Caterpillar GM4.3L Gasoline Engine Service Manual SN 003103 & up – PDF DOWNLOAD

Description

Caterpillar GM4.3L Gasoline Engine Service Manual SN 003103 & up – PDF DOWNLOAD

CATERPILLAR GM4.3L GASOLINE ENGINE SERVICE MANUAL SN 003103 & UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Caterpillar GM4.3L Gasoline Engine Service Manual SN 003103 & up – PDF DOWNLOAD

For use with GC35K-GC70K; GP40, GPL40, GP45, GP50 Lift Trucks

Foreword :

• This service manual is a guide to servicing of Caterpillar ® lift trucks. The instructions are grouped by system. The long, productive life of lift trucks depends upon correct servicing as described in this service manual. Carefully read the respective sections of this manual. Know all the components before attempting to test, repair or rebuild a part or system.
• This manual’s descriptions, illustrations and specifications are for trucks with these model numbers: Caterpillar GP40 and GPL40, GP45, GP50; GC35K-GC70K. Mitsubishi Caterpillar Forklift Inc. (MCFA) reserves the right to change specifications or design without notice and without incurring obligation. Whenever a question arises regarding this engine, or this manual, consult your Caterpillar lift truck dealer for the latest available information.
• Because the service mechanic may be unfamiliar with many of the systems on this machine it is important to use caution when performing service work. Knowledge of the system and/or components is important before the removal or disassembly of any component.
• Because of the size of some of the machine components, the service mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed.

TABLE OF CONTENTS:

