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G25E-3
Daewoo G25E-3 Manuals
Manuals and User Guides for Daewoo G25E-3. We have
3
Daewoo G25E-3 manuals available for free PDF download: Operation & Maintenance Manual, Service Manual
Daewoo G25E-3 Operation & Maintenance Manual (205 pages)
Brand:
Daewoo
| Category:
Trucks
| Size: 22.79 MB
Table of Contents
Table of Contents
3
Information Section
4
Foreword
4
Information Section
4
Literature Information
4
Safety Section
6
Important Safety Information
6
Safety
7
Warning Signs and Labels
7
Parking Brake
11
General Hazard Information
12
All Maintenance and Repair, Except Every
12
Operation Information
13
Maintenance Information
16
Fire Extinguisher
18
Operator Restraint System(if Equipped)
19
Avoiding Lift Truck Tipover
23
Safety Rules
25
How to Survive in a Tipover
30
General Section
32
Specifications
32
Noise and Vibration
52
Capacity Chart
53
Serial Number
63
Operator's Warning and Identification Plate
66
Operation Section
67
Operator's Station and Monitoring Systems
67
Lift Truck Controls
71
Parking Brake Lever
72
Accelerator Pedal
72
Refueling
74
Before Starting the Engine
77
Starting the Engine
80
Dual Fuel System (if G424 Dual Fuel Engine Equipped)
83
Dual Fuel System (G424E Engine Only)
85
Lift Truck Operation
88
(If Equipped)
91
Advanced Diagnostics
106
Displaying Fault Codes
107
Codes)
108
Table A. MI-04 Diagnostic Fault Codes (Flash Codes)
108
Auto Shift Controller ASC-100 (if Equipped)
114
Operating Techniques
117
Parking the Lift Truck
121
Lift Fork Adjustment
122
Storage Information
123
Transportation Hints
124
Towing Information
125
Maintenance Section
126
Inspection, Maintenance and Repair of Lift Truck Forks
126
Daily Inspection
128
Tire Inflation Information
130
Torque Specifications
131
Cooling System Specifications
133
Coolant Water
134
Antifreeze
134
Fuel Specifications
135
Quick Reference to Maintenance Schedule
135
Lubricant Information
137
Engine/Hydraulic Oil
137
Lubricant Viscosities and Refill Capacities
139
Maintenance Intervals
140
When Required
144
Engine Valve Lash (DB33A Diesel Engine Only) - Check, Adjust
144
Fuel Tank Filter Cap and Screen (if Equipped) - Clean
144
Seat, Hood Latch & Support Cylinder - Check, Lubricate
145
Fuses, Bulbs, Circuit Breaker & Relay - Change, Reset
146
Fuse & Relay (G424E/G430E Only)
147
Priming the Fuel System (Diesel Engine Only)
149
Tires and Wheels (D, G-Series) - Inspect, Check
152
Carriage Roller Extrusion - Adjust
153
Every 10 Service Hours or Daily
154
Inspect Engine for Fluid Leaks
154
Engine Oil Level - Check
154
Coolant Level - Check
154
Air Cleaner Indicator-Check
155
Inspect Foot Pedal Operation (G424E/G430E Only)
155
Inspect Engine for Exhaust Leaks
155
Walk-Around Inspection - Inspect
156
Mast Channels - Lubricate
157
Transmission Oil Level - Check
157
Parking Brake - Inspect
158
First 50 - 100 Service Hours or a Week
159
Engine Oil & Filter (DB33A Diesel Engine Only) - Change
159
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
160
Drive Axle Oil - Change
161
Parking Brake - Test, Adjust
162
First 250 Service Hours or a Month
164
Hydraulic Return Filter - Change
164
Engine Valve Lash (B3.3 Diesel Engine Only) - Check, Adjust
164
Every 250 Service Hours or Monthly
165
Air Intake System - Check, Clean
165
Hydraulic Oil Level - Check
167
Drive Axle Oil Level - Check
168
Mast, Carriage, Lift Chains & Attachments - Inspect, Lubricate
168
Steering Mechanism - Check, Lubricate
168
Battery Terminal - Clean, Inspect
169
