Doosan G25E-5 Manuals

Manuals and User Guides for Doosan G25E-5. We have 5 Doosan G25E-5 manuals available for free PDF download: Service Manual, Operation & Maintenance Manual

Doosan G25E-5 Service Manual (326 pages)

LP/gasoline and LP/dual fuel engines

Brand: Doosan | Category: Engine | Size: 14 MB

Important Safety Information
2
Table of Contents
4
Chapter 1. General Information

8
Precautions before Service

8
- Electrical System
  9
Tightening Torque

11
Recommended Lubricants and Capacities

12
Engine Model and Engine Serial Number

13
General Specification

14
Engine Power and Torque

16
Chapter 2 . RECOMMENDED

17
General Maintenance

17
Cooling System Maintenance

22
- Coolant Recommendation
  22
- Check Coolant Level
  22
- Inspect Coolant Hoses
  22
- Checking Coolant Leaks
  23
- Specific Gravity Test
  23
- Checking and Adjusting Drive Belt
  24
- Adjusting
  25
- Checking Belt for Damage
  25
- Ignition System Maintenance
  26
- Inspect Battery System
  26
- Inspect Ignition System
  26
- Inspection of Spark Plug
  27
Fuel System Maintenance

29
Maintenance Schedule

32
Chapter 5 . ENGINE MANAGEMENT

34
General Information

34
- Specifications
  36
Chapter 3 . ENGINE MECHANICAL

39
- Torque Specification
  39
Special Tools

40
- Troubleshooting
  42
Timing Belt System

43
- Removal
  44
- Inspection
  45
- Assembly
  47
PCV Valve

49
- Outline and Operation Principle
  49
- Service Procedure
  50
Intake and Exhaust System

51
- Exhaust Manifold
  53
- Cooling System
  55
- Testing and Adjusting
  56
- Cooling System Recommendation
  59
- Coolant Pipe and Hose
  61
- Water Pump
  62
- Thermostat
  64
Cylinder Head Assembly

66
Lubrication System

75
- Testing and Adjusting
  76
- Oil Pressure Switch
  78
- Front Case and Oil Pump
  79
CAM Shaft, HLA, Timing Chain

84
- Removal
  85
- Inspection
  86
Crankshaft

91
Flywheel and Housing

95
Piston and Connection Rod

96
- Engine Block
  102
Cylinder Block

111
- Specifications
  119
- Coil-On-Plug Ignition System
  120
- Cop Components
  120
- Ignition System
  120
- Inspection of Ignition Timing
  123
- Inspection of Ignition Coil
  124
- Inspection of Spark Plug
  125
Charging System

127
- Troubleshooting
  129
- Troubleshooting Procedure
  130
- Disassembly and Installation
  135
Starting System

140
- Diagnosis Procedure
  141
- Start Relay Tests
  143
- Starter
  145
  - Removal and Installation
    146
  - General Information
    151
- Service Standard
  156
- Component Location
  157
- G420FE EMS (Engine Management System Overview
  161
- LPG Fuel System Operation
  164
- MPI Gasoline System Operation
  171
- Electronic Throttle System
  172
Chapter 4 . ENGINE ELECTRICAL

173
Ignition System

173
- Exhaust System
  174
- Secm
  176
  - SECM Wiring Diagrams for G420FE
    179
  - G420F EMS (Engine Management System Overview
    181
- LPG Fuel System Operation
  184
- MPI Gasoline System Operation
  188
- SECM Wiring Diagrams for G420F
  189
EMS Inspection and Repair

190
- Engine Control Module (Secm)
  190
- Camshaft Position Sensor
  192
- Crank Shaft Position Sensor
  193
- MAP (Manifold Absolute Pressure) Sensor
  194
- Iat (Intake Air Temperature)
  195
- Oxygen Sensor (Pre-Catalyst)
  196
- Oxygen Sensor (Post-Catalyst)
  197
- ECT (Engine Coolant Temperature) Sensor
  198
- LP Fuel Temperature Sensor
  200
- Angle Sensor-Accelerator
  201
- Transmission Oil Temperature Switch
  202
- Ground Speed Limit Switch (Optional)
  203
- Electronic Throttle Body
  204
Chapter 6 . LPG FUEL DELIVERY

205
G420FE LP System Inspection and Repair

205
- Hose Connections
  206
- Removal and Installation of
  207
- Removal and Installation of CA100 Mixer for G420FE
  208
- Tests and Adjustments
  210
  - N-2007 Regulator Service Testing
    211
  - AVV (Air Valve Vacuum) Testing
    213
  - Idle Mixture Adjustment
    214
- Parts Description
  217
G420F LPG System Inspection and Repair

221
- G420F Fuel System Connections
  222
  - Removal and Installation of N-2001 LP Regulator/Converter
    223
  - Removal and Installation of CA100 Mixer for G420F
    224
- Tests and Adjustments
  226
  - AVV (Air Valve Vacuum) Testing
    228
- Idle Mixture Adjustment
  229
- Parts Description
  231
Chapter 7 . MPI GASOLINE FUEL