Caterpillar GM4.3L Gasoline Engine Service Manual SN 003103 & up – PDF DOWNLOAD

Sealers, Adhesives, and Lubricants 1
How to Read This Manual 2
Removal and Installation 3
Special Tools and Equipment 4
Use of RTV and Anaerobic Sealer (Gasket Eliminator) 8
Determining When to Overhaul the Engine 8
Precautions 9
Precautions for Disassembly and Assembly 9
General Precautions 10
Engine Replacement 13
Removal Procedure 13
Installation Procedure 13
Specifications 14
Engine Specifications – Gas and LP 14
General Specifications 17
Major Nuts and Bolts Tightening Torque 21
Diagnostic Information and Procedures 23
Base Engine Misfire Diagnosis 23
Engine Compression Test 25
Engine Noise Diagnosis 25
Valve Train Diagnosis (General) 25
Valve Train Diagnosis (Noise Diagnosis) 26
Engine Mechanical – 4 3L 29
Oil Consumption Diagnosis 29
Low or No Oil Pressure Diagnosis and Testing 29
Oil Leak Diagnosis 29
Repairing the Leak 30
Intake Manifold 31
Intake Manifold Removal Procedures 31
Intake Manifold Installation 32
Exhaust Manifold 35
Oil Level Indicator and Tube Removal 36
Exhaust Manifold and Heat Shields Removal 36
Exhaust Manifold Clean and Inspect 36
Exhaust Manifold Installation and Heat Shields 36
Oil Level Indicator and Tube Installation 37
Cylinder Head and Valves 38
Valve Rocker Arm Cover Removal (Left) 39
Valve Rocker Arm Cover Removal (Right) 39
Valve Rocker Arm and Push Rod Removal 39
Valve Lifter Removal 40
Valve Stem Oil Seal and Valve Spring Removal 41
Cylinder Head Removal 42
Cylinder Head Disassembly and Assembly 44
Cylinder Head Clean and Inspect 45
Valve Guide Reaming/Valve and Seat Grinding 47
Valve Stem Oil Seal and Valve Spring Installation 47
Valve Lifter Installation 48
Valve Rocker Arm and Push Rod Installation 48
Valve Rocker Arm Cover Left Installation 49
Cylinder Head Installation 49
Engine Lubrication 51
TABLE OF CONTENTS
Oil Pan, Pump and Filter 52
Oil Pan Removal 53
Oil Pump Removal 54
Oil Filter Adapter Removal 54
Oil Pump Disassembly 55
Oil Pump Assembly 57
Oil Filter Adapter Installation 59
Oil Pump Installation 59
Oil Pan Installation 60
Front Cover, Timing Chain, and Crankshaft Balancer 61
Engine Front Cover Removal 62
Engine Front Cover Oil Seal Removal 62
Timing Chain and Sprockets Removal 62
Crankshaft Balancer Removal 62
Crankshaft Balancer Installation 63
Timing Chain and Sprockets Installation 63
Engine Front Cover Oil Seal Installation 63
Engine Front Cover Installation 64
Balancer and Camshaft 65
Balance Shaft Removal 66
Camshaft Removal 67
Camshaft Bearing Removal 68
Camshaft and Bearings Clean and Inspect 68
Camshaft Bearing Installation 69
Camshaft Installation 69
Balance Shaft and Bearing Clean and Inspect 70
Balance Shaft Installation 70
Crankshaft, Flywheel, Rear Seal, and Bearings 71
Engine Flywheel Removal 72
Crankshaft Rear Oil Seal and Housing Removal 72
Crankshaft, Bearings, and Bearing Cap Removal 72
Service Prior to Assembly 73
Crankshaft, Bearings and Bearing Cap Installation 73
Bearing Clearance Measuring Procedures 73
Micrometer Method for Crankshaft Bearings 74
Crankshaft Rear Oil Seal and Housing Installation 74
Engine Flywheel Installation 74
Cylinder Block 75
Cylinder Block Cleaning 76
Cylinder Block Inspection 77
Reboring the Cylinders 78
Cylinder Block Installation 79
Piston and Connecting Rod 83
Piston, Connecting Rod, and Bearing Removal 84
Piston and Connecting Rod Disassembly 85
Piston and Connecting Rod Cleaning and Inspect 85
Piston Selection 86
Piston, Connecting Rod and Bearing Installation 86
Piston and Connecting Rod Assembly 88
Carburetor, Gasoline 89
Carburetor Assembly (Upper) 91
Carburetor Assembly (Lower) 92
Carburetor Disassembly 93
Air Horn Disassembly 93
Table of Contents
Carburetor Body Disassembly 95
General Cleaning Procedure 97
Carburetor Inspection 97
Carburetor Assembly 98
Air Horn Assembly 100
Carburetor Adjustment 105
Operational Adjustments 108
Carburetor Installation 108
Electrical Throttle and Governor Control System 109
System Operation 109
Input/Output Interfaces 110
Schematic 111
Method of Operation 112
Speed Control 112
GM 4 3L Engine ECU Diagnostic Tester 113
Ignition System and Distributor 115
Ignition System – Distributor 116
Distributor Removal 117
Distributor Disassembly 117
Distributor Assembly 117
Spark Plug Wires and Coil Wire Removal 118
Spark Plug Wires and Coil Wire Installation 118
Coil Removal 119
Coil Installation and Testing 119
Ignition Sensing Coil Testing 119
Distributor Installation 120
Ignition Timing 121
Spark Plug 122
Alternator and V-Belt 123
Alternator 124
Accessory Drive Belt Replacement 125
Starter Motor 126
Starter Motor Testing 127
Troubleshooting 127
Disassembly 128
Component Inspection and Repair 129
Fuel System – Gas 132
Fuel Pump and Fuel Hose 133
Fuel Pump Disassembly and Reassembly 134
Inspection 135
Main Point of Reassembly 135
Fuel System – LP 136
Maintenance Checks 137
Impco Model VFF-30 Fuel Lock 138
Model J Regulator 140
LPG Pressure Regulator Service Procedures 140
On-Vehicle Pressure Test 141
Regulator Disassembly, Inspection, Cleaning, and Assembly 141
Regulator Bench Test 141
LPG Pressure Regulator Installation Tips 141
LP Regulator/Lockout – Removal and Replacement GF40K Disassembly Steps 141
Impco CA 100 Air Fuel Mixer 142
Model CA100 Carburetor Repair Kit Installation Instructions 143
LPG Carburetor Adjustment Procedure-co/exhaust Analyzer 145
Governor Speed Adjustment Procedure 145

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

 S.V