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Doosan D20G, Service Manual

The Doosan D20G product manual offers comprehensive information on its Specifications, Systems Operation, Testing & Adjusting procedures. This essential manual is available for free download at manualshive.com, providing users with easy accessibility to optimize their experience with the Doosan D20G equipment.

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Maintenance Section 

- 139 - 

 

Drive Axle Oil - Change 

Park the lift truck on a level surface. Apply the 
parking brake. Place the directional control lever in 
NEUTRAL and stop the engine. 
 

 

1.

 

Remove drain plug . Allow the oil to drain into a 
suitable container. Clean the drain plug. 

 
 

2.

 

Install the drain plug. 

 

3.

 

Remove the dip stick/filler cap. 
Fill the drive axle housing with oil. 

See “Refill Capacities”. 

 

4.

 

Start the lift truck. 
With the engine at low idle, place the directional 
control lever to the NEUTRAL. 

 

 

5.

 

Remove the drain plug. Maintain the oil level 
until the oil flows out. 

 

6.

 

Install the drain plug. 

 

 

7.

 

Install the dip stick/filler cap. 

 

NOTE: 

Tighten the dipstick plug fully not to allow 

foreign parts(rain, water etc) to enter into 
drive axle. 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for D20G

Page 1: ... are updated or supplements are added they will be provided separately TITLE FORM NUMBER Service Manual Contents SB4318E00 Safety SB2003E00 Torque Specifications SB2004E00 ENGINE 3 3 Liter B3 3 Diesel Engine SB4310E00 4TNV98 4TNE98 Diesel Engine SB4319E00 G424F FE LP Gasoline Engine SB4320E00 POWER TRAIN Power Train SB4218E01 VEHICLE SYSTEM Vehicle System SB4219E01 Vehicle System D A SB4220E01 Hyd...

Page 2: ......

Page 3: ...achine has just been stopped because fluids can be hot 10 Always use tools that are in good condition and be sure you understand how to use them before performing any service work 11 Reinstall all fasteners with same part number Do not use a lesser quality fastener if replacements are necessary Do not mix metric fasteners with standard nuts and bolts 12 If possible make all repairs with the machin...

Page 4: ...rmed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures Determine type of metal being welded and select correct welding procedure and electrodes rods or wire to provide a weld metal strength equivalent at least to that of parent metal 15 Do not damage wiring during removal operations Reinstall the wiring so it ...

Page 5: ...Specifications TORQUE SPECIFICATIONS SB2004E00 D e c 1 9 9 8 ...

Page 6: ... of rust and corrosion Clean hardware with a non corrosive cleaner and apply engine oil to threads and bearing face If thread lock or other compounds are to be applied do not apply engine oil METRIC NUTS AND BOLTS THREAD SIZE mm M6 M8 M10 M12 M14 M16 M20 M24 M30 M36 N i m 12 3 28 7 55 10 100 20 160 30 240 40 460 60 800 100 1600 200 2700 300 lb i ft 9 2 20 5 40 7 75 15 120 22 175 30 340 44 600 75 1...

Page 7: ...0 50 620 80 900 100 1300 150 1800 200 2400 300 3100 350 lb i ft 9 2 18 0 4 5 35 7 50 11 75 15 120 20 160 30 275 35 460 60 660 75 950 100 1325 150 1800 225 2300 250 STANDARD TORQUE INCH TAPERLOCK STUDS THREAD SIZE inch 1 4 5 16 3 8 7 16 1 2 5 8 3 4 7 8 1 1 1 8 1 1 4 1 3 8 1 1 2 N i m 8 3 17 5 35 5 45 10 65 10 110 20 170 30 260 40 400 60 500 70 650 80 750 90 870 100 lb i ft 6 2 13 4 26 4 33 7 48 7 8...

Page 8: ... 3 16 12 1 5 16 12 1 5 8 12 1 7 8 12 2 1 2 12 N i m 5 0 1 5 12 2 20 4 30 5 40 5 100 15 135 15 200 25 250 25 300 40 300 40 300 40 300 40 lb i ft 45 15 lbi in 110 20 lbi in 15 3 22 4 30 4 75 10 100 10 150 20 185 20 225 30 225 30 225 30 225 30 STANDARD TORQUE O RING FACE SEAL FITTING NUT THREAD SIZE inch 9 16 18 11 16 16 13 16 16 1 14 1 3 16 12 1 7 16 12 1 11 16 12 2 12 N i m 16 3 30 4 50 7 90 10 120...

Page 9: ... O ring seal 5 as far back on fitting body 2 as possible Hold these components in this position Turn the fitting into the part it is used on until backup washer 4 just makes contact with the face of the part it is used on 2 To put the fitting assembly in its correct position turn the fitting body 2 out counterclockwise a maximum of 359û Tighten locknut 3 to the torque shown in the correct chart fo...

Page 10: ...ver the last thread on the body The remainder of space is used whenever the fitting is removed and installed again 5 of 7 37û FLARED AND STRAIGHT THREAD O RING FITTINGS 37û FLARED O RING FITTING PLUG SWIVEL NUTS 37û FLARED AND STRAIGHT THREAD O RING FITTINGS EXCEPT O RING FACE SEAL FITTINGS NOMINAL TUBE O D STANDARD TORQUE METRIC 3 18 4 76 6 35 7 94 9 52 9 52 12 70 15 88 19 05 22 22 25 40 31 75 38...

Page 11: ...o seat the sleeve Flex Fittings Put nut and sleeve over the tubing and push tube in to counterbore of fitting body as far as possible Tighten the nut until it is against the hex part of the fitting body 6 of 7 45û FLARED AND 45û INVERTED FLARE FITTINGS INVERTED 45û FLARED 45û FLARED 45û FLARED AND 45û INVERTED FLARE FITTINGS NOMINAL TUBE O D STANDARD TORQUE METRIC 3 18 4 76 6 35 7 94 9 52 11 11 12...

Page 12: ...t 22 2 38 4 44 5 55 6 N i m 23 3 33 4 38 4 50 5 lb i ft 17 2 24 3 28 3 37 4 THREAD SIZE inch 45û FLARE FITTING END STEEL TUBES STANDARD TORQUE ALUMINUM TUBES STANDARD TORQUE PIPE THREAD SIZE inch 1 16 27 1 8 27 1 4 18 3 8 18 1 2 14 3 4 14 1 11 1 2 1 1 4 11 1 2 1 1 2 11 1 2 2 11 1 2 THREADS WITH 1E2200E SEALANT THREADS WITHOUT SEALANT N i m 15 20 25 35 45 60 75 95 110 130 N i m 20 25 35 45 60 75 90...

Page 13: ...Service Manual B3 3 Diesel Engine D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 D20S 3 D25S 3 D30S 3 D32S 3 D33S 3 D20G D25G D30G SB4310E00 Jan 2008 ...

Page 14: ......

Page 15: ...following symbol Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on the produ...

Page 16: ......

Page 17: ...s Excessive 38 Coolant Contamination 39 Coolant Loss 40 Lubricating Oil Pressure Is Low 41 Oil Level Rises 42 Coolant Temperature above Normal 43 Excessive Noise 44 Excessive Noise Continued 45 Engine Vibration Excessive 46 Complete Engine Complete Engine 47 Engine Disassembly 47 Engine Assembly 66 Engine System Engine System 95 Bearing Connecting Rod 95 Bearing Main 100 Bearing Thrust 105 Camshaf...

Page 18: ...aft and Camshaft Bushing 212 Crankshaft 213 Timing Gear 214 Flywheel 215 Cylinder 216 Piston 217 Connecting Rod Piston Ring and Piston Pin 218 Oil Pump 219 Regulator Valve 220 Thermostat 221 Capscrew Markings and Torque Values 222 Capscrew Markings and Torque Values Metric 222 Capscrew Markings and Torque Values U S Customary 223 Fraction Decimal Millimeter Conversions 224 Newton Meter to Foot Pou...

Page 19: ...is organized to provide an easy flow from problem identification to problem correction A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms Section TS The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end user to the correct procedure for making the repair Complete the followin...

Page 20: ...he engine can be damaged if the Caution instructions are not followed Indicates a REMOVAL or DISASSEMBLY step Indicates an INSTALLATION or ASSEMBLY step INSPECTION is required CLEAN the part or assembly PERFORM a mechanical or time MEASUREMENT LUBRICATE the part or assembly Indicates that a WRENCH or TOOL SIZE will be given TIGHTEN to a specific torque PERFORM an electrical MEASUREMENT Refer to an...

Page 21: ...the engine or parts used in your application The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition The illustrations are intended to show repair or replacement procedures The procedure will be the same for all applications although the illustration can differ th8sesa Ca8vagc ...

Page 22: ...gine dataplate shows specific information about the engine The engine serial number ESN and control parts list CPL provide information for ordering parts and for service needs NOTE The engine dataplate must not be changed unless approved by Cummins Engine Company Inc 00900249 00900248 ...

Page 23: ...mber of liters qt from Low to High 1 5 liters 1 6 qt Cooling System Naturally Aspirated Coolant Capacity Engine Only 4 5 liters 4 75 qt 82 C 180 F Standard Modulating Thermostat Range Start Fully Open 95 C 203 F Maximum Pressure Cap Sea Level 50 kPa 7 psi Air Induction System Naturally Aspirated Maximum Allowable Intake Restriction at Rated Speed and Load with Dirty Filter Element 762 mm H2O 30 in...

Page 24: ...he major external engine components filters and other service and maintenance points Some external components will be at different locations for different engine models 1 Intake Manifold 2 Starting Motor 3 Fuel Injection Pump 4 Crankshaft Pulley 5 Fan 6 Fuel Filter 7 Oil Fill Cap 00900138 Intake Side Naturally Aspirated ...

Page 25: ...Diesel Engine Engine Identification 11 1 Oil Fill Cap 2 Thermostat Housing 3 Alternator 4 Dipstick 5 Oil Filter 6 Exhaust Manifold 00900139 Exhaust Side Naturally Aspirated ...

Page 26: ...Diesel Engine Engine Identification 12 00900141 Front View Naturally Aspirated Rear View Naturally Aspirated 00900140 ...

Page 27: ... Oil Strainer 2 Oil Pump 3 Oil Cooler Optional 4 Regulator Valve 5 Oil Filter 6 Safety Valve 7 Crankshaft 8 Camshaft 9 Piston 10 Intake and Exhaust Valve 11 Rocker Arm 12 Timing Gear 13 Cooling Water 00900146 Exhaust Side Naturally Aspirated ...

Page 28: ... of teeth 22 5 Driveshaft 6 Drivenshaft 7 Driven Gear number of teeth 7 8 Regulator Valve 9 Valve Spring Oil pump Type Gear Type Gear drive number of teeth 7 Oil pump drive gear number of teeth 22 Driven gear number of teeth 7 Pump Speed Engine Speed x 1 182 Regulator Valve Set Pressure 490 50kPa 71 7psi 00900148 Oil Pump ...

Page 29: ...ication 15 1 Fuel supply from tank 2 Hand priming pump 3 Fuel filter 4 Water in fuel sensor 5 Fuel pump 6 Fuel shutoff solenoid 7 High pressure fuel line 8 Injector 9 Fuel drain manifold 10 Fuel return to tank 05900870 Fuel System ...

Page 30: ... Injection Pipe No 1 7 Fuel Injection Pipe No 2 8 Fuel Injection Pipe No 3 9 Fuel Injection Pipe No 4 10 Spill Tube A Fuel Inlet from Fuel Tank B To Fuel Tank C To Fuel Injection Pump D To Fuel Injection Nozzle Fuel Injection Pump Maker Zexel Type VE Lubrication Method Forced Lubrication with Fuel Governor Type Mechanical All speed Type 00900150 Fuel Injection Pump ...

Page 31: ...zzle spring 5 Spring seat 6 Intermadiate Plate 7 Nozzle Body 8 Retaining Nut 9 Needle A Fuel Inlet from injection pump B Fuel Injection to cylinder C Fuel Return to fuel tank Fuel Injection Nozzle Maker Zexel Injection Pressure 40 MPa Adjustment of Injection Pressure By Shim 00900151 Fuel Injection Nozzle ...

Page 32: ...e Engine Identification 18 1 Radiator 2 Thermostat 3 Water Temperature Gauge 4 Water Pump 5 Water Manifold 6 Cylinder Head 7 Piston 8 Cylinder Block 9 Oil Cooler optional A From Oil Pump oil 00900147 Cooling System ...

Page 33: ...Diesel Engine Engine Identification 19 1 Filtered Air 2 Air Heater 3 Intake Manifold 4 Intake Valve Port 00900227 Air Intake System ...

Page 34: ...Diesel Engine Engine Identification 20 1 Exhaust Valve Port 2 Exhaust Manifold 00900232 Exhaust System ...

Page 35: ...ad to the cause and correction of the problem Follow these basic troubleshooting steps Get all the facts concerning the complaint Analyze the problem thoroughly Relate the symptoms to the basic engine systems and components Consider any recent maintenance or repair action that can relate to the complaint Double check before beginning any disassembly Solve the problem by using the symptom charts an...

Page 36: ...OK Fuel inlet restriction Check for fuel inlet restriction OK Fuel lift pump is malfunctioning The pump output pressure Replace the fuel lift pump if necessary OK Fuel pump overflow valve is malfunctioning Check the overflow valve OK Air in the fuel system Check for air in the fuel system Repair source of leak and bleed air from the system OK Air intake system restriction is above specification Ch...

Page 37: ...st on the injector s OK Correction Fuel grade is not correct for the application or the fuel quality is poor Operate the engine from a tank of high quality fuel OK Fuel supply line restriction between the fuel pump and the injection Check the fuel supply line from the fuel pump to the cylinder head for sharp bends that can cause restriction OK Internal engine damage Analyze the oil and inspect the...

Page 38: ...e starter service manual OK Battery voltage is low Check the batteries and the unswitched battery supply circuit OK Engine driven units are engaged Disengage engine driven units OK Starting circuit component is malfunctioning Refer to the electric schematic OK Starting motor pinion or ring gear is damaged Remove the starting motor and inspect the gear Refer to starter manual OK Lubricating oil doe...

Page 39: ...ntinued Cause Correction Lubricating oil level is above specification Check the oil level Verify the dipstick calibration and oil pan capacity Fill the system to the specified level OK Internal engine damage Analyze the oil and inspect the filters to locate an area of probable damage ...

Page 40: ... the fuel cut solenoid valve Troubleshoot and repair the circuit wiring OK Engine does not start when voltage is applied to the fuel cut solenoid valve Replace the fuel cut solenoid valve OK Clogged prefilter Clean the prefilter OK Clogged fuel filter or strainer Clean or replace the fuel filter or strainer OK Clogged or leaking fuel piping Clean and repair the fuel piping OK Feed pump is damaged ...

Page 41: ... drive units are not engaged Check the Battery and recharge or replace OK Improper fuel is being used Drain fuel and replace with correct fuel OK Clogged air cleaner element Clean or replace the air cleaner element OK Clogged prefilter Clean the prefilter OK Clogged fuel filter or strainer Clean or replace the fuel filter or strainer OK Leakage clogging air in fuel system Repair and clean the fuel...

Page 42: ...ettings OK Overhead components are damaged Inspect the rocker levers rocker shafs and valve for excessive damage Replace as necessary OK Defective or clogged injection nozzle Replace the defective or clogged injection nozzle OK Injection pump is malfunctioning Repair or replace the injection pump OK Worn piston ring or cylinder resulting in low compression Replace the worn piston ring or cylinder ...

Page 43: ...Clean and repair the fuel piping OK Clogged or leaking fuel piping Clean and adjust the overhead settings OK Overhead adjustments are not correct Measure and adjust the overhead settings OK Defective contact of valve or valve seat Resulting in low compression Replace the cylinder head OK Defective or clogged injection nozzle Replace the defective or clogged injection nozzle OK Injection pump is ma...

Page 44: ...ainer Clean and or replace the fuel filter or strainer OK Clogged or leaking fuel piping Clean and repair the fuel piping OK Feed pump piston is damaged or seized Replace the feed pump OK Overhead components are damaged Inspect the rocker levers rocker shafts and valves for excessive damage Replace as necessary OK Injection pump is malfunctioning Replace the injection pump OK Gear train damaged or...

Page 45: ...ed is adjusted too low Adjust the low idle speed OK Clogged prefilter Clean the prefilter OK Clogged fuel filter or strainer Clean or replace the fuel filter or strainer OK Line between the fuel tank and feed pump are clogged or have air in them Clean and repair the lines OK Line between the feed pump and the injector nozzle are clogged or have air in them Clean and repair the lines OK Injection p...

Page 46: ...ean the fuel tank breather OK Full throttle can not be achieved because the fuel lever linkage is bent or not adjusted correctly Repair or adjust the fuel lever linkage OK Clogged prefilter Clean the prefilter OK Clogged fuel filter or strainer Clean and or replace the fuel filter or strainer OK Clogged or leaking fuel piping Clean and repair the fuel piping OK Feed pump is defective Replace the f...

Page 47: ...e or seat Resulting in low compression Replace the cylinder head OK Defective or clogged injection nozzle Replace the defective or clogged injection nozzle OK Injection pump is malfunctioning Replace the injection pump OK Worn piston ring or cylinder resulting in low compression Replace the worn piston ring or cylinder ...

Page 48: ...striction Check the exhaust system for any restrictions OK Intake air leak between turbocharger and cylinder head Inspect for air leaks OK Exhaust leaks at the manifold Check and correct any leaks in the exhaust manifold gaskets Check for a cracked exhaust manifold OK Clogged nozzles Clean the nozzles OK Throttle lever return spring linkage or air throttle cylinder damaged or improperly adjusted C...

Page 49: ...g the engine from a temporary supply of number 2 diesel fuel Check fuel specifications for proper fuel grade OK Fuel injection pump timing is not correct Put the engine at top dead center Check and adjust the fuel timing OK Injector sealing washer not correct Check to see if an extra sealing washer is installed under injector Remove any additional sealing washer Only one is required OK Injectors w...

Page 50: ...ke system is contaminated with dust Remove and clean intake manifold OK Dipstick is not calibrated correctly Verify the dipstick is correctly marked OK Breather or breather hose is clogged Clean the breather and breather hose OK Rear crankshaft seal or seal surface is damaged Repair or replace seal and surface OK Valve stem guide or seal is damaged Repair or replace the damaged component OK Worn o...

Page 51: ...breather and breather hose OK Lubricating oil filter is clogged Replace the filter OK Exhaust gas is black Refer to Exhaust Gas Is Black Incomplete Combustion OK Defective contact of valve or valve seat resulting in low compression Repair the valve or valve seat OK Worn piston ring or cylinder resulting in low Compression Replace the worn piston ring or cylinder ...

Page 52: ...ck the fuel lines fuel connections and fuel filters for leaks Check the fuel lines to the supply tanks Refer to the OEM s service manual OK Poor quality fuel or No 1 fuel is being used Assure good quality No 2 diesel fuel is being used OK Intake or exhaust restriction Refer to troubleshooting logic for Exhaust Gas is Blake OK Defective or clogged injection nozzle Replace the defective or clogged i...

Page 53: ...ant change interval Drain and flush the system Fill the system with the Correct mixture of coolant and water OK Lubricating oil cooler for powertrain is damaged Refer to the OEM s service manual OK Cylinder head gasket is cracked or damaged Replace the cylinder head or gasket OK Cylinder block is cracked or porous Replace the cylinder block ...

Page 54: ...asket or drain cock leaks OK Overheating or compression gases are leaking Resulting in loss through the radiator overflow Review the operation for overheating and low power Refer to troubleshooting logic for Coolant Temperature Above Normal OK Transmission cooler is leaking if equipped Check for mixing of coolant and transmission fluid OK Cylinder head gasket is leaking Check or replace the head g...

Page 55: ...ce the oil lever or oil pressure sensor OK Lubricating oil filter is clogged Replace the filter OK Fuel or coolant is in the lubricating oil Refer to Oil Level Rises symptom tree OK Regulator or relief valve is not adjusted Correctly Adjust the regulator or relief valve OK Lubricating oil pan strainer is clogged Clean the strainer OK Lubricating oil suction tube is damaged Repair or replace the su...

Page 56: ...ump seal Replace the auxiliary pump Refer to the OEM s service manual OK Injector sleeve is damaged Replace the injector sleeve OK Fuel injector is leaking inside cylinder head Replace the injector OK Injector pump seal is leaking Remove and repair the injection pump OK Cylinder head or head gasket is cracked or damaged Replace the cylinder head or gaeket OK Cylinder block is cracked or porous Rep...

Page 57: ...is worn Replace the fan belt or pulley OK Water temperature gauge is malfunctioning Replace the water temperature gauge OK Radiator fin is clogged or crushed Clean repair or replace the radiator OK Radiator core is clogged Clean and repair the radiator OK Thermostat is defective and does not open Replace the thermostat OK Water pump is damaged Replace the water pump OK Cylinder head or head gasket...

Page 58: ...is Black troubleshooting tree OK Gear train backlash is not adjusted correctly Adjust the backlash for the gear train OK Idler gear bushing is damaged or missing Replace the idler gear bushing OK Defective or clogged injection nozzle Replace the defective or clogged injection nozzle OK Overhead adjustments are not correct Measure and adjust the overhead settings OK Overhead components are damaged ...

Page 59: ...Symptoms 45 Excessive Noise Continued Cause Correction Injection pump is adjusted incorrectly Adjust or replace the injection pump OK Worn piston ring or cylinder resulting in low compression Replace the worn piston ring or cylinder ...

Page 60: ...the alignment Refer to the OEM s service manual OK Gear train backlash is not adjusted correctly Adjust the backlash for the gear train OK Overhead components are damaged Inspect the rocker levers rocker shafts and valves for excessive damage Replace as necessary OK Cam bushing is worn Replace the cam bushing OK Injection pump is adjusted incorrectly Adjust or replace the injection pump OK Main be...

Page 61: ... Engine Removal NOTE Put tag on all hoses lines linkage and electrical connections as they are removed to identify location and aid the installation process WARNING Always disconnect the negative cable first Disconnect the battery cables WARNING Allow the engine to cool before draining to avoid burns from hot liquid WARNING Coolant is toxic Keep away from children and animals Save for reuse or dis...

Page 62: ...rolonged contact with used engine oil Always use the proper procedures to dispose of the oil Drain the lubricating oil Engine Oil 7 5 liters 1 98 U S gal Disconnect the starter cable engine ground straps cab or chassis to engine hoses tubing electrical wires and hydraulic lines Disconnect the intake and exhaust system pipes Disconnect the drive units from the flywheel housing and flywheel WARNING ...

Page 63: ...emove the engine from the equipment Prepare a stable stand Part No 3375193 or 3375194 which will prevent the engine from falling over Engine Weight approx 255 kg 562 lb Remove the starting motor Install the bracket Part No 3163625 on the engine ra400ha 00900154 00900156 00900207 ...

Page 64: ... the engine openings to prevent dirt and debris from entering the engine Fan Pulley WARNING Be careful not to injure your fingers or damage the alternator when moving the alternator toward the cylinder block Loosen the mounting capscrew of the adjustment plate 1 Loosen the alternator mounting capscrew and nut Move the alternator toward the cylinder block and remove the belt 2 Remove the fan pulley...

Page 65: ...ment plate and spacer Remove the remaining capscrew and alternator Lubricating Oil Filter Remove the lubricating oil filter Dipstick Guide Remove the dipstick and dipstick guide Water Pump Remove the mounting capscrews water pump gasket and o ring Discard the gasket and o ring 00900159 00900155 00900160 00900161 ...

Page 66: ...iscard the gasket Fuel Injection Tubing Remove the clamp Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head Intake Manifold Remove the eight capscrews intake manifold and air inlet connection Remove the grid heated if equipped Remove the four capscrews air inlet connection and o ring Discard the o ring 00900162 00900163 00900164 18900025 ...

Page 67: ... NOTE When removing the injector clean around the injector and insert a blind plug to prevent dust or dirt from entering the engine NOTE Mark the injectors with tags showing the cylinder number and keep it in a safe place If there is no abnormality in the injector install it in the same position during assembly Rocker Lever Cover Remove the three capscrews isolator assemblies rocker lever cover an...

Page 68: ... Indexing Screw 6 Pedestal Mounting Stud 7 Cup Plug 8 Snap Ring 9 Thrust Washer if equipped 10 Rocker Lever Pedestal 11 Rocker Lever 12 Adjusting Screw Rocker Arm Assembly Remove the mounting capscrews and the rocker arm assembly NOTE When removing the rocker arm loosen the locknut and turn the adjustment screw counterclockwise 2 to 3 turns 00900251 00900169 ...

Page 69: ...ly Cylinder Head Assembly WARNING This component weighs 23 kg 50 lb or more To avoid personal injury use a hoist or get assistance to lift this component Remove the mounting capscrews cylinder head assembly and gasket Discard the gasket Cylinder Head Assembly Disassembly Using the spring pusher Part No 3398179 compress the valve spring and remove the valve collets Loosen the spring and remove the ...

Page 70: ...ure to do so will result in the need to remove the front gear cover Remove the gear cover access cap Rotate the engine until the keyway is vertical Remove the nut and washer from the fuel injection pump shaft Remove the injection pump support bracket Remove the two mounting capscrews Remove the fuel injection pump Remove the key PTO Shaft if applicable Remove the two capscrews flange o ring and PT...

Page 71: ...asket Discard the gasket Lubricating Oil Suction Tube Remove the two mounting capscrews lubricating oil suction tube and o ring Discard the o ring Crankshaft Pulley Remove the capscrew and mounting plate Remove the crankshaft pulley using flange puller Part No 3397890 00900178 00900179 00900180 00900212 ...

Page 72: ...The noise damper must be removed prior to removing the front oil seal Remove the front oil seal from the gear housing cover Lubricating Oil Pump Remove the five capscrews and the lubricating oil pump Idler Gear Remove the capscrew retainer plate and idler gear NOTE If a PTO is installed the idler gear uses a bearing 00900181 00900182 00900183 00900184 ...

Page 73: ...en removing the camshaft lightly rotate the shaft while being careful not to damage the bushing Flywheel WARNING This component weighs 23 kg 50 lb or more To avoid personal injury use a hoist or get assistance to lift this component WARNING The pilot is short so the flywheel can come off suddenly Remove the six capscrews retaining plate coupling and flywheel 00900185 00900186 00900187 ...

Page 74: ...t assistance to lift this component Remove the nine capscrews rear oil seal and flywheel housing Remove the rear oil seal Block Water Heater NOTE Be sure the engine coolant has been drained Disconnect the block heater electrical cord Loosen the block heater retaining nut Remove the block heater from the block 00900188 00900189 cs900wf cs900mb ...

Page 75: ...rea CAUTION Do not use emery cloth or sandpaper to remove carbon from the cylinder bores Aluminum oxide or silicon particles from these materials can cause serious engine damage Use a scraper or a blunt edged instrument to loosen the carbon deposits Do not damage the cylinder with the scraper Remove the remaining carbon deposits with an abrasive pad Part Number 3823258 or equivalent pi900we ck9bre...

Page 76: ...el bristles during operation thus causing additional contamination An alternative method to remove the carbon ridge is to use a high quality steel wire wheel installed in a drill or die grinder On pistons with anodized coatings do not stamp the anodized coating on the outer rim Mark each piston according to the cylinder location Rotate the crankshaft to position the connecting rod caps at bottom d...

Page 77: ...crews Remove the connecting rod cap Remove the lower connecting rod bearing Mark the cylinder number and the letter L lower on the flat surface of the bearing tang Push the connecting rod and piston assembly out of the cylinder bore Care must be taken not to damage the connecting rod or bearing Remove the upper rod bearing Mark the cylinder number and the letter U upper on the flat surface of the ...

Page 78: ...tate the cylinder block so that the bottom of the block is facing up Measure the end play of the crankshaft using a dial gauge NOTE The end play measurement is necessary for determining the wear of the thrust bearing and abnormal wear of the crankshaft Crankshaft End Play mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 Remove the mounting capscrews of the main bearing cap Remove the main bearing cap and l...

Page 79: ...e crankshaft against the cylinder block and damage the sliding surface Remove the crankshaft Remove the upper main bearing NOTE Mark the main bearings and thrust bearing so that they can be installed into the correct position Tappet Remove the tappet 00900204 00900205 00900205 ...

Page 80: ...Ring Expansion Tool 1 3397773 Piston Ring Compressor 1 Setting the Unit in the Repair Stand Install bracket Part No 3163625 to the cylinder block WARNING This component weighs 23 kg 50 lb or more To avoid personal injury use a hoist or get assistance to lift this component The engine lifting equipment must be designed to lift the engine without causing personal injury Put the engine block on the s...

Page 81: ...before installation Debris behind the bearing can cause severe engine damage NOTE Coat the inside face of the bearing with engine oil SAE 30 before installation Align the protrusion of the upper main bearing with the notch in the cylinder block Install the upper main bearings CAUTION Do not hit the crankshaft against the cylinder block Damage to the block or crankshaft can occur Position the crank...

Page 82: ...n bearing cap must face toward the front of the engine New main bearing mounting capscrews must be used Coat the capscrew threads and seat face with engine oil Position the main bearing caps and capscrews CAUTION Install each thrust bearing with the oil groove on the outside Failure to do so will cause engine damage or failure CAUTION Do not let the thrust bearings slip out of place Engine damage ...

Page 83: ...Capscrews Step 1 113 N m 83 ft lb 2 Loosen all capscrews completely 3 132 N m 98 ft lb After tightening the mounting capscrews make sure the crankshaft rotates smoothly Measure the crankshaft end play using a dial indicator Crankshaft End Play mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 00900220 00900222 00900202 ...

Page 84: ...ylinder without the rings installed The number stamped on the connecting rod and cap at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews to the connecting rod CAUTION The connecting rods and connecting rod caps are not interchangeable The connecting rods and connecting rod caps are machined as an assembly Failure will re...

Page 85: ... degrees apart CAUTION If using a strap type ring compressor make sure the inside end of the strap does not hook on a ring gap and break the ring Use piston ring compressor Part Number 3164330 or equivalent to compress the rings Lubricate the cylinder bore with clean 15W 40 engine lubricating oil The cylinder block must be clean before assembly Inspect the cylinder bores for reuse 00900228 pi9rihb...

