Daewoo G424 Engine Service Repair Workshop Manual 

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This service manual PDF download for the G424 Daewoo Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Daewoo G424 Gasoline/LP Engine
Daewoo G424 LP Engine (Low Emission Version)

G20E-3, G25E-3, G30E-3, GC20E-3, GC25E-3, GC30E-3


TABLE OF CONTENTS :

GENERAL INFORMATION 
SPECIFICATIONS 
MAINTENANCE 
ENGINE SYSTEM 
STARTING SYSTEM
CHARGING SYSTEM
IGNITION SYSTEM 
GASOLINE FUEL SYSTEM
LPG FUEL SYSTEM 
LPG FUEL SYSTEM (LOW EMISSION VERSION)
DUAL FUEL SYSTEM
GOVERNING SYSTEM 
LUBRICATION SYSTEM
COOLING SYSTEM
BASE ENGINE SERVICE PROCEDURE 
ADJUSTMENT AND TROUBLESHOOTING
SPECIAL TOOLS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : SB2215E01
Total Pages : 199


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GENERAL INFORMATION .......................................4
How to Read This Manual ....................................4
Precaution Before Service....................................6
General .................................................................8
Tightening Torque .................................................9
Sealant................................................................12
SPECIFICATIONS ...................................................13
General Specification..........................................13
Service Specification ..........................................14
MAINTENANCE ......................................................17
Test Fuel System for Leaks ................................17
Check Engine Oil Level ......................................17
Inspect Engine for Fluid Leaks ...........................17
Change Engine Oil and Filter .............................17
Inspect Accessory Drive Belts ............................18
Inspect Electrical System....................................18
Inspect Vacuum lines and fitting .........................18
Check Coolant Level...........................................18
Inspect Coolant Hoses........................................18
Inspect Ignition System.......................................18
Replace Spark Plug............................................18
Replace LP fuel filter element.............................19
Test Fuelock (electric).........................................19
Replace Gasoline Fuel filter ...............................20
Inspect Gasoline Carburetor...............................20
Inspect Pressure Regulator/Vaporizer ................20
Inspect LP Mixer (Standard LP Truck)................20
Inspect Variable Venturi Air/Fuel Mxer (Low Emission LP Truck)....................................20
Inspect Complete Exhaust System for Leaks,damage ....................................................20
Engine Control Unit (ECU) and others
(Low Emission LP Truck)....................................20
Maintenance Schedule .......................................21
ENGINE SYSTEM ...................................................22
Engine Overview.................................................22
Timing System ....................................................25
Silent Shaft Mechanism......................................26
Auto Lash Adjuster..............................................27
Intake and Exhaust System................................28
Electrical System ................................................30
STARTING SYSTEM...............................................32
General Description ............................................32
Start Relay Test ..................................................35
Start Motor ..........................................................36
Operation.......................................................36
Removal and Installation...............................39
Disassembly and Reassembly ......................42
CHARGING SYSTEM..............................................47
General Description ............................................47
Alternator ............................................................47
IGNITION SYSTEM .................................................50
Breakerless Ignition System ...............................50
Distributor............................................................51
Removal and Installation ....................................54
Distributor, disassembly and reassembly ...........56
GASOLINE FUEL SYSTEM....................................58
General Description ............................................58
Geasoline Carburetor, Operation........................59
Removal and Installation ....................................64
Gasoline Carburetor Disassembly and Reassembly............................66
LPG FUEL SYSTEM ...............................................73
General Description ............................................73
Electric Fuelock Model ..................................73
Converter.......................................................74
Fuel Tank.......................................................75
LP Relief Valve ..............................................75
Carburetor .....................................................76
Tests or Adjustments...........................................77
