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Doosan G424F User Manual

Doosan G424F
306 pages
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Service Manual
G424FE LP/Dual Fuel Engine
G
424F LP Engine
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5
SB4251E00
May. 2007

Table of Contents

Questions and Answers:

Doosan G424F Specifications

General IconGeneral
Engine ModelG424F
ManufacturerDoosan
Number of Cylinders4
Displacement2.4 L
AspirationNaturally Aspirated
Cooling SystemLiquid-Cooled

Summary

Chapter 1. General Information

Precautions before Service

Covers safety precautions and general guidelines before performing service on the engine.

Tightening Torque

Provides a table of tightening torques for standard parts and notes on applicable conditions.

Recommended Lubricants and Capacities

Details recommended lubricants for the engine and their capacities.

Engine Model and Engine Serial Number

Explains how to identify the engine model and serial number.

General Specification

Lists detailed specifications for the engine's mechanical and electrical systems.

Engine Power and Torque

Presents engine power and torque data for different models.

Chapter 2. Recommended Maintenance

General Maintenance

Covers essential maintenance tasks like fuel system checks, fluid leak inspections, and electrical system checks.

Engine Oil Classification

Provides guidelines for selecting engine oil based on API and SAE classifications.

Cooling System Maintenance

Details coolant recommendations, level checks, hose inspections, and leak checks.

Ignition System Maintenance

Covers inspection of battery, ignition system, timing, and spark plugs.

Fuel System Maintenance

Includes procedures for replacing fuel filter elements and testing fuel lock-off operation.

Maintenance Schedule

Outlines recommended maintenance intervals for various engine systems.

Chapter 3. Engine Mechanical System

General Information

Provides an overview of the engine's mechanical system and its components.

Technical Specifications

Lists detailed technical specifications for engine components like crankshaft, cylinders, pistons, and valves.

Recommended Torque Values

Provides a comprehensive list of torque values for various engine fasteners.

Troubleshooting

Offers a guide to diagnosing common engine mechanical problems and their remedies.

Engine Exploded View

Illustrates the engine components with numbered references for identification.

Intake manifold and gasket

Details the components, removal, cleaning, and installation of the intake manifold.

Exhaust Manifold and Gasket

Covers the components, removal, cleaning, and installation of the exhaust manifold.

Timing Belt

Provides information on timing belt components, removal, inspection, and installation.

PCV Valve

Explains the PCV valve's outline, operation principle, removal, inspection, and troubleshooting.

Cooling System

Describes the cooling system's general operation, testing, and adjustment procedures.

Lubrication System

Details the lubrication system's general description, testing, and common problems.

Oil Pan

Covers the removal, cleaning, inspection, and installation of the oil pan.

Oil Pump

Provides procedures for the removal and installation of the oil pump.

Cylinder Block

Details the cylinder block's removal, cleaning, inspection, reconditioning, and honing.

Crankshaft

Covers the crankshaft's removal, cleaning, inspection, measure, and installation.

Pistons and/or Connecting Rods

Provides procedures for the removal, measure, inspection, disassembly, and assembly of pistons and connecting rods.

Chapter 4. Engine Electrical System

Specifications

Lists specifications for ignition coil, spark plug, starter motor, and alternator.

Ignition System

Details the wasted spark ignition system, its components, and troubleshooting for misfires.

Spark Plug Wire Inspection

Covers inspection and replacement procedures for spark plug wires.

Spark Plug Replacement

Provides steps for removing, installing, and inspecting spark plugs.

Charging System

Explains the general description, alternators, and troubleshooting for the charging system.

Troubleshooting Procedure

Provides a step-by-step guide for troubleshooting electrical system issues.

Starting System

Covers the starting system's general description, components, diagnosis, and troubleshooting.

Chapter 5. Engine Management System (EMS)

General Information

Provides an overview of the EMS, including specifications for SECM and sensors.

LP Fuel Components Specification

Lists specifications for LP fuel system components like filters, regulators, and mixers.

Gasoline Fuel Components Specification

Details specifications for gasoline fuel system components like pump, filter, and injectors.