Page 86: ...d to the crankshaft journal Lubricate the threads and underside of the connecting rod capscrew heads with clean 15W 40 lubricating engine oil WARNING The number stamped on the rod and cap at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews Tighten the two capscrews in alternating sequence Torque Value Step 1 39 n m 29 ft...

Page 87: ... is not properly oriented tang opposite the camshaft it will contact the camshaft and lock the engine If the connecting rod is not properly oriented tang opposite the camshaft it will contact the camshaft and lock the engine Camshaft Bushings Apply Loctite primer to the outside diameter of the camshaft bushing and the inside of the camshaft bore of the cylinder block Allow the primer to dry Apply ...

Page 88: ...t bushing even with the front face of the cylinder block Use a clean lint free cloth to wipe off any excessive Loctite CAUTION Make sure there is no Loctite in the oil hole or severe engine damage can occur Make sure the lubricating oil hole in the camshaft bushing is aligned with the camshaft oil hole in the cylinder block A 3 2 mm 0 126 in diameter rod must be able to pass through the lubricatin...

Page 89: ...0 MAX 0 0138 Idler Gear Camshaft Align the match marks of the idler gear crankshaft gear and camshaft gear The match marks are identified as follows Crankshaft Gear and Idler Gear A Idler Gear and Camshaft Gear B Fuel Pump and Idler Gear C Lower case letters identify oil pump and accessory drive which are not timed If a PTO accessory drive is used on the engine the idler gear uses two bearings Ins...

Page 90: ...r 0 08 mm to 0 19 mm 0 0031 in to 0 007 in Aspirated C Injection pump gear and idler gear 0 07 mm to 0 29 mm 0 003 in to 0 011 in a Camshaft gear and oil pump gear 0 15 mm to 0 30 mm 0 006 in to 0 012 in Backlash b Camshaft gear and PTO gear 0 03mm to 0 050mm 0 0012 in 0 0035 in Replacement Limit 0 40 mm 0 0157 in Clearance Between Bushing and Shaft 0 015 mm to 0 050 mm 0 0006 in to 0 002 in Repla...

Page 91: ...he flywheel housing mounting capscrews in the sequence shown in the illustration Torque Value 69 N m 51ft lb Flywheel Install the guide pins Part Number 3376696 or equivalent into the empty capscrew holes 180 degrees apart Determine the capscrew thread design and size and install two T handles in the flywheel 180 degrees apart on a horizontal plane Install the coupling retaining plate and flywheel...

Page 92: ...Value 19 N m 14 ft lb Measure the end play of the lubricating oil pump drive gear Lubricating Oil Pump Drive Gear End Play mm in 0 020 MIN 0 0008 0 070 MAX 0 0028 Gear Housing Cover NOTE A noise damper is installed on some engines The noise damper must be installed prior to installing the front oil seal Install the front oil seal using tool Part No 3824498 Fill 40 to 60 percent of the space in the...

Page 93: ...ws Tighten the capscrews Torque Value 19 N m 14 ft lb Measure the distance in height between the cylinder block and the gear housing cover Maximum Height Difference 0 15 mm 0 0059 in Crankshaft Pulley Align the crankshaft pulley with the crankshaft key Install the crankshaft pulley mounting plate and capscrew Tighten the capscrew Torque Value 93 N m 69 ft lb Lubricating Oil Suction Tube Install a ...

Page 94: ...amshaft gear Install the o ring flange and two capscrews Tighten the capscrews Torque Value 19 N m 14 ft lb Fuel Injection Pump Rotary CAUTION Make sure the key does not fall into the gear housing Failure to do so can result in engine damage Install the Woodruff key into the fuel injection pump Align the key in the fuel injection pump with the keyway in the injection pump gear Install the fuel inj...

Page 95: ...mp mounting capscrews Torque Value 31 N m 23 ft lb Install the mounting bracket capscrews Torque Value 12 N m 14 ft lb Torque Value 14 N m 23 ft lb Install the fuel pump drive access cover Tighten the two capscrews Torque Value 10mm 13 N m 10 ft lb Torque Value 12mm 19 N m 14 ft lb Cylinder Head Assembly NOTE Coat the stems of the intake and exhaust valves and the inside of the valve guides with e...

Page 96: ... the top of the valve stem with a plastic hammer to make certain the cotter is completely fitted Remove all carbon and dirt from the contact surfaces of the cylinder block and the cylinder head Remove all burrs and damage and clean out all the dirt from inside the cylinder block Failure to follow these steps will result in severe engine damage Install a new cylinder head gasket with the TOP mark f...

Page 97: ... Tighten the capscrews in the sequence shown Torque Value Cylinder Head Capscrews Step 1 69 N m 51 ft lb 2 108 N m 80 ft lb 3 Rotate 90 degrees NOTE The cylinder head capscrews can be reused five times Make a punch mark on the capscrew head each time the capscrew is used If there are already five marks on the capscrew head the capscrew must be replaced Push Rods NOTE If there is no abnormality in ...

Page 98: ...cker Lever Pedestal 11 Rocker Lever 12 Adjusting Screw Rocker Arm Assembly NOTE Check that the ball of the adjustment screw is fitted properly into the socket of the pushrod before tightening the capscrews If the valve spring tension pushes against the rocker arm loosen the locknut and turn the adjustment screw back to prevent strain on the pushrod Install the rocker arm assembly and eight capscre...

Page 99: ...ctor Coat the injectors with anti sieze compound Part No 3824879 before installation CAUTION Be careful not to damage the tip of the injector when installing NOTE When installing the injector clean around the injector and do not allow dust or dirt to enter the engine NOTE If there is no abnormality in the injector install it in the same position during assembly Install the injector washer and moun...

Page 100: ...lue 40 N m 30 ft lb Fuel Injection Tubing NOTE Before installing the fuel injection tubing blow compressed air through it to clean it Position the fuel injection tubing and loosely install the sleeve nuts on the fuel injection pump and the cylinder head Tighten the clamp Tighten the banjo fittings Torque Value 20 N m 15 ft lb Exhaust Manifold Install a new gasket the exhaust manifold and the eight...

Page 101: ...que Value 19 N m 14 ft lb Dipstick NOTE Apply Loctite sealant Part No 3375068 or equivalent to the outside of the dipstick tube CAUTION Excessive sealant can run back into the engine and cause damage to other components Install the dipstick guide Install the dipstick Lubricating Oil Filter Install the lubricating oil filter NOTE Some engines will have an oil filter cooler mounted between the oil f...

Page 102: ...might cut the o ring Lubricate the new heater o ring with clean engine oil The locking channel T Bar should be threaded out to the end of the bolt If so equipped do not remove the retaining wire used to position the channel T Bar Hook the element and one leg of the channel T Bar into the hole as illustrated cs9pxea cs900wg cs9orwa cs900wh ...

Page 103: ...a plastic hammer to tap the heater in until the shoulder contacts the block Tighten the locking bolt Torque Value 2 0 N m 18 in lb Do not over tighten the locking bolt Insert the power cord into the socket being careful to align the pins with the sockets of the power cord Tighten the retaining nut by hand Do not apply power until the cooling system is filled and run the engine long enough for the ...

Page 104: ...apscrew Install the spacer mounting capscrew and adjustment plate Loosely install the washer and adjustment capscrew Fan Pulley Install the fan pulley Position the fan belt 2 into the fan pulley groove and loosely tighten the adjustment capscrew 1 00900159 00900255 00900158 ...

Page 105: ...in to 0 39 in when pushed with finger pressure of 6 kg 13 lb at a point midway between the fan pulley and the crankshaft pulley Tighten the adjustment capscrew 1 Torque Value Mounting Capscrew 31 N m 23 ft lb Adjustment Capscrew 31 N m 23 ft lb Fan Install the spacer fan four capscrews Tighten the capscrews Torque Value 31 N m 23 ft lb Remove the covers on all the engine openings that were install...

Page 106: ...signed to lift the engine without causing personal injury Engine Weight approx 330 kg 660 lb Remove the engine from the stand Remove the bracket Part No 3163625 from the engine Install the starting motor NOTE The o ring is used only on wet flywheel housings Install all the chassis components that were removed during removal of the engine from the equipment WARNING 00900208 00900207 00900156 ...

Page 107: ...RNING Always connect the negative cable last Connect the battery cables WARNING Some state and federal agencies in the United States of America have determined that used oil is carcinogenic and can cause reproductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil Always use the proper procedures to dispose of the oil Fill the engine with lubricating oil En...

Page 108: ...s Save for reuse or dispose of in accordance with local regulations Fill the engine with engine coolant NOTE Remove all tags that were put on all hoses lines linkage and electrical connections as they were removed to identify location during the removal process WARNING ra800wn fp8hola ...

Page 109: ... knocking sound A connecting rod noise occurs when the engine is not loaded Check by first applying a load and then unloading and listening for the noise The connecting rod bearing shells are identified by steel stamped characters on the back of the bearings The characters indicate either standard STD or the amount of oversize OS Use a barring tool to rotate the crankshaft to the bottom dead cente...

Page 110: ...ng rod cap and mark it with the letter L lower and the cylinder number from which it was removed Push the connecting rod away from the crankshaft to allow the upper bearing shell to be removed Remove the upper bearing shell and mark it with the letter U upper and the cylinder number from which it was removed cx9bega cx9begc cx9csma cx9beme ...

Page 111: ...riate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the bearing and connecting rod caps with solvent Dry with compressed air Inspect the connecting rod caps connecting rod bearing saddles and capscrews for nicks cracks burrs scratches or fretting Inspect the bearings for damage Refer to Parts Reuse Guidelines for more information on bearin...

Page 112: ... size stamped on the back NOTE Oversize service rod bearings are available for use with a crankshaft that has been machined undersize Determine the size of the removed rod bearing and obtain a set of the same size Use an outside diameter ball tipped micrometer to measure the connecting rod bearing thickness B3 3 Connecting Rod Bearing Thickness mm in Standard 3 80 MIN 0 1496 4 00 MAX 0 1575 B3 3 C...

Page 113: ...chined undersize on the connecting rod or main bearing journals is marked on the front counterweight If the crankshaft is marked check the bearing shell part number to make sure the correct bearing size is used NOTE Used bearings must be installed in the same location from which they were removed Refer to Procedure 001 054 for connecting rod bearing installation instructions mb900gb 01900184 ...

Page 114: ...ber 3824564 or equivalent and magnetic base Part Number 3377399 or equivalent Crankshaft End Play Mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 NOTE Mark the thrust bearings so the bearings can be installed in the correct position during assembly NOTE The main bearing cap mounting capscrews must be replaced after each use Remove the mounting capscrews of the main bearing cap Remove the main bearing cap ...

Page 115: ...r a wire brush The bearings can be damaged NOTE Make sure the bearings are marked for location The bearings must be installed in their original locations if used again Use solvent and a soft bristle brush to clean bearings Dry with compressed air Inspect all main bearing caps and main bearing crankshaft journals for dents cracks deep scoring overheating and other damage Determine the size of the m...

Page 116: ... face of the bearing with clean SAE30 engine lubricating oil before installation The number stamped on the main bearing cap must be the same as the number stamped on the cylinder block Align the protrusion in the lower main bearing with the notch in the cap Install the lower main bearing into the main bearing cap NOTE New main bearing mounting capscrews must be used The casting number or cast arro...

Page 117: ...he main bearing cap must face toward the front of the engine The thrust bearing is located on the main bearing closest to the rear of the engine number 5 Align the lower thrust bearing with the dowel pin Install the upper thrust bearing Tighten the mounting capscrews in the order shown in the illustration Torque Value Step 1 113 N m 83 ft lb Step 2 Loosen all capscrews completely Step 3 132 N m 98...

Page 118: ...Diesel Engine Engine System 104 NOTE Mark the lower main bearings and the two lower thrust bearings so that they can be installed in the correct position Remove the upper thrust bearing 00900205 ...

Page 119: ...y injury CAUTION Do not use a scraper or a wire brush The bearings can be damaged NOTE Make sure the bearings are marked for location The bearings must be installed in their original locations if used again Use solvent and a soft bristle brush to clean bearings Dry with compressed air NOTE If damage is found on any of the thrust bearings make sure to inspect the crankshaft block and main bearing c...

Page 120: ...elines for the dimensions of the standard and undersize main bearing journals CAUTION Confirm that there is no dirt or dust stuck to the rear face of the bearing before installation Debris behind the bearing can cause severe engine damage Coat the inside face of the bearing with clean SAE30 engine lubricating oil before installation Align the protrusion in the thrust bearing with the notch in the ...

Page 121: ... follow the manufacturer s recom mendations for use Wear goggles and protective clothing to reduce the possibility of personal injury WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury Use solvent or steam to clean the camshaft Dry with compressed air CAUTION Do not touch the machined surfaces with bare hands this can cause rus...

Page 122: ...teria Inspect the camshaft gear teeth for pitting Inspect for cracks at the roots of the teeth Measure the outside diameter of camshaft bearing journals Camshaft Bearing Journals Tolerance Journal Standard Size Shaft Hole Standard Clearance Clearance Limit Number1 Number2 and Number3 50 5 mm 2 00 in 0 080 to 0 110 mm 0 003 to 0 004 in 0 030 to 0 040 mm 0 001 to 0 002 in 0 040 to 0 140 mm 0 016 to ...

Page 123: ...1 673 in Thrust Clearance Standard MIN Repair Limits MAX 3 0 150 to 0 350 mm 0 0059 to 0 0138 in 0 50 mm 0 0197 in NOTE When installing the camshaft rotate the camshaft slightly while being careful not to damage the bushing Install the thrust plate camshaft assembly and two capscrews Tighten the capscrews through the casting holes in the camshaft gear Torque Value 19 N m 14 ft lb Measure the end p...

Page 124: ...iver set Part Number 3823942 or equivalent to remove the camshaft bushing from the number 1 camshaft bore NOTE Make sure the camshaft bore in the cylinder block and the outside diameter of the bushing are clean of oil and dirt Mark the camshaft bushing and cylinder block and align the lubricating oil hole in the cylinder block with the lubricating hole in the camshaft bushing 01900260 01900261 019...

Page 125: ... Use extreme care not to apply Loctite to the oil hole in the camshaft bushing Use a small camshaft bushing driver set Part Number 3823942 or equivalent to install the camshaft bushing even with the front face of the cylinder block Use a clean lint free cloth to wipe off any excessive Loctite CAUTION Make sure there is no Loctite in the oil hole or severe engine damage can occur Make sure the lubr...

Page 126: ...t to clean the camshaft gear Dry with compressed air NOTE If nicks or burrs can not be removed with abrasive pad Part Number 3823258 or equivalent replace the camshaft and camshaft gear Refer to Procedure 001 008 for camshaft removal Inspect the camshaft gear for cracked chipped or broken teeth Inspect the camshaft gear teeth for discoloration or signs of excessive heat bluing If any damage is pre...

Page 127: ...s well as protective clothing Hot steam can cause serious injury WARNING When using solvents acids or alkaline materials for cleaning follow manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Use solvent or...

Page 128: ...t be replaced if it has any of the listed damage Inspect the connecting rod and connecting rod cap for damage Replace the connecting rod if the I beam or connecting rod cap is damaged Inspect the connecting rod and connecting rod cap for fretting damage on the mating surfaces The connecting rod and connecting rod cap must be replaced as an assembly if fretting damage is visible on either piece Che...

Page 129: ...umbers must match the numbers on the connecting rod and must be installed with the characters aligned to prevent damage to the connecting rods and crankshaft CAUTION Use a vise with brass jaws to hold the connecting rod Notches scratches or dents in the I beam area can cause engine failure Place the connecting rod into a vise with brass jaws Install the connecting rod cap onto the connecting rod L...

Page 130: ... Diameter Mm in 33 00 MIN 1 299 33 025 MAX 1 300 If the connecting rod crankshaft bore inside diameter is not within specifications the connecting rod must be replaced This procedure describes the magnetic particle inspection for the connecting rod and connecting rod cap Use a magnetic particle testing machine The connecting rod and connecting rod cap must be assembled during this process Use the ...

Page 131: ...itical shaded areas WARNING When using a steam cleaner wear safety glasses or a face shield as well as protective clothing Hot steam can cause serious injury WARNING When using solvents acids or alkaline materials for cleaning follow manufacturer s recommenda tions for use Wear goggles and protective clothing to reduce the possibility of personal injury CAUTION The connecting rod must be demagneti...

Page 132: ...to 400 amperes direct current or rectified alternating current Use an ultraviolet light Check for indications of cracks The magnetic particles tend to form on sharp corners and edges Do not mistake these for cracks Any indications of cracks are not acceptable Prepare the machine for a coil shot Make sure the capscrew is near one side of the coil and not in the center Apply 1000 to 1350 ampere turn...

Page 133: ...s for use Wear goggles and protective clothing to reduce the possibility of personal injury WARNING Wear eye and face protection when using compressed air Flying debris and dirt can cause personal injury CAUTION The capscrew must be demagnetized completely and cleaned thoroughly Any small metal particles will cause engine damage Demagnetize the capscrew thoroughly Use solvent to clean the capscrew...

Page 134: ...e the main bearings Refer to Procedure 001 006 Remove the crankshaft from the cylinder block Use fine crocus cloth to polish the machined surfaces Use a bristle brush to clean the oil drillings NOTE If more than two threaded holes are damaged in one end the crankshaft must be replaced Inspect the threaded capscrew holes for damage Use one of the following methods to repair any threaded holes Chase...

Page 135: ...eep scoring overheating or other damage NOTE Oversize thrust bearings are available if the thrust distance is not within specifications If the crankshaft must be machined to use an oversize thrust bearing refer to the Alternative Repair Manual Bulletin 3379035 for machining instructions Measure the thrust clearance 1 Crankshaft installed or crankshaft thrust width minus block thrust width bearing ...

Page 136: ...talled minus crankshaft journal diameter Refer to procedure 001 026 Measurements mm in Bearing Clearance 0 043 to 0 103 0 0 0017 to 0 0041 Check the roundness 2 of the bearing journal Connecting Rod Bearing Journal mm in Out of Roundness 0 020 MAX 0 0008 Measure the connecting rod crankshaft pin journal 3 Connecting Rod Crankshaft Pin Journal Diameter mm in Standard 56 91 MIN 2 241 57 00 MAX 2 244...

Page 137: ...0 09 0 0035 WARNING This assembly weighs 23 kg 50 lb or more To reduce the possibility of personal injury use a hoist or get assistance to lift this assembly CAUTION Do not hit the crankshaft against the cylinder block Failure to do so can result in damage to the block or crankshaft Lubricate the upper main bearings with clean engine lubricating oil Install the upper main bearings Refer to Procedu...

Page 138: ...Diesel Engine Engine System 124 NOTE The crankshaft must rotate freely by hand 02900058 ...

Page 139: ...f excessive heat make sure to inspect the associated idler gear for damage Inspect the crankshaft gear teeth for discolorations or signs of excessive heat bluing Inspect for cracks and broken or chipped teeth If any damage is present replace the crankshaft and crankshaft gear Refer to Procedure 001 016 for crankshaft removal ks8gesa ...

Page 140: ...njury WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury WARNING Some solvents are flammable and toxic Read the manufacturer s instructions before using WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt...

Page 141: ... the mating surface and pulley bore areas for damage Align the crankshaft pulley with the crankshaft key Install the crankshaft pulley mounting plate and capscrew Tighten the capscrew 14mm Capscrew With PTO 176 n m 130 ft lb 14 mm Capscrew Without PTO 93 n m 69 ft lb 18 mm Capscrew All 372 n m 274 ft lb da2pusa 00900180 ...

Page 142: ...ont gear cover Clean the gear cover seal bore and crankshaft surface of all oil dirt and seal residue NOTE If the crankshaft has excessive wear the crankshaft must be replaced Inspect the crankshaft for excessive wear Fill 40 to 60 percent of the space in the seal lip with grease Use a crankshaft seal installer Part Number 3164900 or equivalent to install the seal in the front gear cover Install t...

Page 143: ... of seal leaks Clean and dry the rear crankshaft sealing surface Clean and dry the flywheel housing seal bore Inspect the crankshaft sealing area and flywheel housing bore for burrs or raised material Remove the burrs or raised material with crocus cloth Fill 40 to 60 percent of the space in the seal lip with grease Use crankshaft seal installer Part Number 3164900 or equivalent to install the cra...

Page 144: ... visual or dimensional inspection to isolate the problem The cylinder bores are machined directly into the cylinder block during production The size and condition of the cylinder bore is critical to engine performance and life During repair make sure to inspect the cylinder bores carefully It will also be necessary to deglaze the cylinder walls before reassembly A 30 degree crosshatch pattern is n...

Page 145: ...nd laundry detergent to clean the cylinder bores WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury CAUTION Clean the cylinder bores immediately after deglazing or premature wear of the bores and rings can result Rinse the cylinder bores until the detergent is removed Dry the cylinder block with compressed air ck9breh ck9brei c...

Page 146: ...ove the protective tape and cloth and clean the crankshaft journals WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Use a s...

Page 147: ... 25 MIN 2 726 69 75 MAX 2 746 0 50 69 50 MIN 2 736 69 70 MAX 2 744 0 75 69 25 MIN 2 726 69 45 MAX 2 734 1 00 69 00 MIN 2 717 69 20 MAX 2 724 Measure the inner diameter of the camshaft bushing 3 Camshaft Bushing Inside Diameter Standard Repair Limit 50 50 mm 1 988 in 50 60 mm 1 992 in Measure the cylinder bore 1 Cylinder Bore Dimensions Inside Diameter Tolerance Repair Limit Standard Bore 95 00 mm ...

Page 148: ...o reduce the possibility of personal injury WARNING Some solvents are flammable and toxic Read the manufacturer s instructions before using WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the front gear cover and cover gasket surface with solvent Dry with compressed air Clean the cylinder block gasket surface Inspect...

Page 149: ...e System 135 CAUTION Apply gasket sealant Part Number 3164067 or equivalent to the gear cover mounting surface Install the new gasket gear cover and 17 capscrews Tighten the capscrews Torque Value 19n m 14 ft lb 00900181 ...

Page 150: ...anufacturer s recommendations for use Wear goggles and protective clothing to avoid personal injury WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury Use solvent to clean the idler gear Dry with compressed air NOTE If the burrs or raised material can not be removed with an abrasive pad or equivalent the camshaft idler gear mus...

Page 151: ...ar The match marks are identified as follows A Crankshaft gear and idler gear B Idler gear and camshaft gear C Fuel pump and idler gear NOTE Lower case letters identify oil pump and accessory drive which are not timed NOTE If a PTO accessory drive is used on the engine the idler gear uses two bearings Install the idler shaft rear bearing rear spacer plate and idler gear Install the front bearing p...

Page 152: ...Diesel Engine Engine System 138 Position the fuel injection pump assembly temporarily Measure the backlash of each gear with a dial indicator 3376050 or equivalent 00900244 ...

Page 153: ...ot use the bead blast method to clean the piston The piston can be damaged by blast material embedded in the aluminum CAUTION Do not clean the pistons in an acid tank The piston can be damaged by the acid Soak the pistons in cold parts cleaner Soaking the pistons overnight will usually loosen the carbon deposits WARNING Wear appropriate eye and face protection when using compressed air Flying debr...

Page 154: ...mpressed air Flying debris and dirt can cause bodily injury Wash the pistons again in a strong solution of detergent in hot water Dry with compressed air NOTE If severe piston damage has occurred check the turbocharger cylinder head and exhaust components for damage from debris Inspect the piston for damage and excessive wear Check the top ring grooves skirt and pin bore Measure the piston skirt d...

Page 155: ...System 141 Measure the pin bore NOTE Measure the pin bore in the center area of the bore The bore profile is tapered on the edges and will result in a measurement error Piston Pin Bore Diameter mm in 30 00 NOM 1 181 pi9brtc ...

Page 156: ...ing and scoring can be caused by Engine overheating Oil dilution Improper maintenance of the lubrication system Piston cooling nozzle malfunction Oil ring plugged by deposits Scuffing and scoring on the piston rings indicates a breakdown of the oil film on the cylinder liner wall causing transfer of material from the piston ring face to the cylinder liner Oil ring plugging is indicated by deposits...

Page 157: ...6 MIN 0 0024 0 10 MAX 0 0039 Second 0 03 MIN 0 0012 0 07 MAX 0 0028 Oil Control 0 03 MIN 0 0012 0 07 MAX 0 0028 Position each ring in the cylinder below the ring reversal area and use a piston to square it with the bore Use a feeler gauge to measure the piston ring gap Piston Ring Gap mm in 0 30 MIN 0 012 Top 0 45 MAX 0 018 0 30 MIN 0 012 Second 0 45 MAX 0 018 0 25 MIN 0 0098 Oil Control 0 45 MAX ...

Page 158: ... used be careful not to over expand the ring The top surface of the top and intermediate rings are identified as illustrated The oil control ring can be assembled with either side up Position the oil ring expander in the control ring groove Install the oil control ring with the end gap 180 degrees from the ends of the expander pi9rige pi9rigb pi9rihc pi9rise ...

Page 159: ...piston rings Use piston ring expander Part Number 3823137 or equivalent to install the intermediate ring NOTE The top ring has a shiny chrome appearance Use piston ring expander Part Number 3823137 or equivalent to install the top ring Position the rings so the ring gap are 120 degrees apart pi9rihb pi900ac pi900ad ...

Page 160: ...s and the cylinder walls A blowby measurement can help detect the problem Refer to Procedure 014 010 for blowby measurement A free floating hollow piston pin is used to attach the piston to the connecting rod Lubricating the pin and journal is accomplished by residual spray from piston cooling Rotate the crankshaft with an engine barring tool until the pistons are below the carbon deposits which a...

Page 161: ...n abrasive pad Part Number 3823258 or equivalent WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury CAUTION Do not use the steel wire wheel in the piston travel area Operate the wheel in a circular motion to remove the deposits NOTE An inferior quality wire wheel will lose steel bristles during operation thus causing addition...

Page 162: ...ng rod caps at bottom dead center for removal Mark each connecting rod and connecting rod cap according to the cylinder number location NOTE Do not remove the capscrews from the connecting rods at this time Loosen the connecting rod capscrews Use a rubber hammer to hit the connecting rod capscrews to loosen the caps Remove the connecting rod capscrews Remove the connecting rod cap pi900gc 01d00094...

Page 163: ...number and the letter U upper on the flat surface of the bearing tang The piston and connecting rod assemblies must be installed in the same cylinder number from which they were removed to provide proper fit of worn mating surfaces if parts are reused Use a tag to mark the cylinder number from which each piston and rod assembly were removed Place the rod and piston assemblies in a container to pro...

Page 164: ...ot required Remove the piston pin Remove the connecting rod from the piston Make sure the FRONT marking on the piston and the numbers on the connecting rod and cap are oriented as illustrated Install the retaining ring in the pin groove on the front side of the piston cx9rrma pi9pima pi900gd pi9rrhb ...

Page 165: ...ons do not require heating to install the pin however the pistons do need to be at room temperature or above Install the connecting rod Install the piston pin Install the second retaining ring Use the piston ring expander Part Number 3823137 or equivalent to install the piston rings pi9pima pi9piwa cx9rrma pi901ac ...

Page 166: ...e rings installed The number stamped on the connecting rod and cap at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews to the connecting rod CAUTION The connecting rods and connecting rod caps are not interchangeable The connecting rods and connecting rod caps are machined as an assembly Failure will result if the connec...

Page 167: ...degrees apart CAUTION If using a strap type ring compressor make sure the inside end of the strap does not hook on a ring gap and break the ring Use piston ring compressor Part Number 3164330 or equivalent to compress the rings Lubricate the cylinder bore with clean 15W 40 engine lubricating oil The cylinder block must be clean before assembly Inspect the cylinder bores for reuse 01d00296 pi800hd ...

Page 168: ...od to the crankshaft journal Lubricate the threads and underside of the connecting rod capscrew heads with clean 15W 40 lubricating engine oil CAUTION The number stamped on the rod and cap at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews Tighten the two capscrews in alternating sequence Torque Value Step1 39 n m 29 ft...

Page 169: ...9 0 40 MAX 0 0160 CAUTION To reduce the possibility of engine damage the crankshaft must rotate freely CAUTION If the connecting rod is not properly oriented tang opposite the camshaft it will contact the camshaft and lock the engine Check for freedom of rotation as the connecting rod caps are installed If the crankshaft does not rotate freely check the installation of the connecting rod bearings ...

Page 170: ...d Replacement Limit A Crankshaft gear and idler gear 0 08 to 0 19 mm 0 0031 to 0 007 in B Camshaft gear and idler gear 0 08 to 0 19 mm 0 0031 to 0 007 in C Injection pump gear and idler gear 0 07 to 0 29 mm 0 003 to 0 011 in a Camshaft gear and oil pump gear 0 07 to 0 29 mm 0 003 to 0 011 in b Camshaft gear and PTO gear 0 15 to 0 30 mm 0 006 to 0 012 in 0 40 mm 0 0157 in Measure the clearance betw...

Page 171: ...ness can be too great when the room temperature vulcanized RTV sealant cures NOTE The camshaft thrust bearing has two bearings Both have a steel back with an aluminum overlay The thrust bearing must be installed with the smooth sides against each other Inspect the thrust bearing for damage Measure the bearing thickness Camshaft Thrust Bearing Thickness mm in 0 150 MIN 0 0059 0 350 MAX 0 0138 Insta...

Page 172: ...ead assembly and gasket Discard the gasket Use a valve spring compressor Part Number 3163292 or equivalent to compress the valve spring s and remove the valve collets Loosen the spring and remove the spring seat and valve spring NOTE When removing the valve s mark them in the location where the valve was installed This will aid in the assembly procedure Raise the cylinder head and remove the valve...

Page 173: ...les and protective clothing to reduce the possibility of personal injury CAUTION Do not use caustic or acidic solutions to clean the cylinder head capscrews Use of this type of solvent can cause corrosion to the capscrews Use a petroleum based solvent to clean the capscrews Clean the capscrew thoroughly with a wire brush or a soft wire wheel or use a non abrasive bead blast to remove deposits from...