Carburetor Adjustment ..................................77
Fuel System Leak Check ..............................79
Recommendation for LP Fuel System ..........80
LP Converter - Check, Clean ........................81
Disassembly and Assembly................................82
LPG Carburetor.............................................82
LP Gas Fuelock.............................................84
LP Gas Converter..........................................85
LPG FUEL SYSTEM (LOW EMISSION VERSION)..87
General Description ............................................87
LP Carburetor................................................89
Vacuum switch (MAP) ...................................90
Vacuum switch ..............................................90
LP Converter .................................................91
Fuel Control Valve .........................................92
Fuelock Valve ................................................92
Engine Control Unit (ECU) ............................93
Oxygen Sensor..............................................94
Catalytic Muffler.............................................95
Tests or Adjustments...........................................96
LP Carburetor - Check, Clean.......................97
LP Converter-Check,Clean ...........................97
Inspection of Fuelock Valve ..........................97
Inspection of Fuel Control Valve ...................97
Inspection of Vacuum switch.........................97
Inspection of Vacuum switch (MAP)..............97
Inspection of Oxygen sensor.........................98
Disassembly and Assembly................................99
LPG Carburetor.............................................99
LP Gas Converter........................................101
DUAL FUEL SYSTEM...........................................102
GOVERNING SYSTEM .........................................103
General Description ..........................................103
Governor,Disassembly and Reassembly..........104
LUBRICATION SYSTEM.......................................106
General Description ..........................................106
Testing and Adjusting........................................107
Engine Oil...............................................107
Lubrication System Problem ..................107
Oil Pressure Check ................................109
COOLING SYSTEM...............................................110
General Description ..........................................110
Testing and Adjusting ........................................111
Cooling System Visual Inspection ...............111
Cooling System Tests ..................................111
Thermostat...................................................113
Cooling system Heat Problem.....................114
Cooling System Recommendation ..............114
Belt Adjustment............................................116
V-belt Diagnosis...........................................116
Serivce Procedure ............................................117
Draining and Filling Cooling System ...........117
Flushing the Cooling System.......................118
Radiator Service ..........................................118
Removal & Install Water Temperature Sender..119
BASE ENGINE SERVICE PROCEDURE .............120
Timing Belt ........................................................120
Intake Manifold .................................................129
Exhaust Manifold and Water Pump ..................130
Rocker Arms and Camshaft..............................133
Cylinder Head and Valves ................................139
Front Case and Oil Pan....................................145
Piston and Connecting Rod..............................154
Crankshaft and Cylinder Block .........................162
ADJUSTMENT AND TROUBLESHOOTING........169
Adjustment........................................................169
Valve Clearnce Adjustment .........................169
Ignition Timing Adjustment ..........................169
Idle Speed Adjustment ................................171
Air Governor Adjustment .............................171
Anti-Hunting Adjustment..............................171
Troubleshooting ................................................172
Engine Performance....................................172
Engine Starting Problems ...........................172
Charging System Problems ........................173
Instrument Problems ...................................173
Engine Noise...............................................174
Oil Pressure Diagnostics.............................176
Oil Pressure Problems ................................177
Water in Engine...........................................178
Engine Overheting.......................................179
LP Fuel System (Standard and/or Low Emission Version)....180
Troubleshooting Flow Chart ........................187
General ..................................................187
Engine ....................................................189
Carburetor ..............................................190
Electrical Components ...........................192
SPECIAL TOOLS..................................................195