Engine Oil & Filter (DB33A Diesel, LP-Gas & Gasoline Engine Only) - Change
169
PCV Valve System - Inspect, Clean
170
Wheel Bolts & Nuts - Inspect
171
Every 500 Service Hours or 3 Months
172
Belts - Check, Adjust
172
Mast Hinge Pin - Lubricate
172
Tilt Cylinders - Check, Adjust, Lubricate
172
Crosshead Rollers - Inspect
173
Transmission Oil Filter - Change
174
Overhead Guard - Inspect
174
Drive Axle Oil & Strainer - Change, Clean
174
Steer Suspension - Inspect
175
Parking Brake - Test, Adjust
175
Inching & Braking Control Shaft - Lubricate
176
Horn and Lights (if Equipped) - Check
176
Engine Oil & Filter (B3.3 Diesel Engine Only) - Change
176
Fuel Strainer (B3.3 Diesel Engine Only) - Clean
178
Inspect Vacuum Lines and Fittings (G424E/G430 Engine Only)
179
Fuel Trim Valve(FTV) Inspection
179
(G424E/G430E Engine Only)
179
Inspect Electrical System (G424E/G430E Engine Only)
179
Inspect VR Sensor - Clean (G424E/G430E Engine Only)
179
Fuel Filter (B3.3 Diesel Engine Only) - Change.178
180
Every 1000 Service Hours or 6 Months
181
Hydraulic Return Filter, Breather & Strainer - Check, Change
181
Transmission Oil, Oil Filter & Strainer - Check, Clean, Change
182
Lift Chains - Test, Check, Adjust
182
Universal Joint - Inspect
184
Carburetor (LP-Gas, Gasoline & Dual Fuel Engine Only) - Adjust, Clean
184
Air Intake System - Change
185
Inspect Coolant Hoses (LP Engine Only)
185
LP Regulator/Converter Inspection (LP Engine Only)
185
Fuel Lines & Fittings - Check
186
Inspect Mixer Assembly (G424E/G430E Engine Only)
186
Inspect Throttle Assembly (G424E/G430E Engine Only)
186
Fuel Filter (DB33A Diesel Engine Only) - Change
186
Every 1500 Service Hours or 9 Months
187
Inspect Ignition System (LP-Gas, Gasoline & Dual Fuel Engines Only)
187
Replace Spark Plugs (LP-Gas, Gasoline & Dual Fuel Engines Only)
187
Replace LP Fuel Filter Element (LP-Gas, Dual Fuel Engine Only)
188
Fuel Filter(LP-Gas Engine Only)
189
Testing Fuel Lock-Off Operation
189
Only)
189
Every 2000 Service Hours or Yearly
190
Fuel Filter(G424 Gasoline & Dual Fuel Engine Only) - Change
190
Engine Valve Lash (B3.3 Diesel Engine Only) - Check, Adjust
190
Steer Wheel Bearings - Reassemble
191
Drive Wheel Bearing (Power Shaft and Drive Wheel) - Reassemble
193
Cooling System - Clean, Change
194
Forks - Inspect
195
Every 2500 Service Hours or 15 Months
197
Hydraulic Oil - Check, Clean, Change
197
Inspect Battery System
197
Checking the TMAP Sensor (G424E/G430E Engine Only)
199
Inspect for Intake Leaks
199
Only)
199
Replace PCV Valve and Breather Element - Change
199
(LP-Gas, Gasoline and Dual Fuel Engines)
199
Every 3000 Service Hours or 18 Months
200
Timing Belt [G424(E) LP-Gas, Gasoline Dual Fuel Engine Only] - Change
200
Timing Belt for Counterbalance Shaft [G424(E) LP-Gas, Gasoline & Dual Fuel Engine Only] - Change
200
Every 4500 Service Hours or Two Years
201
Replace Oxygen Sensor (G424E/G430E Engine Only)
201
Index Section
202
Index
202
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Daewoo G25E-3 Service Manual (199 pages)
Brand:
Daewoo
| Category:
Engine
| Size: 7.78 MB
Table of Contents
Important Safety Information
2
Table of Contents
3
General Information
5
How to Read this Manual
5
Precaution before Service
7
General
9
Tightening Torque
10
Sealant
13
Specifications
14
General Specification
14
Service Specification
15
Maintenance
18
Test Fuel System for Leaks
18
Check Engine Oil Level
18
Inspect Engine for Fluid Leaks
18
Change Engine Oil and Filter
18
Inspect Accessory Drive Belts
19