Page 174: ... use the cylinder head capscrews again under the following conditions Corrosion or pitting that exceeds 1 sq cm 0 155 sq in in area 10 mm 3 8 in x 10 mm 3 8 in is an acceptable area 13 mm 1 2 in x 13 mm 1 2 in is not an acceptable area Corrosion or pitting that exceeds 0 12 mm 0 005 in in depth Corrosion or pitting is located with 3 2 mm 1 8 in of the fillet Corrosion or pitting is located within ...

Page 175: ...er to the manufacturer s specifications for the correct size of the cylinder head capscrews If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded and replaced Immediately after cleaning and inspecting the capscrew Apply a film of clean lubricating engine oil to all capscrews that are to be used again Coat the stems of the intake and exhaust valves ...

Page 176: ...he valve stem with a plastic hammer to make sure the valve cotter is completely seated Measure the cylinder head valve seat recession 2 Valve Seat Specifications mm in Intake 1 00 0 100 NOM 0 039 0 004 Exhaust 0 90 0 100 NOM 0 035 0 004 Repair limit on the intake valve seat is 2 00 mm 0 079 in Repair limit on the exhaust valve seat is 1 90 mm 0 075 in Valve seat angle 4 is 45 degrees with a tolera...

Page 177: ... facing up WARNING This component weighs 23 kg 50 lb or more To reduce the possibility of personal injury use a hoist or get assistance to lift this component Coat the capscrew s threads with antiseize compound Part Number 3824879 or equivalent Install the cylinder head using four head capscrews as guides The cylinder head capscrews can be used up to five times Make a punch mark on the capscrew he...

Page 178: ... pulley 1 with pointer 2 NOTE The engraved mark on the crankshaft pulley will read 1 4 TOP The No 4 intake valve will start to open when the No 1 cylinder comes near compression top dead center Loosen the lock nut 3 on the adjustment screw 4 Insert the feeler gauge 5 between the valve stem 6 and the rocker arm 7 Adjust the clearance with the adjustment screw until slight drag is felt on the feeler...

Page 179: ...ntake valves No 1 and No 3 Adjust the valve clearances for exhaust valves No 1 and No 2 Rotate the crankshaft in the normal direction one revolution Adjust the valve clearances for intake valves No 2 and No 4 Adjust the valve clearances for exhaust valves No 3 and No 4 Tighten the locknut to secure the adjustment screw Locknut Torque Value N m ft lb 39 2 MIN 28 9 49 MAX 36 1 0390078 0390079 039007...

Page 180: ... 10 Rocker lever pedestal 11 Separating spring 12 Pedestal mounting capscrews NOTE When removing the rocker arm loosen the locknut and turn the adjustment screw counterclockwise 2 to 3 turns Remove the mounting capscrews and the rocker lever assembly Remove the snap rings for each rocker lever Remove the rocker lever shaft and thrust washers if equipped Remove the rocker lever pedestals and rocker...

Page 181: ...rsonal injury The pedestals are made from powdered metal and will continue to show wetness after they have been cleaned and dried Rinse parts with clean hot water Dry parts with compressed air Inspect the rocker lever for cracks excessive wear in the bore and the contact surface of the valve stem Measure the rocker lever bore Rocker Lever Bore Diameter mm in 19 NOM 0 75 03900105 03900106 rh9bdsa r...

Page 182: ...equipped Install the snap rings for each rocker lever NOTE Check that the ball of the adjustment screw is fitted properly into the socket of the pushrod before tightening the capscrews If the valve spring tension pushes against the rocker arm loosen the locknut and turn the adjustment screw back to prevent strain on the pushrod NOTE Tighten the middle pedestal capscrew first Install the rocker lev...

Page 183: ...ressed air Flying debris and dirt can cause personal injury Clean the rocker lever cover with a strong solution of detergent in hot water Dry the rocker lever cover with compressed air Inspect the rocker lever cover for cracks and other damage Install the new gasket Install the rocker lever cover o rings isolator assemblies and three capscrews Tighten the capscrews Torque Value 9 n m 80 in lb 0390...

Page 184: ...ing debris and dirt can cause personal injury Clean the push rods in a strong solution of detergent in hot water Dry with compressed air Inspect the push rod ball and socket for signs of scoring Check for cracks where the ball and the socket are pressed into the tube NOTE When a push rod is replaced the corresponding tappet must be replaced also Check the push rods for roundness and straightness U...

Page 185: ...ve the tappets WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the tappets with a strong solution of detergent in hot water Dry the tappets with compressed air When a new camshaft is installed new tappets and push tubes must also be installed When the tappets need to be replaced the corresponding push tubes must also...

Page 186: ...ingle pit can not be greater than 2 mm 0 078 in 2 Interconnection of pits is not allowed 3 Total pits when added together must not exceed 6 mm 0 236 in in diameter or total of 4 percent of the tappet face 4 No pitting is allowed on the edges of the wear face of the tappet Measure the valve stem diameter 28 mm 1 1 in from the face of the tappet Valve Tappet Stem Diameter mm in 16 NOM 0 63 Lubricate...

Page 187: ...muffler or personal injury will occur WARNING To avoid personal injury keep hands long hair jewelry and loose fitting or torn clothing away from fans and other moving parts Adjust the overhead Refer to Adjusting Valve Clearance procedure Remove the spill tube Disconnect the fuel injection tubing NOTE Disconnect the fuel shut off solenoid 0390077 0390166 0390163 ...

Page 188: ...per sealing washer and the hold down clamp Use only one washer NOTE A light coat of clean 15W 40 engine oil between the washer and injector can help hold the washer in place during installation Install the adapter to the nozzle holder mounting section of the cylinder to be measured Tighten the adapter Adapter Capscrews N m ft lb 39 MIN 29 49 MAX 36 Connect the compression gauge to the adapter NOTE...

Page 189: ... force of 6 kg 13 2 lb at a point midway between the fan pulley and the alternator pulley Fan Belt Deflection mm in 7 0 MIN 0 28 10 0 MAX 0 39 Adjusting the Fan Belt Tension Loosen the mounting capscrew of the alternator 1 and belt tension adjustment capscrew 2 Using a bar raise the alternator and adjust the fan belt tension Tighten the adjustment capscrew and the mounting capscrew Torque Value Ad...

Page 190: ...front gear cover Remove the gear cover access cap Rotate the engine until the keyway is vertical Remove the nut and washer from the fuel injection pump shaft Remove the injection pump support bracket Remove the two mounting capscrews Remove the fuel injection pump Remove the key Inspect the fuel injection pump body for cracks or other damage 05900254 fs9keaa 05900868 ...

Page 191: ...mp flange into the gear housing with the mounting nuts Damage to fuel pump housing can occur Hand tighten the mounting nuts The fuel pump must be free to move in the slots Install the fuel injection pump washer and nut Torque Value 70 n m 52 ft lb Refer to the rotary fuel injection timing in this procedure to make sure the fuel pump is timed correctly Tighten the fuel injection pump mounting capsc...

Page 192: ...ter on the gear cover to the TDC line on the crankshaft pulley The fuel pump drive access cover can be removed to confirm the timing marks are aligned between the fuel pump drive gear and the idler gear if easier than removing the valve cover This is to confirm that the engine is at TDC Remove the distributor head bolt and copper washer from the injection pump Discard the copper washer 14900071 05...

Page 193: ... 0 3 0 04 0 01 Check the degree markings on the crankshaft pulley with the pointer and that is the timing of the engine If the timing needs to be adjusted rotate the crankshaft approximately 45 degrees in the reverse direction of engine rotation Rotate the crankshaft in the normal direction of engine rotation until the pointer on the gear cover lines up with the correct timing mark on the cranksha...

Page 194: ...opper washer into the fuel injection pump Torque Value 17 n m 13 ft lb Install the fuel pump drive access cover 10 mm 13 n m 10 ft lb 12 mm 19 n m 14 ft lb If the fuel lines are opened the low pressure lines can be vented by pumping the hand lever on the fuel filter head 14900074 14900071 00900221 ...

Page 195: ...y or death when working on the fuel system Vent the high pressure fuel lines Loosen the fitting at the number 1 injector Place the fuel control in the run position Crank the engine so air can vent from the fuel lines Tighten the fitting Torque Value 30 n m 22 ft lb Continue this process through the remaining three injectors until the engine runs smoothly WARNING Keep your body clear of test spray ...

Page 196: ... equals 41 bar 595 psi Leakage Test a Open the valve b Operate the lever to hold pressure 20 bar 290 psi below opening pressure c No drops should fall from the tip within 10 seconds Chatter Test The chatter test indicates the ability of the needle valve to move freely and correctly atomize the fuel An audible sound should be heard as the valve rapidly opens and closes A well optimized spray patter...

Page 197: ...t jawed vise and remove the nozzle nut Remove the nozzle needle valve and intermediate plate NOTE To avoid damage place the injector nozzle and needle valve in a suitable bath of clean test oil Remove the nozzle holder from the vise then remove the pressure spindle pressure spring and shims filsema fi900fb fi900fc fi900fd ...

Page 198: ...with fuel oil before assembly WARNING Install the same thickness of shims that were removed in disassembly Use the pressure spring to make sure the shims are installed flat Install the shims Clamp the nozzle holder in a soft jawed vise and install the spindle Install the intermediate plate fi900ab fi900ha fi900ce fi900ad ...

Page 199: ...Diesel Engine Engine System 185 Install the needle valve and nozzle assembly Install the nozzle nut fi900ce fi900ob ...

Page 200: ...engine stopped Remove the oil pressure sensor and install the pressure gauge NOTE Measure the oil pressure while the engine is warm oil temperature minimum 82 C 180 F Start the engine and measure the oil pressure Lubricating Oil Pressure kPa ft lb 210 MIN 30 700 MAX 102 Disconnect the two cooling lines from the cylinder block and the lubricating oil cooler Remove the lubricating oil cooler horizon...

Page 201: ...d hoses with a strong solution of detergent in hot water Dry the components with compressed air Inspect the lubricating oil cooler and hoses for cracks or other damage Install the lubricating oil cooler horizontal mount on the lubricating oil filter head adapter Torque Value 79 n m 58 ft lb Connect the two cooling lines to the cylinder block and the lubricating oil cooler 07900330 07900331 0790032...

Page 202: ...lds the regulator spring and valve in the lubricating oil pump Remove the lubricating oil pressure regulator from the lubricating oil pump Inspect the valve spring and body for damage or excessive wear Inspect the valve for scoring Replace the lubricating oil pump if damage is found 07900322 07900323 ...

Page 203: ... 38 lb N A 2 30 kg 5 07 lb Replace the lubricating oil pump if not within specification Install the lubricating oil pressure regulator assembly into the lubricating oil pump Install the retaining pin that holds the regulator in the lubricating oil pump Valve and Body Clearance Standard Size Tolerance Standard Clearance Valve Body 1 11 mm 0 43 in 0 050 mm to 0 077 mm 0 002in to 0 003 in 0 020 mm to...

Page 204: ...d radial 2 clearance Axial and Radial Pump Gear Clearance Inspection Item Standard Clearance Limit 1 Axial 0 030 to 0 085 mm 0 0012 to 0 0033 in 0 10 mm 0 0039 in 2 Radial 0 045 to 0 090 mm 0 0018 to 0 0035 in 0 13 mm 0 0051 in Install the lubricating oil pump 1 Install the spacer 3 and five mounting capscrews 2 Tighten the capscrews Torque Value 19 n m 14 ft lb 07900326 07900326 07900327 ...

Page 205: ... manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury WARNING Some solvents are flammable and toxic Read the manufacturer s instructions before using WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the lubricating oil suction tube and o ring surfaces...

Page 206: ...lb Loosen the alternator mounting capscrew 3 and the belt tension adjustment capscrew 2 Move the alternator down the adjustment bar until the drive belt is loose Remove the drive belt 1 Inspect the drive belt for the following Cracks Glazing Tears or cuts Excessive wear Install the drive belt Using a breaker bar raise the alternator on the adjustment bar 1 and adjust the fan belt tension to specif...

Page 207: ...equivalent Fan Belt Deflection n lb New Belts 324 MIN 73 378 MAX 85 Used Belts 216 MIN 49 270 MAX 61 Loosen the mounting capscrew of the alternator 1 and belt tension adjustment capscrew 2 Using a breaker bar raise the alternator and adjust the fan belt tension to specification Tighten the adjustment capscrew and the mounting capscrew Adjustment Capscrew 31 n m 23 ft lb Mounting Capscrew 66 n m 49...

Page 208: ...ris fall into the thermostat cavity when cleaning the gasket surfaces Failure to do so can cause engine damage Clean the mating surfaces Inspect the thermostat 1 for damage such as obstructions caused by debris broken springs or stuck or missing vent pins Make sure the thermostat is clean and free from corrosion 08900320 08900321 08900322 ...

Page 209: ...owly at a temperature of 77 C 171 F so the wax element in the thermostat has sufficient time to react to the rising water temperature The thermostat thermal open lift is 8 mm 0 315 in when immersed in hot water for 4 to 5 minutes Install the seal and thermostat into water pump cavity Remove the two capscrews and the thermostat housing from the water pump Inspect the thermostat housing for cracks o...

Page 210: ... is toxic Keep away from children and pets If not reused dispose of in accordance with local environmental regulations Drain the cooling system by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet A drain pan with a capacity of 20 liters 5 gal will be adequate in most applications Check for damaged hoses and loose or damaged hose clamps Replace as neces...

Page 211: ... or a commercially available equivalent Use 0 5 kg 1 0 lb of sodium carbonate for every 23 liters 6 gal of water WARNING Coolant is toxic Keep away from children and pets If not reused dispose of in accordance with local environmental regulations Operate the engine for 5 minutes with a coolant temperature above 82 C 180 F Shut the engine off and drain the cooling system CAUTION The cooling system ...

Page 212: ... must be flushed again until the water is clean CAUTION The cooling system must be filled properly to prevent air locks in the cooling passages Failure to vent the cooling system properly can cause damage to the cooling system Adequate venting is provided for a fill rate of 10 liters minute 2 6 gal minute CAUTION Do not use water alone for coolant Damage from corrosion can severely damage the engi...

Page 213: ...s full of coolant or that the coolant level has risen to the hot level in the recovery container on the system if equipped When you troubleshoot overheating remember that too much oil in the oil pan can cause additional heat from friction when the rod journals are submerged in oil Overfilling with oil raises the oil temperature that is transferred to the coolant system at the oil cooler The system...

Page 214: ...enting is provided for a fill rate of 10 liters minute 2 6 gal minute NOTE Excess air in the cooling system can lead to overheating and low coolant levels NOTE A 50 percent mixture of antifreeze and water must be premixed before filling the system The ability of antifreeze to remove heat from the engine is not as good as water so pouring antifreeze into the engine first could contribute to an over...

Page 215: ...disturb the coolant flow and will not solve an overheating problem Water will cause rust formation reducing the flow in the smaller coolant passages CAUTION A sudden loss of coolant from a heavily loaded engine can result in severe damage to the pistons and cylinder bore Also water used as a coolant for even a relatively short period can result in the cup plugs rusting through allowing the coolant...

Page 216: ...leak between the systems head gasket oil cooler etc Transmission fluid can also leak into the coolant through radiator bottom tank transmission oil coolers Water Pump The water pump pulls coolant from the bottom of the radiator and pumps it through the engine back to the top of the radiator for cooling Reduced or interrupted flow will result in the engine running hot The pump is belt driven from t...

Page 217: ...e flow or replacing the pump As stated in the coolant discussion an obstruction in the passages can interrupt flow The following steps are for troubleshooting the Radiator Fans and Shutters Air forced through the fins of the radiator by a fan cools the coolant pumped through the radiator Environmental debris paper straw lint dust etc can obstruct the fins and stop the flow of air which will reduce...

Page 218: ...r If the shutters fail to open when needed the engine can run hot Failure of the shutters to close can result in too much airflow and the engine running cold Make sure that the air temperature sensor is functioning correctly Check the air operated shutter controls Check for air leaks fn900kd ...

Page 219: ... engine is a minimum temperature of 50 C 122 F Adjust the overhead Refer to Procedure 003 004 Remove the fuel drain line WARNING Fuel is flammable Keep all cigarettes flames pilot lights arcing equipment and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system Remove the high pressure fuel lines Dis...

Page 220: ...r Remove the injector for each cylinder Lubricate the sealing lips of the sleeve with antiseize compound Part Number 3824879 or equivalent Assemble the injector sealing sleeve a new copper washer use only one washer and the injector hold down clamp A light coat of clean 15W 40 lubricating engine oil between the washer and the injector can help hold the washer in place during installation of the in...

Page 221: ... adapter Connect the compression gauge to the compression adapter Start the engine With the pointer on the gauge stabilized check and read the gauge Engine Compression kPa psi 2944 NOM 427 Remove the compression gauge when test is complete Install the fuel drain line Install the high pressure fuel lines Connect the fuel shutoff valve 14900060 14900062 06900274 00900163 ...

Page 222: ...20 to 0 0031 in Clearance Limit 0 20 mm 0 0079 in Intake 2 Head Thickness Exhaust 1 40 to 1 60 mm 0 0551 to 0 0630 in Repair Limit 1 00 mm 0 039 in Intake 0 35 mm 0 0138 in 1 Valve Clearance at Cold and Warm Exhaust 0 50 mm 0 0197 in Tolerance 0 02 mm 0 0008 in VALVE GUIDE Intake 5 Protrusion Above Cylinder Head Surface Exhaust 14 5 mm 0 571 in Tolerance 0 2 mm 0 0079 in VALVE SPRING Free Length 4...

Page 223: ... Hole Nominal 19 mm 0 75 in Tolerance 0 030 mm 0 0012 in 0 010 mm 0 0004 in Clearance Between Rocker Arm and Shaft 0 010 to 0 050 mm 0 0004 to 0 0020 in Clearance Limit 0 12 mm 0 0047 in 1 Bend of Shaft Repair Limit 0 20 mm 0 0079 in PUSH ROD 2 Bend of Push Rod Repair Limit 0 30 mm 0 012 in TAPPET 3 Clearance Between Tappet and Tappet Hole 0 012 to 0 048 mm 0 0005 to 0 0020 in Clearance Limit 0 12...

Page 224: ... Limit 0 30 mm 0 012 in Intake 1 00 0 100 mm 0 039 0 004 in Repair Limit 2 00 mm 0 079 in 2 Valve Seat Exhaust 0 90 0 100 mm 0 035 0 004 in Repair Limit 1 90 mm 0 075 in 3 Nozzle Protrusion 3 12 0 28 mm 0 123 0 011 in Tolerance 2 700 to 3 500 mm 0 106 to 0 138 in 4 Valve Seat Angle 45 Tolerance 0 15 Repair Limit Judge condition of contact surface by vacuum test 18900011 ...

Page 225: ...mm 2 756 in Repair Limit 70 200 mm 2 764 in U S 0 25 69 750 mm 2 746 in Repair Limit 69 950 mm 2 754 in U S 0 50 69 500 mm 2 736 in Repair Limit 69 700 mm 2 744 in U S 0 75 69 250 mm 2 726 in Repair Limit 69 450 mm 2 734 in 2 Inner Diameter of Main Bearing U S 1 00 69 000 mm 2 717 in Repair Limit 69 200 mm 2 724 in 3 Inner Diameter of Cam Bushing 50 500 mm 1 988 in Repair Limit 50 600 mm 1 992 in ...

Page 226: ...ft 0 03 mm 0 0012 in Intake 42 69 mm 1 681 in Repair Limit 42 20 mm 1 661 in 2 Cam Height Exhaust 43 04 mm 1 694 in Repair Limit 42 50 mm 1 673 in 3 Thrust Clearance 0 150 to 0 350 mm 0 0059 to 0 0138 in Repair Limit 0 50 mm 0 0197 in CAMSHAFT BUSHING 4 Clearance to Cam No 1 No 2 No 3 0 040 to 0 140 mm 0 0016 to 0 0055 in Repair Limit 0 25 mm 0 0098 in 18900015 ...

Page 227: ... 68 86 mm 2 711 in Roundness Repair Limit 0 020 mm 0 0008 in 2 Clearance 0 043 to 0 103 mm 0 0017 to 0 0041 in Clearance Limit 0 25 mm 0 0098 in STD 57 000 mm 2 244 in Repair Limit 56 91 mm 2 241 in U S 0 25 56 750 mm 2 234 in Repair Limit 56 66 mm 2 231 in U S 0 50 56 500 mm 2 224 in Repair Limit 56 41 mm 2 221 in U S 0 75 56 250 mm 2 215 in Repair Limit 56 16 mm 2 211 in Crank Pin Journal U S 1 ...

Page 228: ...ar and idler gear 0 07 mm to 0 29 mm 0 003 in to 0 011 in a Camshaft gear and oil pump gear 0 07 mm to 0 29 mm 0 003 in to 0 011 in 1 Bend of Shaft b Camshaft gear and PTO gear 0 15 mm to 0 30 mm 0 006 in to 0 012 in Replacement Limit 0 40 mm 0 0157 in 2 Clearance Between Bushing and Shaft 0 015 mm to 0 050 mm 0 0006 in to 0 002 in Replacement Limit 0 10 mm 0 0039 in 3 End Play of Idler Gear 0 03 ...

Page 229: ... Remarks FLYWHEEL 1 Face Runout of Flywheel Housing Repair Limit 0 30 mm 0 012 in 2 Radial Runout of Flywheel Housing Repair Limit 0 35 mm 0 014 in 3 Face Runout of Flywheel Repair Limit 0 15 mm 0 0059 in 4 Radial Runout of Flywheel Repair Limit 0 20 mm 0 079 in 18900013 ...

Page 230: ...ylinder Ref Inspection Item Standard Remarks CYLINDER Bore STD ID 95 00 mm 3 740 in Tolerance 0 022 mm 0 0008 in Repair Limit ID 95 15 mm 3 746 in Roundness of Cylinder 1 Cylindricity of Cylinder Repair Limit 0 02 mm 0 0008 in 18900020 ...

Page 231: ...94 85 mm 3 734 in 2 Top 0 06 to 0 10 mm 0 0024 to 0 0039 in 2 0 mm 0 079 in Repair Limit 0 15 mm 0 0059 in 3 Second 2 0 mm 0 079 in Repair Limit 0 20 mm 0 0079 in 4 Clearance Between Piston Ring Groove and Piston Ring Oil 0 03 to 0 07 mm 0 0012 to 0 0028 in 4 0 mm 0 158 in Repair Limit 0 15 mm 0 0059 in Width of Groove Nominal 18900020 ...

Page 232: ...e Limit 2 00 mm 0 079 in C Piston Ring Gap Oil 0 25 to 0 45 mm 0 0098 to 0 018 in Clearance Limit 1 50 mm 0 059 in CONNECTING ROD 2 Bend B Torsion T Maximum 0 20 0 30 mm 0 0078 0 0118 in Repair Limit 0 25 0 35 mm 0 0098 0 0138 in 3 Inner Diameter of Bushing Hole 33 00 mm 1 299 in Tolerance 0 025 mm 0 001 in CONNECTING ROD BUSHING 1 Clearance Between Bushing and Piston Ring Small End 0 020 to 0 039...

Page 233: ...l Pump Ref Inspection Item Standard Remarks 1 Axial 0 030 to 0 085 mm 0 0012 to 0 0033 in Clearance Limit 0 10 mm 0 0039 in 2 Clearance of Pump Gear Radial 0 045 to 0 090 mm 0 0018 to 0 0035 in Clearance Limit 0 13 mm 0 0051 in 18900017 ...

Page 234: ... 0 050mm 0 077mm 0 002 in 0 003 in 0 020 mm 0 020mm 0 0008 in 0 0008 in 0 030 to 0 097 mm 0 001 to 0 004 in Standard Repair Limit Free Length Installed Length Installed Load Free Length Installed Load 2 Regulator Valve SprIng Naturally Aspirated 33 1 mm 1 30 in 27 8 mm 1 09 in 2 44 kg 5 38 lb 2 30 kg 5 07 lb Replace 3 Regulator Valve Set Pressure Standard 5 0 0 5 kg cm Repair or Replace Spring 189...

Page 235: ...Temperature 82 C 2 C 180 F 2 F Fully Open Temperature 95 C 203 F Fully Open Lift Minimum 8 mm 0 315 in when immersed in a hot water bath at 95 C 203 F for 4 to 5 minutes Fully Open Shall open fully when immersed in hot water bath at a temperature between 77 C 171 F and 95 C 203 F for 4 to 5 minutes Replace 18900024 ...

Page 236: ...lues in place of those specified in other sections of this manual 3 The torque values in the table are based on the use of lubricated threads 4 When the ft lb value is less than 10 convert the ft lb value to in lb to obtain a better torque with an in lb torque wrench Example 6 ft lb equals 72 in lb Capscrew Markings and Torque Values Metric Body Size Torque Torque Torque Diameter Cast Iron Aluminu...

Page 237: ...20 25 55 60 40 45 25 35 20 25 7 16 14 20 60 65 45 50 45 55 35 40 90 95 65 70 45 55 35 40 1 2 13 20 95 100 70 75 75 80 55 60 130 150 95 110 75 80 55 60 9 16 12 18 135 150 100 110 110 115 80 85 190 210 140 155 110 115 80 85 5 8 11 18 180 210 135 155 150 160 110 120 255 290 190 215 150 160 110 120 3 4 10 16 325 365 240 270 255 285 190 210 460 515 340 380 255 285 190 210 7 8 9 14 490 530 360 390 380 4...

Page 238: ...5 64 0 7031 17 859 7 32 0 2188 5 556 23 32 0 7188 18 256 15 64 0 2344 5 953 47 64 0 7344 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 2656 6 747 49 64 0 7656 19 447 9 32 0 2813 7 144 25 32 0 7813 19 844 19 64 0 2969 7 541 51 64 0 7969 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 3281 8 334 53 64 0 8281 21 034 11 32 0 3438 8 731 27 32 0 8438 21 431 23 64 0 3594 9 128 55 64 0 8594 21 82...

Page 239: ...8 13 115 85 215 159 20 15 120 89 220 162 25 18 125 92 225 165 30 22 130 96 230 170 35 26 135 100 235 173 40 30 140 103 240 177 45 33 145 107 245 180 50 37 150 111 250 184 NOTE To convert from Newton Meters to Kilogram Meters divide Newton Meters by 9 803 Pipe Plug Torque Values Size Torque Torque Thread Actual Thread O D In Aluminum Components In Cast Iron or Steel Components in in N m ft lb N m f...

Page 240: ...retical tap drill size for approximately 60 and 75 of full thread depth Generally it is recommended that drill sizes be selected in the 60 range as these sizes will provide about 90 of the potential holding power Drill sizes in the 75 range are recommended for shallow hole tapping less than 1 1 2 times the hole diameter in soft metals and mild steel 17800013 ...

Page 241: ...37 inches of mercury in Hg kilopascal kPa 3 3769 0 29613 inches of water in H2 O kilopascal kPa 0 2488 4 019299 inches of mercury in Hg millimeters of mercury mm Hg 25 40 0 039370 inches of water in H2 O Millimeters of water mm H2 O 25 40 0 039370 bars bars kilopascals kPa 100 001 0 00999 Pressure bars bars millimeters of mercury mm Hg 750 06 0 001333 Temperature fahrenheit F centigrade C F 32 1 8...

Page 242: ...ngine Special Tools 228 Special Tools Style Tool No Tool name ST 647 Standard Puller 3163086 Lubriplate Multi Purpose Lubricant 3163720 Dowel Pin Extractor 3164067 Silicone Sealant 3164438 Depth Gauge Assembly ...

Page 243: ...Diesel Engine Special Tools 229 Style Tool No Tool name 3164900 Crankshaft Seal Installer 3375066 Sealant 3375068 Sealant 3822709 Thread Repair Inserts 3823258 Abrasive Pad ...

Page 244: ...esel Engine Special Tools 230 Style Tool No Tool name 3823942 Small Bushing Driver Set 4918219 Precision Straightedge 3822509 Injector Bore Brush 3824379 Antiseize Lubricant 4918219 Precision Straightedge ...

Page 245: ...Diesel Engine Special Tools 231 Style Tool No Tool name ST 647 Standard Puller 3164488 Digital Multimeter 3164489 Digital Multimeter 3164491 Pressure Vacuum Module 3375326 Bearing Separator Tool ...

Page 246: ...ine Special Tools 232 Style Tool No Tool name 3377462 Digital Optical Tachometer 3823705 Graduated Beaker 3824510 QD Contact Cleaner 4918193 Injection Timing Gauge Kit 4818677 Fuel Pump Drive Gear Retention Tool ...

Page 247: ...ial Tools 233 Style Tool No Tool name 4918679 Fuel Return Flow Hose Fuel Pump ST 1273 Pressure Gauge 3164325 Fuel System Leak Tester 3164617 Fuel Return Flow Hose fuel rail pressure relief valve 3164706 Injector Remover ...

Page 248: ...Diesel Engine Special Tools 234 Style Tool No Tool name 3376579 Filter Cutter 3376946 Injection Nozzle Tester 3376947 Injector Nozzle Cleaning Kit 3400157 Fuel Filter Wrench 3823705 Graduated Beaker ...

Page 249: ...Diesel Engine Special Tools 235 Style Tool No Tool name 3824879 Antiseize Lubricant 3163338 Black Light Lamp 3164067 Silicone Sealant 3164491 Pressure Vacuum Module 3375273 Pressure Gauge Kit ...

Page 250: ...Diesel Engine Special Tools 236 Style Tool No Tool name 3376579 Tube Filter Cutter 3400157 Oil Filter Wrench 3400158 Oil Filter Wrench 3823876 Lubricating Oil Cooler Test Kit CC 2800 Refractometer ...

Page 251: ...Diesel Engine Special Tools 237 Style Tool No Tool name ST 1138 Belt Tension Gauge 3164488 Digital Multimeter 3164489 Digital Multimeter 3375066 Sealant 3376050 Dial Indicator Assembly ...

Page 252: ...ine Special Tools 238 Style Tool No Tool name 3377399 Magnetic Base Indicator Holder 3822524 Belt Tension Gauge 3822985 Combustion Leak Test Kit 3822994 Engine Coolant Analyzer 3824319 Coolant Dam Pressure Tester ...