SB2101E02
SB2003E00
SB2004E00
SB2215E01
    Index
        GENERAL INFORMATION
            How To Read This Manual
            Precautions Before Servce
            General
            Tightening Torque
            Sealant
        SPECIFICATIONS
            General Specifications
            Service Specifications
        MAINTENANCE
            Test Fuel System for Leaks
            Check Engine Oil Level
            Inspect Engine for Fluid Leaks
            Change Engine Oil &Filter
            Inspect Accessory Drive Belts
            Inspect electrical system
            Inspect Vacuum Lines and Fittings
            Check Coolant Level
            Inspect Coolant Hoses
            Inspect Ignition System
            Replace Spark Plugs
            Replace LP Fuel Filter Element
            Replace Gasoline Fuel Filter (Gasoline Truck and Dual Fuel Truck)
            Inspect Gasoline Carburetor
            Inspect Pressure

Regulator/Vaporizer
            Inspect LP Mixer

(Standard LP Truck)
            Inspect Variable Venturi

Air/Fuel Mixer

(Low Emission LP Truck)
            Inspect Complete Exhaust System for Leaks, Damage
            Engine Control Unit(ECU) and others

(Low Emission LP Truck)
            Maintenance Schedule
        ENGINE SYSTEM
            Engine Overview
            Timing System
            Silent Shaft Mechanism
            Auto Lash Adjuster
            Intake and Exhaust System
            Electrical System
        STARTING SYSTEM
            General Description
            Start Relay Tests
            Starter Motor
                Operation
                Removal and Installation
                Disassembly And Reassembly
        CHARGING SYSTEM
            General Description
            Alternators
        IGNITION SYSTEM
            Breakerless Ignition System
            Distributor
            Removal and Installation
            Disassembly and Reassembly
        GASOLINE FUEL SYSTEM
            General Description
            Gasoline Carburetor - Operation
            Removal and Installation
            Gasoline Carburetor

Disassembly and Reassembly
        LP FUEL SYSTEM
            General Description
                Electric Fuelock Model
                Converter
                Fuel Tank
                LP Relief Valve
                Carburetor
            Tests or Adjustments
                Carburetor Adjustment
                Fuel System Leak Check
                Recommendation For LP Fuel Systems
                LP Converter - Check, Clean
            Disassembly & Assembly
                LPG Carburetor
                LP Gas Fuelock
                LP Gas Converter
        LPG FUEL SYSTEM (LOW EMISSION VERSION)
            General Description
                LP Carburetor(Variable Venturi)
                Vacuum Switch (MAP)
                Vacuum Switch
                LP Converter
                Fuel Control Valve
                Fuel Lock - Off
                Engine Control Unit (ECU)
                Oxygen Sensor
                Catalytic Muffler
            Tests or Adjustments
                LP Carburetor-Check, Clean
                LP Converter-Check, Clen
                Inspection of Fuel Lock - Off
                Inspection of Fuel Control Valve
                Inspection of Vacuum Switch
                Inspection of Vacuum Switch (MAP)
                Inspection of Oxygen Sensor
            Disassembly & Assembly
                LPG Carburetor
                LP Gas Converter
        DUAL FUEL SYSTEM
        GOVERNING SYSTEM
            General Description
            Air Governor

Disassembly and Reassembly
        LUBRICATION SYSTEM
            General Description
            Testing & Adjusting
                Engine Oil
                Lubrication System Problems
                Oil Pressure Check
        COOLING SYSTEM
            General Description
            Testing & Adjusting
                Cooling System Visual Inspection
                Cooling System Tests
                Thermostat
                Cooling System Heat Problems
                Cooling System Recommendation
                Belt Adjustment
                V-Belt Diagnosis
            Service Procedures
                Draining and Filling the Cooling System
                Flushing the Cooling System
                Radiator Service
                Remove & Install Water

Temperature Sender
        BASE ENGINE SERVICE PROCEDURE
            Timing Belt
            Intake Manifold
            Exhaust Manifold and Water Pump
            Rocker Arms And Camshaft
            Cylinder Head And Valves
            Front Case And Oil Pan
            Piston And Connecting Rod
            Crankshaft And Cylinder Block
        ADJUSTING AND TROUBLESHOOTING
            Adjustment
                Valve Clearance Adjustment
                Ingition Timing Adjustment
                Idling Speed Adjustment
                Air Governor Adjustment
                Anti-Hunting Adjustment
            Troubleshooting
                Engine Performance
                Engine Starting Problems
                Engine Starting Problems (Continued)
                Charging System Problems
                Instrument Problems
                Engine Noise
                Engine Noise (Continued)
                Oil Pressure Diagnostics
                Oil Pressure Problems
                Water in Engine
                Engine Overheating
                LP Fuel System (Standard and/or Low Emission Version)
                Troubleshooting Flow Chart
                    General
                    Base Engine
                    Carburetor
                    Electrical components
        SPECIAL TOOLS
SB4005E01
    Index
        GENERAL INFORMATION
            Shop Safety
            Fuel Information
                What is LPG?
                1.3 Air Temperature Versus

