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G424FE
Doosan G424FE User Manual
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Service Manual
G
424
FE LP/Dual Fuel Engine
G
424
F LP Engine
G20P-5, G25P-5, G30P-5, G33P-5, G35C-5
GC20P-5, GC25P-5, GC30P-5, GC33P-5
SB4251E00
May
.
2007
2
Table of Contents
Default Chapter
3
Important Safety Information
3
Table of Contents
5
Index
6
Chapter 1. GENERAL INFORMATION
9
Precautions before Service
9
Electrical System
10
Tightening Torque
12
Recommended Lubricants and Capacities
13
Engine Model and Engine Serial Number
14
General Specification
15
G424F/G424FE Engine Power and Torque
17
Chapter 2. RECOMMENDED MAINTENANCE
18
General Maintenance
18
Test Fuel System for Leaks
18
Inspect Engine for Fluid Leaks
18
Inspect Vacuum Lines and Fittings
18
Inspect Electrical System
18
Inspect Foot Pedal Operation
18
Engine Oil Classification
19
Checking Engine Oil Level
20
Replacing Engine Oil and Filter
20
Checking Compressed Pressure
21
Cooling System Maintenance
22
Coolant Recommendation
22
Check Coolant Level
22
Inspect Coolant Hoses
22
Checking Coolant Leaks
23
Specific Gravity Test
23
Relation between Coolant Concentration and Specific Gravity
23
Checking and Adjusting Drive Belt
24
Adjusting
24
Checking Belt for Damage
24
Ignition System Maintenance
25
Inspect Battery System
25
Inspect Ignition System
25
Inspection of Ignition Timing
25
Inspection of Spark Plug
26
Fuel System Maintenance
28
Replace LP Fuel Filter Element
28
Testing Fuel Lock-Off Operation
28
Pressure Regulator/Converter Inspection
29
Inspect Air/Fuel Valve Mixer Assembly
29
Inspect for Intake Leaks
29
Inspect Throttle Assembly
29
Checking the TMAP Sensor
29
Exhaust System Maintenance
29
Inspect Engine for Exhaust Leaks
29
Maintenance Schedule
30
Chapter 3. ENGINE MECHANICAL SYSTEM
32
General Information
32
Engine Outline
32
Technical Specifications
33
Shells Selection Table
35
Recommended Torque Values
38
Troubleshooting
40
Engine Exploded View
41
Intake Manifold and Gasket
43
Exhaust Manifold and Gasket
47
Timing Belt
49
Timing Belt Tensioner
53
PCV Valve
54
Crankcase Ventilation
55
Service Procedure
56
Camshaft Timing Pulley And/Or Seal
57
Crankshaft Timing Pulley
57
Crankshaft Front Seal
58
Crankshaft Accessory Pulley
59
Timing Belt Rear Cover
59
Camshaft Case Cover and Gasket
59
Rocker Arms, Linkage, Valve Lifters with
61
Cylinder Head and Eegine
61
Cooling System
62
Testing and Adjusting
64
Cooling System Recommendation
67
Thermostat Housing
68
Water Pump
69
Lubrication System
70
Oil Pan
73
Oil Pump
74
Oil Pump Assembly
75
Camshaft Case Assembly
76
Cylinder Head
80
Valve, Spring or Seal
81
Engine Disassembly
83
Engine Assembly
87
Cylinder Block
92
Crankshaft
93
Pistons And/Or Connecting Rods
99
Rings
101
Chapter 4. ENGINE ELECTRICAL SYSTEM
103
Specifications
103
Ignition System
104
Wasted Spark DIS Ignition System
104
Inspection of Ignition Coil
105
Spark Plug Wire Inspection
106
Spark Plug Wire Replacement
106
Spark Plug Replacement
107
Spark Plug Inspection
107
Charging System
109
General Description
109
Troubleshooting Procedure
112
Starting System
117
General Description
117
Diagnosis Procedure
118
Start Relay Tests
120
Troubleshooting
121
Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)
123
General Information
123
Specifications
123
Service Standard
128
Component Location
129
G424FE EMS (Engine Management System) Overview
133
General Description
133
LPG Fuel System Operation
136
MPI Gasoline System Operation
143
Electronic Throttle System
144
Ignition System
145
Exhaust System
146
Secm
148
SECM Wiring Diagrams for G424FE
151
G424F EMS (Engine Management System) Overview
154
General Description
154
LPG Fuel System Operation
157
Electronic Throttle System
161
Ignition System
161
Secm
161
SECM Wiring Diagrams for G424F LP Engine
162
EMS Inspection and Repair
163
Engine Control Module (SECM)
163
Camshaft Position Sensor
165
IAT (Intake Air Temperature) Sensor
169
Oxygen Sensor (Pre-Catalyst)
170
Oxygen Sensor (Post-Catalyst)
171
ECT (Engine Coolant Temperature) Sensor
172
LP Fuel Temperature Sensor
174
Angle Sensor-Accelerator
175
Transmission Oil Temperature Switch
176
Ground Speed Limit Switch (Optional)
177
Electronic Throttle Body
178
Chapter 6. LPG FUEL DELIVERY SYSTEM
179
G424FE LP System Inspection and Repair
179
Removal and Installation
179
Hose Connections
180
Removal and Installation of N-2007 LP Regulator
182
Removal and Installation of CA100 Mixer for G424FE
183
Tests and Adjustments
185
N-2007 Regulator Service Testing
185
AVV (Air Valve Vacuum) Testing
187
Connection of the MI-07 Service Tool
187
Idle Mixture Adjustment
188
Parts Description
191
CA100 Mixer for G424FE Engine
191
N-2007 Regulator for G424FE Engine
193
G424F LPG System Inspection and Repair
195
Removal and Installation
195
G424F Fuel System Connections
196
Removal and Installation of N-2001 LP Regulator/Converter
197
Removal and Installation of CA100 Mixer for G424F
198
Tests and Adjustments
200
N-2001 Regulator Service Testing
200
AVV (Air Valve Vacuum) Testing
202
Connection of the MI-07 Service Tool
202
Idle Mixture Adjustment
203
Parts Description
205
CA100 Mixer for G424F Engine
205
CA100 Disassembly and Service
207
CA100 Disassembled Service
208
N-2001 Regulator for G424F Engine
209
N2001 Regulator Disassembly Steps
211
N2001 Disassembled Service
213
Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM
214
Specification
214
Components Location
215
Fuel Pressure Test
216
Injector
218
Injector Inspection
219
Fuel Pump
221
Chapter 8. BASIC TROUBLESHOOTING
222
Preliminary Checks
222
Before Starting
222
Visual/Physical Check
222
Basic Troubleshooting Guide
223
Customer Problem Analysis Sheet
223
Basic Inspection Procedure
224
Connector Inspection Procedure
225
Symptom Troubleshooting Guide Chart
229
Basic Troubleshooting
235
Intermittents
235
Surges And/Or Stumbles
236
Engine Cranking but will Not Start / Difficult to Start
237
Lack of Power, Slow to Respond / Poor High
239
Acceleration
239
Detonation / Spark Knock
241
Backfire
242
Dieseling, Run-On
242
Rough, Unstable, Incorrect Idle, or Stalling
243
Cuts Out, Misses
245
Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell
246
High Idle Speed
247
Excessive Exhaust Emissions or Odors
248
Diagnostic Aids for Rich / Lean Operation
249
Chart T-1 Restricted Exhaust System Check
250
Chapter 9. ADVANCED DIAGNOSTICS
251
Reading Diagnostic Fault Codes
251
Displaying Fault Codes (DFC) from SECM Memory
251
Clearing Fault (DFC) Codes
251
Fault Action Descriptions
252
Fault List Definitions
252
Table 1. Fault List Definitions
253
Dfc Probable Fault Action
263
Table 2. Diagnostic Fault Codes (Flash Codes)
263
Turnonmil
268
For Open Circuit
268
SECM Pin A6 (EST4) to OEM Ignition
268
Ignition Module Pin a
268
B (of both Connectors)
268
Refer to Application Manual for Specific
269
N/A
270
For Shorts
270
Module Pin D (4-Pin Connector)
270
Verify GND on Ignition Module Pin a
270
Engine Details
270
Appendix
281
Service Tool Software (Motoview)
281
Introduction
281
Connection of the Service Tool
282
Motoview Display Screens
283
SECM Field Update with Service Tool
295
Ground Speed Limits (Option)
299
LPG and LPG Fuel Tanks
301
Lpg Fuel Tanks
302
Lpg Fuel Tank Components
302
Regulatory Compliance
305
Special Conditions for Safe Use
305
Abbreviations
306
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Doosan G424FE Specifications
General
Brand
Doosan
Model
G424FE
Category
Engine
Language
English
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