Page 253: ...ervice Manual 4TNV98 4TNE98 Diesel Engine D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 4TNV98 EM0Q3 EM0Q4 EM0Q5 D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 4TNE98 EM0QC EM0QD EM0QE D20G D25G D30G 4TNE98 SB4319E00 Jan 2008 ...

Page 254: ......

Page 255: ...following symbol WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on t...

Page 256: ......

Page 257: ...Units of Force 28 Units of Torque 28 Units of Pressure 28 Units of Power 28 Units of Temperature 28 Section 2 PERIODIC MAINTENANCE Before You Begin Servicing 29 Introduction 40 The Importance of Periodic Maintenance 40 Performing Periodic Maintenance 40 Yanmar Replacement Parts 40 Required EPA ARB Maintenance USA Only 40 EPA ARB Installation Requirements USA Only 40 Periodic Maintenance Schedule 4...

Page 258: ...Injection Pump 152 Checking and Adjusting Fuel Injection Timing 157 Determining the Fuel Injection Timing Specification 157 Checking Fuel Injection Timing 158 Adjusting Fuel Injection Timing 161 Fuel Injectors 163 Removal of Fuel Injectors 163 Testing of Fuel Injectors 164 Disassembly and Inspection of Fuel Injectors 165 Adjusting Fuel Injector Pressure 166 Reassembly of Fuel Injectors 167 Install...

Page 259: ...id Oil Pump 215 Oil Pump Components 215 Disassembly of Oil Pump 216 Cleaning and Inspection 216 Reassembly of Oil Pump 217 Section 7 STARTER MOTOR Before You Begin Servicing 219 Introduction 221 Starter Motor Information 221 Starter Motor Specifications 222 Starter Motor Troubleshooting 223 Starter Motor Components 224 Starter Motor 225 Removal of Starter Motor 225 Disassembly of Starter Motor 225...

Page 260: ......

Page 261: ...ection Pump 12 Engine Oil Filter 13 Dipstick Engine Oil 14 Governor Lever 15 Intake Manifold 16 Fuel Filter 17 Fuel Inlet 18 Fuel Return to Fuel Tank 19 Top Filler Port Engine Oil 20 Rocker Arm Cover 21 Air Intake Port From Air Cleaner 22 Flywheel 23 Starter Motor 24 Exhaust Manifold 25 Alternator 4TNE98 ENGINE Figure 4 1b 1 Fuel Filter Water Separator 2 Top Filler Port Engine Oil 3 Governor Lever...

Page 262: ...tion of the engine nameplate is shown Figure 4 2 1 4 Engine Nameplate Typical Emission Control Regulations EPA ARB Regulations USA Only Yanmar engines meet Environmental Protection Agency EPA U S Federal emission control standards as well as the California Air Resources Board ARB California regulations Only engines that conform to ARB regulations can be sold in the State of California Refer to the...

Page 263: ...might find on your engine EPA ARB Labels EPA Greater than or Equal to 50 HP SAE 37kW EPA and ARB The 97 68 EC Directive Certified Engines The engines described in this manual have been certified by the 97 68 EC Directive To identify the engines that meet this certification the 97 68 EC emission control label is affixed on the engines 97 68 EC Engine Family The EPA ARB labels and the 97 68 EC label...

Page 264: ...ilter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessary See the Periodic Maintenance Schedule on page 39 for the replacement frequency Please note that the word diesel is implied throughout this manual when the word fuel is used Fuel Filter Water Separator The fuel filter water separator removes contaminants sediments and water from the di...

Page 265: ... the engine cooling fan circulates air through the radiator the heat is transferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increases When the pressure reaches a preset value the release valve in ...

Page 266: ...t not exceed 0 35 by volume Less than 0 1 is preferred The total aromatics content should not exceed 35 by volume Less than 30 is preferred The PAH polycyclic aromatic hydrocarbons content should be below 10 by volume The metal content of Na Mg Si and Al should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity The wear mark of WS1 4 should be Max 0 018 in 460 μm at H...

Page 267: ... the precautions and concerns above may affect the warranty coverage of your engine Filling The Fuel Tank DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep...

Page 268: ...diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog Note that a typical fuel tank is shown The fuel tank on your equipment may be ...

Page 269: ... out of the air bleed port is free of bubbles 4 Tighten the air bleed port 5 Wipe up any spills and properly dispose of fuel 6 NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear To prime the fuel system on engines not equipped with an electric fuel system 1 Place an approved con...

Page 270: ...d E 5 JASO Service Category DH 1 Definitions API Classification American Petroleum Institute ACEA Classification Association des Constructeurs Européens d Automobilies JASO Japanese Automobile Standards Organization NOTE Be sure the engine oil engine oil storage containers and engine oil filling equipment arefree of sediment and water Change the engine oil after the first 50 hours of peration and ...

Page 271: ... at the top or the side engine oil filler port Figure 4 5 5 4 Wait three minutes and check the oil level 5 Add more oil if necessary 6 Reinstall the oil cap Figure 4 5 4 and hand tighten Over tightening may damage the cap Engine Oil Capacity Typical NOTE These are the engine oil capacities associated with a deep standard oil pan The oil capacity will vary dependant upon which optional oil pan is u...

Page 272: ...drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury CAU...

Page 273: ...ontainer Water quality is important to coolant performance Yanmar recommends that soft distilled or demineralized water be used to mix with coolants NEVER mix extended or long life coolants and conventional green coolants NEVER mix different types and or colors of extended life coolants Replace the coolant every 1000 engine hours or once a year Filling Radiator with Engine Coolant Fill the radiato...

Page 274: ...ant will leak out instead of going into the reserve tank 7 Run the engine until it is at operating temperature Check the level of engine coolant in the reserve tank When the engine is running and the engine coolant is at normal temperature the coolant level in the tank should be at the FULL HOT mark Figure 4 6 6 If the engine coolant is not at the FULL HOT mark Figure 4 6 6 add additional engine c...

Page 275: ... information described in Principal Engine Specifications is for a standard engine To obtain the information for the engine installed in your driven machine please refer to the manual provided by the driven machine manufacturer Engine rating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric Condition Room temperature 77 F 25 C Atmospheric pressure 29 53 in Hg 100 kPa 750 mm Hg Relative hu...

Page 276: ...em Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 42 57 psi 0 29 0 39 MPa 2 96 3 98 kgf cm Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm or greater Electric Starting Starter Motor DC12V 3 1 hp 2 3 kW Alternator DC12V 40A Starting System Recommended Battery Capacity 12V 64 Amp Hour 5h rating Dimensions L W H 28 31 x 19 61 x 29 21 in 719 x 498 x 7...

Page 277: ...adiator Lubricating System Forced Lubrication With Trochoid Pump At normal operating speeds oil pressure is 42 57 psi 0 29 0 39 MPa 3 0 4 0 kgf cm At idle oil pressure is No less than 18 5 psi 0 13 Mpa 1 3kgf cm Electric Starting Starter Motor DC12V 3 1 hp 2 3 kW Alternator DC12V 80A Starting System Recommended Battery Capacity 12V 622 CCA Cold Cranking Amps Dimensions L W H 28 0 x 20 3 x 29 8 in ...

Page 278: ... 36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm See Troubleshooting By Measuring Compression Pressure on page 236 Compression Pressure at 250 rpm 250 min 4TNE98 425 428 psi 2 93 2 95 MPa 29 31 kgf cm 341 psi 2 35 MPa 24 kgf cm Deviation Between Cylinders 29 43 psi 0 2 0 3 MPa 2 3 kgf cm Oil Pressure Switch Operating Pressure 5 8 8 8 psi 0 04 0 06 MPa 0 4 0 6 kgf cm Max when cold 86 psi 0 59 MPa ...

Page 279: ...Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure CAUTION The tightening torque in the Standard Torque Chart see General Service Information section should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy ...

Page 280: ...f the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and lock nuts 1 8 mm 7 ft lb 87 in lb 9 8 N m 1 0 kgf m 1 4 mm 14 ft lb 173 in lb 19 6 N m 2 0 kgf m 3 8 mm 22 ft lb 29 4 N m 3 0 kgf m PT PLug 1 2 mm 43 ft lb 58 8 N m 6 0 kgf m Item Nominal Thread Diameter x Pitch Tightening Torque Remarks M8 9 12 ft lb 112 148 in lb 12 7 16 7 N m 1 3 1 7 kgf m M10 ...

Page 281: ... minute g gram gal gallon U S gal hr gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower U S hr hour I D inside diameter ID identification IDI indirect injection in inch in Aq inches Aqueous water in Hg inches Mercury in lb inch pound j joule JASO Japanese Automobile Standards Organization k kelvin kg kilogram kgf cm kilogram force per square centimeter kgf m kilogram...

Page 282: ... x 0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N Units of Torque ft lb x 1 3558 N m ft lb x 0 1383 kgf m in lb x 0 1130 N m in lb x 0 0115 kgf m kgf m x 7 2330 ft lb kgf m x 86 8000 in lb kgf m x 9 8070 N m N m x 0 7376 ft lb N m x 8 8510 in lb N m x 0 1020 kgf m Units of Pressure psi x 0 0689 bar psi x 6 8950 kPa psi x 0 0703 kg cm bar x 14 5030 psi bar x 100 0000 kPa bar x 29 5300 in...

Page 283: ...ine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury DANGER FIRE AND...

Page 284: ...ith the engine running Failure to comply will result in death or serious injury DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static e...

Page 285: ... under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Place an approved container under the air bleed port when you prime the fuel system Never use a shop rag to catch the fuel Wipe up any spills immediately ALWAYS cl...

Page 286: ... result in death or serious injury WARNING SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine NEVER start the engine in gear Sudden movement of the engine and or machine c...

Page 287: ...from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury WARNING ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence...

Page 288: ...cid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury WARNING ...

Page 289: ...meone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING BURN HAZARD If you must drain the engine oil w...

Page 290: ...coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engi...

Page 291: ...o start and the engine oil may not flow easily Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated outside of this standard temperature range CAUTION NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow th...

Page 292: ...ing This may damage the starter motor pinion and or ring gear CAUTION It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of...

Page 293: ...arranty coverage on your engine See Yanmar Limited Warranty in Warranty Section Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a CAUTION If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent sc...

Page 294: ...e to comply could result in death or serious injury Perform periodic maintenance procedures in an open level area free from traffic If possible perform the procedures indoors to prevent environmental conditions such as rain wind or snow from damaging the machine Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts ...

Page 295: ...d to establish definitively The following should be treated only as a general guideline CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at the intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the...

Page 296: ...ent Check Battery Check Engine Oil Level Check Engine Oil Pressure Indicator Drain and Fill Engine Oil Engine Oil Replace Engine Oil Filter 1st time 2nd and after Engine Speed Control Check and Adjust Governor Lever and Engine Speed Control Inspect Clean and Test Fuel Injectors Emission Control Warranty Inspect Crankcase Breather System Check and Refill Fuel Tank Level Check Fuel Filter Indicator ...

Page 297: ...r serious injury 0000009en 4TNE98 For D25S 5 Only WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWA...

Page 298: ...he scheduled periodic maintenance if the fuel filter indicator comes on The fuel filter water separator contains a sensor to detect the amount of water and contaminants This sensor sends a signal to an indicator to alert the operator Drain the fuel filter water separator as follows Figure 5 1 1 Position an approved container under the fuel filter water separator Figure5 1 1 to collect the contamin...

Page 299: ... oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfi...

Page 300: ...to collect waste oil Figure 5 1 6 Remove the oil drain plug Figure 5 2 1 from the engine oil pan Allow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain plug Figure 5 2 1 and tighten to 139 8 47 0 ft lb 53 9 63 7 N m 5 5 6 5 kgf m 8 Dispose of used oil properly Remove the engine oil filter as follows 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Fig...

Page 301: ...ny engine oil is spilled wipe it away with a clean cloth Check and Adjust Cooling Fan V Belt The V belt will slip if it does not have the proper tension This will prevent the alternator from generating sufficient power Also the engine will overheat due to the engine coolant pump pulley slipping Check and adjust the V belt tension deflection as follows 1 Press the V belt down with your thumb with a...

Page 302: ...ting run the engine for 5 minutes or more Check the tension again using the specifications for a used V belt Used V Belt Tension A B C 3 8 1 2 in 10 14 mm 1 4 3 8 in 7 10 mm 5 16 1 2 in 9 13 mm Every 50 Hours of Operation After you complete the initial 50 hour maintenance procedures perform the following procedures every 50 hours thereafter Drain Fuel Filter Water Separator Check Battery Drain Fue...

Page 303: ... are discovered The cup of the separator is made from semi transparent material In the cup is a red colored float ring The float ring will rise to the surface of the water to show how much needs to be drained Also some optional fuel filter water separators are equipped with a sensor to detect the amount of contaminants This sensor sends a signal to an indicator to alert the operator Drain the fuel...

Page 304: ... CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to...

Page 305: ...ive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel...

Page 306: ...e fins apply detergent thoroughly clean and rinse with tap water CAUTION NEVER use high pressure water or compressed air at greater than 28 psi 193 kPa 19 686 mmAq or a wire brush to clean the radiator fins Radiator fins damage easily Figure 5 10 Check and Adjust Cooling Fan V Belt Check and adjust the cooling fan V belt every 250 hours of operation after the initial 50 hour V belt maintenance See...

Page 307: ... low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor Clean Air Cleaner Element Note that a typical air cleaner is shown in Figure 5 12 and Figure 5 13 for illustrative purposes only The engine performance is adversely aff...

Page 308: ...ER operate the engine with the air cleaner element s removed This may allow foreign material to enter the engine and damage it Every 500 Hours of Operation Perform the following maintenance every 500 hours of operation Replace Engine Oil and Engine Oil Filter Replace Air Cleaner Element Replace Fuel Filter Clean Fuel Filter Water Separator Replace Engine Oil and Engine Oil Filter CAUTION Only use ...

Page 309: ...e rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will all...

Page 310: ...or leaks 4TNE98 for D25S 5 Only Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow 1 Stop the engine and allow it to cool 2 Close all fuel cocks in fuel line 3 Disconnect the fuel filter sensor connector Figure 5 14a 1 Figure 5 14a 4 Place an approved container under fuel filter 5 Carefully open the drain plug Figure 5 15a 1 to drai...

Page 311: ...stall the new fuel filter Figure 5 14 2 by turning it to the right Figure 5 14 4 until it contacts the mounting surface Tighten one additional turn 18 Open all fuel cocks in the fuel line 19 Reconnect the fuel filter sensor connector Figure 5 14 1 20 Prime the fuel system See Priming the Fuel System on page 15 21 Check for fuel leaks Applicable Fuel Filter Part No Figure 5 14 2 4TNE98 A409559 Clea...

Page 312: ...ater Separator on page 41 4 Turn the retaining ring Figure 5 15 5 to the left Figure 5 15 10 and remove the cup Figure 5 15 6 If equipped disconnect the sensor wire Figure 5 15 7 from the cup before removing the cup 5 Carefully hold the cup to prevent fuel from spilling If you spill any fuel clean up the spill completely 6 Remove the float ring Figure 5 15 8 from the cup Pour the contaminants into...

Page 313: ...on and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engi...

Page 314: ...all and tighten the drain plug or close the drain cock in the radiator Reinstall and tighten the cylinder block drain plug or reconnect the coolant hose at the oil cooler 6 Fill radiator and engine with engine coolant See Filling Radiator with Engine Coolant on page 19 Adjust Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the va...

Page 315: ...his procedure is considered normal maintenance and is performed at the owner s expense This procedure is not covered by the Yanmar Limited Warranty Inspect Crankcase Breather System Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine The EPA ARB requires that the crankcase breather system is inspected every 1500 hours There are three di...

Page 316: ... Fuel Hoses and Engine Coolant Hoses CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ...

Page 317: ...ts and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection whe...

Page 318: ...dversely affect the properties of the engine coolant CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced CAUTION Any part dete...

Page 319: ...cting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method CAUTION Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion ...

Page 320: ...sion 4TNV98 4 Valve Head Intake Exhaust 0 0142 0 0220 in 0 36 0 56 mm 0 0138 0 0217 in 0 35 0 55 mm 0 0315 in 0 8 mm 0 0315 in 0 8 mm See Valve Recession on Page 95 and 98 Intake 120 Seat Angle Exhaust 90 Valve Seat 4 Valve Seat Correction Angle 40 150 See Valve Face and Valve Seat on Page 96 and 99 4TNE98 Engine Inspection Item Standard Limit Reference Page Combustion Surface Distortion Flatness ...

Page 321: ...nd 103 Valve Guide Installation Method Cold fitted Valve Stem Seal Projection From Cylinder Head 0 460 0 472 in 11 7 12 0 mm See Reassembly of Intake and Exhaust Valves on page 98 4TNE98 Engine Inspection Item Standard Limit Reference Page Guide Inside Diameter 0 3156 0 3161 in 8 015 8 030 mm 0 3189 in 8 10 mm Valve Stem Outside Diameter 0 3136 0 3142 in 7 965 7 980 mm 0 3110 in 7 90 mm Intake Val...

Page 322: ...nspection Item Model Standard Limit Reference Page 4TNV98 4 Valve Head 1 5630 in 39 7 mm 1 5433 in 39 2 mm Free Length 4TNE98 1 87 in 47 5 mm 4TNV98 4 Valve Head 0 0551 in 1 4 mm Squareness 4TNE98 0 05 in 1 2 mm See Inspection of Valve Springs on page 97 and 101 Camshaft and Timing Gear Train Specifications Camshaft Inspection Item Standard Limit Reference Page End Play 0 0020 0 0079 in 0 05 0 20 ...

Page 323: ...0 mm Camshaft Outside Diameter 1 9655 1 9665 in 49 925 49 950 mm 1 9642 in 49 890 mm Flywheel End Oil Clearance 0 0020 0 0039 in 0 050 0 100 mm 0 0083 in 0 210 mm See Inspection of Camshaft on page 125 Idler Gear Shaft and Bushing Inspection Item Standard Limit Reference Page Shaft Outside Diameter 1 8091 1 8100 in 45 950 45 975 mm 1 8071 in 45 900 mm Bushing Inside Diameter 1 8110 4 8120 in 46 00...

Page 324: ...Connecting Rod Journals Oil Clearance 0 0015 0 0029 in 0 038 0 074 mm 0 0059 in 0 150 mm See Inspection of Crankshaft on Page 124 Journal Outside Diameter 2 5572 2 5576 in 64 952 64 962 mm 2 5552 in 64 902 mm Bearing Inside Diameter 2 5590 2 5598 in 65 000 65 020 mm Bearing Insert Thickness 0 0785 0 0791 in 1 995 2 010 mm Main Bearing Journal Oil Clearance 0 0015 0 0027 in 0 038 0 068 mm 0 0059 in...

Page 325: ...spection Item Standard Limit Reference Page Ring Groove Width 0 0803 0 0811 in 2 040 2 060 mm Ring Width 0 0764 0 0772 in 1 940 1 960 mm 0 0756 in 1 920 mm Side Clearance 0 0031 0 0047 in 0 080 0 120 mm Top Ring End Gap 0 0098 0 0177 in 0 250 0 450 mm 0 0213 in 0 540 mm Ring Groove Width 0 0819 0 0825 in 2 080 2 095 mm 0 0864 in 2 195 mm Ring Width 0 0776 0 0783 in 1 970 1 990 mm 0 0768 in 1 950 m...

Page 326: ... page 124 Connecting Rod Big End Inspection Item Standard Limit Reference Page 4TNV98 0 0079 0 0157 in 0 20 0 40 mm Side Clearance Thrust Clearance 4TNE98 0 0051 0 0091 in See Inspection of Connecting Rod on page 124 See Special Torque Chart on page 69 for other specifications Tappet Inspection Item Standard Limit Reference Page Tappet Bore Block Inside Diameter 0 4724 0 4731 in 12 000 12 018 mm 0...

Page 327: ...m or less 0 0012 in 0 03 mm See Inspection of Cylinder Block on page 121 Special Torque Chart Torque for Bolts and Nuts Component Thread Diameter and Pitch Torque Lubricating Oil Application Thread Portion and Seat Surface Cylinder Head Bolt M11 x 1 25 mm 76 83 ft lb 103 1 112 9 N m 10 5 11 5 kgf m Applied Connecting Rod Bolt M10 x 1 0 mm 40 43 ft lb 53 9 58 8 N m 5 5 6 0 kgf m Applied Flywheel Bo...

Page 328: ... 9 127 5 N m 11 0 13 0 kgf m Applied Fuel Injector Bolt 4TNV98 M8 x 1 25 mm 17 21 ft lb 22 6 28 4 N m 2 3 2 9 kgf m Not Applied Fuel Pump Drive Gear Nut 4TNV98 M18 x 1 5 mm 83 90 ft lb 113 123 N m 11 5 12 5 kgf m Not Applied High Pressure Fuel Lines Bolt 4TNV98 M12 x 1 5 mm 174 217 in lb 19 6 24 5 N m 2 0 2 5 kgf m Not Applied Fuel Return Line Joint Bolt 4TNV98 M6 x 1 0 mm 70 86 in lb 7 8 9 8 N m ...

Page 329: ... 551 in 14 mm 0 787 in 20 mm 2 Valve Guide Tool For Installing Valve Guide Locally Manufactured L1 L2 d1 d2 0 787 in 20 mm 3 937 in 100 mm 1 181 in 30 mm 1 299 in 33 mm 4 Connecting Rod Bushing Replacer For Removal Installation of Connecting Rod Bushing Locally Manufactured 5 Valve Spring Compressor For Removal Installation of Valve Spring Yanmar Part No 129100 92630 Model d1 d2 d3 L1 L2 L3 4TNV98...

Page 330: ...Camshaft Bushing Tool For Extracting Camshaft Bushing Locally Manufactured Yanmar Part No Cylinder Bore 9 Flex Hone For Preparation of Cylinder Walls 129400 92440 3 504 3 976 in 89 101 mm 10 Piston Ring Compressor For Installing Piston Yanmar Part No 95550 002476 The Piston Insertion Tool is Applicable for 2 362 4 921 in 60 125 mm Diameter Pistons 11 Piston Ring Expander For Removal Installation o...

Page 331: ...y Available For holding the dial gauge when measuring 4 Micrometer Locally Available For measuring the outside diameters of crankshaft pistons piston pins etc 5 Cylinder Bore Gauge Locally Available For measuring the inside diameters of cylinder liners bearing bores etc 6 Calipers Locally Available For measuring outside diameters depth thickness and width 7 Depth Micrometer Locally Available For m...

Page 332: ...and valve adjustment clearance 12 Battery Coolant Tester For checking concentration of antifreeze and the battery electrolyte charge status 13 Digital Thermometer For measuring temperatures Contact Type For measuring revolution by contacting the revolving shaft Photoelectric Type For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft 14 Tachometer Fue...

Page 333: ...ion 15 Circuit Tester For measuring resistance voltage and continuity of electrical circuits Compression Gauge Kit For measuring compression pressureGauge Set Part No TOL 97190080 16 New Comperssion Test Adaptor Adapter for direct injection 2 valve cylinder headAdapter Part No 119802 92950 ...

Page 334: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 80 Cylinder Head Cylinder Head Components 4TNV98 Engine Figure 6 36 ...

Page 335: ... 14 Valve Adjusting Screw Lock Nut Primary 15 Rocker Arm Shaft Aligning Stud 16 Fuel Injector Retainer 17 Valve Stem Seal 18 Valve Guide 19 Cylinder Head 20 Intake Valve 21 Exhaust Valve 22 Cylinder Head Gasket 23 Fuel Injector Nozzle Protector 24 Fuel Injector Nozzle Seat 25 Valve Spring 26 Valve Bridge Guide 27 Spring Retainer 28 Valve Keepers 29 Valve Bridge 30 Valve Bridge Seat 31 Valve Adjust...

Page 336: ...ge7 31 Figure 6 37 CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 3 Disconnect the fuel return hose Figure 6 37 2 from the cylinder head 4 Disconnect the hoses Figure 6 37 3 from the cold start...

Page 337: ...se a flat blade screwdriver Figure 6 39 to remove the fuel injection line grommets Figure 6 40 1 from the valve cover Figure 6 40 3 and fuel injectors Figure 6 40 2 There is a notch at the 3 o clock position in the valve cover opening to insert the screwdriver Figure 6 39 3 Remove the valve cover nuts Figure 6 40 4 4 Remove the O ring Figure 6 40 5 on each valve cover nut Figure 6 40 5 Remove the ...

Page 338: ...6 Identify all parts so that they will be reinstalled in their original locations Figure 6 41 Disassembly of Rocker Arm Assembly NOTE Identify the rocker arms so they can be reinstalled with the original matching valve and pushrod 1 Remove the rocker arm shaft alignment studs Figure 6 42 5 from the rocker arm shaft supports Figure 6 42 6 2 Slide the supports wave washers Figure 6 42 7 rocker arms ...

Page 339: ...lts Figure 6 44 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 44 2 Place the cylinder head on the work bench to prevent damage to the combustion surface Figure 6 44 Removal of Intake and Exhaust Valves 1 Place the cylinder head on the work bench with the combustion side down 2 Using the valve spring compressor tool compress one of the valve sprin...

Page 340: ...inal location 7 Remove the injector nozzle protectors Figure 6 46 6 and the seats Figure 6 46 7 8 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure 6 46 5 from the cylinder head 9 Remove the valve stem seals Figure 6 46 4 Removal of Valve Guides NOTE Removal of the valve guides should be postponed until inspection and measurement procedures have...

Page 341: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 87 4TNE98 Engine Figure 6 1 ...

Page 342: ...ap 10 Valve Keepers 11 Spring Retainer 12 Valve Spring 13 Valve Stem Seal 14 Valve Guide 15 Intake Valve 16 Exhaust Valve 17 Cylinder Head Gasket 18 Cylinder Head 19 Glow Plug 20 Glow Plug Cover 21 Push Rod 22 Support Bracket Bolt 23 Rocker Arm Shaft Spring 24 Support Bracket Stud 25 Support Bracket 26 Rocker Arm 27 Rocker Arm Shaft Retaining Ring 28 Valve Adjusting Screw Lock Nut 29 Valve Adjusti...

Page 343: ...ove the exhaust manifold bolts Figure 6 2 4 and nuts Figure 6 2 5 Remove the exhaust manifold Figure 6 2 6 Discard the exhaust manifold gasket Figure 6 2 7 3 Remove the water pump from the engine See Disassembly of Engine Coolant Pump on 205 4 Remove the fuel injectors from the cylinder head See Removal of the Fuel Injectors on page 196 Removal of Glow Plugs 1 Remove the glow plug cover Figure 6 3...

Page 344: ...r Arm Assembly 1 Remove the rocker arm shaft alignment screw Figure 6 7 1 from the support bracket that secures the rocker arm shaft Figure 6 7 2 2 Remove the retaining rings Figure 6 7 3 from the ends of the rocker arm shaft Figure 6 7 2 3 Slide the rocker arm shaft Figure 6 7 2 out of the rocker arm support brackets Figure 6 7 4 springs Figure 6 7 5 and rocker arms Figure 7 6 NOTE The rocker arm...

Page 345: ...er head bolts Figure 6 9 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 9 2 Position the cylinder head on the work bench to prevent damage to the combustion surface Figure 6 9 Removal of Intake Exhaust Valves 1 Place the cylinder head on the work bench with the combustion side down 2 Using the valve spring compressor tool compress one of the valve...

Page 346: ...hem so they can be installed in their original location 7 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure 6 11 6 from the cylinder head Removal of Valve Guides 1 Using a drift pin and hammer drive the valve guides Figure 6 12 1 out of the cylinder head Figure 6 12 Cleaning of Cylinder Head Components WARNING FUME BURN HAZARD Always read and fo...

Page 347: ...vice as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit Inspection of Push Rods Push Rod Bend 1 Place the push rods on a flat inspection block or layout bed 2 Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the block or layout bed 3 Use a feeler gauge to measure ...

Page 348: ...he valve guides while they are installed in cylinder head Use a telescoping gauge and micrometer to measure the inside diameter at each end of the valve guide Measure in three places and 90 apart Figure 6 51 See Intake Exhaust Valve and Guide on page 67 for the service limit Replace the valve guides if not within specification Figure 6 51 Inspection of Cylinder Head Cylinder Head Distortion Place ...

Page 349: ...ce limit Figure 6 53 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed Use a feeler gauge to measure the gap Figure 6 54 See Intake Exhaust Valve and Guide on page 67 for the service limit Figure 6 54 Valve Recession NOTE The valve guides must be installed ...

Page 350: ... valves and valve seats can be lapped or ground to return them to serviceable condition Severely worn or damaged components will require replacement Coat the valve seat with a thin coat of bluing compound Install the valve and rotate to distribute bluing onto the valve face The contact pattern should be approximately centered on the valve face Figure 6 57 1 and even in width Figure 6 57 Also visua...

Page 351: ...res Check for fractures on the inside and outside portions of the springs If the valve spring is fractured replace the valve spring Corrosion Check for corrosion of spring material caused by oxidation Squareness Use a flat surface and a square to check each spring for squareness Figure 6 59 See Valve Spring on page 68 for the service limit Figure 6 59 Free Length Use a caliper to measure the lengt...

Page 352: ... after removing the valve guides from the freezer insert the valve guides Figure 6 62 1 in their proper positions 4TNV98 Engine 4TNE98 Engine Figure 6 62 3 Finish installing the valve guides Figure 6 63 1 into the cylinder head to the proper height Figure 6 63 3 using the valve guide installation tool Figure 6 63 2 See Intake Exhaust Valve and Guide on page 67 Figure 6 63 Reassembly of Intake and ...

Page 353: ... its exhaust port side 4 Place all the valves Figure 6 66 5 in their proper location in the cylinder head 4TNV98 Engine 4TNE98 Engine Figure 6 66 5 Place the cylinder head on the workbench with the combustion side down Install the valve spring Figure 6 66 3 and spring retainer Figure 6 66 2 6 Using the valve spring compressor tool compress the valve spring 7 Insert the valve keepers Figure 6 66 1 ...

Page 354: ...67 2 on the cylinder block 2 Position the cylinder head on the on the cylinder head gasket 4TNV98 Engine 4TNE98 Engine Figure 6 67 3 Lightly oil the threads of the cylinder head bolts Figure 6 67 1 Tighten the bolts to the specified torque in two steps as shown in the chart below Tighten in the sequence shown in Figure 6 68 See Special Torque Chart on page 73 for specification First Step 1 2 of fi...