Air Temperature Versus Power Output
                Altitude Versus Power Output
            General Description General Description & Operation
                Engine Component Description
                Lubrication
                Thread Repair
                Cleanliness and Care
                Replacing Engine Gaskets
                Use of RTV and Anaerobic Sealer
                Separating Parts
                Tools and Equipment
        SPECIFICATIONS
            Technical Data
                General Description
                Fuel System
                Cooling System
                Lubrication System
                Engine Electrical
                Exhaust System (Low Emission Version Only)
            Engine Mechanical Data
                Fastener Tightening Specifications
                Sealers, Adhesives and Lubricants
                Engine Mechanical Specifications
        MAINTENANCE
            Test fuel system for leaks
            Inspect engine for fluid leaks
            Engine Crankcase Oil
                Oil Recommendations
                Checking/Filling Engine Oil Level
                Changing Engine Oil And Filter
            Accessory Drive Belts
            Inspect electrical system
            Inspect vacuum lines and fittings
            Inspect fuel lines and fittings
            Engine Compression Check
            Cooling System
                Checking coolant Level
                Inspect coolant hoses
            Inspect ignition system
            Replace spark plugs
            Replace LP Fuel Filter Element
            Test fuel lock (electric)
            Inspect pressure regulator/vaproizer
            Inspect LP mixer(standard LP truck)
            Inspect variable venturi air/fuel mixer (low emission LP truck)
            Inspect complete exhaust system for leaks, damage
            Engine Control Unit (ECU) and others (low emission LP truck)
            Maintenance Schedule
        TROUBLESHOOTING
            Engine Performance
            Engine Starting Problems
            Charging System Problems
            Instrument Problems
            Engine Noise
            Oil Pressure Diagnostics
            Oil Pressure Problems
            Water in Engine
            Engine Overheating
            LP Fuel system (Sandard and/or

Low Emission Version)
        STARTING SYSTEM
            General Description
            Start Relay Tests
            Starting Motors
        CHARGING SYSTEM
            General Description
            Alternators
                Remove & Install Alternator
        IGNITION SYSTEM
            General Information
                Conventional Ignition Systems
                High Energy Ignition Systems
                    Module
                    Pulse Generator
                    Magnetic Flux Path
                    Current Limiting Circuit
                    Dwell Control Circuit
                    Ignition Coil
                    HEl Models
                Electronic Spark Timing (EST) Distributor
                Spark Plug Wires
                Spark Advance Curves
            Delco Electronic Spark Timing(EST) Distributor Service
                General Description
                EST Distributor Component Testing
                EST Distributor Removal
                EST Distributor Disassembly
                EST Distributor Installation(Engine Not Disturbed)
                EST Distributor Installation(Engine Disturbed)
                Ignition Timing - EST System
        LP FUEL SYSTEM
            General Information
                Electric Fuelock Models
                Converter
                Fuel Tank
                LP Relief Valve
                Carburetor
            Tests or Adjustments
                Carburetor Adjustment
                Fuel System Leak Check
                Recommendation For LPFuel Systems
                LP Converter - Check, Clean
            Disassembly & Assembly
                LP Gas Carburetor
                LP Gas Fuelock
                LP Gas Converter
        LP FUEL SYSTEM (LOW EMISSION VERSION)
            General Description
                System Overivew
                Fuel Lock (Electric)
                Pressure Regulator/Vaporizer
                    Pressure Regulator Theory of Operation
                Variable Venturi Air/Fuel Mixer
                    Variable Venturi Air/Fuel Mixer Theory of Operation
                Catalytic Muffler
                Engine Control Unit (ECU)
                Oxygen Sensor
                Vacuum Switch (MAP)
                Fuel Control Valve
            Tests or Adjustments
                LP Carburetor-Check, Clean
                LP Converter-Check, Clean
                Inspection of Fuel Lock Valve
                Inspection of Fuel Control Valve
                Inspection of Vacuum Switch(MAP)
                Inspection of Oxygen Sensor
            Disassembly & Assembly
                LP Converter
        GOVERNOR SYSTEM
            General Description
            Governor Operation
            Adjustment Procedures
        LUBRICATION SYSTEM
            General Description
            Testing & Adjusting
                Lubrication System Problems
                Oil Pressure Check
        COOLING SYSTEM
            General Description
            Testing & Adjusting
                Cooling System Visual Inspection
                Cooling System Tests
                Thermostat
                Cooling System Heat Problems
                Cooling System Recommendation
                Belt Adjustment
                V-Belt Diagnosis
            Service Procedures
                Draining and Filling the Cooling System
                Flushing the Cooling System
                Radiator Service
                Thermostat Replacement
                Water Pump Replacement
                Remove & Install Water Temperature