Service Standard

Lists service standards for basic idle RPM and ignition timing, along with tightening torques.

Component Location

Shows the location of key EMS components such as sensors and actuators.

G424FE EMS (Engine Management System) Overview

Provides a detailed overview of the MI-07 Engine Management System for G424FE engines.

LPG Fuel System Operation

Explains the operation principles of the MI-07 system on an LPG fuel system.

SECM

Details the Small Engine Control Module (SECM) functions, including fuel, speed, and ignition management.

Speed Management

Explains the drive-by-wire system for engine speed control via electronic throttle.

Ignition Management

Covers how the SECM controls ignition timing based on engine conditions.

Chapter 6. LPG FUEL DELIVERY SYSTEM

G424FE LP System Inspection and Repair

Covers removal and installation procedures for the G424FE LP fuel system.

Removal and Installation of N-2007 LP Regulator

Provides steps for removing and installing the N-2007 LP regulator.

Removal and Installation of CA100 Mixer for G424FE

Details the procedures for removing and installing the CA100 mixer.

Tests and Adjustments

Covers service testing for regulators and mixers, including break-off and pressure tests.

N-2007 Regulator Service Testing

Provides specific tests for checking the N-2007 regulator/converter operation.

Pressure Test

Explains procedures for performing primary and secondary stage pressure tests.

AVV (Air Valve Vacuum) Testing

Details how to test for excessive or inadequate pressure drop across the CA100 mixer.

Idle Mixture Adjustment

Covers the procedure for adjusting the idle mixture screw for optimal emissions and performance.

Chapter 7. MPI Gasoline Fuel Delivery System

Specification

Lists specifications for the MPI gasoline fuel system components.

Components Location

Shows the location of key components in the gasoline fuel delivery system.

Fuel Pressure Test

Details procedures for releasing internal pressure and measuring fuel pressure.

Inspect Fuel Leakage On Connection

Covers checking for fuel leaks at connections and pressure gauge readings.

Injector

Provides information on injector inspection, operation, resistance measurement, and installation.

Fuel Pump

Covers the removal and installation of the fuel pump assembly, including filter and regulator.

Chapter 8. Basic Troubleshooting

Preliminary Checks

Basic checks to perform before starting troubleshooting, including visual and system checks.

Basic Inspection Procedure

Guides on inspecting electronic parts resistance, intermittent problems, and connectors.

Electrical Circuit Inspection Procedure

Details methods for checking open and short circuits in electrical systems.

Symptom Troubleshooting Guide Chart for MPI Gasoline System

Provides a chart to diagnose starting and idling issues in the MPI gasoline system.

Rough, Unstable, Incorrect Idle, or Stalling

Troubleshooting steps for engines that crank but don't start or have unstable idling.

Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell

Addresses issues related to poor fuel economy and excessive fuel consumption.

Excessive Exhaust Emissions or Odors

Troubleshooting guide for excessive CO, HC, or NOx emissions.

Chapter 9. Advanced Diagnostics

Clearing Fault (DFC) Codes

Procedure to clear stored Diagnostic Fault Codes from the SECM memory.

Reading Diagnostic Fault Codes

Explains how to retrieve and interpret diagnostic fault codes displayed by the MIL.

Fault Action Descriptions

Lists and describes the specific actions taken by the SECM for each detected fault.

Fault List Definitions

Provides definitions for various faults related to sensors and system inputs.

Appendix

Service Tool Software (MotoView)

Introduction to the MotoView service tool for system diagnostics.

Connection of the Service Tool

Step-by-step guide on connecting the service tool to the SECM for diagnostics.

MotoView Display Screens

Describes various screens within the MotoView software for diagnostics and overrides.

Faults Screen Tab

Details how fault codes are displayed and managed within the service tool.

Ground Speed Limits (Option)

Explains how to activate and set ground speed limits using the MotoView service tool.

LPG And LPG Fuel Tanks

Provides information on LPG fuel supply, tank composition, and fuel tank components.

Regulatory Compliance

Covers EPA/CARB emissions certification and safety precautions for electronic controls.

Abbreviations

Lists common abbreviations used throughout the manual.

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