Page 355: ...ir original locations Figure 6 69 IMPORTANT The wave washers Figure 6 70 2 must be installed with the bow facing the rocker arms Figure 6 70 1 Figure 6 70 IMPORTANT Ensure the lubrication holes Figure 6 71 1 in the rocker arm shaft are oriented correctly with respect to the rocker arms Figure 6 71 2 Figure 6 71 3 Lubricate the rocker arm shaft Slide the rocker arm supports Figure 6 72 6 wave washe...

Page 356: ...ft Slide the rocker arm support brackets Figure 6 30 4 springs Figure 6 30 5 and rocker arms Figure 6 30 6 onto the shaft NOTE The rocker arm shaft fits tightly in the rocker arm support brackets Clamp the support bracket in a padded vise and twist the rocker arm shaft to remove Reverse this process when you reinstall the rocker arm shaft into the support brackets NOTE To properly align the rocker...

Page 357: ...ten the bolts to specification 7 Reconnect the fuel injector return hose and fuel injection pump coolant hoses 8 Reinstall the high pressure fuel line grommets into the valve cover 9 Reinstall the high pressure and fuel return lines See Installation of the Fuel Injectors on page 167 10 Reinstall the coolant pump See Reassembly of Engine Coolant Pump on page 208 11 Reinstall the alternator 12 Recon...

Page 358: ...ible in the timing port of the flywheel housing If there is no valve clearance and the cylinder is at TDC of the compression stroke extreme wear or damage to the cylinder head or valves may be possible If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center afte...

Page 359: ...r on page 103 NOTE If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center after turning and make adjustment for other cylinders in the order of firing by turning the crankshaft ...

Page 360: ...ing grid on the flywheel Position where both the intake and exhaust valves are closed 3 Make sure there is clearance Figure 6 77 5 between the valve bridge Figure 6 77 1 and the rocker arm Figure 6 77 3 IMPORTANT Do not loosen or tighten the valve adjusting screw lock nut without holding the valve bridge Always hold the valve bridge using a wrench to prevent bending of the valve stems 4 Loosen the...

Page 361: ...cations on page6 6 between the rocker arm Figure 6 82 2 and valve bridge Figure 6 82 3 Record the results and use this value as an indication of wear Figure 6 82 9 If adjustment is required proceed to the next step 10 Loosen the valve adjusting screw lock nut Figure 6 83 5 and valve adjusting screw Figure 6 83 4 on the rocker arm Figure 6 83 3 and check the clearance gap Figure 6 83 2 for evidence...

Page 362: ...gure 6 83 4 while tightening the valve adjusting screw lock nut Figure 6 83 5 Recheck the clearance 13 Apply oil to the contact surface between the adjusting screw and push rod 14 Rotate the crankshaft to measure and adjust the set of valves Continue until all valves are measured and adjusted ...

Page 363: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 109 Crankshaft and Camshaft Components Figure 6 84 ...

Page 364: ...ler Gear 18 Oil Pickup O Ring 19 Oil Pickup 20 Crankshaft 21 Parallel Pin 22 Crankshaft Gear Key 23 Crankshaft Gear 24 Crankshaft Pulley 25 Main Bearing Inserts 26 Main Bearing Cap 27 Oil Pan 28 Thrust Bearings 29 Flywheel 30 Connecting Rod Cap 31 Connecting Rod Bearing Inserts 32 Connecting Rod 33 Wrist Pin Bushing 34 Circlip 35 Wrist Pin 36 Piston 37 Oil Ring 38 Second Compression Ring 39 Top Co...

Page 365: ...gine falling during work on the engine 6 Clean the engine by washing with solvent air or steam cleaning Carefully operate so as to prevent any foreign matter or fluids from entering the engine or any fuel system or electrical components remaining on the engine 7 Drain the engine oil into a suitable container Remove the oil filter 8 Remove the cylinder head See 4 Valve Cylinder Head on page 80 9 Re...

Page 366: ...not allow the gear being checked to move axially as excess end play could cause a false reading Figure 6 86 1 Fuel Injection Pump Drive Gear 2 Camshaft Drive Gear 3 Auxiliary Drive Gear Optional 4 Crankshaft Drive Gear 5 Direction of Rotation 6 Oil Pump Drive Gear 4TNV94L 4TNV106 7 Idler Gear Measuring Idler Gear to Crankshaft Gear Backlash 1 Install a dial indicator as shown in Figure 6 87 Figure...

Page 367: ...sing a gear puller 3 Removal of the camshaft gear requires the camshaft be removed and placed in a press Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement See Removal of Camshaft on page 114 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump...

Page 368: ...y Method A Install a dial indicator Figure 6 92 1 on the cylinder block Move the camshaft Figure 6 92 2 back and forth to measure the end play Record the measurement See Camshaft on page 68 for the service limit Figure 6 92 Method B Use a feeler gauge to measure the clearance between the thrust plate Figure 6 93 1 and front camshaft bearing Figure 6 93 2 See Thrust Bearing on page 70 for the servi...

Page 369: ...ocation 6 Remove the camshaft drive gear Figure 6 94 4 only if the gear or camshaft require replacement Use a knife edge puller and a press to remove the gear The gear is a shrink fit and will need to be heated to 356 392 F 180 200 C to remove Removal of Gear Case or Front Plate NOTE The camshaft must be removed before the gear case front plate can be removed See Inspection of Camshaft on page 125...

Page 370: ...mpossible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing the pistons NOTE Pistons can fall from cylinder block if the engine is inverted Rotate the engine so the connecting rods are horizontal before removing the connecting rod caps 1 Using a feeler gauge measure the connecting rod side clearance as shown Figure 6 97 See Connecting Rod on page 72 fo...

Page 371: ...f Compare the width of the flattened PLASTIGAGE to the graduation marks on the package Figure 6 99 1 The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance Figure 6 99 g Repeat with remaining connecting rods IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston removal Damage to the bearing journal may re...

Page 372: ...led Removal of Crankshaft 1 Remove the flywheel Figure 6 101 1 from the crankshaft 2 Remove the bolts from the rear oil seal assembly Figure 6 101 2 3 Remove the assembly from the engine Figure 6 101 3 Before removing the main bearing caps measure the crankshaft end play Use either of the following two methods Method A Install a dial gauge Figure 6 102 1 on the cylinder block Move the crankshaft F...

Page 373: ... the markings on the main bearing caps or mark them yourself so they can be reinstalled in the same order as they were removed Do not remove the bearing inserts at this time NOTE The arrows on the main bearing caps point to the flywheel end of the engine Figure 6 104 5 Measure bearing oil clearance prior to removing the crankshaft to determine extent of wear Record the measurements a Wipe oil from...

Page 374: ... the crankshaft gear unless the gear or crankshaft are damaged and require replacement 8 If necessary remove the crankshaft gear Figure 6 107 1 parallel pin Figure 6 107 2 and key Figure 6 107 3 If using a gear puller be careful not to damage the threads in the end of the crankshaft Figure 6 107 Inspection of Crankshaft and Camshaft Components WARNING FUME BURN HAZARD Always read and follow safety...

Page 375: ...nce Oil clearance should be checked during disassembly to determine the extent of wear and during assembly to ensure long engine life The same procedure is done for both connecting rods and main bearings Inspection of Cylinder Block 1 Ensure that oil passages are clear and unobstructed 2 Check for discoloration or evidence of cracks If a fracture is suspected use the color check method or the Magn...

Page 376: ...g grooves 4 Measure the diameter of the piston skirt at 90 to the wrist pin bore as shown Figure 6 111 Measurements must be taken at a specified distance Figure 6 111 1 from the bottom of the piston based on engine model Record the measurements See Piston on page 71 for specifications Figure 6 111 5 Subtract the piston measurement from the greatest measurement acquired during cylinder inspection s...

Page 377: ...ifications Replace the piston if not within specification Figure 6 114 10 To measure piston ring end gap insert each compression piston ring Figure 6 115 1 one at a time into the cylinder Use a piston with the piston rings removed to slide the ring into the cylinder bore until it is approximately 1 18 in 30 mm Figure 6 115 2 from the bottom of the bore Remove the piston Measure the end gap Figure ...

Page 378: ...diameter See Crankshaft on page 70 for specifications Inspection of Tappets 1 Inspect the tappet contact surfaces for abnormal wear Figure 6 117 1 Normal wear will be even as shown in Figure 6 117 2 Slight surface defects can be corrected using an oilstone Figure 6 117 2 Measure the outside diameter of the tappet stem Figure 6 118 1 See Tappet on page 72 for the service limit Figure 6 118 3 Measur...

Page 379: ...cation grind the journals and install undersize bearings or replace the crankshaft Figure 6 120 Inspection of Camshaft 1 Use V blocks and a dial indicator to check camshaft bend Figure 6 121 Place the indicator on the center bearing journal Figure 6 121 2 Rotate the camshaft and observe the runout See Camshaft on page 68 for specifications 3 Measure the height of each lobe Figure 6 122 1 See Camsh...

Page 380: ...e condition Slight imperfections can be corrected by honing alone 1 Boring Significant cylinder damage may be corrected by boring the cylinder to an oversize dimension Refer to the appropriate parts catalog for available oversize pistons and piston rings Boring a cylinder should always be done in a properly equipped machine shop A bored cylinder should always be finished with a hone to properly pr...

Page 381: ... with hot water and dry with compressed air Apply clean engine oil to all steel surfaces to prevent rusting Reassembly of Crankshaft and Piston Components NOTES Proceed slowly Make no forced assemblies unless a pressing operation is called for All parts must be perfectly clean and lightly lubricated when assembled Use new gaskets seals and O rings during assembly Liberally apply clean engine oil t...

Page 382: ...ston and connecting rod are different depending on engine model Piston to Connecting Rod Orientation By Model Orient the piston identification mark stamped on top of the piston on the same side as the rod and cap match marks stamped on the connecting rod NOTE The actual appearance of the match marks on the piston and connecting rod may vary but they will always be in the same locations Figure 6 12...

Page 383: ... on Connecting Rod 4 Rod and Cap Match Marks 5 Flywheel End of Engine 6 Camshaft Side of Engine 1 Lubricate and reinstall the wrist pin Figure 6 131 3 through the piston and connecting rod 2 Reinstall the second circlip Figure 6 131 4 and ensure it is securely seated in the groove Figure 6 131 NOTE If installing new piston rings the end gap must be checked and adjusted as necessary See Inspection ...

Page 384: ...ression ring Figure 6 133 1 This ring is identified by its silver color and barrel shaped face profile IMPORTANT The oil ring expander Figure 6 133 4 end gap must be located 180 from the oil ring Figure 6 133 3 end gap Figure 6 133 6 Stagger the piston ring end gaps at 120 intervals Figure 6 134 1 2 3 Do not position the top piston ring end gap in line with the wrist pin Figure 6 134 1 Top Compres...

Page 385: ...igure6 70 3 through the piston and wrist pin bushing 6 Install the second circlip Figure6 70 4 7 Install the piston rings Use piston ring pliers to install the piston rings Install each piston ring on the piston with the punched manufacturer s mark Figure6 72 1 facing upward Figure 6 72 Install the top compression ring second compression ring and oil ring Figure 6 73 Stagger the piston ring joints...

Page 386: ...gure 6 135 1 and thrust bearing Figure 6 135 2 in the cylinder block and main bearing caps Apply a liberal coat of clean engine oil to the bearings and crankshaft journals 3 Place the crankshaft into the engine IMPORTANT The main bearing caps are numbered and have arrows for proper positioning The No 1 cap is at the flywheel end The arrows point toward the flywheel end of the engine 4 Reinstall th...

Page 387: ...page 73 for specifications Figure 6 136 Installation of Pistons IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston installation Damage to the crankshaft bearing journal may result 4TNV98 Engine 1 Lubricate the piston piston rings and cylinder with clean engine oil or assembly lubricant 2 Rotate the crankshaft so the crankpin for the piston being installed is ...

Page 388: ...he engine and the embossed mark on the connecting rod Figure 6 138 3 must face the flywheel end Figure 6 138 5 of the engine Figure 6 138 1 Fuel Injection Pump Side of Engine 2 Piston Identification Mark 3 Embossed Mark on Connecting Rod 4 Rod and Cap Match Marks 5 Flywheel End of Engine 6 Camshaft Side of Engine 4 Reinstall the bearing inserts Figure 6 140 1 in the connecting rod and cap 5 Apply ...

Page 389: ...install the piston into No 1 cylinder Be sure the punched mark on the connecting rod is facing the fuel injector side and the embossed mark on the connecting rod is facing the flywheel Figure 6 78 4 Install the connecting rod bearing halves Figure6 79 1 and connecting rod cap Figure6 79 2 Tighten the connecting rod bolts to the specified torque Figure 6 79 5 Install the remaining pistons in their ...

Page 390: ...der block so that gravity will keep the tappets Figure 6 143 5 in place and out of the way of the camshaft lobes when the camshaft is being reinstalled NOTE If the engine is not installed on an engine repair fixture stand the engine upright on the flywheel end mounting flange NOTE The tappets are mushroom shaped and must be installed from inside the engine crankcase 3 Lubricate the tappets with cl...

Page 391: ...ward the top of the engine 6 Ensure all three timing marks Figure 6 144 A B C are aligned 7 When all gears are properly aligned tighten the idler gear retaining bolts to specified torque See Special Torque Chart on page 73 for specifications Installation of Gear Case Cover 1 Apply a continuous bead of Three Bond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting area of the gear cas...

Page 392: ...lt hole 3 Reinstall the oil pan and tighten the bolts securely Figure 6 149 Final Reassembly of Engine 1 Reinstall the starter motor 2 Reinstall the cylinder head See Reassembly of Cylinder Head on page 88 for the 4 valve cylinder head 3 Reinstall the engine in the machine 4 Reconnect the fuel and coolant lines 5 Reinstall the alternator 6 Reconnect and adjust the throttle cable 7 Reconnect all el...

Page 393: ... could result in death or serious injury WARNING Never inject fuel toward you Since the fuel is injected at high pressure from the nozzle it may penetrate the skin resulting in injury Never inject fuel toward a fire source Atomized fuel is highly flammable and may cause a fire or burn skin WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous s...

Page 394: ...before engaging the transmission or any PTOs Engaging the transmission or PTO at an elevated engine speed could result in an unexpected movement of the equipment CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall...

Page 395: ...ith or removing these devices may void the Yanmar Limited Warranty Figure 7 1 The following describes the features of the MP fuel injection pump manufactured by Yanmar The fuel injection pump is a very important component of the engine It is capable of making very precise fuel delivery adjustments according to the varied loads applied to the engine All of the fuel injection pump components are ver...

Page 396: ...engine not continuing to run with the key switch returned to the ON or RUN position or the engine failing to stop when the key switch is turned to the OFF position Use a multimeter or continuity light to check for 12V at the stop solenoid connector in the correct sequence Cold Start Device The Yanmar TNV model engines are equipped with a cold start device CSD The cold start device is located in th...

Page 397: ...ar Nut 4TNV98 83 91 ft lb 113 123 N m 11 5 12 5 kgf m Not Applied High Pressure Fuel Injection Line Nuts 22 25 ft lb 29 34 N m 3 0 3 5 kgf m Not Applied Fuel Return Line Bolts 69 87 in lb 7 8 9 8 N m 0 8 1 0 kgf m Not Applied Fuel Injection Pump Mounting Nuts 17 21 ft lb 23 28 N m 2 3 2 9 kgf m Not Applied Fuel Injector Nozzle Case Nut 30 33 ft lb 39 2 44 1 N m 4 4 5 kgf m Not Applied Fuel Injecti...

Page 398: ... 5 MPa 5 0 kgf cm after about 5 hours of operation due to the initial break in of the engine When adjusting a new fuel injector or after it has been disassembled for service adjust the fuel injector 72 5 psi 0 5 MPa 5 0 kgf cm higher than the above standard NOTE All fuel injectors have a three character identification mark Figure7 2 1 The first character starts with V or W Figure7 2 Fuel injector ...

Page 399: ...spray pattern of fuel injection nozzle and measuring injection pressure Dial Indicator Mituotoyo 2050SB Locally Available Check and adjust fuel injection timing 2 Extension Rod Mituotoyo 303613 Locally Available 3 Fuel Injection Pump Plunger Adapter M16 4TNV98 Yanmar Part No 158090 51841 Mount dial indicator to fuel injection pump 4 Plunger Adapter Clamp Yanmar Part No 23000 013000 Clamps stem of ...

Page 400: ...lter 5 Air Bleed Orifice 6 Fuel Supply Line 7 Low Pressure Gallery 8 Pressure Control Valve 9 Trochoid Pump 10 Oil Seal 11 Fuel Injection Pump Cam 12 Engine Crankcase 13 Tappet 14 High Pressure Gallery 15 Overflow Orifice 16 Accumulator 17 Timer Piston 18 Mono Plunger 19 Distributor Shaft 20 Fuel Return Line 21 High Pressure Fuel Injection Lines 22 Fuel Injector ...

Page 401: ...Injection Pump Drive Gear Nut 9 Lock Washer 10 Fuel Injection Pump Drive Gear Assembly DO NOT remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub 11 Coolant Lines for Cold Start Device 12 Fuel Injection Pump Insulator 13 Diesel Fuel Injection Pump 14 Rear Fuel Injection Pump Support 15 Fuel Filter Water Separator 16 Electric Fuel Supply Pu...

Page 402: ...el injection pump CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 7 Finish loosening all the fuel line nuts and remove the high pressure fuel lines as an assembly being careful not to bend any o...

Page 403: ...ure 7 9 2 from the pump IMPORTANT Take care to not damage or bend the oil line In some applications it may be preferable to remove the complete oil line assembly from the engine before proceeding NOTE On models 4TNV98 the cover is larger and retained by 7 bolts Figure 7 9 15 Remove the fuel injection pump drive gear cover Figure7 10 1 from the gear case cover Figure7 10 2 NOTE The fuel injection p...

Page 404: ...ion pump to become misaligned On 4TNV98 model engines the idler gear is visible Make a reference mark Figure 7 12 1 across both the fuel injection pump drive gear and the idler gear Figure7 12 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel inje...

Page 405: ...carefully remove the drive gear nut Figure 7 15 1 and lock washer Figure 7 15 2 Figure 7 15 22 Locate the mark stamped into the upper outside mounting boss of the fuel injection pump Highlight this mark and make a corresponding mark on the gear case or front plate Figure 7 16 1 Figure 7 16 NOTE Some model engines may require the intake manifold and fuel injection pump insulator Figure 7 17 2 be re...

Page 406: ... the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulati...

Page 407: ... reference marks made earlier 4TNV98 model engines Figure 7 21 1 Figure 7 21 2 If installing the fuel injection pump on an engine with the front gear case cover removed the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks A B C on the fuel injection pump drive gear idler gear and crankshaft drive gear Ensure all three timing marks Figure 7 22 A B C ar...

Page 408: ...and tighten the drive gear nut to the specified torque See Special Torque Chart on page 143 Figure 7 23 If reinstalling the original fuel injection pump Align the reference marks Figure 7 24 1 previously made on both the fuel injection pump mounting flange and gear case or front plate Figure 7 24 Tighten the fuel injection pump retaining nuts to specification See Special Torque Chart on page 143 I...

Page 409: ...re 7 27 1 by the calculated positive amount adjust the fuel injection pump to the calculated value If the difference between the timing index numbers is a negative number the replacement injection pump must be retarded Figure 7 27 3 rotated toward the engine by the calculated negative amount Each mark on the timing sticker represents 0 5 timing change The above calculated difference indicates that...

Page 410: ... the pump cover and tighten the cover bolts 10 Reconnect the fuel return lines fuel supply line and coolant lines to the fuel injection pump 11 Reinstall the fuel injection high pressure lines Tighten the nuts to specification See Special Torque Chart on page 143 IMPORTANT When reinstalling a new or repaired fuel injection pump it is important to add engine oil to the fuel injection pump to provid...

Page 411: ...all the cooling fan guard if equipped 16 Prime the fuel system See Priming the Fuel System on page 15 17 Operate the engine and check for fuel and coolant leaks Checking and Adjusting Fuel Injection Timing Determining the Fuel Injection Timing Specification 1 Locate and record the fuel injection pump timing index number Figure 7 34 1 stamped into the boss on the engine side of the fuel injection p...

Page 412: ...4 17 6 Fuel injection Timing Record the calculated fuel injection timing specification Checking Fuel Injection Timing NOTE Some fuel may drain from the fuel injection pump during this process Make provisions to contain any such spillage 1 Turn off the fuel valve in the fuel supply hose and the fuel return hose 2 Clamp shut the fuel injection pump fuel return hose leading to fuel filter Figure 7 36...

Page 413: ...tate the crankshaft in a clockwise direction while looking through the flywheel inspection port Figure7 39 1 Rotate the crankshaft until the injection timing marks on the flywheel are visible Figure 7 39 7 Typical flywheel markings are as shown in Figure 7 40 1 NOTE A typical flywheel will have multiple timing grids depending on the number of cylinders Any grid can be used to check the fuel inject...

Page 414: ...longer marks is approximately 2 0 cm and the distance from the TDC mark is approximately 4 0cm the answer is approximately 2 This indicates there is 10 2x5 between the TDC mark and the first longer mark on the timing grid That means the first longer mark on the timing grid indicates 10 BTDC the second longer mark indicates 15 BTDC and the third timing mark indicates 20 BTDC If the answer is 3 that...

Page 415: ... Adjusting Fuel Injection Timing on page 161 13 If the injection timing is correct remove the dial indicator and adapter Replace the pump plunger plug and its copper gasket and tighten to specifications Replace the flywheel inspection port cover Open the fuel supply valve and remove the clamp from the fuel supply hose and the fuel return hose 14 Prime the fuel system Operate the engine and check f...

Page 416: ...fuel injection pump until the dial indicator reads 2 5 mm 0 098 in 6 To advance the injection timing rotate the top of the fuel injection pump away from the engine 7 To retard the injection timing rotate the top of the fuel injection pump toward the engine 8 When the dial indicator reads 2 5 mm 0 098in of pump plunger lift and the target timing mark on the flywheel aligns with the reference mark o...

Page 417: ... 4 Remove the fuel injector mounting clamp bolts Figure7 48 2 Lift the injector mounting clamps Figure7 48 3 away from injector 5 Remove the fuel injector Figure7 48 4 from the cylinder head Figure 7 48 NOTE The fuel injectors can be removed by manually pulling them out of the fuel injector wells 6 Remove the injector nozzle protector Figure 7 48 5 and seat Figure 7 48 6 from the cylinder head Dis...

Page 418: ...s highly flammable and may cause a fire or burn skin CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury Figure 7 49 4 Pump the operating lever of the tester slowly observing the...

Page 419: ...ee Adjusting Fuel Injector Pressure on page 166 Disassembly and Inspection of Fuel Injectors CAUTION Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 1 Clean carbon from used injectors using clean diesel fuel Hardened deposits or varnish can be cleaned using a brass wire brush Figure 7 52 1 Fuel Return Passage 2 Injector ID Location...

Page 420: ...ical pull the nozzle valve about 2 3 of the way out Figure 7 54 c Release the valve It should fall smoothly to its seat by it s own weight Figure 7 54 8 Replace the fuel injector assembly if it fails any inspection Adjusting Fuel Injector Pressure The fuel injectors open when pressure reaches a predetermined pressure threshold They close when the pressure is reduced below that threshold The pressu...

Page 421: ... vise with the nozzle end up 2 Reinstall the shims nozzle spring nozzle spring seat valve stop spacer nozzle valve and nozzle body 3 Reinstall the nozzle case nut Tighten it to specification See Special Torque Chart on page 143 Installation of the Fuel Injectors 4 Valve Cylinder Head 1 Reinsert a new nozzle seat Figure 7 57 6 and nozzle protector Figure 7 57 5 in the cylinder head for each injecto...

Page 422: ...e Fuel Injector 29 4 ft lbs 39 2 N m 4 kgf m Not Applied See Installation of Fuel Injectorson page 200 Fuel Pump Drive Gear Nut 43 5 51 0 ft lbs 59 69 N m 6 0 7 0 kgf m Not Applied See Installation of the Fuel Injection Pumpon page 192 Measuring Instruments No Tool Name Application Illustration 1 Fuel Injector Tester For measuring injection spray pattern of fuel injection nozzle and injection pres...

Page 423: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 169 Fuel System Components Figure 7 1 ...

Page 424: ...by the feed pump in order to feed fuel into the injection pump chamber Although the fuel pressure in the pump chamber is proportional to the pump revolution excessive fuel is returned to the suction system by the regulating valve when the pressure exceeds the specified value The fuel is then sent to the plunger via the fuel path in the distributor head The plunger applies high pressure to the fuel...

Page 425: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 171 Structure And Operation Of Fuel Injection Pump Figure 7 3 ...

Page 426: ...holder Governor Figure 7 5 The governor is located above the inspection pump chamber and mainly consists of a flyweight holder and governor lever assembly The flyweight holder holds four flyweights and governor sleeves and is supported by the governor shaft The drive gear engages with the flyweight holder gear to increase the revolutions of the drive shaft and to turn the flyweight holder assembly...

Page 427: ...he advance direction counter revolution direction to early the injection timing Thus the timer controls the fuel injection timing according to the fuel pressure in the pump chamber Feed Pump Vane Type Figure 7 7 The feed pump functions to feed fuel from the fuel tank to the pump chamber The feed pump consists of the rotor blade vane and liner The rotor is driven by the drive shaft The liner is loc...

Page 428: ... the fuel feeding pressure of the feed pump the fuel compresses the regulating valve spring to lift the piston The fuel is then returned to the suction side as shown by the arrow in the figure It is therefore possible to regulate the pump chamber pressure by changing the set force of the regulating valve spring Figure 7 9 Figure 7 9 shows typical relationships between pump revolutions and pump cha...

Page 429: ...activate the plunger s reciprocating operation When the inlet port of the plunger barrel being pressed into the distributor head and the inlet slit of the plunger overlap the plunger draws fuel and applies pressure to it When the outlet port of the plunger barrel and the outlet slit of the plunger align the high pressure fuel opens the delivery valve to be injected into the engine combustion chamb...

Page 430: ...njection Process Figure 7 12 Figure 7 13 The plunger begins rotating at the same time the lifting process of the cam disc begins When the inlet port of the plunger barrel is covered by the plunger pressure feeding of fuel is initiated At the same time the highly pressurized fuel presses up the delivery valve when the outlet slit of the plunger meets the outlet port of the plunger barrel The fuel i...

Page 431: ...ring so the delivery valve closes to terminate pressure feeding of fuel Uniform Pressure Process Figure 7 16 Figure 7 17 When the plunger turns a further 180 after the end of fuel injection the uniform pressure slit of the plunger meets the outlet port of the plunger barrel As a result the pump chamber is connected to the outlet port thereby making the pressure in the chamber and outlet port equal...

Page 432: ...essurized resulting in non injection state Fuel Injection Volume Adjustment Mechanism Figure 7 19 The fuel injection volume is increased or decreased by changing the control sleeve position resulting in change of the effective stroke The effective stroke represents the plunger s stroke from the time the inlet port and inlet slit close until the cutoff port overruns the control sleeve which is prop...

Page 433: ...uel in the pipe by the amount equal to the suck back stroke of the piston Delivery Valve Holder with Damping Valve Figure 7 21 The delivery valve holder with damping valve functions to prevent cavitation erosion in the pipe at high speed unstable fuel injection and secondary injection When high pressure fuel is fed from the plunger it is mainly sent to the nozzle through the outer periphery of the...

Page 434: ...es the governor sleeve and presses the governor lever assembly to the right The governor lever assembly mainly consists of the corrector leer tension lever and start lever Corrector lever fulcrum M is fixed by the pivot bolt of the pump housing Furthermore the corrector lever cannot move since it is pressed both by the spring at the bottom and the full load adjusting screw at the top The tension a...

Page 435: ...ing which is connected to the control lever Movement of the control lever is capable of changing the set force of the governor spring On the upper back of the tension lever is the idle spring The governor is controlled at all speeds by means of the start governor and idle springs Figure 7 24 Figure7 24 shows the typical injection volume control characteristics of the all speed governor ...

Page 436: ...nsion lever is pulled until it comes into contact with press in pin M3 by governor spring force At the same time the start lever is released from the tension lever by the start spring force to press the governor sleeve to the left THe flyweight then closes completely and the start lever moves the control sleeve to the start increasing position to the right with M2 being the fulcrum Thus the engine...

Page 437: ...of the governor spring becomes zero Therefore the flyweight opens outwardly even at low revolutions to move the governor sleeve to the right This makes the start lever turn clockwise with M2 being the fulcrum to move the control sleeve in the direction to reduce the fuel volume The governor sleeve stops at a point where the flyweight centrifugal and idle spring force are balanced to ensure stable ...

Page 438: ...lt the tension of the governor spring becomes maximum At this time the tension lever is fixed at the position where is contacts pin M3 being pressed into the pump housing The idle spring is completely compressed to connect the start lever and the tension lever at point A thereby holding the control sleeve at the full load position At this time the flyweight is pressed by the governor sleeve and is...

Page 439: ...s to make the governor lever assembly turn clockwise with fulcrum M2 As a result the control sleeve moves in the direction of no injection to the left for controlling speed so as not to exceed the full load maximum speed When the accelerator pedal is not pressed down fully the set force of the governor spring changes accordingly in order to achieve governor control based on the governor spring set...

Page 440: ...load position is determined by the amount the full load adjusting screw is driven When the screw is driven the corrector lever turns counterclockwise with M1 being the fulcrum to move the control sleeve to the fuel increase direction When the screw is loosened the control sleeve moves to the fuel decrease direction ...

Page 441: ... installed in the low pressure side The timer piston slides horizontally based on the balance between the spring force and changes in the pump chamber pressure The movement of the timer piston turns the roller holder assembly via the pin When pump revolutions increase and the pump chamber pressure exceeds the set force of the timer spring the timer piston moves in the direction to compress the spr...