Sender
        BASE ENGINE SERVICE PROCEDURE
            Disassembled View (1 of 4)
            Disassembled View (2 Of 4)
            Disassembled View (3 Of 4)
            Disassembled View (4 Of 4)
            Draining Fluids and Oil Filter

Removal
            Engine Flywheel Removal
            Distributor Removal
            Ignition Coil Removal
            Lift Bracket Removal
            Spark Plug Removal
            Intake/Exhaust Manifold Removal
            Crankshaft Pulley Removal
            Valve Rocker Arm Cover Removal
            Pushrod Cover Removal
            Intake/Exhaust Manifold Disassemble and Assemble
            Intake/Exhaust Manifold Clean and Inspect
            Water Pump Removal
            Valve Rocker Arm and Pushrod Removal
            Measuring Camshaft Lobe Lift
            Valve Train Components Inspect(Cylinder Head)
            Valve Lifter Removal
            Cylinder Head Removal
            Oil Pan Removal
            Oil Pump Removal
            Oil Level Indicator and Tube Removal
            Engine Front Cover Removal
            Measuring Crankshaft and Camshaft Sprocket Runout
            Measuring Timing Sprocket Teeth Backlash
            Crankshaft Sprocket Removal
            Camshaft Removal
            Crankshaft and Camshaft Sprocket Inspect
            Timing Gear Oil Nozzle Removal
            Piston, Connecting Rod and Bearing Removal
            Crankshaft and Bearings Clean

and Inspect (Connecting Rod

Bearing Clearance)
            Crankshaft Rear Oil Seal and Housing Removal
            Crankshaft, Bearings and Bearing Cap Removal
            Crankshaft and Bearings Clean

and Inspect
            Crankshaft and Bearings Clean

and Inspect (Main Bearing

Clearance)
            Camshaft Bearing Removal
            Distributor Lower Bushing and Thrust Washer Removal
            Oil Filter Bypass Valve Removal and Installation
            Cylinder Block Clean and Inspect
            Cylinder Bore Measurements
            Cylinder Boring and Honing
            Distributor Lower Bushing and Thrust Washer Installation
            Piston and Connecting Rod Disassemble
            Piston and Connecting Rod

Clean and Inspect
            Piston Selection
            Piston and Connecting Rod

Assemble
            Camshaft and Bearings Clean

and Inspect
            Camshaft Sprocket and Retainer

Removal and Installation
            Camshaft Bearing Installation
            Oil Pump Disassemble
            Oil Pump Clean and Inspect
            Oil Pump Assemble
            Cylinder Head Disassemble
            Cylinder Head Clean and Inspect
            Rocker Arm Stud Removal and

Installation
            Cylinder Head Assemble
            Crankshaft, Bearings and

Bearing Cap Installation
            Crankshaft Rear Oil Seal and

Housing Installation
            Piston, Connecting Rod and

Bearing Installation
            Timing Gear Oil Nozzle Installation
            Crankshaft Sprocket Installation
            Camshaft Installation
            Engine Front Cover and Oil Seal Installation
            Oil Pump Installation
            Oil Pan Installation
            Crankshaft Pulley Installation
            Cylinder Head Installation
            Valve Lifter Installation
            Valve Rocker Arm and Pushrod

Installation
            Pushrod Cover Installation
            Valve Rocker Arm Cover

Installation
            Oil Level Indicator and Tube Installation
            Water Pump Installation
            Intake/Exhaust Manifold Installation
            Spark Plug Installation
            Lift Bracket Installation
            Ignition Coil Installation
            Distributor Installation
            Engine Flywheel Installation
            Engine Block Coolant Plug/Oil

