User Manuals: Doosan GC25P-3 Forklift Truck

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Doosan GC25P-3 Service Manual

Doosan GC25P-3 Service Manual (182 pages)

G430 LP Engine

Brand: Doosan | Category: Engine | Size: 9 MB

Table of Contents

Important Safety Information
2
Table of Contents
4
General Information

8
- Shop Safety
  8
- Fuel Information
  9
- General Description & Operation
  12
  - Engine Component Description
    12
  - Lubrication
    12
  - Thread Repair
    12
  - Cleanliness and Care
    13
  - Replacing Engine Gaskets
    13
  - Use of RTV and Anaerobic Sealer
    14
  - Separating Parts
    15
  - Tools and Equipment
    15
Specifications

16
- Technical Data
  16
  - General Description
    16
  - Fuel System
    16
  - Cooling System
    17
  - Lubrication System
    17
  - Engine Electrical
    17
  - Exhaust System (Low Emission Version Only)
    17
- Engine Mechanical Data
  18
Maintenance

21
Troubleshooting

27
- Engine Performance
  27
- Engine Starting Problems
  27
- Charging System Problems
  28
- Instrument Problems
  28
- Engine Noise
  29
- Oil Pressure Diagnostics
  31
- Oil Pressure Problems
  32
- Water in Engine
  33
- Engine Overheating
  34
- LP Fuel System
  35
- (Sandard And/Or Low Emission Version)
  35
Starting System

43
- General Description
  43
- Start Relay Tests
  46
- Starting Motors
  47
Charging System

48
- General Description
  48
- Alternators
  48
  - Remove & Install Alternator
    50
Ignition System

51
- General Information
  51
  - Conventional Ignition Systems
    51
  - High Energy Ignition Systems
    52
    
    Module
    53
    
    Pulse Generator
    53
    
    Magnetic Flux Path
    54
    
    Current Limiting Circuit
    54
    
    Dwell Control Circuit
    55
    
    Ignition Coil
    56
    
    Hel Models
    58
  - Electronic Spark Timing (EST) Distributor
    60
  - Spark Plug Wires
    62
  - Spark Advance Curves
    62
- Delco Electronic Spark Timing (EST) Distributor Service
  63
Lp Fuel System

70
- General Information
  70
  - Electric Fuelock Models
    70
  - Converter
    71
  - Fuel Tank
    72
  - LP Relief Valve
    72
  - Carburetor
    73
- Tests or Adjustments
  74
- Disassembly & Assembly
  79
  - LP Gas Carburetor
    79
  - LP Gas Fuelock
    81
  - LP Gas Converter
    82
Lp Fuel System (Low Emission Version)

84
- General Description
  84
  - System Overview
    84
  - Fuel Lock (Electric)
    86
  - Pressure Regulator/Vaporizer
    86
    
    Pressure Regulator Theory of Operation
    87
    
    Variable Venturi Air/Fuel Mixer
    88
  - Variable Venturi Air/Fuel Mixer Theory of Operation
    89
  - Catalytic Muffler
    90
  - Engine Control (ECU)
    91
  - Oxygen Sensor
    92
  - Vacuum Switch
    92
  - Fuel Control Valve
    93
- Tests or Adjustments
  94
- Disassembly & Assembly
  97
  - LP Converter
    97
Governor System

98
- General Description
  98
- Governor Operation
  99
- Adjustment Procedures
  100
Lubrication System

102
- General Description
  102
- Testing & Adjusting
  103
  - Lubrication System Problems
    103
  - Oil Pressure Check
    104
Cooling System

105
- General Description
  105
- Testing & Adjusting
  106
  - Cooling System Visual Inspection
    106
  - Cooling System Tests
    106
  - Thermostat
    108
  - Cooling System Heat Problems
    109
  - Cooling System Recommendation
    109
  - Belt Adjustment
    111
  - V-Belt Diagnosis
    111
- Service Procedures
  112
  - Draining and Filling the Cooling System
    112
  - Flushing the Cooling System
    113
  - Radiator Service
    113
  - Thermostat Replacement
    114
  - Water Pump Replacement
    115
  - Remove & Install Water Temperature Sender
    116
Base Engine Service Procedure