Page 442: ... fuel path connected to the inlet port of the plunger barrel When the ignition switch is turned on power is supplied to the magnetic valve to lift the armature thus opening the fuel path On the contrary when the ignition switch is turned off the armature is powered by the force of the spring installed in the armature to close the fuel path As a result no fuel is fed to the plunger stopping the eng...

Page 443: ...g and damaging the fuel return line fitting Then loosen the high pressure fuel line nuts Figure7 32 3 on the fuel injection pump Finish loosening all the high pressure fuel line nuts and remove the fuel lines as an assembly Be careful not to bend any of the fuel lines CAUTION Remove the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injecti...

Page 444: ...while loosening the V belt Failure to comply may result in minor or moderate injury 9 Remove the cooling fan Figure7 35 1 spacer if equipped Figure7 35 2 and V belt Figure7 35 3 Figure 7 35 10 Remove the seven bolts from the fuel injection pump cover Figure7 36 1 on the front gear case Remove the cover NOTE The cover is secured with an adhesive sealant Use a gasket scraper to separate the cover fr...

Page 445: ...drive gear retaining nut Figure7 39 1 and lock washer Figure7 39 2 Figure 7 39 13 Using a two bolt gear puller remove the injection pump drive gear Figure7 39 3 from the injection pump shaft NOTE The injection pump shaft is tapered with a woodruff key Once you have applied some pressure with the puller A slight hammer tap on the center puller bolt will help pop the gear from the shaft 14 Remove th...

Page 446: ... made on the pump drive gear with the mark you made on the idle gear See Figure7 37 Figure 7 41 3 Install the drive gear retaining nut Figure7 42 1 and washer Figure7 42 2 While holding the engine with a wrench on the crankshaft pulley bolt torque the retaining nut to 43 5 51 ft lbs 59 69 N m 5 5 4 kgf m Figure 7 42 4 Thoroughly clean all old sealant from the fuel injection pump cover Figure7 43 1...

Page 447: ... bolt Figure 7 45 2 that fastens it to the cylinder block Figure 7 45 9 Reinstall the two bolts Figure7 45 1 to the L shaped bracket that holds the injection pump at the bottom rear Tighten the two bolts and the bolt that secures the bracket to the cylinder block to specified torque 10 Reinstall the high pressure fuel lines Replace the high pressure fuel lines as an assembly Be careful not to bend...

Page 448: ...e the fuel system and check for leaks Checking Adjustment Of Fuel Injection Timing 1 Using a wrench on the front crankshaft pulley bolt rotate the engine clockwise until the timing mark on the crankshaft pulley is aligned with the O or TDC Top Dead Center mark on the timing grid of the gear case cover 2 Remove the center bolt Figure7 47 1 and sealing washer from the rear of the fuel injection pump...

Page 449: ...ey is aligned with the mark at 4 6 and 8 5 ATDC After Top Dead Center on the timing grid on the gear case cover 8 5deg ATDC 8 If the injection timing is correct the dial indicator should read 0 038 0 041 in 0 97 1 03 mm 9 If the injection timing is not correct loosen the three fuel Injection pump mounting nuts and the bolts retaining the bottom rear L shaped injection pump mounting brackets Rotate...

Page 450: ...pump Finish loosening all the high pressure fuel line nuts and remove the fuel lines as an assembly Be careful not to bend any of the fuel lines CAUTION Remove the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines NOTE It is n...

Page 451: ...ing in injury Never inject fuel towards a fire source Atomized fuel is highly flammable and may cause fire or skin burning 4 Pump the operating lever of the tester slowly observing the pressure reading at the point where the fuel injector begins spraying fuel The fuel injectors for these engines should begin spraying fuel at 1711 1914 PSI 11 8 13 2 MPa The opening pressure may be adjusted by addin...

Page 452: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 198 Figure 7 54 8 If the fuel injector fails any of these tests it should be repaired or replaced as necessary ...

Page 453: ...iform Atomization is excessively one sided Although atomized the needle does not pulsate burner like shape Bar shape with excessive after drops Drops bar shape Possible Cause Normal 1 Normally caused by carbon contamination of the nozzle tip 2 Sometimes caused by flaws in or damage to the needle tip 1 Caused by excessive carbon contamination of the nozzle tip 2 Sometimes caused by contamination 1 ...

Page 454: ...injectors Torque to 29 4ft lb 39 2N m 5 Install the fuel return line fitting using new copper gaskets 6 Tighten the fuel return line retaining nuts to 32 5ft lb 44 1N m CAUTION When loosening or tightening the lines at the fuel injectors you must hold the fuel injector with a second wrench to prevent the injector from turning and damaging the fuel return line fitting 7 Reinstall the high pressure ...

Page 455: ...the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must serv...

Page 456: ...ult in minor or moderate injury CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may ...

Page 457: ...oolant pump This engine coolant pump is representative of the coolant pumps used on other TNV model engines For specific part detail see the parts catalog for the engine you are working on Cooling System Diagram Figure 8 1 1 Cylinder Head 2 Thermostat 3 Engine Coolant Pump 4 Radiator 5 Coolant Recovery Tank 6 Engine Oil Cooler 7 Cylinder Block Not standard on all models ...

Page 458: ...ump Components Figure 8 2 1 Thermostat Cover 2 Thermostat Cover Gasket 3 Thermostat 4 Thermostat O Ring 5 Special O Ring 6 Engine Coolant Pump 7 Temperature Switch 8 Gasket 9 Engine Coolant Pump Gasket 10 V Belt 11 Engine Coolant Pump V Pulley 12 Spacer 13 Engine Coolant Fan ...

Page 459: ...ge Replace the coolant pump if any of these conditions are present CAUTION If the engine coolant pump must be replaced replace the engine coolant pump as an assembly only Do not attempt to repair the engine coolant pump or replace individual components IMPORTANT Make sure the engine and engine coolant are not hot 1 Before removing the engine coolant pump or thermostat it will be necessary to drain...

Page 460: ...ut of the way CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 6 Remove the engine coolant fan guard if equipped engine coolant fan Figure 8 7 1 spacer Figure 8 7 2 and engine coolant pump V pulley Figure 8 7 3 Figure 8 7 7 Disconnect the coolant hoses and the temperature switch lead w...

Page 461: ...e 8 10 1 and an accurate thermometer Figure 8 10 2 in warm water Figure 8 10 2 Slowly increase the temperature of the water using an external heat source 3 The thermostat is operating properly if it starts to open at the temperature value stamped on the flange of the thermostat and fully opens as the temperature of the water is increased Radiator Cap 1 Check for proper operation of the radiator ca...

Page 462: ...et Install a new special O ring Figure 8 12 5 on assembly between the engine coolant pump and the joint CAUTION Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the same as a commercially available O ring the material is different 2 Reinstall the engine coolant pump bolts Tighten the bo...

Page 463: ...se the drain cock in the radiator Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler 8 Fill the radiator and engine with engine coolant See Drain Flush and Refill Cooling System With New Coolant on page 59 CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or...

Page 464: ... and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could s...

Page 465: ...an assembly CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating pr...

Page 466: ...PM At Low Idle Speed 42 57 psi 0 29 0 39 MPa 3 0 4 0 kgf cm All Models 8 8 psi 0 06 MPa 0 6 kfg cm or greater Outer Rotor Outside Clearance All Models Standard Limit Reference Page 0 0039 0 0061 in 0 100 0 155 mm 0 0098 in 0 25 mm Check Outer Rotor Outside Clearance on page 216 Outer Rotor Side Clearance All Models Standard Limit Reference Page 0 0020 0 0039 in 0 05 0 10 mm 0 0059 in 0 15 mm Check...

Page 467: ...0 0 5108 in 12 955 12 975 mm 0 5096 in 12 945 mm 4TNV98 Rotor Clearance 0 0014 0 0026 in 0 035 0 065 mm 0 0041 in 0 105 mm Check Rotor Shaft Clearance on page 216 Gear Case Bearing I D 0 5110 to 0 5126 in 12 980 13 020 mm 0 5138 in 13 05 mm Rotor Shaft O D 0 5089 to 0 5106 in 12 925 12 970 mm 0 5085 in 12 915 mm 4TNE98 Rotor Clearance 0 0004 to 0 0026 in 0 010 to 0 065 mm 0 0041 in 0 105 mm Check ...

Page 468: ...4TNV98 4TNE98 Diesel Engine Section 6 Lubrication System 214 Lubrication System Diagram Figure 9 1 ...

Page 469: ... the mechanical oil pressure test gauge indicates good oil pressure replace the faulty oil pressure switch or sending unit or faulty machine oil pressure gauge in instrument panel If the mechanical oil pressure test gauge indicates low oil pressure troubleshoot the lubrication system to locate the cause of the low oil pressure See Troubleshooting Charts on page 190 Repair as necessary Trochoid Oil...

Page 470: ...ove the oil pump assembly bolts Remove the oil pump assembly Figure 9 16 1 from the gear case housing Figure 9 16 2 Figure 9 16 Cleaning and Inspection Wash the oil pump oil pressure regulator and oil pump cavity Inspect for wear or damage Replace as necessary CAUTION If any oil pump component clearance exceeds its limit the oil pump must be replaced as an assembly Check Outer Rotor Outside Cleara...

Page 471: ...r Figure 9 19 1 Figure 9 19 Record the measurement s and see Check Outer Rotor Side Clearance on page 217 for the service limits Check Rotor Shaft Clearance Determine the rotor shaft clearance Measure the outside diameter of the rotor shaft Figure 9 20 1 and the bore diameter in the gear case housing Figure 9 20 2 Calculate the difference between the two measurements to determine the clearance Fig...

Page 472: ... 22 4 Reinstall the gear case cover and crankshaft pulley See Installation of Gear Case Cover on page 137 5 Reinstall the engine coolant pump V pulley Figure 9 23 1 spacer Figure 9 23 2 engine cooling fan Figure 9 23 3 and engine cooling fan guard if equipped Figure 9 23 6 Reinstall the V belt Tighten the V belt to the proper tension as described in Check and Adjust Cooling Fan V Belt on page 47 ...

Page 473: ...l jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING SHOCK HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury ...

Page 474: ...bined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the specified value CAUTION The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general cleaning Do not use high ...

Page 475: ...rocedures for a representative starter motor For specific part detail see the Yanmar Parts Catalog for the engine you are working on Starter Motor Information No Load Loaded DOOSAN Part Number Mfg Mfg Part Number Specification Terminal Voltage Amp erage Draw rpm Terminal Voltage Amp erage Draw Torque rpm A408417 Hitachi S13 204 DC12V 3 1 hp 2 3 kW 11 140A MAX 4100 7 7 400 Max 97 in lb 11 0 N m 1 1...

Page 476: ...umber of Teeth M3 9 Difference O ring Oil Seal Dry none Application Standard Spring Force 7 868 lbf 35 N 3 6 kgf Standard 0 591 in 15 mm Brush Height Limit 0 354 in 9 mm Series Coil Resistance 0 27 Ω at 68 F 20 C Magnetic Switch Shunt Coil Resistance 0 60 Ω at 68 F 20 C Standard 1 437 in 36 5 mm Outside Diameter Limit 1 398 in 35 mm Standard 0 001 in 0 03 mm Run Out Limit 0 008 in 0 2 mm Standard ...

Page 477: ...4TNV98 4TNE98 Diesel Engine Section 7 Starter Motor 223 Starter Motor Troubleshooting ...

Page 478: ...embly 5 Return Spring 6 Pinion Stop 7 Retaining Ring 8 Gear Housing 9 Shift Lever 10 Torsion Spring 11 Plunger 12 Dust Covers Shims 13 Magnetic Switch Assembly Solenoid 14 Cover 15 M6 Bolts 2 used 16 Armature Assembly 17 Field Coil Assembly 18 Positive Brushes 19 Negative Brushes 20 Brush Holder Assembly 21 Rear Cover 22 M5 Through Bolts 2 used 23 M4 Bolts 2 used ...

Page 479: ...c repair procedures are the same The following procedures are typical and may differ from the stater being serviced Removal of Starter Motor 1 Disconnect the battery cables at the battery negative cable first 2 Remove the electrical wires from the magnetic switch assembly 3 Remove the starter mounting bolts Figure 11 2 1 Remove the starter motor from the flywheel housing Figure 11 2 Disassembly of...

Page 480: ...ace On the positive side remove the brush from the brush holder assembly Figure 11 5 1 Figure 11 5 5 Remove the brush holder assembly Figure 11 6 1 from the armature assembly Figure 11 6 3 Figure 11 6 6 Pull the armature assembly Figure 11 6 3 out from the field coil assembly Figure 11 6 2 7 Remove the two M6 bolts Figure 11 7 1 retaining the magnetic switch assembly Figure 11 7 2 to the gear hous...

Page 481: ...remove the retaining ring Figure 11 10 1 from the shaft of the pinion Figure 11 10 12 Disassemble the pinion stop Figure 11 11 3 return spring Figure 11 11 4 pinion clutch assembly Figure 11 11 1 and pinion shaft Figure 11 11 5 Figure 11 11 Cleaning and Inspection Armature Commutator Surface Inspection If the commutator surface is rough polish the surface with a 500 to 600 emery cloth Figure 11 12...

Page 482: ...ated in Figure11 14 4 An abnormal commutator condition is indicated in Figure11 14 5 Figure 11 14 See Starter Motor Specifications on page 222 for the service limit Armature Coil Continuity Test Check for continuity between the commutator segments using a multimeter Figure 11 15 The multimeter should indicate continuity Figure 11 15 If the multimeter does not indicate continuity replace the armatu...

Page 483: ...l terminals using a multimeter Figure11 18 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the field coil assembly Figure 11 18 Field Coil Insulation Test Check for continuity between the field coil terminal and the yoke using a multimeter Figure11 19 The multimeter should not indicate continuity If the multimeter indicates continuity replace the fi...

Page 484: ...ng a multimeter Figure11 21 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Figure 11 21 Series Coil Continuity Test Check for continuity between the S and M terminals using a multimeter Figure11 22 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Figure 11 22 Co...

Page 485: ...hould rotate freely in the drive direction and is locked by turning it in the opposite direction Replace the pinion clutch assembly if the results are different Figure 11 24 Slide the pinion clutch assembly on the shaft It should slide smoothly on the shaft Figure11 25 Rust too much grease or damage could prevent the pinion clutch from sliding smoothly If the pinion clutch assembly does not slide ...

Page 486: ...y and pinion assembly to the gear housing Reinstall and tighten the three M4 bolts 4 Apply a small amount of high temperature lithium grease obtain locally to the sliding portions of the shift lever Figure 11 28 1 Reassemble the torsion spring Figure 11 28 2 shift lever and dust cover s Figure 11 28 3 plunger Figure 11 28 4 and magnetic switch assembly Figure 11 28 5 Figure 11 28 5 Reassemble the ...

Page 487: ...hrough bolts Reconnect the wire to the magnetic switch assembly Tighten the M8 nut Reinstall the cover over the connection Figure 11 32 Check Pinion Projection Length 1 Connect the positive lead from a battery to the S terminal 2 Connect the negative lead to the M terminal 3 Lightly pull the pinion away from the gear housing 4 Turn the switch ON and measure the pinion moving distance L in the thru...

Page 488: ...11 35 5 4 Connect a voltmeter Figure 11 35 7 to the battery negative terminal Figure 11 35 5 and the main positive battery terminal Figure 11 35 3 on the starter motor 5 Install a switch Figure 11 35 6 in a circuit between the battery positive terminal Figure 11 35 2 and the starter magnetic switch solenoid terminal Figure 11 35 8 on the starter motor 6 Use a suitable tachometer to monitor the rpm...

Page 489: ...r Gauge Set Part No TOL 97190080 Adapter for direct injection 2 valve cylinder head Yanmar Adapter Part No 119802 92950 Adapter for direct injection 4 valve cylinder head for 4TNV94L 98 98T Yanmar Adapter Part No 129906 92950 Compression Gauge Kit Adapter for direct injection 4 valve cylinder head for 4TNV106 T Yanmar Adapter Part No 123907 92950 ...

Page 490: ... on page 147 CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 3 Turn off the fuel supply valve in the fuel supply line Disconnect the fuel injection pump stop solenoid at the connector This preve...

Page 491: ...ence Value Compression Pressure at 250 rpm 250 min 1 Engine Model Standard Limit Deviation Between Cylinders 4TNV98 483 513 psi 3 33 3 53 MPa 34 36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm 29 43 psi 0 2 0 3 MPa 2 3 kgf cm Engine Speed and Compression Pressure Use for Reference Figure 14 2 ...

Page 492: ...ressure at 250 rpm 250 min 1 Engine Model Standard Limit Deviation Between Cylinders 4TNE98 426 15 psi 2 94 0 1 MPa 30 1 kgf cm 341 15 psi 2 35 0 1 MPa 24 1 kgf cm 29 to 43 psi 0 2 to 0 3 MPa 2 to 3 kgf cm Engine Speed and Compression Pressure Use for Reference Figure 13 2 ...

Page 493: ... the valve clearance Replace the gasket 4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified torque Intake Exhaust Valve Sticking valve Replace the intake exhaust valve 5 Valve Seat Gas leak due to worn valve seat or foreign matter trapped in valve Lap the valve seat Piston Piston Ring 6 Cylinder Gas leak due to scratching or wear Perform honing and use an...

Page 494: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 240 Troubleshooting Charts ...

Page 495: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 241 ...

Page 496: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 242 ...

Page 497: ...m Note The following wiring diagram is representative of a common installation using a Yanmar engine The actual installation may be equipped with a variety of electrical components and wiring harnesses Contact the machine manufacturer for specific information 4TNV98 Engine ...

Page 498: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 244 4TNE98 Engine ...

Page 499: ...Service Manual G424FE LP Engine G424F LP Gasoline Engine G20G G25G G30G SB4320E00 Jan 2008 ...

Page 500: ......

Page 501: ...following symbol WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on t...

Page 502: ......

Page 503: ...System 23 Inspect Ignition System 23 Inspection of Ignition Timing 23 Inspection of Spark Plug 24 Fuel System Maintenance 26 Replace LP Fuel Filter Element 26 Testing Fuel Lock off Operation 26 Pressure Regulator Converter Inspection 27 Inspect Air Fuel Valve Mixer Assembly 27 Inspect for Intake Leaks 27 Inspect Throttle Assembly 27 Checking the TMAP Sensor 27 Exhaust System Maintenance 27 Inspect...

Page 504: ...ration 134 Electronic Throttle System 141 Ignition System 142 DIS COMPONENTS 143 MISFIRES 143 Exhaust System 143 SECM 145 SECM Wiring Diagrams for G424FE 148 G424F EMS Engine Management System Overview 150 General Description 150 LPG Fuel System Operation 153 MPI Gasoline System Operation 157 Electronic Throttle System 158 Ignition System 158 SECM 158 SECM Wiring Diagrams for G424F Engine 159 EMS ...

Page 505: ...15 Inspect Fuel Leakage On Connection 215 Injector 215 Component Location 215 Description 215 Specification 215 Schematic diagram 215 Injector Inspection 216 Resistance Measurement Between Terminals 216 Removal 216 Inspection 217 Installation 217 Fuel Pump 218 Removal Including Fuel Filter And Fuel Pressure Regulator 218 Chapter 8 BASIC TROUBLESHOOTING Preliminary Checks 219 Before Starting 219 Vi...

Page 506: ...ult List Definitions 249 Table 1 Fault List Definitions 250 Table 2 Diagnostic Fault Codes Flash Codes 260 Appendix Service Tool Software MotoView 279 Introduction 279 Connection of the Service Tool 280 MotoView Display Screens 281 SECM field update with Service Tool 293 Ground Speed Limits Option 297 LPG And LPG Fuel Tanks 299 Regulatory Compliance 303 Special Conditions for Safe Use 303 Abbrevia...

Page 507: ...on put mating marks to the parts where no function is adversely affected Special Tool Be sure to use Special Tools when their use is specified for the operation Use of substitute tools will result in malfunction of the part or damage it Tightening Torque Tighten the part properly to specified torque Sealant Use specified brand of sealant Use of sealant other than specified sealant may cause water ...

Page 508: ...th detergent Oil and Grease Before reassembly apply specified oil to the rotating and sliding parts Genuine Part When the part is to be replaced be sure to use genuine part For selection of appropriate parts refer to the Parts Catalog Electrical System 1 Be sure to disconnect the battery cable from the negative terminal of the battery 2 Never pull on the wires when disconnecting connectors 3 Locki...

Page 509: ... 5 minutes and at idle speed for more than 10 minutes 3 Avoid spark jump tests Do spark jumps only when absolutely necessary Perform this test as rapidly as possible and while testing never race the engine 4 Do not measure engine compression for an extended time Engine compression tests must be made as rapidly as possible 5 Do not run the engine when the fuel tank is nearly empty This may cause th...

Page 510: ...1 5 2 0 2 5 M10 1 25 2 5 3 0 4 0 5 0 NOTE The torques shown in the table are standard vales under the following conditions 1 Nuts and bolt are made of steel bar and galvanized 2 Galvanized plain steel washers are inserted 3 All nuts bolts plain washers are dry NOTE The torques shown in the table are not applicable 1 When spring washers toothed washers and the like are inserted 2 If plastic parts a...

Page 511: ...Classification SJ or above SAE 10W30 or SAE 5W30 Coolant Antifreeze Automotive antifreeze suitable for gasoline engines having aluminum alloy parts Concentration level 50 normal Concentration level 40 tropical Lubricant Capacities Description G20 25 30G 5 Oil Pan 4 25 Oil Filter 0 3 Engine Oil liters Total 4 5 Engine 3 0 Radiator Hoses 6 0 Coolant liters Total 9 0 ...

Page 512: ...ystem available Open loop LP Carburetion system Closed loop MPI Gasoline system Muffler is standard Indication of Engine Model and Serial Number Engine Model Engine Serial Number G424FE G424F 30700001 to 39999999 Features and Benefits of G424FE G424F Engine Al head with valve seat inserts Aluminum head and valve seat system SOHC 8 valve system Timing belt system Distributorless Ignition system Ele...

Page 513: ... Aluminum with seat inserts COMPRESSION RATIO 9 6 1 COMPRESSION PRESSURE 1 240 kPa 180psi Minimum Intake Valve 17 30 BTDC 76 30 ABDC VALVE TIMING Exhaust Valve 58 30 BBDC 35 30 ATDC FIRING ORDER 1 3 4 2 WEIGHT 120 kg ENGINE ROTATION Counter Clockwise CCW when viewed from Flywheel End FUEL TYPE LPG Dual Fuel LPG or Gasoline CRANK VENTILATION Foul Air System with PCV IGNTION SYSTEM IGNITION TYPE Dis...

Page 514: ...EM GASOLINE FUEL SYSTEM Closed loop MPI System and In Tank Fuel Pump System Electric Fuel Pump 12V Fuel Filter Strainer FUEL PUMP MODULE Gasoline Pressure Regulator 3 5 bar FUEL INJECTOR ASS Y Electric Fuel Injector 12V ENGINE ELECTRIC ENGINE CONTROL MODULE ECM 12 V operation volt 48 pins of I O CRANK SENSOR VR Variable Reluctance CAM SENSOR Hall sensor Dual fuel engine only TMAP Intake Air Temp M...

Page 515: ...e G424FE G424F ENGINE MODEL unit G424FE LP G424F LP G424F GAS kW 46 2 46 2 44 7 hp 62 62 60 PS 62 9 62 9 60 8 RATED POWER rpm 2 550 2 550 2 550 N m 181 181 172 ibf ft 134 134 127 Kgf m 18 5 18 5 17 5 MAX TORQUE rpm 2 200 2 200 2 200 GOVERNED SPEED rpm 2 600 2 600 2 600 LOW IDLE rpm 750 750 750 ...

Page 516: ...the fuel lock off and allow fuel to flow to the pressure regulator converter Apply additional leak check solution to the regulator converter fuel connections and housing Repeat leak inspection as listed above Repair any fuel leaks before continuing Inspect Engine for Fluid Leaks Start the engine and allow it to reach operating temperatures Turn the engine off Inspect the entire engine for oil and ...

Page 517: ...l engines to enhance excellent performance and maximum effect 1 Observe the API classification guide 2 Proper SAE classification number should be selected within ambient temperature ranges Do not use the lubricant with SAE classification number and API grade not identified on the container 1 10W 30 engine oil is recommended If 10W 30 is not applicable proper engine oil will be possible according t...

Page 518: ...e oil contains potentially harmful contaminants which may cause skin cancer Exercise caution in order to minimize the length and frequency of contact of your skin to used oil In order to preserve the environment used oil and used oil filter must be disposed of only at designated disposal sites 1 Drain engine oil 1 Remove the oil filler cap 2 Remove the oil drain plug and drain the oil into a conta...

Page 519: ...o the spark hole during checking compressed pressure When cranking the engine to test compressed pressure necessarily open the throttle valve be fore cranking 6 Install the compression gauge to the spark plug hole 7 With the throttle valve opened crank the engine to measure the compressed pressure Standard 250 400 rpm Limit 1 240 kPa 8 Repeat steps no 6 7 over all cylinders ensuring that the press...

Page 520: ...osphates to precipitate out of solution increases with increasing water hardness Hard water or water with high levels of calcium and magnesium ions encourages the formation of insoluble chemicals especially after a number of heating and cooling cycles DOOSAN prefers the use of distilled water or deionized water to reduce the potential and severity of chemical insolubility Acceptable Water Water Co...

Page 521: ...tester take care not to spill the coolant When removing installing the tester as well as testing take care not to deform the filler neck 4 Replace parts if leak is detected Specific gravity test 1 Measure specific gravity of the coolant using a hydrometer 2 After measuring the coolant temperature calculate specific gravity using the following table Relation between Coolant concentration and Specif...

Page 522: ...r adjusting lock bolt B 1 2 1 5kg m Alternator support bolt A 2 2 5kg m 3 Tighten the bolt A and then tighten B to the specified torque CAUTION If the belt tension is too excessive noise as well as early wear of belt occurs and the water pump bearing and alternator bearing are damaged If the belt is too loose due to early wear of belt and insufficient power of alternator battery and water pump bec...

Page 523: ...ies OFF Transmission In neutral position Parking brake ON 2 Inspection 1 Connect the timing light 2 Measure RPM RPM Low Idle 750 15rpm NOTE If RPM is not normal it is impossible to measure the proper ignition timing so measure it at a normal RPM 3 Inspect the standard ignition timing BTDC 5 5 4 If ignition timing is out of the standard inspect sensors concerned with ignition timing CAUTION Because...

Page 524: ...are not to come foreign materials into spark plug mounting hole 3 Check the spark plug as below 1 Insulator broken 2 Terminal worn 3 Carbon deposit 4 Gasket damaged or broken 5 Porcelain insulator of spark plug clearance 4 Check the plug clearance using a plug clearance gauge and if the value is not within the specified values adjust it by bending the ground clearance When installing a new sparkpl...

Page 525: ...ake care not to over tighten it to prevent cylinder head threads from damage Tightening torque 2 2 5 kg m SPARK PLUG ANALYSIS State Contact point is black Contact point is white Description Density of the fuel mixture is thick Density of the fuel mixture is thin Lack of air intake Ignition timing is fast Spark plug is tight Lack of torque ...

Page 526: ...damage Replace if necessary 8 Re assemble the filter assembly aligning the scribe lines on the top and bottom covers 9 Install the cover retaining screws tightening the screws in an opposite sequence across the cover 10 Open the fuel valve by slowly turning the valve counterclockwise 11 Crank the engine several revolutions to open the fuel lock off DO NOT START THE ENGINE Turn the ignition key swi...

Page 527: ...sing for coking cracks and missing cover retaining clips Repair and or replace as necessary NOTE Refer to Chapter 5 for procedures on removing the mixer and inspecting the throttle plate Checking the TMAP Sensor Verify that the TMAP sensor F is mounted tightly into the manifold or manifold adapter E with no leakage If the TMAP is found to be loose remove the TMAP retaining screw and the TMAP senso...

Page 528: ...28 Maintenance Schedule NOTE The MI 07 fuel system was designed for use with LPG fuel that complies with HD5 or HD10 LPG fuel standards Use of non compliant LPG fuel may require more frequent service intervals and will disqualify the user from warranty claims ...

Page 529: ...G424F FE Service Manual Chapter 2 Recommended Maintenance 29 ...

Page 530: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 30 Chapter 3 ENGINE MECHANICAL SYSTEM General Information Engine Outline ...

Page 531: ...mber 2 Crankshaft end clearance 0 02 0 352 mm Shells See color definitions below under Table of Spare Shells CYLINDERS AND PISTONS Clearance between piston and cylinder skirt lower area 0 010 a 0 030 mm Maximum saddle out of roundness 0 127 mm Crankshaft maximum warping 0 127 mm Piston stroke 100 mm Piston bore 87 5 mm Distance between piston head in the TDC and block surface 0 11 a 0 43 mm Angle ...

Page 532: ...vailable oversize 0 075 a 0 150 e 0 250 mm Valve seat eccentricity tolerance between maximum and minimum readings 0 050 mm Valve seat widths Intake 1 3 1 4 mm Exhaust 1 7 1 8 mm CAMSHAFT End clearance 0 04 0 16 mm Camshaft maximum warping 0 04 mm OIL PUMP Clearance between Driven gear and case 0 11 a 0 19 mm Drive gear and crescent 0 35 a 0 45 mm Gear and cover 0 03 a 0 10 mm Pressure 1400 RPM 282...

Page 533: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 33 Shells Selection Table MAIN BEARINGS STANDARD SIZE ALL MEASURES ARE IN MILLIMETERS ...

Page 534: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 34 MAIN BEARINGS 0 50 UNDERSIZE ...

Page 535: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 35 CONNECTING ROD BEARINGS CONNECTING ROD BEARINGS 0 25 UNDERSIZE 0 50 UNDERSIZE ...

Page 536: ...belt tensioner to alternator support 25 Fuel distributor tube to intake manifold 22 30 Fuel supply and return line to throttle valve guards 15 Water pump to cylinder block 25 Coolant pipe to cylinder block 20 Crankshaft main bearing cap to cylinder block 50 N m 45 15 Oxygen sensor to exhaust manifold 35 44 Crankcase oil baffle plate and bridge bolts 20 Camshaft housing cover to camshaft housing 8 ...

