Doosan G424 Gasoline,LP Engine G424 LP Engine (Low Emission Version) G20E-3,G25E-3,G30 Service Manua

[zizouhiche]

Download this document, you need 150 Gallons

Doosan G424 Gasoline,LP Engine G424 LP Engine (Low Emission Version) G20E-3,G25E-3,G30 Service Manual
Size: 7.5mb
Language: English
Type: pdf
Pages: 199

G424 Service Manual Index
Index
GENERAL INFORMATION .......................................4
How to Read This Manual ....................................4
Precaution Before Service....................................6
General .................................................................8
Tightening Torque .................................................9
Sealant................................................................12
SPECIFICATIONS ...................................................13
General Specification..........................................13
Service Specification ..........................................14
MAINTENANCE ......................................................17
Test Fuel System for Leaks ................................17
Check Engine Oil Level ......................................17
Inspect Engine for Fluid Leaks ...........................17
Change Engine Oil and Filter .............................17
Inspect Accessory Drive Belts ............................18
Inspect Electrical System....................................18
Inspect Vacuum lines and fitting .........................18
Check Coolant Level...........................................18
Inspect Coolant Hoses........................................18
Inspect Ignition System.......................................18
Replace Spark Plug............................................18
Replace LP fuel filter element.............................19
Test Fuelock (electric).........................................19
Replace Gasoline Fuel filter ...............................20
Inspect Gasoline Carburetor...............................20
Inspect Pressure Regulator/Vaporizer ................20
Inspect LP Mixer (Standard LP Truck)................20
Inspect Variable Venturi Air/Fuel Mxer
(Low Emission LP Truck)....................................20
Inspect Complete Exhaust System for
Leaks,damage ....................................................20
Engine Control Unit (ECU) and others
(Low Emission LP Truck)....................................20
Maintenance Schedule .......................................21
ENGINE SYSTEM ...................................................22
Engine Overview.................................................22
Timing System ....................................................25
Silent Shaft Mechanism......................................26
Auto Lash Adjuster..............................................27
Intake and Exhaust System................................28
Electrical System ................................................30
STARTING SYSTEM ...............................................32
General Description ............................................32
Start Relay Test ..................................................35
Start Motor ..........................................................36
Operation.......................................................36
Removal and Installation...............................39
Disassembly and Reassembly ......................42
CHARGING SYSTEM..............................................47
General Description ............................................47
Alternator ............................................................47
IGNITION SYSTEM .................................................50
Breakerless Ignition System ...............................50
Distributor............................................................51
Removal and Installation ....................................54
Distributor, disassembly and reassembly ...........56
GASOLINE FUEL SYSTEM....................................58
General Description ............................................58
Geasoline Carburetor, Operation........................59
Removal and Installation ....................................64
Gasoline Carburetor
Disassembly and Reassembly............................66
LPG FUEL SYSTEM ...............................................73
General Description ............................................73
Electric Fuelock Model ..................................73
Converter.......................................................74
Fuel Tank.......................................................75
LP Relief Valve ..............................................75
Carburetor .....................................................76
Tests or Adjustments...........................................77
Carburetor Adjustment ..................................77
Fuel System Leak Check ..............................79
Recommendation for LP Fuel System ..........80
LP Converter - Check, Clean ........................81
Disassembly and Assembly................................82
LPG Carburetor.............................................82
LP Gas Fuelock.............................................84
LP Gas Converter..........................................85
LPG FUEL SYSTEM (LOW EMISSION VERSION)..87
General Description ............................................87
LP Carburetor................................................89
Vacuum switch (MAP) ...................................90
Vacuum switch ..............................................90
LP Converter .................................................91
Fuel Control Valve.........................................92
Fuelock Valve ................................................92
Engine Control Unit (ECU) ............................93
Oxygen Sensor..............................................94
Catalytic Muffler.............................................95
Tests or Adjustments...........................................96
LP Carburetor - Check, Clean.......................97
LP Converter-Check,Clean ...........................97
Inspection of Fuelock Valve ..........................97
Inspection of Fuel Control Valve ...................97
Inspection of Vacuum switch.........................97
Inspection of Vacuum switch (MAP)..............97
Inspection of Oxygen sensor.........................98
Disassembly and Assembly................................99
LPG Carburetor.............................................99
LP Gas Converter........................................101
2G424 Service Manual Index 3
DUAL FUEL SYSTEM...........................................102
GOVERNING SYSTEM .........................................103
General Description ..........................................103
Governor,Disassembly and Reassembly..........104
LUBRICATION SYSTEM.......................................106
General Description ..........................................106
Testing and Adjusting........................................107
Engine Oil...............................................107
Lubrication System Problem ..................107
Oil Pressure Check ................................109
COOLING SYSTEM...............................................110
General Description ..........................................110
Testing and Adjusting ........................................111
Cooling System Visual Inspection ...............111
Cooling System Tests ..................................111
Thermostat...................................................113
Cooling system Heat Problem.....................114
Cooling System Recommendation ..............114
Belt Adjustment............................................116
V-belt Diagnosis...........................................116
Serivce Procedure ............................................117
Draining and Filling Cooling System ...........117
Flushing the Cooling System.......................118
Radiator Service ..........................................118
Removal & Install Water Temperature Sender..119
BASE ENGINE SERVICE PROCEDURE .............120
Timing Belt ........................................................120
Intake Manifold .................................................129
Exhaust Manifold and Water Pump ..................130
Rocker Arms and Camshaft..............................133
Cylinder Head and Valves ................................139
Front Case and Oil Pan....................................145
Piston and Connecting Rod..............................154
Crankshaft and Cylinder Block .........................162
ADJUSTMENT AND TROUBLESHOOTING ........169
Adjustment........................................................169
Valve Clearnce Adjustment .........................169
Ignition Timing Adjustment ..........................169
Idle Speed Adjustment ................................171
Air Governor Adjustment .............................171
Anti-Hunting Adjustment..............................171
Troubleshooting ................................................172
Engine Performance....................................172
Engine Starting Problems ...........................172
Charging System Problems ........................173
Instrument Problems ...................................173
Engine Noise...............................................174
Oil Pressure Diagnostics.............................176
Oil Pressure Problems ................................177
Water in Engine...........................................178
Engine Overheting.......................................179
LP Fuel System
(Standard and/or Low Emission Version)....180
Troubleshooting Flow Chart ........................187
General ..................................................187
Engine ....................................................189
Carburetor ..............................................190
Electrical Components ...........................192
SPECIAL TOOLS ..................................................195