User Manuals: Daewoo GC25E-3 5000 Capacity Forklift

Daewoo GC25E-3 Service Manual (199 pages)

Brand: Daewoo | Category: Engine | Size: 7 MB

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
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
Gasoline Fuel System

59
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
- 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
- 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

User Manuals: Daewoo GC25E-3 5000 Capacity Forklift

Daewoo GC25E-3 Operation & Maintenance Manual (205 pages)

Table of Contents

Table of Contents

Information Section

Safety Section

General Section

Operation Section

Maintenance Section

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

Daewoo GC25E-3 Service Manual (199 pages)

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

Daewoo GC25E-3 Service Manual (88 pages)

Table of Contents

Working with Lpg Equipment

Chapter 0 Lpg and Lpg Fuel Tanks

Chapter 1 Engine Specification

Chapter 2 MI-04 Lpg System Operational Overview

Chapter 3 MI- 04 Maintenance Schedule

Chapter 4 MI-04 Lp Basic Troubleshooting

Chapter 5 MI-04 Lp Advanced Diagnostics

Chapter 6 MI-04 Electrical Connections

Chapter 7 N2001 Pressure Regulator /Converter

Chapter 8 N-Ca55-500Tr Air/Fuel Mixer

Chapter 9 Test and Adjustments

Chapter 10 Service Tool Kit

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