Page 537: ...gnition module to camshaft housing 12 Relief valve plug to oil pump 45 60 Toothed belt cover lower part to rear toothed belt cover 4 Toothed belt tension roller to oil pump 20 Spark plug to cylinder head 25 Cylinder head and camshaft housing to cylinder block 25 180 10 2 1 Use new nuts 2 Use new bolts 3 Rectum thread before reuse and insert bolts with screw locking compound red The installation ti...

Page 538: ...g Noisy timing belt Incorrect belt tension Correct belt tension Low coolant level Coolant leak from Heater or radiator hose Defective radiator cap Thermostat housing Radiator Water pump Repair or replace parts Retighten clamp or replace Replace gasket or housing Replace Replace parts Radiator clogged Foreign material into coolant Replace coolant Abnormally high coolant temperature Thermostat defec...

Page 539: ...EARING 58 BOLT 59 CRANKSHAFT 60 RING 61 KEY 62 BEARING KIT 80 FILTER 81 FITTING 86 VALVE 87 SENSOR 90 BOLT 91 BOLT 92 SEAL 97 PIN 98 BEARING KIT 99 PLATE 100 CAP 101 BOLT 102 PUMP 103 SEAL 104 PIN 105 GASKET 106 PUMP 107 BOLT 108 SEAL 109 SEAL 110 PIPE 111 BOLT 112 BOLT 113 BAFFLE 114 SEAL 115 PLUG 117 CLAMP 118 HOSE 120 SPRING 121 PLUG 122 SEAL 123 PLUG 124 VALVE 125 GASKET 126 PIN 129 SEAL 130 S...

Page 540: ... RETAINER 94 RETAINER 95 WIRE 96 WIRE 97 WIRE 98 WIRE 99 WIRE KIT 100 STRAP 104 COIL 105 BOLT 107 GASKET 108 MANIFOLD 113 HOSE 115 COVER 116 BOLT 117 ADAPTER 118 BOLT 119 COVER 120 BOLT 121 SPROCKET 122 WASHER 123 BOLT 124 BELT 125 TENSIONER 126 BOLT 128 SPACER 129 KEY 130 SEAL 131 SPROCKET 132 WASHER 133 BOLT 134 SEAL 135 HOUSING 136 SENSOR 137 BOLT 140 SEAL 141 THERMOSTAT 142 BOLT 143 INJECTOR 1...

Page 541: ...et Components 1 Gasket 2 Intake Manifold Assy 3 Stud Bolt 4 Nut 5 Fitting 6 Tmap 7 Bolt 8 Bracket Stay 9 Washer 10 Bolt 11 Washer 12 Bolt 13 Pipe 14 Plug 15 Hose 16 Hose 17 Clamp 18 Washer 19 Bolt 20 Hose 21 Clamp 22 Washer 23 Bolt 24 Hose 25 Clamp 26 Block 27 Bracket 28 Fitting 29 Plug ...

Page 542: ...sconnect the fitting of gasoline fuel hose from the fuel tank G424FE DF 6 Disconnect the fuel hose and balance line air hose 7 Disconnect carburetor assembly by using 5mm hex bit socket wrench handle 8 Disconnect the PCV hose by using a screw driver 9 Remove bracket attaching bolts by using 17mm spanner 10 If necessary remove the fuel rain from intake manifold by using 12mm socket wrench and exten...

Page 543: ...ighten Nuts 18 22 N m 13 16 lb ft Obs Tighten the intake manifold nuts in a crisscross sequence from the center to the ends 7 Put the pipe on the manifold 8 With a 10 mm socket wrench extension and proper torque wrench tighten Tighten Bolts 5 6 N m 3 7 4 4 lb ft 9 Insert the TMAP onto manifold with greased o ring 10 With an E 8 socket wrench extension and proper torque wrench tighten Tighten Bolts...

Page 544: ...ten Tighten Clamps 1 1 5 N m 0 75 1 1 lb ft 17 Bracket stay and its attaching nuts without tightening 18 With a 17 mm torque spanner tighten Tighten Nuts 35 40 N m 25 8 29 5 lb ft 19 A new gasket between mixer assembly and intake manifold 20 Mixer assembly and its attaching nuts without tightening 21 With a 5mm hex bit socket wrench and torque wrench tighten by using thread locker ...

Page 545: ...e Manual Chapter 3 Engine Mechanical System 45 Exhaust Manifold and Gasket Components 1 Gasket 2 Adapter Exhaust Manifold 3 Bolt 4 Washer 5 O2 Sensor 6 Stud Bolt 7 Washer 8 Bolt 9 Exhaust Manifold 10 Shield 11 Gasket ...

Page 546: ...n Install or connect 1 New gasket between the exhaust manifold and cylinder head 2 Exhaust manifold and attaching nuts without tightening 3 With a 13 mm socket wrench extension and torque wrench tighten Tighten Nuts 18 22 N m 13 16 lb ft 4 New gasket between the exhaust manifold and adapter 5 Exhaust adapter and attaching bolts Without tightening 6 With a 6mm hex bit socket extension and torque wr...

Page 547: ...Mechanical System 47 Timing Belt Components 1 Cover 2 Bolt 3 Adapter 4 Bolt 5 Cover 6 Bolt 7 Sprocket 8 Washer 9 Bolt 10 Belt timing 11 Tensioner Timing Belt 12 Bolt 13 Spacer 14 Key 15 Seal 16 Sprocket 17 Washer 18 Bolt 19 Bolt 20 Stud 21 Nut ...

Page 548: ...y mark with the oil pump case flange in the no 1 cylinder combustion stroke 5 Loosen the timing belt Tensioner bolt with a 13 mm combination wrench releasing belt tension 6 Timing belt marking the running direction front edge of the belt in case of using the same belt Timing Belt Inspection 1 Check the belt for oil or dust deposit and replace it if necessary In case of small amount of oil or dust ...

Page 549: ...detached 4 Tooth is excessively worn out initial step Tooth loaded from canvas is worn elastic canvas fiber rubber is worn color is faded in white canvas structure is deformed 5 Tooth is excessively worn out final step Tooth loaded from canvas is Worn and rubber is worn off tooth width is narrowed 6 Tooth bottom is cracked 7 Tooth is missing 8 The side of belt is severely worn out 9 The side of be...

Page 550: ... Allen wrench turn clockwise the Tensioner installation shaft up to the NEW marking point mm Detail B The needle may move from the right side up to the final adjusting position Tighten the bolt For used timing belts follow the same procedure but with the belt adjustment in the USED position This change is suggested due to the used belt presenting a different course of action regarding the new belt...

Page 551: ...this section 2 Timing belt Tensioner bolt in the oil pump case with a 13 mm socket wrench and handle 3 Timing belt Tensioner Install or connect 1 Tensioner in the oil pump case Important The lug 1 in the Tensioner base should be lodged in the hole 2 of the oil pump case 2 Tensioner attaching bolt without tightening 3 Timing belt see Timing Belt Installation in this section ...

Page 552: ...ondition No operating Engine condition At idle or deceleration PCV valve No operating PCV valve Full operating Vacuum path Clogged Vacuum path Small Engine condition Proper operating Engine condition High speed and overload PCV valve Proper operating PCV valve Light operating Vacuum path Big Vacuum path Very big ...

Page 553: ... actual engine geometry Herringbone separator lies on horizontal Shown here in vertical for viewing ease Oil Pan Cam Carrier Cylinder Head Engine Block Cover Assy Oil Pan Baffle Oil Pump Assy Secondary Vent Fresh Air Port Primary Vent to PCV Oil Drainbacks 7 total 2 at front 2 at rear 3 mid on exhaust side External Crankcase Breather Tube Oil Fill Cap Hi C C Pressure Liquid Oil Foul Air Fresh Air ...

Page 554: ...ve B nut 3 If the plunger is not moved it means that PCV valve is clogging so clean or replace PCV valve TROUBLESHOOTING 1 Disconnect the vacuum hose from the PCV valve 2 With the engine at idle Check the intake manifold for vacuum when clogging the opened end of PCV valve NOTE The plunger in PCV valve will move back and forth 3 If vacuum is not detected clean or replace PCV valve and vacuum hose ...

Page 555: ... New seal in the camshaft case with the aid of tool KM 422 camshaft pulley washer and bolt 2 Camshaft timing pulley and its bolt with a 22 mm wrench to lock the camshaft and a 17 mm socket wrench and torque wrench tighten Tighten Bolt 40 50 N m 30 37 lb ft 3 Camshaft case cover see Camshaft Case Cover Installation in this Section 4 Timing belt see Timing Belt Installation in this section Crankshaf...

Page 556: ...With the aid of pliers remove the seal Installation Install or connect 1 New seal to the crankshaft Important Install tool KM 417 protecting sleeve on the crankshaft end with its outer surface lubricated and the chamfered area turned to the outside of the vehicle Install the seal in the protecting sleeve Place installer KM 417 and bolt and install the seal in its lodging 2 Remove tool and protecti...

Page 557: ...th a 10 mm socket wrench extension and torque wrench tighten Tighten Bolts 4 10 N m 3 7 lb ft 4 Breather hoses in the camshaft case cover 5 Spark plug cables on the supports Crankshaft Accessory Pulley Removal Remove or disconnect 1 V pulley belt see V Pulley Belt Removal in this section 2 Crankshaft accessory pulley attaching bolt with a 13 mm socket wrench and handle 3 Crankshaft pulley 4 TDC se...

Page 558: ...r cover attaching bolts and nuts with a T30 Torx socket wrench extension and handle 5 Timing belt rear cover Installation Install or connect 1 Timing belt rear cover and attaching bolts and nuts without tightening 2 With a T30 Torx wrench and extension tighten Tighten Bolts 5 10 N m 4 7 lb ft Nuts 5 10 N m 4 7 lb ft 3 Crankshaft timing pulley see Crankshaft Timing Pulley Installation in this secti...

Page 559: ...is section 2 Attach tool KM 565 A in the camshaft case supporting it over the spring plate corresponding to the rocker arm to be removed 3 Drive the tool pressing the valve spring 4 Rocker arm linkage 5 Valve lifter Installation Install or connect 1 Valve lifter linkage and rocker arm 2 Release the valve spring 3 Remove tool KM 565 A 4 Camshaft case cover see Camshaft Case Cover Installation in th...

Page 560: ...s equipped with a shroud to increase the efficiency of the fan and cause the air to be pushed through the radiator and away from the lift truck If the coolant is hot and the cooling system pressure is too high some coolant flows to the top of radiator through the tube to recovery tank The cooling system pressure is controlled by cap When the cooling system pressure goes above its rated pressure a ...

Page 561: ...t housing has two outlet ports Upper outlet port is connected to distribution block and lower outlet is connected to coolant pipe and coolant flow is recirculated to water inlet through coolant pipe until thermostat is open The distribution block has 5 ports as shown a picture ...

Page 562: ...t made Make a visual inspection of the cooling system before testing with testing equipment Cooling System Visual Inspection WARNING Do not loosen the filler cap or pressure cap on a hot engine Steam or hot coolant can cause severe burns 1 After the engine is cool loosen the filler cap on a radiator with a pressure cap turn it to the first stop to let pressure out of the cooling system Then remove...

Page 563: ... as follows A403658 76 to 100 kPa 11 to 14 5 psi 4 If the pressure cap is bad install a new pressure cap Cooling System Leak Check To test the cooling system for leaks use the following procedure WARNING If the engine has been in operation and the coolant is hot slowly loosen the pressure cap to the first stop and let the pressure out of the cooling system then remove the pressure cap 1 Remove pre...

Page 564: ...ake the water in the pan move around This keeps all of the water at the same temperature 4 The thermostat must start to open when the temperature is 82 C 180 F The thermostat must be fully open at 96 C 205 F Cooling System Heat Problems To check if there is a good reason for heat problems do the checks that follow 1 The indications of a heat problem are as follows a High coolant temperature indica...

Page 565: ...rotection Clean the cooling system if it is contaminated if the engine overheats or if foaming is observed in the radiator Old coolant should be drained system cleaned and new coolant added as recommended with the commercially available automotive antifreeze Filling at over 20 liters per minute can cause air pockets in the cooling system After draining and refilling the cooling system operate the ...

Page 566: ...the intake manifold 7 Thermostat housing to cylinder head attaching bolts with a 13 mm socket and handle 8 Pull out the thermostat housing and remove the lower hose to the thermostat housing with a 10 mm socket wrench and handle 9 Thermostat housing Installation Install or connect 1 A new O ring in the thermostat housing to the cylinder head 2 Lower hose to the thermostat housing and clamps 3 Use ...

Page 567: ...to identify the assembly position 5 Water pump attaching pump with a 6 mm Allen wrench and handle 6 Water pump and O ring Installation Install or connect 1 New O ring in the water pump 2 Water pump observing the mark made in the disassembly to identify the proper assembly position 3 Water pump attaching bolts without tightening 4 With a 6 mm Allen wrench and torque wrench tighten Tighten Bolts 20 ...

Page 568: ...d pressure feed oil system and the oil reserved in the oil pan is fed with pressure to each part of engine After the oil pressure is adjusted through the relief valve the oil is fed to the cylinder blocks and cylinder head In the cylinder head the oil is forcibly fed to the camshaft journals rocker arm pivots and further cam surfaces OIl Filter ...

Page 569: ...s operated The chart in figure is a guide to selection the proper crankcase oil IMPORTANT Oils containing solid additives non detergent oils or low quality oils are not recommended for use in G424F E Engine Engine Oil Viscosity Recommendation NOTE In normal case the recommended engine oil for G424F E engine is SAE 10W 30 But if the excessive valve noise occurs up to five minutes after a cold start...

Page 570: ...n on when the key switch is turned to the ON position The light will turn off after the engine is started and while the engine is running lidicating normal oil pressure The light will turn on during operation only when there is insufficient engine oil pressure to properly lubricate the engine s internal parts If the oil light comes on indicating the pressure is low check for the causes that follow...

Page 571: ...faces of the new gasket Inspect Oil pan for warping Installation Install or connect 1 Adhesive sealant in the oil pan 2 Oil pan to engine attaching bolts without tightening 3 Transmission flange to oil pan attaching bolts without tightening 4 With an 18 mm socket wrench extension and torque wrench tighten the transmission flange to oil pan bolts Tighten Bolts 18 22 N m 13 16 lb ft 5 With a Torx E1...

Page 572: ...9 Oil pump attaching bolt with a 5 mm Allen wrench 10 Oil pump Installation Install or connect 1 Oil pump new gasket to the cylinder block 2 Oil pump to the cylinder block and attaching bolts without tightening 3 With a 5 mm Allen wrench and torque wrench tighten the oil pump attaching bolts Tighten Bolts 6 10 N m 4 4 7 lb ft 4 Oil screen to the oil pump and attaching bolts without tightening 5 Oi...

Page 573: ...6 Oil filter gallery plug with a 19 mm combination wrench 7 Relief valve plug with a 24 mm combination wrench 8 Sealing washer 9 Spring 10 Valve plunger Clean All pump parts Inspect Parts for wear Measure Play between the following parts Driven gear and case which should be 0 11 0 19 mm Drive gear and crescent which should be 0 35 0 45 mm Gear and cover which should be 0 03 0 10 mm Assemble 1 Plun...

Page 574: ...Run the engine and let it idle until it stops by lack of fuel Start the engine for about 5 seconds so as to obtain full pressure relief in the fuel system 2 Battery negative cable 3 Hose connecting the Mixer assembly to the air cleaner with an 8 mm socket wrench extension and handle loosen the clamps 4 Electric harness to intake manifold front area support with a 10 mm socket wrench extension and ...

Page 575: ...17 Heat sink attaching bolts with a 10 mm socket wrench and handle 18 Exhaust heat sink 19 Exhaust pipe to exhaust manifold attaching bolts with a 13 mm socket wrench and handle 20 Hot air pipe attaching bolt from the cylinder block with a 13 mm socket wrench extension and handle 21 Hot air pipe hose clamp to radiator lower hose attaching bolt with a 7 mm socket wrench and handle 22 Hot air pipe h...

Page 576: ...aft drain the engine oil apply zinc ditiophosphate additive in the camshaft lobes and rocker arms and add the remaining additive to the new engine oil 2 Camshaft lock and attaching bolt without tightening 3 With a 5 mm Allen wrench and torque wrench give the final tightening Tighten Bolts 4 10 N m 4 Camshaft case rear cover with a new gasket and attaching bolts without tightening 5 With a 10 mm so...

Page 577: ...nd torque wrench tighten Tighten Bolts 14 20 N m 10 15 lb ft 16 Thermostat see Thermostat Installation in this section 17 Hot air pipe hose together with clamp in the radiator lower hose 18 With a 7 mm socket wrench extension and torque wrench tighten Tighten Clamp 4 5 N m 3 3 6 lb ft 19 Hot air pipe support in the cylinder block with the attaching bolt without tightening 20 With a 13 mm socket wr...

Page 578: ...ch tighten Tighten Bolt 7 8 N m 5 5 8 lb ft 37 Radiator lower hose with clamp with special clamp pliers 38 Hose connecting the throttle valve body mixer to the air cleaner with its clamp 39 Refill the cooling system 40 Battery negative cable 41 Change the engine oil in view of possible water contamination Cylinder Head Removal Remove or disconnect 1 Camshaft case assembly see Camshaft Case Assembl...

Page 579: ...mm socket wrench extension and handle and remove the manifold 3 Exhaust manifold to cylinder head nuts with a 13 mm socket wrench extension and handle remove the exhaust manifold 4 Valve lock with the aid of valve spring compressor 5 Spring plate 6 Spring 7 Seal with seal pliers 8 Valve Inspect Cylinder head for cracks in the exhaust passages and combustion chambers Valves for head burning face cr...

Page 580: ...em until obtaining a 92 15 angle The face angle can also be considered regarding the valve head which should be 44 Installation Install or connect 1 Valve seal with the aid of tool KM 352 2 Spring and spring plate 3 Valve lock with the aid of valve spring compressor 4 Exhaust manifold with a new gasket to the cylinder head and use new nuts without tightening 5 With a 13 mm socket wrench extension ...

Page 581: ... damaging the engine and cylinder head inner components 11 Camshaft cover attaching bolts with a 10 mm socket and handle remove the camshaft cover 12 Camshaft pulley attaching bolt using a 17 mm combination wrench and a 22 mm wrench to attach the camshaft remove the camshaft pulley 13 Install tool S 9407182 and attach the engine flywheel with a 19 mm combination wrench attach the tool bolt 14 Cran...

Page 582: ...emoved by using a 19 mm socket wrench extension and handle 26 Camshaft case 27 Rocker arms linkages and valve lifters without mixing them so that they may be further assembled in the same position 28 Camshaft and gasket 29 Turn the engine 180 to have access to the engine oil pan 30 Oil pan attaching bolts with a Torx E12 wrench extension and handle remove the engine oil pan 31 Oil strainer attachi...

Page 583: ... rod caps 38 Install tool T 9806681 in the connecting rod and remove the piston Obs Repeat this procedure to remove the other piston 39 Turn the crankshaft until the second and third connecting rods stay with the attaching bolt turned upward 40 Second and third connecting rod bearing attaching bolt with a 14 mm socket wrench extension and handle remove the connecting rod caps 41 Install tool T 980...

Page 584: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 84 ...

Page 585: ... bearing cap side grooves with sealant 4 Main bearing attaching bolts without tightening with a Torx E12 wrench extension and handle Important With a plastic mallet slightly tap the crankshaft on both directions so as to mainly seat the thrust bearing rear face 5 Tighten the main bearing attaching bolts with a Torx E12 wrench extension and torque wrench Tighten Bolts 50 N m 45 15 6 Crankshaft seal...

Page 586: ...hten Bolts 19 21 N m 14 15 5 lb ft Obs One of the bolts only can be installed and tightened after the oil strainer is installed 14 Oil strainer and attaching bolts in the oil pump with a 10 mm socket wrench and torque wrench tighten Tighten Bolts 4 10 N m 3 7 lb ft 15 Adhesive sealant in the cylinder block and install the oil pan and attaching bolts with a Torx E12 wrench and torque wrench tighten...

Page 587: ... 24 Water pump and attaching bolts with a 6 mm Allen wrench and torque wrench Obs See the reference mark between water pump and block Tighten Bolts 20 30 N m 14 7 22 lb ft 25 New seal ring in the thermostat housing 26 Thermostat housing in the cylinder block and its attaching bolts with a 13 mm socket wrench and torque wrench Tighten Bolts 10 20 N m 7 15 lb ft 27 Belt rear cover and bolts and atta...

Page 588: ... lb ft 37 Camshaft cover and attaching bolts with a 10 mm socket wrench and torque wrench Tighten Bolt 4 10 N m 3 7 lb ft 38 Timing pulley Important Timing pulley keeping stretched the side opposite to the water pump observing the engine RPM direction if using the same belt Align the camshaft timing pulley mark with the timing pulley rear cover mark Align the crankshaft timing pulley mark with the...

Page 589: ...ching bolts with a 13 mm socket wrench and torque wrench Tighten Bolts 20 30 N m 15 22 lb ft 46 Crankcase breather tube hose to the valve cover with clamp pliers attach the same 47 A new phase and reference sensor seal ring in the crankshaft 48 Crankshaft position sensor in the cylinder block together with its attaching bolts with a Torx Bit E10 wrench and torque wrench tighten Tighten Bolt 4 8 N ...

Page 590: ...tioning The finish after reboring should be made with a cylinder hone The initial honing should be performed with thick stones and finish with thin stones It should not remain glistened but with light strokes so as to help the lubrication Install the cylinder hone and lean the stones the maximum as possible so that the hone does not remain blocked from being manually turned Connect a 19 mm 3 4 in ...

Page 591: ...mble the engine as per instructions under Engine Disassembly in this section Clean Parts and dry with blown air Inspect Crankshaft saddles for scratches roughness or other abnormalities Measure Crankshaft warping as follows Support the crankshaft by bearings 1 and 5 of the cylinder block leaving the shells only over these 2 bearings On bearing 3 support the probe of a dial gauge The total reading ...

Page 592: ...bolts and tighten to the specification Measure the shell inner bore and saddle diameter corresponding to the bearing in the crankshaft Installation Install or connect 1 Upper shells in the block lubricate the surface turned toward the saddle with engine oil 2 Crankshaft 3 Main bearing caps with the shells lubricated on the surfaces turned toward the saddle Important The bearing caps should be inst...

Page 593: ...he specified clearance is 0 070 0 302 mm 0 003 0 012 in 6 A new seal in the crankshaft with tool KM 658 7 Piston connecting rod assembly with the aid of the universal band positioning the piston arrow turned toward the engine front end Important Lubricate the rings and cylinders Simultaneously guide the connecting rod bearing with tool T 9806681 Install the connecting rod upper shell lubricated on...

Page 594: ...nly can be installed and tightened after installing the oil strainer 14 Oil strainer and attaching bolts in the oil pump with a 10 mm socket wrench and torque wrench tighten Tighten Bolt 4 10 N m 3 7 lb ft 15 Adhesive sealant in the cylinder block and install the crankcase and attaching bolts tighten with a Torx E12 wrench and torque wrench Tighten Bolts 6 10 N m 4 5 7 lb ft 16 Oil filter Obs Only...

Page 595: ...t Nut 6 8 N m 4 4 5 8 lb ft 28 Flywheel and bolts without tightening use a 17 mm wrench and handle Obs Use new bolts 29 Attach the flywheel with tool S 9407182 30 Tighten the flywheel bolts with a 17 mm socket wrench and torque wrench Tighten Bolts 35 N m 26 lb ft 30 15 31 Thrust washer in the crankshaft 32 Thrust key in the crankshaft 33 Timing pulley thrust washer and attaching bolt with a 17 mm...

Page 596: ... a 13 mm combination wrench for old timing belts follow the same procedure but adjusting the belt in the USED position This change is suggested due to the old belt presenting a different course of action regarding the new belt 39 Timing belt front cover and attaching bolts with a 10 mm socket wrench and torque wrench Tighten Bolts 6 8 N m 4 4 5 8 lb ft 40 A new gasket in the intake manifold 41 Int...

Page 597: ...3 mm box end wrench remove the pump 4 Generator attaching bolt with a 14 mm box end wrench remove the generator 5 Cylinder head see Cylinder Head Removal in this section 6 Turn the engine 180 to have access to the engine crankcase 7 Engine crankcase attaching bolts with a Torx E12 wrench extension and handle remove the crankcase from the engine 8 Oil strainer attaching bolt with a 10 mm socket wre...

Page 598: ...in piston head Disassemble 1 Piston pin placing the piston in the support base J 8606014 and using puller T 9806680 1 with universal handle M 840911A and press 2 Connecting rod in the piston Assemble 1 Connecting rod in the piston Clean The piston varnish clean the grooves with a proper scraper unclog the oil grooves and holes 2 Piston pin for this proceed as follows Warm the connecting rod from 2...

Page 599: ...il control ring 0 40 1 40 mm 0 016 0 055 in Measure Gap between rings and grooves which should be Upper compression ring 0 060 0 092 mm Lower compression ring 0 030 0 062 mm Installation Install or connect 1 Rings in the piston following the installation sequence of the openings and considering that the vertical dash line C corresponds to the pin position B Oil control ring C Spacer ring D Oil con...

Page 600: ...il strainer and attaching bolts to the oil pump with a 10 mm socket wrench and torque wrench give the final tightening Tighten Bolt 4 10 N m 3 7 lb ft 8 Adhesive sealant in the cylinder block and install the crankcase and attaching bolts with a Torx E12 wrench and torque wrench tighten Tighten Bolts 5 10 N m 4 5 7 lb ft 9 Turn tool M 780668 180 so that the engine stay with the pistons turned upwar...

Page 601: ...l Item Specification Primary resistance 0 15Ω Secondary Load resistance 2 500Ω Spark Plug Item Specification Spark plug gap 0 7 0 8mm Starter Motor Item Specification Output 12V 1 4 kW Pinion tooth number 8 Alternator Item Specification Rated output 13 5V 80A RPM 1 000 18 000rpm Voltage regulator type Electronic Built in type ...

Page 602: ... mounted near the spark plugs The DIS system eliminates the wear associated with most distributor type ignition systems The wasted spark ignition fires pairs of cylinders at each ignition event One cylinder fires on the compression stroke as is normal However the complementary pair in the firing order is fired simultaneously while that particular cylinder is on the exhaust stroke Since the ionized...

Page 603: ...cations If resistance is out of specifications the coil is bad and needs to be replaced Also pay close attention to the tube that wraps around the spark pug Cracks can allow voltage to jump to ground causing a misfire The spark plug terminal should also fit tightly If a coil tests bad and is replaced cleaning the connector and wiring harness terminals can often avoid future problems Corrosion at e...

Page 604: ... from the coil pack Installation Install or connect Note If the boot to wire movement has occurred the boot will give a false visual impression of being fully seated Ensure that the boots have been properly assembled by pushing sideway on the installed boots Failure to properly seat the terminal onto the spark plug will lead to wire core erosion an result in an engine misfire or crossfire conditio...

Page 605: ...8 to 0 9 mm 0 031 to 0 035 in 3 Head start the spark plugs in the corresponding cylinders See Figure 82 CAUTION Only use a spark plug socket or wrench to tighten the spark plugs Do not force the spark plug into the cylinder head Any misalignment can damage the aluminum threads in the cylinder head and may required the replacement of the cylinder head 4 Tighten the spark plug to 20 N m 15 Ibf ft Sp...

Page 606: ...k plug torque The correct torque is 20 N m 15 lbf ft Insufficient torque can prevent correct spark plug operation An over torqued spark plug causes the insulator to crack c Inspect for sign of tracking that occurred near the insulator tip instead of the center electrode 4 d Inspect for a broken or worn side electrode 3 e Inspect for a broken worm or loose center electrode 4 by shaking the spark pl...

Page 607: ...s mounted on the rotor This fan pulls air through the holes in the back of the alternator to cool the rectifier bridge and regulator The air exits the front of the alternator The alternator converts mechanical and magnetic energy to alternating current AC and voltage This process is done by rotating a direct current DC electromagnetic field rotor inside a three phase stator The alternating current...

Page 608: ...aused by lack of pan belt tension and faulty function of wiring connector and voltage regulator One of most important thing during troubleshooting of charging system is determining the reason between overcharging and lack of charging So prior to inspection of alternator check the battery for charging Faulty alternator causes the following symptoms 1 Faulty battery charging 1 IC regulator fault Sho...

Page 609: ...Reset or replace Faulty voltage regulator or alternator Inspect alternator Faulty wiring Repair With the engine started warning lamp is not turned off Battery needs often charging Corrosion or wear of battery cable Repair or replace Faulty voltage regulator Charging warning lamp illuminates Replace Overcharged Voltage detection wring fault Replace Loose or worn drive belt Correct or replace Loose ...

Page 610: ...G424F FE Service Manual Chapter 4 Engine Electrical System 110 Troubleshooting Procedure Inspection before Starting 1 Alternator and drive belt tension inspection ...

Page 611: ...G424F FE Service Manual Chapter 4 Engine Electrical System 111 2 Alternator and outer terminal connection inspection ...

Page 612: ...ter 4 Engine Electrical System 112 3 Battery outer terminal inspection Inspection after Starting 1 When starting belt slip and noise inspection 2 Inspection of battery voltage at idling At this time charge battery only 13 2 15 4V ...

Page 613: ...er reads 20A and at that time measure voltage Result 1 If voltmeter reading is within the standard it is normal 2 If voltmeter reading is more than the standard mostly wiring is faulty In this case inspect wirings between the alternator and the battery terminal as well as between the alternator B terminal and the fusible link 3 Also prior to re test check and repair the connecting part for loosene...

Page 614: ...switch at HIGH measure the maximum output current using a ammeter NOTE This test should be done as soon as possible to measure the exact maximum current because output current drops rapidly after starting the engine Result 1 Ammeter reading should be as same as the load If the reading is low even though the alternator output wire is normal remove the alternator from the vehicle and inspect it Outp...

Page 615: ...cts in the solenoid close the circuit between the battery and the starting motor just before the pinion engages the ring gear This causes the starting motor to rotate This type of motor turn on is a positive shift starting motor When the engine begins to run the overrunning clutch portion of the pinion drive prevents damage to the armature caused by excessive speeds The clutch does this by breakin...

