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G25P-3
Doosan G25P-3 Service Manual
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G430 LP Engine
Standard Version
Low Emission Version
G20P-3,
G25P-3,
G30P-3
GC20P-3, GC25P-3,
GC30P-3
SB4005E01
Oct.
2001
Service Manual
2
Table of Contents
Default Chapter
2
Important Safety Information
2
Table of Contents
4
General Information
8
Shop Safety
8
Fuel Information
9
What Is LPG
9
Air Temperature Versus Power Output
10
Altitude Versus Power Output
11
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
Fastener Tightening Specifications
18
Sealer, Adhesives and Lubricants
18
Engine Mechanical Specifications
19
Maintenance
21
Test Fuel System for Leaks
21
Inspect Engine for Flluid Leaks
21
Engine Crankcase Oil
21
Oil Recommendations
21
Checking/Filling Engine Oil Level
22
Changing Engine Oil and Filter
22
Accessory Drive Belts
22
Inspect Electrical System
22
Inspect Vacuum Lines and Fittings
23
Inspect Fuel Lines and Fittings
23
Engine Compression Check
23
Cooling System
23
Checking Coolant Level
23
Inspect Coolant Hoses
24
Inspect Ignition System
24
Replace Spark Plugs
24
Replace LP Fuel Filter Element
24
Test Fuel Lock (Electric)
25
Inspect Pressure Regulaator/Vaproizer
25
Inspect LP Mixer (Standard LP Truck)
25
Inspect Variable Venturi Air/Fuel Mixer (Low Emission LP Truck)
25
Inspect Complete Exhaust System for Leaks, Damage
25
Engine Control Unit (ECU) and Others (Low Emission LP Truck)
25
Maintenance Schedule
26
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
General Description
63
EST Distributor Component Testing
63
EST Distributor Removal
65
Cleaning and Inspection
66
EST Distributor Disassembly
66
EST Distributor Installation (Engine Not Disturbed)
67
EST Distributor Installation (Engine Disturbed)
67
Ignition Timing - EST System
67
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
Carburetor Adjustment
74
Fuel System Leak Check
76
Recommendation for Lpfuel Systems
77
LP Converter - Check, Clean
78
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
LP Carburetor-Check, Clean
94
LP Converter-Check, Clen
95
Inspection of Fuel Lock Valve
95
Inspection of Fuel Control Valve
95
Inspection of Vacuum Switch(MAP)
96
Inspection of Oxygen Sensor
96
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
4
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Doosan G25P-3 Specifications
General
Displacement
2.4 L
Fuel Type
LPG
Engine Model
G424
Aspiration
Naturally Aspirated
Cooling System
Water-cooled
Net Power
24.8 kW (33.2 hp)
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