240
Specification

240
Components Location

241
Fuel Pressure Test

242
Injector

244
Injector Inspection

246
Fuel Pump

248
Chapter 8. Basic Troubleshooting

249
- Visual/Physical Check
  249
- Before Starting
  249
Preliminary Checks

249
Basic Troubleshooting Guide

250
- Customer Problem Analysis Sheet
  250
- Basic Inspection Procedure
  251
- Connector Inspection Procedure
  252
- Symptom Troubleshooting Guide Chart
  256
Basic Troubleshooting

262
Chapter 9. Advanced Diagnostics

278
Reading Diagnostic Fault Codes

278
Clearing Fault (Dfc) Codes

278
Fault Action Descriptions

279
Fault List Definitions

279
- Table 1. Fault List Definitions
  280
Dfc Probable Fault Action

290
- Table 2. Diagnostic Fault Codes (Flash Codes)
  290
  - Output Open, Possibly Open EST5 Signal or Defective
    295
  - Spark Module
    295
  - Output Open, Possibly Open EST6 Signal or Defective
    295
  - For Open Circuit
    295
  - SECM Pin A6 (EST4) to OEM Ignition
    295
  - Ignition Module Pin a
    295
  - B (of both Connectors)
    295
  - Refer to Application Manual for Specific
    296
  - N/A
    297
  - For Shorts
    297
  - Module Pin D (4-Pin Connector)
    297
  - Verify GND on Ignition Module Pin a
    297
  - Engine Details
    297
Appendix Service Tool Software (Motoview)

308
- Service Tool Connection to SECM
  309
- Service Tool Display
  310
- SECM Field Update with Service Tool
  315
Ground Speed Limits (Option)

319
LPG and LPG Fuel Tanks

321
- Lpg Fuel Tank Components
  322
- Lpg Fuel Tanks
  322
Regulatory Compliance

325
Special Conditions for Safe Use

325
Abbreviations

326

Doosan G25E-5 Operation & Maintenance Manual (252 pages)

FORKLIFTS

Brand: Doosan | Category: Lifting Systems | Size: 9 MB

Table of Contents

3
- Information Section
  
  4
  - Foreword
    4
    
    Literature Information
    4
    
    Environment Management
    5
    
    Maintenance Intervals
    5
- Safety Section
  
  6
  - Important Safety Information
    6
  - Safety
    7
    
    Warning Signs and Labels
    7
    
    General Warning to Operator
    8
    
    Hand Placement Warning
    9
    
    No Standing on Fork Warning
    9
    
    No Standing under Fork Warning
    9
    
    Pressure Warning
    9
    
    Moving Fan Warning
    10
    
    No Riders Warning
    10
    
    Parking Brake
    11
    
    All Maintenance and Repair, Except Every
    12
    
    General Hazard Information
    12
    
    Before Starting the Lift Truck
    13
    
    Mounting and Dismounting
    13
    
    Operation Information
    13
    
    Before Operating the Lift Truck
    14
    
    Operating the Lift Truck
    14
    
    Starting the Lift Truck
    14
    
    Lift Truck Parking
    15
    
    Crushing or Cutting Prevention
    16
    
    Fluid Penetration
    16
    
    Maintenance Information
    16
    
    Pressure Air
    16
    
    Burn Prevention
    17
    
    Fire or Explosion Prevention
    17
    
    Operator Restraint System(if Equipped)
    19
    
    Seat Adjustment
    20
    
    Avoiding Lift Truck Tipover
    23
    
    Lift Truck Stability
    23
    
    Stability and Center of Gravity
    23
    
    Lift Truck Stability Base
    24
    
    Safety Rules
    25
    
    How to Survive in a Tipover
    31
- General Section
  
  32
- Operation Section
  
  70
  - Operator's Station and Monitoring Systems
    70
    
    Engine Compartment
    73
  - Seat Switch System (if Equipped)
    74
    
    Tilt Steering Column
    75
  - Lift Truck Controls
    76
    
    Accelerator Pedal
    76
    
    Direction Control Lever
    76
    
    Service Brake Pedal
    76
    
    Transmission Inching Control Pedal
    76
    
    Lift Control
    77
    
    Parking Brake Lever
    77
    
    Sideshift Attachment (if Equipped)
    77
    
    Tilt Control
    77
  - Refueling
    78
    
    Changing Lp Tanks
    79
  - Before Starting the Engine
    81
    
    Walk - Around Inspection
    81
  - Starting the Engine
    83
    
    Diesel Engine
    84
    
    Lp Engine
    84
    
    Starting a Cold Diesel Engine
    84
    
    Starting a Warm Diesel Engine
    84
  - Dual Fuel System
    86
    
    Changing from Gasoline to Lp – Gas
    86
    
    After Starting the Engine
    88
  - Lift Truck Operation
    89
    
    Basic Troubleshooting (Gasoline)
    100
    
    Blink Code Function
    142
    
    Malfunction Indicator Lamp (Mil) Operation
    143
  - Mono-Ped Control System (Option)
    152
  - Auto Shift Controller ASC-100 (if Equipped)
    153
    