Filter Installation
        SPECIAL TOOS AND EQUIPMENT
SB2013E02
    CONTENTS
        1. GENERAL INFORMATION
            1.1. General Repair Instructions
            1.2. Engine Specifications
            1.3. Torque Specifications
            1.4. Major Parts Fixing Bolts
            1.5. Engine Repair Kit
            1.6. Repair
        2. Engine Assembly
            2.1. General Description
            2.2. Disassembly
            2.3. Inspection and Repair
            2.4. Engine Reassembly
        3. Lubricating System
            3.1. General Description
            3.2. Oil Pump
            3.3. Oil Filter
            3.4. Oil Cooler
        4. Cooling System
            4.1. General Description
            4.2. Water Pump
            4.3. Thermostat
        5. Fuel System
            5.1. General Description
            5.2. Fuel Filter
            5.3. Injection Nozzle
        6. Special Tool List
SB2007E02
    Index
        Specifications
            Alternator
        Systems Operation
            Alternator
                CS-121 Alternator Operation
                    Alternator Components
                    Alternator Operation Schematic
                Introduction
        Testing And Adjusting
            Alternator
                Alternator Output Test
                Machine Test
            Troubleshooting
                Troubleshooting Problem List
                Troubleshooting Problems
SB2008E01
    Index
        Specifications
            Alternator
        Systems Operation
            Alternator
                Alternator Operation
                    Alternator Components
                    Alternator Operation Schematics
                    Regulator Operation
                Introduction
        Testing And Adjusting
            Alternator Component Tests
                Brush Tests
                Capacitor Test
                Rectifier Tests
                Regulator Test
                Rotor Field Winding Tests
                Stator Tests
            Alternator Output Test
                Bench Test
                Machine Test
            Troubleshooting
                Troubleshooting Problem List
                Troubleshooting Problems
        Disassembly and Assembly
            Alternator
                Assemble Alternator
                Disassemble Alternator
SB2009E01
    Index
        Specification
            Starting Motor
        Systems Operation
            Starting Motor
                Introduction
                Starting Motor Operation Diagrams
        Testing And Adjusting
            Starting Motor
                Off Machine No Load Test
                On Machine Starting Motor
Diagnosis Procedure
                Starting Motor Component Tests
            Troubleshooting
                Troubleshooting Problem List
                Troubleshooting Problems
        Disassembly And Assembly
            Starting Motor
                Assemble Starting Motor
                Disassemble Starting Motor
SB2102E01
    Index
        Specifications
            Drive Axle Mounting Group
            Drive Tire Installation
            Drive Wheel Installation
            Final Drives And Wheels
            Forward / Reverse Clutch

Elements
            Forward And Reverse Control

Group
            Tightening Torques
            Torque Converter
            Transmission Solenoid
            Valve Block Elements

(On top of transmission)
            Valve Spring in Transmission Bearing Plate
        Systems Operation
            Basic Control Schematic
            Drive Axle
            Hydraulic System
            Torque Converter
            Transmission
            Transmission Hydraulic System
        Testing And Adjusting
            Troubleshooting
                Check List During Operation
                Check List From Operation Noises
                Check List From Pressure Tests
                Visual Checks
            Transmission and Drive Axle Tests And Adjustments
                Adjustment of Crown Wheel
                Adjustment of Wheel Bearings
                Adjustments on Drive axle and Transmission
                Converter Stall Test
                Electric Control System Tests
                Inching Pedal Adjustment
                Installation of Pinion
                Maintenance Transmission and Drive Axle
                Transmission Pressure Tests
SB2103E01
    Index
        Transmission
            Assembly Input Shaft
            Assembly Output Shaft
            Assembly Reverse Shaft
            Assembly Transmission Housing
            Disassembly/Assembly Hub Drive Axle
            Disassembly Input Shaft
            Disassembly Output Shaft
            Disassembly Reverse Shaft
            Disassembly Transmission Housing
        Drive Axle
            Adjustment Bevel Pinion
            Adjustment Disassembly/Assembly of