117
- Disassembled View (1 of 4)
  117
- Disassembled View (2 of 4)
  118
- Disassembled View (3 of 4)
  119
- Disassembled View (4 of 4)
  120
- Draining Fluids and Oil Filter Removal
  121
- Engine Flywheel Removal
  122
- Distributor Removal
  122
- Ignition Coil Removal
  123
- Lift Bracket Removal
  123
- Spark Plug Removal
  123
- Intake/Exhaust Manifold Removal
  123
- Crankshaft Pulley Removal
  124
- Valve Rocker Arm Cover Removal
  124
- Pushrod Cover Removal
  124
- Intake/Exhaust Manifold Disassemble and Assemble
  125
- Intake/Exhaust Manifold Clean and Inspect
  125
- Water Pump Removal
  126
- Valve Rocker Arm and Pushrod Removal
  126
- Measuring Camshaft Lobe Lift
  127
- Valve Train Components Inspect (Cylinder Head)
  128
- Valve Lifter Removal
  128
- Cylinder Head Removal
  129
- Oil Pan Removal
  129
- Oil Pump Removal
  129
- Oil Level Indicator and Tube Removal
  130
- Engine Front Cover Removal
  130
- Measuring Crankshaft and Camshaft Sprocket Runout
  131
- Measuring Timing Sprocket Teeth Backlash
  131
- Crankshaft Sprocket Removal
  132
- Camshaft Removal
  132
- Crankshaft and Camshaft Sprocket Inspect
  132
- Timing Gear Oil Nozzle Removal
  133
- Piston, Connecting Rod and Bearing Removal
  133
- Crankshaft and Bearings Clean and Inspect (Connecting Rod Bearing Clearance)
  135
- Crankshaft Rear Oil Seal and Housing Removal
  137
- Crankshaft, Bearings and Bearing Cap Removal
  137
- Crankshaft and Bearings Clean and Inspect
  138
- Crankshaft and Bearings Clean and Inspect (Main Bearing Clearance)
  140
- Camshaft Bearing Removal
  142
- Distributor Lower Bushing and Thrust Washer Removal
  143
- Oil Filter Bypass Valve Removal and Installation
  143
- Cylinder Block Clean and Inspect
  144
- Cylinder Bore Measurements
  144
- Cylinder Boring and Honing
  145
- Distributor Lower Bushing and Thrust Washer Installation
  146
- Piston and Connecting Rod Disassemble
  146
- Piston and Connecting Rod Clean and Inspect
  147
- Piston Selection
  149
- Piston and Connecting Rod Assemble
  150
- Camshaft and Bearings Clean and Inspect
  151
- Camshaft Sprocket and Retainer Removal and Installation
  153
- Camshaft Bearing Installation
  154
- Oil Pump Disassemble
  155
- Oil Pump Clean and Inspect
  156
- Oil Pump Assemble
  157
- Cylinder Head Disassemble
  158
- Cylinder Head Clean and Inspect
  159
- Valve Guide Reaming/Valve and Seat Grinding
  161
- Rocker Arm Stud Removal and Installation
  163
- Cylinder Head Assemble
  164
- Crankshaft, Bearings and Bearing Cap Installation
  165
- Crankshaft Rear Oil Seal and Housing Installation
  166
- Piston, Connecting Rod and Bearing Installation
  167
- Timing Gear Oil Nozzle Installation
  168
- Crankshaft Sprocket Installation
  168
- Camshaft Installation
  169
- Engine Front Cover and Oil Seal Installation
  169
- Oil Pump Installation
  170
- Oil Pan Installation
  170
- Crankshaft Pulley Installation
  171
- Cylinder Head Installation
  171
- Valve Lifter Installation
  172
- Valve Rocker Arm and Pushrod Installation
  172
- Pushrod Cover Installation
  174
  - Valve Rocker Arm Cover Installation
    174
  - Oil Level Indicator and Tube Installation
    175
  - Water Pump Installation
    175
  - Intake/Exhaust Manifold Installation
    175
  - Spark Plug Installation
    176
  - Lift Bracket Installation
    176
  - Ignition Coil Installation
    176
  - Distributor Installation
    177
  - Engine Flywheel Installation
    177
  - Engine Block Coolant Plug/Oil Filter Installation
    178
Special Tools and Equipment

179
- Low Emission Version Only
  182

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