhaust system

z Measure exhaust back pressure

Incorrect ignition control Incorrect air/fuel control Incorrect throttle position

See Advanced Diagnostics & See

G424E/G430E Engine Service Manual

-96-

Problem Probable Cause Corrective Action Excessive Fuel Consumption/LP G Exhaust Smell

Operation Section

Air/Fuel Mixer malfunction Check mixer

z See G424E/G430E Engine Service

Manual

Air filter clogged Check air filter

z Clean/replace as required

Vacuum leak Check system vacuum hoses from

regulator to FTV and mixer

z Repair/replace as necessary

Pressure regulator malfunction/fuel pressure too high

Test pressure regulator operation

z See G424E/G430E Engine Service

Manual

Faulty FTV Check FTV for housing cracks or

obstructions

z See Advanced Diagnostics FTV

operation

z Repair and/or replace as necessary

Weak ignition and/or spark control See Advanced Diagnostics Incorrect air/fuel control See Advanced Diagnostics Exhaust system leaks Repair exhaust system Oxygen sensor failure Replace as necessary

z See Advanced Diagnostics

-97-

Operation Section

Basic Troubleshooting (Gasoline)

Problem Probable Cause Corrective Action Engine Cranking

Fuel tank empty Fill fuel container

but Will Not Start (Gas)

Clogged fuel filter Repair/replace as required

Faulty vapor connection between the pressure regulator/ converter and the mixer (LPG)

Electric Fuel Pump malfunction (GAS)

Fuel Pressure regulator malfunction Test pressure regulator operation

Fuel Injector malfunction Test Injector operation

Incorrect air/fuel or ignition/ spark control No VR Sensor Signal Verify the VR signal is present

z The tank should be at least ¼ full to

properly prime the fuel pump.

z Fuel select switch is not on GAS z See Maintenance section Primary

and Secondary Fuel Filter replacement

Check connection

z Verify no holes in hose z Clamps must be tight z Look for kinked, pinched and/or

collapsed hose

Check electrical connection

z Check Relay and fuse

Turn key ON and verify pump is operating

z See G424E/G430E Dual Fuel

Engine Service Manual

z See G424E/G430E Dual Fuel

Engine Service Manual

See Advanced Diagnostics

z See Advanced Diagnostics

-98-

Doosan D20S-3, D25S-3, D30S-3, D33S-3, G25E-3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual