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Doosan G420F User Manual
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Service Manual
G
420
FE LP/Dual Fuel Engine
G
420
F LP/Gasoline Dual Fuel Engine
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
G20E-5, G25E-5, G30E-5
GC20E-5, GC25E-5, GC30E-5, GC33E-5
SB4241E00
Apr
. 2007
2
Table of Contents
Default Chapter
2
Important Safety Information
2
Table of Contents
4
Chapter 1. General Information
8
Precautions before Service
8
Electrical System
9
Tightening Torque
11
Recommended Lubricants and Capacities
12
Engine Model and Engine Serial Number
13
General Specification
14
Engine Power and Torque
16
Chapter 2 . RECOMMENDED
17
General Maintenance
17
Engine Oil Classification
18
Checking Engine Oil Level
19
Replacing Engine Oil and Filter
19
Checking Compressed Pressure
20
Adjusting Timing Belt Tension
21
Cooling System Maintenance
22
Coolant Recommendation
22
Check Coolant Level
22
Inspect Coolant Hoses
22
Checking Coolant Leaks
23
Specific Gravity Test
23
Checking and Adjusting Drive Belt
24
Adjusting
25
Checking Belt for Damage
25
Ignition System Maintenance
26
Inspect Battery System
26
Inspect Ignition System
26
Inspection of Spark Plug
27
Fuel System Maintenance
29
Replace Lp Fuel Filter Element
29
Testing Fuel Lock-Off Operation
30
Inspect Air/Fuel Valve Mixer Assembly
31
Exhaust System Maintenance
31
Inspect Engine for Exhaust Leaks
31
Inspect for Intake Leaks
31
Inspect Throttle Assembly
31
Checking the Tmap Sensor
31
Maintenance Schedule
32
Chapter 5 . ENGINE MANAGEMENT
34
General Information
34
Specifications
36
Chapter 3 . ENGINE MECHANICAL
39
Torque Specification
39
Special Tools
40
Troubleshooting
42
Timing Belt System
43
Removal
44
Inspection
45
Assembly
47
PCV Valve
49
Outline and Operation Principle
49
Service Procedure
50
Intake and Exhaust System
51
Exhaust Manifold
53
Cooling System
55
Testing and Adjusting
56
Cooling System Recommendation
59
Coolant Pipe and Hose
61
Water Pump
62
Thermostat
64
Cylinder Head Assembly
66
Lubrication System
75
Testing and Adjusting
76
Oil Pressure Switch
78
Front Case and Oil Pump
79
CAM Shaft, HLA, Timing Chain
84
Removal
85
Inspection
86
Crankshaft
91
Flywheel and Housing
95
Piston and Connection Rod
96
Engine Block
102
Cylinder Block
111
Specifications
119
Coil-On-Plug Ignition System
120
Cop Components
120
Ignition System
120
Inspection of Ignition Timing
123
Inspection of Ignition Coil
124
Inspection of Spark Plug
125
Charging System
127
Troubleshooting
129
Troubleshooting Procedure
130
Disassembly and Installation
135
Starting System
140
Diagnosis Procedure
141
Start Relay Tests
143
Starter
145
Removal and Installation
146
General Information
151
Service Standard
156
Component Location
157
G420FE EMS (Engine Management System Overview
161
LPG Fuel System Operation
164
MPI Gasoline System Operation
171
Electronic Throttle System
172
Chapter 4 . ENGINE ELECTRICAL
173
Ignition System
173
Exhaust System
174
Secm
176
SECM Wiring Diagrams for G420FE
179
G420F EMS (Engine Management System Overview
181
LPG Fuel System Operation
184
MPI Gasoline System Operation
188
SECM Wiring Diagrams for G420F
189
EMS Inspection and Repair
190
Engine Control Module (Secm)
190
Camshaft Position Sensor
192
Crank Shaft Position Sensor
193
MAP (Manifold Absolute Pressure) Sensor
194
Iat (Intake Air Temperature)
195
Oxygen Sensor (Pre-Catalyst)
196
Oxygen Sensor (Post-Catalyst)
197
ECT (Engine Coolant Temperature) Sensor
198
LP Fuel Temperature Sensor
200
Angle Sensor-Accelerator
201
Transmission Oil Temperature Switch
202
Ground Speed Limit Switch (Optional)
203
Electronic Throttle Body
204
Chapter 6 . LPG FUEL DELIVERY
205
G420FE LP System Inspection and Repair
205
Hose Connections
206
Removal and Installation of
207
Removal and Installation of CA100 Mixer for G420FE
208
Tests and Adjustments
210
N-2007 Regulator Service Testing
211
AVV (Air Valve Vacuum) Testing
213
Idle Mixture Adjustment
214
Parts Description
217
G420F LPG System Inspection and Repair
221
G420F Fuel System Connections
222
Removal and Installation of N-2001 LP Regulator/Converter
223
Removal and Installation of CA100 Mixer for G420F
224
Tests and Adjustments
226
AVV (Air Valve Vacuum) Testing
228
Idle Mixture Adjustment
229
Parts Description
231
Chapter 7 . MPI GASOLINE FUEL
240
Specification
240
Components Location
241
Fuel Pressure Test
242
Injector
244
Injector Inspection
246
Fuel Pump
248
Chapter 8. Basic Troubleshooting
249
Visual/Physical Check
249
Before Starting
249
Preliminary Checks
249
Basic Troubleshooting Guide
250
Customer Problem Analysis Sheet
250
Basic Inspection Procedure
251
Connector Inspection Procedure
252
Symptom Troubleshooting Guide Chart
256
Basic Troubleshooting
262
Surges And/Or Stumbles
263
Engine Cranking but will Not Start / Difficult to Start
264
Speed Performance / Hesitation During Acceleration
266
Detonation / Spark Knock
268
Backfire
269
Dieseling, Run-On
269
Rough, Unstable, Incorrect Idle, or Stalling
270
Cuts Out, Misses
272
Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell
273
High Idle Speed
274
Excessive Exhaust Emissions or Odors
275
Diagnostic Aids for Rich / Lean Operation
276
Chart T-1 Restricted Exhaust System Check
277
Displaying Fault Codes (DFC) from SECM Memory
278
Chapter 9. Advanced Diagnostics
278
Reading Diagnostic Fault Codes
278
Clearing Fault (Dfc) Codes
278
Fault Action Descriptions
279
Fault List Definitions
279
Table 1. Fault List Definitions
280
Dfc Probable Fault Action
290
Table 2. Diagnostic Fault Codes (Flash Codes)
290
Output Open, Possibly Open EST5 Signal or Defective
295
Spark Module
295
Output Open, Possibly Open EST6 Signal or Defective
295
For Open Circuit
295
SECM Pin A6 (EST4) to OEM Ignition
295
Ignition Module Pin a
295
B (of both Connectors)
295
Refer to Application Manual for Specific
296
N/A
297
For Shorts
297
Module Pin D (4-Pin Connector)
297
Verify GND on Ignition Module Pin a
297
Engine Details
297
Appendix Service Tool Software (Motoview)
308
Service Tool Connection to SECM
309
Service Tool Display
310
SECM Field Update with Service Tool
315
Ground Speed Limits (Option)
319
LPG and LPG Fuel Tanks
321
Lpg Fuel Tank Components
322
Lpg Fuel Tanks
322
Regulatory Compliance
325
Special Conditions for Safe Use
325
Abbreviations
326
4
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Doosan G420F Specifications
General
Brand
Doosan
Model
G420F
Category
Engine
Language
English
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