    Direction Inhibit Point
    153
    
    Product Description
    153
    
    Automatic Mode (Direction Inhibit Mode)
    154
    
    Diagnostics Features
    154
    
    Display for Operator
    154
    
    Display for Troubleshooting
    154
    
    Manual Mode (Fail-Safe Mode)
    155
  - Finger Tip (Option)
    156
    
    Function of Knobs
    156
    
    Lift Control Knob
    156
    
    Tilt Control Knob
    156
    
    Emergency Switch
    157
    
    Sideshift Attachment Control
    157
    
    Warning Lamp
    157
    
    Adjustment of Armrest
    159
    
    Forward and Backward Adjustment
    159
    
    Up and down Adjustment
    159
  - Operating Techniques
    160
    
    Inching into Loads
    160
    
    Lifting the Load
    160
    
    Traveling with the Load
    161
    
    Lifting Drums or Round Objects
    163
    
    Operating in Hot Weather
    163
  - Parking the Lift Truck
    164
    
    If Parking Brake Alarm Equipped
    164
  - Lift Fork Adjustment
    165
    
    Hook-On Type Fork
    165
  - Storage Information
    166
    
    Before Storage
    166
    
    Long Time Storage
    166
  - Transportation Hints
    167
    
    Lift Truck Shipping
    167
  - Towing Information
    168
- Maintenance Section
  
  169
  - Inspection, Maintenance and Repair of Lift Truck Forks
    169
    
    Environment Protection
    169
    
    Bent or Twisted Forks
    170
    
    Causes of Fork Failure
    170
    
    Improper Modification or Repair
    170
    
    Daily Inspection
    171
    
    First Installation
    171
    
    Fork Inspection
    171
    
    Maintenance and Repair
    172
  - Tire Inflation Information
    173
    
    Tire Shipping Pressure
    173
  - Torque Specifications
    174
  - Cooling System Specifications
    176
    
    Coolant Information
    176
    
    Coolant Water
    177
    
    Make Proper Antifreeze Additions
    177
  - Fuel Specifications
    178
    
    Additional Technical Fuel Requirements
    178
    
    Bio-Diesel Fuels
    178
    
    General Fuel Information
    178
    
    Drive Axle Oil
    180
    
    Engine Oil (Deo and Eo)
    180
    
    Hydraulic Oil (HYDO)
    180
  - Lubricant Information
    180
    
    Brake Fluid
    181
    
    Lubricating Grease (Mpgm)
    181
    
    Oil Cooled Disc Brake Only
    181
    
    Transmission Oil
    181
  - Lubricant Viscosities and Refill Capacities
    182
Maintenance Intervals

183

Doosan G25E-5 Operation & Maintenance Manual (264 pages)

Brand: Doosan | Category: Forklifts | Size: 13 MB

Doosan G25E-5 Operation & Maintenance Manual (210 pages)

LIFT TRUCKS

Brand: Doosan | Category: Trucks | Size: 6 MB

Doosan G25E-5 Service Manual (4 pages)

Dual Fuel Engine, Gasoline Dual Fuel Engine

Brand: Doosan | Category: Forklifts | Size: 0 MB

Doosan Categories

Air Compressor Engine Forklifts Excavators Compact Loader

More Doosan Manuals

Doosan G25E-5 Manuals

Doosan G25E-5 Service Manual (326 pages)

Table of Contents

Chapter 1. General Information

Precautions before Service

Tightening Torque

Recommended Lubricants and Capacities

Engine Model and Engine Serial Number

General Specification

Engine Power and Torque

Chapter 2 . RECOMMENDED

General Maintenance

Cooling System Maintenance

Fuel System Maintenance

Maintenance Schedule

Chapter 5 . ENGINE MANAGEMENT

General Information

Chapter 3 . ENGINE MECHANICAL

Special Tools

Timing Belt System

PCV Valve

Intake and Exhaust System

Cylinder Head Assembly

Lubrication System

CAM Shaft, HLA, Timing Chain

Crankshaft

Flywheel and Housing

Piston and Connection Rod

Cylinder Block

Charging System

Starting System

Chapter 4 . ENGINE ELECTRICAL

Ignition System

EMS Inspection and Repair

Chapter 6 . LPG FUEL DELIVERY

G420FE LP System Inspection and Repair

G420F LPG System Inspection and Repair

Chapter 7 . MPI GASOLINE FUEL

Specification

Components Location

Fuel Pressure Test

Injector

Injector Inspection

Fuel Pump

Chapter 8. Basic Troubleshooting

Preliminary Checks

Basic Troubleshooting Guide

Basic Troubleshooting

Chapter 9. Advanced Diagnostics

Reading Diagnostic Fault Codes

Clearing Fault (Dfc) Codes

Fault Action Descriptions

Fault List Definitions

Dfc Probable Fault Action

Appendix Service Tool Software (Motoview)

Ground Speed Limits (Option)

LPG and LPG Fuel Tanks

Regulatory Compliance

Special Conditions for Safe Use

Abbreviations

Doosan G25E-5 Operation & Maintenance Manual (252 pages)

Table of Contents

Table of Contents

Information Section

Safety Section

General Section

Operation Section

Maintenance Section

Maintenance Intervals

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

Index Section