Inspect Electrical System
19
Inspect Vacuum Lines and Fitting
19
Check Coolant Level
19
Inspect Coolant Hoses
19
Inspect Ignition System
19
Replace Spark Plug
19
Replace LP Fuel Filter Element
20
Test Fuelock (Electric)
20
Replace Gasoline Fuel Filter
21
Inspect Gasoline Carburetor
21
Inspect Pressure Regulator/Vaporizer
21
Inspect LP Mixer (Standard LP Truck)
21
Inspect Variable Venturi Air/Fuel Mxer
21
(Low Emission LP Truck)
21
Inspect Complete Exhaust System for Leaks,Damage
21
Engine Control Unit(ECU) and Others (Low Emission LP Truck)
21
Maintenance Schedule
22
Engine System
23
Engine Overview
23
Timing System
26
Silent Shaft Mechanism
27
Auto Lash Adjuster
28
Intake and Exhaust System
29
Electrical System
31
Starting System
33
General Description
33
Start Relay Test
36
Starter Motor
37
Operation
37
Removal and Installation
40
Disassembly and Reassembly
43
Charging System
48
General Description
48
Alternator
48
Ignition System
51
Breakerless Ignition System
51
Distributor
52
Removal and Installation
55
Inspection Ignition Coil/Cables
56
Installation Service Points of IGNITION SYSTEM
56
Distributor, Disassembly and Reassembly
57
Gasoline Fuel System
59
General Description
59
Geasoline Carburetor, Operation
60
Idle System
62
Removal and Installation
65
Gasoline Carburetor Disassembly and Reassembly
67
Lpg Fuel System
74
General Description
74
Electric Fuelock Model
74
Converter
75
Fuel Tank
76
LP Relief Valve
76
Carburetor
77
Tests or Adjustments
78
Carburetor Adjustment
78
Fuel System Leak Check
80
Recommendation for LP Fuel System
81
LP Converter - Check, Clean
82
Disassembly and Assembly
83
LPG Carburetor
83
LP Gas Fuelock
85
LP Gas Converter
86
Lpg Fuel System (Low Emission Version)
88
General Description
88
LP Carburetor
90
Vacuum Switch (MAP)
91
Vacuum Switch
91
LP Converter
92
Fuel Control Valve
93
Fuelock Valve
93
Engine Control Unit (ECU)
94
Oxygen Sensor
95
Catalytic Muffler
96
Tests or Adjustments
97
LP Carburetor-Check, Clean
97
LP Converter-Check,Clean
98
Inspection of Fuelock Valve
98
Inspection of Fuel Control Valve
98
Inspection of Vacuum Switch
98
Inspection of Vacuum Switch (MAP)
98
Inspection of Oxygen Sensor
99
Disassembly and Assembly
100
LPG Carburetor
100
LP Gas Converter
102
Dual Fuel System
103
Governing System
104
Carburetor
104
General Description
104
Governor,Disassembly and Reassembly
105
Lubrication System
107
General Description
107
Testing and Adjusting
108
Engine Oil
108
Lubrication System Problem
108
Oil Pressure Check
110
Cooling System
111
General Description
111
Testing and Adjusting
112
Cooling System Visual Inspection
112
Cooling System Tests
112
Thermostat
114
Cooling System Heat Problem
115
Cooling System Recommendation
115
Belt Adjustment
117
V-Belt Diagnosis
117
Serivce Procedure
118
Draining and Filling the Cooling System
118
Service Procedures
118
Flushing the Cooling System
119
Radiator Service
119
Removal & Install Water Temperature Sender
120
Base Engine Service Procedure
121
Timing Belt
121
Installation Service Points of Base Engine
125
Timing Belt B Installation
126
Intake Manifold
130
Exhaust Manifold and Water Pump
131
Rocker Arms and Camshaft
134
Cylinder Head and Valves
140
Front Case and Oil Pan
146
Piston and Connecting Rod
155
Crankshaft and Cylinder Block
163
Adjustment and Troubleshooting
170
Adjustment
170
Valve Clearnce Adjustment
170
Ignition Timing Adjustment
170
Idle Speed Adjustment
172
Air Governor Adjustment
172
Anti-Hunting Adjustment
172
Troubleshooting
173
Engine Performance