 Bevel Pinion
            Assembly Bevel Pinion
            Assembly Carrier Diff
            Assembly Crown wheel/Adjustment
            Assembly Shaft As
            Disassembly/Assembly Brake Parts
            Disassembly/Assembly Differential
            Disassembly/Assembly Hub Drive Axle
            Disassembly Differential Assembly
            Disassembly Axle
            Disassembly Bevel Pinion
            Disassembly Shaft As
        Special Service Tools
SB2104E00
    Index
        Specifications
            Carriage
            Hydraulic Control Valve
            Hydraulic Pump
            Lift & Tilt Mounting Group
            Lift Cylinders
            Lift Relay Group - Standard Lift
            Lift Relay Group - Full Free Lift
            Lift Relay Group - Full Free Triple Lift
            Mast
            Oil Cooled Disc Brakes
            Parking Brake
            Priority Valve
            Steer Axle and Wheel
            Steer System Check Valve
            Steer Tire Installation
            Steer Wheel Mounting
            Steering Gear
            Steering Wheel
            Tilt Cylinders
        Systems Operation
            Brake System
                Brake Valve
                Oil Cooled Disc Brakes
                Parking Brake
            Hydraulic System
                Basic Schematic - Standard Lift
                Basic Schematic - Full Free Lift or Full Free Triple Lift
                Hydraulic Control Valve
            Steering System
                Hydraulic Operation
                Steering Cylinder
                Steering Gear
        Testing and Adjusting
            Brake System
                Brake System Air Removal
                Parking Brake Test
                Parking Brake Adjustment
            Hydraulic System
                Flow Control Valve Adjustment
                Relief Valve Pressure Check
                Standard Lift Cylinder Air Removal
            Mast and Carriage
                Carriage Adjustment
                Carriage and Mast Height Adjustment
                Chain Adjustments
                Chain Wear Test
                Drift Test
                Forks Parallel Check
                Mast Adjustment
                Tilt Cylinder Alignment
            Steering System
                Steer Wheel Bearing Adjustment
                Steering Axle Stop Adjustment
                Steering Knuckle Bearing Preload
Adjustment
                Steering System Pressure Check
            Troubleshooting
                Brake System (Oil Cooled Disc Type)
                Brake Valve
                Hydraulic System and Mast
                Performance Tests
                Steering System
                Visual Checks
SB2105E00
    Index
        Backrest
        Brake Valve
        Carriage
        Counterweight
        Creeper And Brake Control
        Drive Axle
        Engine
        Forks
        Hood (with seat) Assembly
        Hydraulic Control Valves
        Hydraulic Pump (with Priority Valve) 
        Mast
        Overhead Guard
        Primary Lift Cylinder
        Secondary Lift Cylinders
        Standard Lift Cylinders
        Steer Axle
        Steer Wheels & Bearings
        Steering Cylinder
        Steering Knuckles, Kingpins,
And Bearings
        Steering Unit
        Steering Wheel
        Tie Rods
        Tilt Cylinders
        Transmission
        Universal Joint
SB2220E00
SB4014E00
SB2106E00
SB2216E00
SB4001E00
SB2107E00
SB2302E06
    Table of Contents
        Information Section
            Foreword
            Literature Information
        Safety Section
            Important Safety Information

available.
            Safety
                Warning Signs and Labels
                Parking brake
                General Hazard Information
                Operation Information
                Maintenance Information
                Operator Restraint System(If

Equipped)
                Avoiding Lift Truck Tipover
                Safety Rules
                How to Survive in a Tipover
        General Section
            Specifications
            Noise and Vibration
            Capacity Chart
            Serial Number
            Operator's Warning and Identification Plate
        Operation Section
            Operator's Station and Monitoring Systems
            Lift Truck Controls
            Refueling
            Before Starting the Engine
            Starting the Engine
            Dual Fuel System (If G424 Dual Fuel Engine Equipped)
            Dual Fuel System (G424E/G430E Engine Only)
            Lift Truck Operation
            G424E/G430E Electronic Controlled LP and Dual Fuel Engines(If Equipped)
            Advanced Diagnostics
            Table a. MI-04 Diagnostic Fault Codes (Flash Codes)
            Auto Shift Controller ASC-100 (If Equipped)
            Operating Techniques
            Parking the Lift Truck
            Lift Fork Adjustment
            Storage Information
            Transportation Hints
            Towing Information
        Maintenance Section
            Inspection, Maintenance and Repair of Lift Truck Forks
            Tire Inflation Information
            Torque Specifications
            Cooling System Specifications
            Fuel Specifications
            Lubricant Information
            Lubricant Viscosities and Refill Capacities
            Maintenance Intervals
            When Required
            Every 10 Service Hours or Daily
            First 50 - 100 Service Hours or a Week
            First 250 Service Hours or a Month
            Every 250 Service Hours or Monthly
            Every 500 Service Hours or 3 Months
            Every 1000 Service Hours or 6 Months
            Every 1500 Service Hours or 9 Months
            Every 2000 Service Hours or Yearly
            Every 2500 Service Hours or 15 Months
            Every 3000 Service Hours or 18 Months
            Every 4500 Service Hours or two Years
        Index Section
            Index

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