Doosan G424 GasolineLP Engine G424 LP Engine Service Manual
FILE DETAILS:
Doosan G424 GasolineLP Engine G424 LP Engine Service Manual
Language: English
Size: 7.41 MB
Pages: 199
Format: PDF
Downloadable: YES
DESCRIPTION:
Doosan G424 GasolineLP Engine G424 LP Engine Service Manual
Important Safety Information:
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards.
- This person should also have the necessary training, skills and tools to perform these functions properly. Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product.
- Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety precautions are listed in the “Safety” section of the owner/operation/maintenance publication. Specific safety warnings for all these publications are provided in the description of operations where hazards exist.
- WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol.
TABLE OF CONTENTS:
Doosan G424 GasolineLP Engine G424 LP Engine Service Manual
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
2
G424 Service Manual 3 Index
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
VIDEO PREVIEW OF THE MANUAL:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]