173
Engine Starting Problems
173
Charging System Problems
174
Instrument Problems
174
Engine Noise
175
Oil Pressure Diagnostics
177
Oil Pressure Problems
178
Water in Engine
179
Engine Overheating
180
LP Fuel System
181
(Standard And/Or Low Emission Version)
181
General
188
Troubleshooting Flow Chart
188
Engine
190
Electrical Components
193
Special Tools
196
Daewoo G25E-3 Service Manual (88 pages)
Tier LP Engine Lift Trucks With Tier LP Engine Tier LP Engine
Brand:
Daewoo
| Category:
Engine
| Size: 3.83 MB
Table of Contents
Important Safety Information
2
Table of Contents
6
Working with Lpg Equipment
8
Chapter 0 Lpg and Lpg Fuel Tanks
9
LPG Fuel Supply
9
LPG Fuel Tanks
10
Installing LPG Fuel Tanks
10
LPG Fuel Tank Components
11
Fuel Gauge
11
Service Valve
11
Quick Disconnect Coupling
12
Filler Valve
12
Chapter 1 Engine Specification
13
Indication of Engine Serial Number
13
Specifications(G420E)
14
Specifications(G424E)
15
Chapter 2 MI-04 Lpg System Operational Overview
16
MI-04 General Description
16
MI-04 LP Fuel Filter
18
Fuel Lock-Off (Electric)
18
N-2001 Regulator/Converter
19
N-2001 Theory of Operation
20
MI-04 N-CA55-500TR Mixer
21
N-CA55-500-TR Air/Fuel Mixer Theory of Operation
21
MI-04 Electronic Throttle
23
MI-04 Fuel Trim Valve
24
Heated Exhaust Gas Oxygen Sensor (HEGO)
25
SECM (General Description)
26
SECM (Fuel Management)
26
Catalytic Muffler
27
SECM (Load/Speed Management)
28
MI-04 Ignition Management
30
Chapter 3 MI- 04 Maintenance Schedule
31
Recommended Maintenance Schedule
31
Test Fuel System for Leaks
31
Inspect Engine for Fluid Leaks
31
Inspect Vacuum Lines and Fittings
31
Inspect Electrical System
31
Inspect Acceleration Pedal Operation
32
Check Coolant Level
32
Inspect Coolant Hoses
32
Inspect Battery System
32
Inspect Ignition System
32
Replace Spark Plugs
32
Replace LP Fuel Filter Element
33
Testing Fuel Lock-Off Operation
34
Pressure Regulator/Converter Testing and Nspection
34
Fuel Trim Valve Inspection (FTV)
34
Inspect Air/Fuel Valve Mixer Assembly
34
Inspect for Intake Leaks
35
Inspect Throttle Assembly
35
Checking the TMAP Sensor
35
Inspect Engine for Exhaust Leaks
35
Replace Oxygen Sensor
35
Maintenance Schedule
36
Maintenance Schedule Continued
37
Chapter 4 MI-04 Lp Basic Troubleshooting
38
Basic Troubleshooting
38
Chapter 5 MI-04 Lp Advanced Diagnostics
45
Advanced Diagnostics
45
Reading Diagnostic Fault Codes
45
Displaying Fault Codes (DFC) from SECM Memory
46
Clearing Fault (DFC) Codes
46
Fault Action Descriptions
46
Fault List Definitions
47
Codes)
49
Table A. MI-04 Diagnostic Fault Codes (Flash Codes)
49
Chapter 6 MI-04 Electrical Connections
61
Electrical Connections
62
Resistance Checks
63
Voltage Checks
64
Chapter 7 N2001 Pressure Regulator /Converter
65
Removal and Installation of N2001 LP Regulator/Converter
65
Hose Connections
66
N2001 Removal Steps
67
N2001 Regulator Disassembly Steps
68
N2001 Disassembled Service
70
Chapter 8 N-Ca55-500Tr Air/Fuel Mixer
71
Removal and Installation of the N-CA55-500TR Mixer
71
N-CA55-500TR Mixer Removal Steps
72
N-CA55-500TR Disassembly and Service
73
N-CA55-500TR Disassembled Service
75
Installing the Mixer/Throttle Assembly
76
Chapter 9 Test and Adjustments
79
N2001 Service Testing
79
Primary Stage Test Hardware
80
Primary Stage Pressure Test
80
N-CA55-500TR Service AVV (Air Valve Vacuum) Testing
82
Ignition Timing Adjustment
83
Idle Mixture Adjustment
86
Chapter 10 Service Tool Kit
88
Service Tool Kit
88
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