Page 616: ...wo functions 1 Engages the pinion with flywheel 2 Is a high current switch rated about 1000 amps that actually turns on the starting motor The starting motor solenoid has two coils Pull in coil W draws about 40 amps and hold in coil X requires about 5 amps The instant the start relay closes both coils W and X receive power Battery voltage is applied to the high end of both coils at test point 3 wh...

Page 617: ...tarting motor for more than 30seconds at a time After 30 seconds the cranking must be stopped for two minutes to allow the starting motor to cool This will prevent damage to the starting motor due to excessive heat buildup If the starting motor cranks real slow or does not crank at all do the following procedure 1 Measure battery voltage at the battery posts with the multimeter while cranking or a...

Page 618: ...e rotation 9 Is the engine locked up or hard to turn If it is repair the engine as required If the engine is not hard to turn go to Step 10 10 Does the starting motor crank If it does crank remove the starting motor for repair and or replacement If it does not crank check for blocked engagement of the pinion and flywheel ring gear NOTE Blocked engagement and open solenoid contacts will give the sa...

Page 619: ...ymptom Possible cause Remedy Low battery charging voltage Charge or replace Loose corroded or worn battery cable Repair or replace Inhibitor switch fault Adjust or replace Circuit breaker cut off Reset or replace Start motor fault Repair Impossible cranking Ignition switch fault Replace Low battery charging voltage Charge or replace Loose corroded or worn battery cable Repair or replace Slow crank...

Page 620: ...sitive cable at positive terminal 3 Put labels on wires and cables prior to disconnecting to aid in correct installation 4 Disconnect wires and cables from starter 5 Hold starter so it won t fall Remove capscrews that fasten the starter to the flywheel housing Install capscrews to fasten the starter to the flywheel housing Installation Install or connect 1 Place starter in position in flywheel hou...

Page 621: ...tion Sensor None 0 LP 1 GAS Type Output Voltage Hall effect sensor 0 5 Volts Crankshaft Position Sensor 1 1 Type Tooth wheel VR sensor 58X TMAP Sensor 1 1 MAP sensor Intake Air Temp Sensor Piezo Resistivity type 0 5V output Thermistor type built in MAP sensor 2 0 3 0kohms at 20 C LP Fuel Temperature Sensor 1 None Type Resistance Thermister 2 5kΩ 20 243Ω 90 Oxygen Sensor 2 0 LP 1 GAS Type Output Vo...

Page 622: ... Electronic Throttle System Q ty Components G424FE G424F Items Specifications Electronic Throttle System 1 1 Minimum Electrical Resistance of Throttle Actuator 1 5 ohms Ignition System Components Specification Q ty Components G424FE G424F Items Specifications Ignition Coil Ass y 1 1 Coil Type Coil Supply Voltage Primary Resistance Inductive 8 16 Vdc 0 15 ohm Spark Plug 4 4 Air Gap 0 8 0 9 mm ...

Page 623: ...ure Fuel Inlet Fitting Fuel Outlet Fitting Fuel Supply Temperature at Tank Outlet Primary Pressure Tap Max Flow Coolant Flow to Vaporizer Fuel Outlet Pressure Setpoints Mounting 10 psi to 250 psi 68 95 kPa to 1723 69 kPa 1 4 NPT Two 3 4 NPT fittings with one plugged and one 1 8 NPT fitting with plug 20 F to 120 F 29 C to 49 C 1 8 NPT with plug 50 lbm hr LPG 1 0 gpm 100bhp equipped with 140 F 60 C ...

Page 624: ...F 60 C thermostat 0 5 0 35 inH2O 1 7 lbm hr LPG 1 25 0 87 mbar 1 7 lbm hr LPG 1 35 0 5 inH2O 32 1 lbm hr LPG 3 36 1 25 mbar 32 1 lbm hr LPG CA100 Mixer For G424FE 1 None Fuel Fuel Inlet Fitting Air Intake Flange Mixer Mounting Flange Reference Pressure Ports Air Valve Vacuum AVV Port Size Fuel Inlet Adjustments Idle Air Adjustment Mounting LPG 1 2 NPT Fuel inlet fitted with Delphi temperature sens...

Page 625: ...must be identical within 0 25 inH2O 0 623 mbar at all airflows 1 4 28 UNF Power valve Idle adjustment screw Suitable for on engine mounting in vertical orientation Fuel Trim Valve FTV 2 None Actuator Type Operating Voltage On off two position valve compatible with LPG 8 16 Vdc Gasoline Fuel Components Specification Q ty Components G424FE G424F Items Specifications Gasoline System Requirements Gaso...

Page 626: ...BTDC 5 5 Tightening Torques Items N m kgf m 1bf ft Heated Oxygen Sensor HO2S Sensor 1 50 60 50 60 36 2 43 4 Heated Oxygen Sensor HO2S Sensor 2 50 60 5 0 6 0 36 2 43 4 Crankshaft Position Sensor CKPS 6 0 6 4 3 Camshaft Position Sensor CMPS 4 6 0 4 0 6 2 9 4 3 Engine Coolant Temperature Sensor ECTS 15 20 1 5 2 0 10 8 14 5 Delivery pipe installation 22 28 2 2 2 8 15 7 20 3 ...

Page 627: ...e Manual Chapter 5 Engine Management System EMS 127 Component Location Engine Control Module SECM48 Crankshaft Position Sensor LP Fuel Temperature Sensor Camshaft Position Sensor TMAP Sensor Coolant Temperature Sensor ...

Page 628: ...ce Manual Chapter 5 Engine Management System EMS 128 Pre Catalyst Oxygen Sensor Pedal Angle Sensor Transmission Oil Temperature Switch Post Catalyst Oxygen Sensor Engine Oil Pressure Switch Ground speed limit switch ...

Page 629: ...G424F FE Service Manual Chapter 5 Engine Management System EMS 129 Electronic Throttle Body Ignition Coil N 2007 LP Regulator Fuel Trim Valve FTV LP Fuel Lock off CA100 Mixer ...

Page 630: ...G424F FE Service Manual Chapter 5 Engine Management System EMS 130 Gasoline Injectors and fuel rail Gasoline Fuel Pump Ass y ...

Page 631: ...the catalytic muffler Figure 1 MI 07 LP System for G424FE Engine The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air fuel mixer by modulating the dual fuel trim valves FTV connected to the regulator Reducing the fuel pressure leans the air fuel mixture and increasing the fuel pressure enriches the air fuel mixture To calculate any necess...

Page 632: ... INPUT OUTPUT Crank Sensor Throttle body TMAP sensor Coolant Temp EG oil pressure switch T M Temp switch Accel pedal angle sensor Throttle position sensor Pre Oxygen sensor Post Oxygen sensor LP fuel temp sensor T M Inching pressure switch SECM lgnition coil 2 Fuel trim valves LP fuelock valve CAN communication ...

Page 633: ...firmware and calibration Fuel system sensors and actuators Ignition system including spark plugs cables coils and drivers MI 07 System Features The MI 07 system uses an advanced speed density control strategy for fuel spark and air throttle control Key features include the following Closed loop fuel control with fuel specific controls for LPG Speed load spark control with tables for dwell timing a...

Page 634: ...rypt token USB device to allow access to information LPG Fuel System Operation The principles outlined below describe the operation of MI 07 on an LPG fuel system An LPG fuel system consists of the following components Fuel filter Electric fuel lock off solenoid valve Fuel pressure regulator vaporizer Two orificed fuel trim valves Gas Air mixer with fixed orifice for trim system and fuel temperatu...

Page 635: ...ic The fuel lock off is a safety shutoff valve normally held closed by spring pressure which is operated by an electric solenoid and prevents fuel flow to the regulator converter when the engine is not in operation This is the first of three safety locks in the MI 07 system Figure 4 Electric Fuel Lock Assembly In the MI 07 design power is supplied to the fuel lock off via the main power relay with...

Page 636: ...ost to vaporization engine coolant is supplied by the engine driven water pump and pumped through the regulator Heat provided by this coolant is transferred through to the fuel vaporization chamber N 2007 Operation Refer to Figure 6 Liquid propane at tank pressure enters the N 2007 through the fuel inlet port 1 Propane liquid then flows through the primary valve 2 The primary valve located at the ...

Page 637: ...ows Pressure drop across the mixer air valve must be minimized to assure maximum power output from the engine The mixer fuel inlet is fitted with a thermistor type temperature sensor This permits the SECM to correct fuel pressure to compensate for variations in fuel temperature Left uncorrected fuel temperature variations can cause significant variations in air fuel ratio A higher flow mixer is re...

Page 638: ...enerated is a direct result of throttle position and the amount of air flowing through the mixer to the engine At low engine speeds low AVV causes the air valve diaphragm assembly to move upward a small amount creating a small venturi At high engine speeds high AVV causes the air valve diaphragm assembly to move much farther creating a large venturi The variable venturi air fuel mixer constantly m...

Page 639: ... uses feedback voltage from the O2 sensor to determine the amount of bias needed to the regulator converter In normal operation the N 2007 maintains fuel flow at a constant output pressure due to the calibrated secondary spring The amount of fuel flowing from the N 2007 will vary depending on how far the secondary diaphragm opens the secondary valve in response to the negative pressure signal gene...

Page 640: ...de connects to the AVV port When the FTVs are open AVV is sent to the atmospheric side of the N 2007 secondary diaphragm which lowers the reference pressure closing the N 2007 secondary valve and leaning the air fuel mixture The MI 07 system is calibrated to run rich without the FTV By modulating pulsing the FTVs the SECM can control the amount of AVV applied to the N 2007 secondary diaphragm Incr...

Page 641: ...a mechanical linkage to control the throttle valve To meet fluctuating engine demands a conventional system will typically include a throttle valve actuator designed to readjust the throttle opening in response to engine demand together with an idle control actuator or idle air bypass valve In contrast the MI 07 system uses electronic throttle control ETC The SECM controls the throttle valve based...

Page 642: ...y Spark plugs The SECM through use of embedded control algorithms and calibration variables determines the proper time to start energizing the coil and fire the spark plug This requires accurate crank camshaft position information an engine speed calculation coil energy information and target spark timing The SECM provides a TTL compatible signal for spark control The coil must contain the driver ...

Page 643: ... start in many cases will often have a problem in the crankshaft or camshaft position sensor circuits Loss of sensor signals may prevent the SECM from properly synchronizing thereby preventing the engine from starting and running Exhaust System Heated Exhaust Gas Oxygen Sensors HEGO The MI 07 system utilizes two HEGO O2 sensors One sensor is a pre catalyst sensor that detects the amount of oxygen ...

Page 644: ...rous oxide by the converter resulting in nitrogen gas a harmless emission On the rich cycle the primary pollutant is carbon monoxide By adding the oxygen that was stored on the lean cycle to the carbon monoxide carbon dioxide is produced Inside the catalytic muffler is a three way catalyst as well as sound dampening and spark arresting features The three way catalyst section consists of a honeycom...

Page 645: ...h opens the lock off allowing liquid propane to flow to the N 2007 regulator A stall safety shutoff feature is built into the SECM to close the lock off in case of a stall condition The SECM monitors three engine states Crank when the crankshaft position sensor detects any engine revolutions Stall when the key is in the ON position but the crankshaft position sensor detects no engine revolutions R...

Page 646: ...the throttle valve See Figure 20 SECM self calibration and cross checking compares both signals and then checks for errors Figure 20 Throttle Position Sensor TPS on DV E5 Throttle NOTE The DV E5 throttle is not a serviceable assembly If a TPS sensor fails the assembly should be replaced The MI 07 system also performs minimum min and maximum max speed governing through the SECM and DBW throttle For...

Page 647: ...and speed there are other circumstances under which the SECM may need to vary the ignition timing including low engine coolant temperature air temperature start up and idle speed control SECM Electrical Mounting Recommendations In order to prevent the possibility of any SECM malfunctions due to EMI RFI emissions the SECM mounting and harness recommendations listed below The SECM should be mounted ...

Page 648: ...for G424FE CAUTION PROPER WIRING To prevent system faults be sure to follow good wiring practices Poor wiring may cause unexpected or intermittent failures not related to MI 07 components The schematics on the next pages are wiring diagrams for G424FE engines Figure 22 LP certified system ...

Page 649: ...G424F FE Service Manual Chapter 5 Engine Management System EMS 149 Figure 22 SECM Wiring Diagram for G424FE LP System ...

Page 650: ...le through the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle position in relation to the accelerator pedal position sensor APP command Even engine coolant temperature and adequate oil pressure are monitored by the SECM Figure 2 G424F Dual Fuel System The LPG regulator and the mixer operate as an open loop system since no mixture adjustments are ...

Page 651: ...UT Crank Sensor Throttle body T M Inching pressure switch SECM lgnition coil LP fuelock valve CAN communication TMAP sensor Coolant Temp EG oil pressure switch T M Temp switch Accel pedal angle sensor Throttle position sensor 4 Injectors Fuel Pump CAM sensor Gasoline Only Pre Oxygen sensor Gasoline Only ...

Page 652: ... GAS Camshaft Position Sensor 1 1 Crankshaft Position Sensor 1 1 TMAP Sensor 1 None Fuel Temperature Sensor 1 1 Transmission Oil Temperature Switch 2 0 LP 1 GAS Oxygen Sensors 1 1 Coolant Temperature Sensor 1 1 Engine Oil Pressure Switch 2 None Fuel Trim Valve 1 1 Ignition Coils 1 1 LP Fuel Lock Off Solenoid N 2007 N 2001 LP Regulator CA 100 Certified CA 100 LP Mixer 1 1 Electronic Throttle Body M...

Page 653: ...s point to the SECM to allow a qualified service technician to maintain the system This Mototune software licensed by Mototron Communication is secure and requires a crypt token USB device to allow access to information LPG Fuel System Operation The principles outlined below describe the operation of MI 07 on an LPG fuel system An LPG fuel system consists of the following components Fuel filter su...

Page 654: ...chamber 3 is controlled by the primary diaphragm 4 which reacts to vapor pressure inside the expansion chamber Two springs are used to apply force on the primary diaphragm in the primary diaphragm chamber 5 keeping the primary valve open when no fuel pressure is present A small port connects the expansion chamber to the primary diaphragm chamber At the outlet of the expansion chamber is the second...

Page 655: ...ixer air valve must be minimized to assure maximum power output from the engine A higher flow mixer is required on larger engines A lower flow mixer is required on smaller engines Figure 7 CA100 Mixer CA100 Mixer Operation Vapor propane fuel is supplied to the CA100 mixer by the N 2001 pressure regulator converter The mixer uses a diaphragm type air valve assembly to operate a gas metering valve i...

Page 656: ...es the air valve diaphragm assembly to move much farther creating a large venturi The variable venturi air fuel mixer constantly matches venturi size to engine demand Figure 10 Bottom View of Air Valve Assembly Figure 11 CA100 Mixer Installed with Electronic Throttle A main mixture adjustment valve on the fuel inlet of the CA100 is not used in the MI 07 system however an idle mixture adjustment is...

Page 657: ...fuel as a spray to engine to best combustion under the condition of various engine load and speed For fuel consumption reduction engine performance enhancement and emission reduction ECM controls fuel injection to satisfy air fuel ratio required by system by reflecting induced airflow and air fuel ratio among emission and adjusting injector operating time To enhance these control characteristics q...

Page 658: ...4F engine is the same as that of G424FE engine See Electro nic throttle system of G424FE EMS overview Ignition System The Ignition system of G424F engine is the same as that of G424FE engine See Ignition system of G424FE EMS overview SECM The SECM of G424F engine is the same as that of G424FE engine See SECM of G424FE EMS over view ...

Page 659: ...nk Sensor CAM Sensor Transmission Oil TEMP Switch Oil Pressure Switch Can Sae J1939 To Engine Oil Pressure LAMP Fuel Select Switch Foot Pedal Ground Speed Switch MAP MAT Coolant Temperature Sensor Throttle Body FUEL SELECT NOTE IF NO SELECT SWITCH IS USED A JUMPER MUST BE USED JUMPER A12 TO B1 FOR LP JUMPER A15 TO B1 FOR GASOLINE MAP MAT RED 18 AWG RED RED PINK COLOR COLOR COLOR COLOR COLOR COLOR ...

Page 660: ...0 to 5 V Coolant Temperature Sensor CTS 40 F to 266 F 40ºC to 130ºC range 48K ohm to 85 ohm sensor range Fuel Temperature Sensor FTS 40 F to 266 F 40ºC to 130ºC range 48K ohm to 57 ohm sensor range HEGO 3 0 to 1 V Auxiliary Analog Input 2 0 to 5 V Battery Voltage Vbatt 1 8 18 V With the exception of battery voltage all inputs are 0 5 Vdc ground referenced Resolution should be 0 1 or better Accurac...

Page 661: ...odulated between 8 and 40 Hz with a minimum pulse width resolution of 50 usec Fuel lock off solenoid valve Low side switch 10A peak 4A continuous 45 V max Gasoline fuel pump drive Low side switch 10A 4A continuous 45 V max Electronic Spark Timing EST 4 TTL compatible outputs Software configured for coil on plug ignition system Throttle control 1 H Bridge 5A peak 2 5A continuous at 2500 Hz PWM incl...

Page 662: ...ion switch to OFF position and then disconnect CMPS connector 2 Remove the CMPS from the engine 3 Turn ignition switch to ON position 4 Apply battery voltage to the terminal 1 and ground terminal 3 of CMPS as shown in the figure 5 Install a LED between 5V power and CMPS terminal 2 and then set a steel wheel or anything made of steel hammer wrench bolt and nut etc at the CMPS s tip 6 Rotate the ste...

Page 663: ...tall the CMP sensor into the CMP sensor support plate Note Before installing retaining screw verify the CMP sensor is fully seated 4 Install retaining screw and lock washer Tighten retaining screw Tighten Bolts 6 N m 53lbf in 5 Connect the electrical connectors Verify that the connectors click lock into place 6 Install harness clamp to CMP sensor support plate ...

Page 664: ...ng Belt Front Cover Remove 2 Disconnect the crankshaft rpm sensor electrical harness 3 Remove the capscrew retaining the crankshaft rpm sensor 4 Remove the crankshaft rpm sensor Install 1 Install the crankshaft rpm sensor into the engine block 2 Install the capscrew to retain the crankshaft rpm sensor Tighten capscrew to 8 N m 71 lbf ft 3 Connect the crankshaft rpm sensor electrical harness 4 Inst...

Page 665: ...fects fuel delivery and ignition timing controls in the ECM Ciruit Diagram MAP IAT sensor 3 2 1 4 Sensor power B24 IAT signal B12 Sensor ground B1 MAP signal B18 E C M IAT MAP Sensor Inspection 1 Measure the voltage between terminals 1 and 4 of the MAP sensor connectors Terminal 4 MAP sensor ground Terminal 1 MAP sensor output Engine state Test specification Ignition SW ON 4 5V At idle 0 5 2 0V 2 ...

Page 666: ...tion frim the sensor the ECM will control the necessary amount of fuel injection Ciruit Diagram MAP IAT sensor 3 2 1 4 Sensor power B24 IAT signal B12 Sensor ground B1 MAP signal B18 E C M IAT MAP Sensor Inspection 1 Using a multimeter measure the IAT sensor resistance between terminals 3 and 4 Temperature F Resistance kΩ 0 32 4 5 7 5 20 68 2 0 3 0 40 104 0 7 1 6 IG SW ON 80 176 0 2 0 4 2 If the r...

Page 667: ... the fuel injection duration by using the HO2S signal which is called closed loop fuel control operation Specification Temperature Temperature Front HO2S Heater Resis tance Ω Front HO2S Heater Resistance Ω 20 68 9 2 400 752 17 7 100 212 10 7 500 932 19 2 200 392 13 1 600 1 112 20 7 300 572 14 6 700 1 292 22 5 Schematic Diagram CIRCUIT DIAGRAM HARNESS CONNECTORS C16 HO2S B1 S1 ECM HO2S B1 S1 After ...

Page 668: ... by the catalyst is low due to aging poisoning or misfiring then the oxygen fluctuations are similar to signals from the front oxygen sensor Schematic Diagram CIRCUIT DIAGRAM HARNESS CONNECTORS C22 ECM HO2S B1 S2 After Main Relay 3 4 2 1 B19 HO2S SIGNAL B1 HO2S GND A23 HO2S HEATER B1 S2 1 2 3 4 Signal Wave Form The amplitude of the signal output of the rear HO2S is small compared to the front HO2S...

Page 669: ... the thermistor in the ECTS are connected in series When the resistance value of the thermistor in the ECTS changes according to the engine coolant temperature the output voltage also changes During cold engine operation the ECM increases the fuel injection duration and controls the ignition timing using the information of engine coolant temperature to avoid engine stalling and improve drivability...

Page 670: ...CIRCUIT DIAGRAM HARNESS CONNECTORS Installation 1 Install engine coolant temperature sensor and tighten it to specified torque Tightning torque Engine coolant temperature sensor 15 20Nm 150 200 kg cm 11 15 lb ft 2 Connect the harness connector securely ECM 1 B15_ECT_SIGNAL B1_GND 2 1 2 ...

Page 671: ... FTS by way of a resister in the ECM That is the resistor in the ECM and the thermistor in the FTS are connected in series When the resistance value of the thermistor in the FTS changes according to the LP fuel temperature the output voltage also change Circuit Diagram Harness Connectors Inspection 1 Remove the LP fuel temperature sensor from the adapter connected to LP mixer 2 With the temperatur...

Page 672: ...edal The SECM will override the pedal command above a maximum engine speed and below a minimum idle speed The foot pedal assembly uses two potentiometers to detect pedal position These two signals accelerator pedal position 1 APP1 and accelerator pedal position 2 APP2 are sent directly to the SECM The SECM uses a series of algorithms to self calibrate and cross check the signals from the pedal ass...

Page 673: ...makes engine shutdown with fault set If the T M oil temperature decreases to the 118 C the switch is open again and the engine also can run This function can protect the engine of Tier 3 and Non cert folk lift trucks from damage as overheating Circuit Diagram Harness Connectors Inspection 1 Remove the Transmission Oil Temperature Switch from the transmission 2 Use an ohmmeter to check the continui...

Page 674: ...reasing of the T M oil pressure ECM can control the travel speed of the folk lift trucks with this switch Also the maximum travel speed of Tier 3 and Non cert fork lift trucks is an optional feature that can be easily activated using the MotoView Service Tool This feature may be of particular interest to customers with indoor warehouse operations Circuit Diagram Harness Connectors Inspection 1 Rem...

Page 675: ...rottle position sensors TPS The SECM calculates the correct throttle valve opening that corresponds to the driver s demand makes any adjustments needed for adaptation to the engine s current operating conditions and then generates a corresponding electrical driver signal to the throttle valve actuator Circuit Diagram Harness Connectors Inspection 1 Check for loose dirty or damaged connectors and w...

Page 676: ... cause headache nausea dizziness and unconsciousness and lead to injury or death Always operate the forklift in a well ventilated area Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane CAUTION The regulator converter and mixer are part of a ...

Page 677: ...he connection diagrams below for proper routing and maximum hose lengths when reinstalling system components NOTE Preferred mounting of regulator is off engine Hose Specifications Vacuum hose to comply to SAE 1403 Type I or SAE J30 R7 R8 EPDM textile reinforced 40 F to 257 F 40 C 125 C Inside Diameter 7 32 5 56mm Certified System Connections DWG NO 5555 1201 Figure 26 Hose Connections for Certifie...

Page 678: ...ve minimum ID of 0 46 11 68mm Vapor hose length to be as short as possible and have no restrictions for best regulator performance N 2007 Regulator Plastic WYE Fitting black color for 7 32 5 56mm ID Tube Hose Valve TEV Bosch Canister Plastic WYE Fitting blue color for 7 32 5 56mm ID Tube Hose Adapter temperature sensor Sensor coolant temperature Nipple 625 hex 4mp 2 5L steel Solenoid AFS Lock Off ...

Page 679: ...s 6 Remove the two cooling lines 4 from the regulator NOTE Either drain the coolant system or clamp off the coolant lines as close to the regulator as possible to avoid a coolant spill when these lines are disconnected 7 Remove the fuel vapor outlet hose 5 from the regulator 8 Remove the nipple extension 6 with the lock off from the regulator Figure 28 N 2007 Regulator in Certified System N 2007 I...

Page 680: ... 3 from the fuel temperature sensor fitting 4 7 Disconnect the fuel temperature sensor connector 5 8 Disconnect the wires leading to the electronic throttle body by pinching the lock tabs on either side of the wiring harness connector See Figure 31 for location of connector 9 Loosen the four bolts 6 that secure the mixer adapter throttle body assembly to the intake manifold 10 Remove the mixer 9 t...

Page 681: ...mbly onto the throttle body 8 then drop in the four mounting bolts 6 and gently push down on the assembly until it rests on the throttle body Be careful not to pinch the O ring See Figure 31 6 Attach the mixer throttle body assembly to the intake manifold making sure gasket is in place Tighten the four mounting bolts 7 Connect the wiring harness to the throttle body See Figure 31 for location of c...

Page 682: ...simple vacuum hand pump can be used to simulate the vacuum signal transmitted from the air fuel mixer when the engine is running See listing below for required hardware Break Off Test Secondary Stage Test Hardware 1 Hand vacuum pump 2 Regulator vapor outlet test fitting 3 4 NPT x 1 4 hose barb 3 Union Tee 1 4 NPT with three 1 4 NPT x 1 4 hose barb 4 Vacuum hose 5 0 3 WC Magnehelic gauge inches of ...

Page 683: ...ng This prevents the gauge from reading maximum pressure due to the large velocity of compressed air entering the primary chamber 4 Make sure there is no leakage at any of the fittings The static pressure should read between 40 60 of water column on the Magnehelic gauge and maintain a constant pressure for 60 seconds Figure 36 Magnehelic Gauge Connection to Hose Barb 5 If the pressure reading begi...

Page 684: ...d running at idle 750 rpm place the transmission in Neutral The AVV should be between 5 and 8 H2O of pressure vacuum 4 If the measured pressure drop is excessively high check for sticking or binding of the diaphragm air valve assembly inside the mixer Replace mixer if necessary 5 If the measured pressure drop is low check for vacuum leaks in the manifold throttle mixer TMAP sensor and attached hos...

Page 685: ...ituations follow the procedures below for adjustment of the idle mixture screw Factory Test Preparation 1 Install the MI 07 fuel system wiring harness and SECM 48 control module on the engine 2 All coolant hoses should be attached filled with coolant and bled to remove any air 3 Attach LPG fuel lines 4 Attach wiring harness to battery power 5 Attach exhaust system 6 If present set fuel select swit...

Page 686: ...se the accelerator pedal to increase rpm above idle momentarily rev the engine then release the pedal to return to idle rpm The duty cycle setting should remain within the adjustment range 35 55 Place your thumb over the adjustment port for a more accurate reading by preventing air from leaking past the mixture adjustment screw which may cause the duty cycle to decrease 8 If the FTV duty cycle rea...

Page 687: ... duty cycle turning the screw out counterclockwise should decrease the duty cycle 6 Adjust the idle mixture screw on the mixer until a reading of 35 55 is reached for the FTV Duty Cycle in Closed Loop Idle Figure 41 If engine idle performance is unstable screw the idle screw in slightly to see if stability is obtained but in no case should duty cycle exceed 60 7 Use the accelerator pedal to increa...

Page 688: ...210 10 SST 4 3 Mixer Cover 1 4 Mixer Spring 1 5 Diaphragm 1 6 Air Valve Assembly 1 7 Gas Valve Cone part of air valve assembly 1 8 Mixer Body 1 9 Expansion Plug Cap Ø 1 2 x 1 16 thick Ø 12 7mm x 27mm 1 10 Fuel Inlet 1 11 Air Horn Gasket 1 12 Air Horn Adapter 2 1 16 52 37mm 1 13 Fillister Head Screws SEMS Lockwasher 10 24 UNC x 5 8 4 14 Throttle Body Gasket 1 15 Fillister Head Screws SEMS Split Loc...

Page 689: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 189 Exploded View of CA100 Mixer Certified Figure 44 CA100 Certified Mixer Exploded View ...

Page 690: ...phragm Secondary Assembly 1 8 Lever Secondary 1 9 Seat Secondary 1 10 Valve Primary 1 11 Fillister Head Screws SEMS Split Lockwasher 12 24 x 5 8 6 12 Pan Head Screw SEMS Ext Tooth Lockwasher 12 24 x 1 4 1 13 Body Gasket 1 14 Back Plate 1 15 O ring Size 107 GLT Viton 1 16 Bottom Plate Gasket 1 17 Plate Cover 1 18 Fillister Head Screws SEMS Split Lockwasher 12 24 x 1 3 8 6 19 Hex Head Screws SEMS Sp...

Page 691: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 191 Exploded View of N 2007 Regulator Certified Figure 46 N 2007 Certified Regulator Exploded View ...

Page 692: ...ausea dizziness and unconsciousness and lead to injury or death Always operate the forklift in a well ventilated area Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane CAUTION The regulator converter and mixer are part of a certified system ...

Page 693: ...257 F 40 C 125 C Inside Diameter 7 32 5 56mm DWG NO 5555 1243 Figure 27 Hose Connections for Non Certified Systems DIAGRAM NOTES Only one 90 fitting permissible on vapor fuel line between mixer and regulator Vapor fuel fittings regulator and mixer must have minimum ID of 0 46 11 68mm Vapor hose length to be as short as possible and have no restrictions for best regulator performance Fuel outlet mu...

Page 694: ...ess to the remaining hose clamps 5 Remove the two cooling lines 4 from the regulator NOTE It will be necessary to either drain the coolant system or clamp off the coolant lines as close to the regulator as possible to avoid a coolant spill when these lines are disconnected 6 Remove the fuel vapor outlet hose 5 from the regulator Figure 29 N 2001 Regulator in Non Certified System N 2001 Installatio...

Page 695: ...e engine shuts down 3 Key switch in OFF position 4 Remove the air cleaner hose 1 5 Remove the vacuum line 2 6 Remove vapor fuel inlet line 3 from the mixer 6 7 Disconnect the wires leading to the electronic throttle body by pinching the lock tabs on either side of the wiring harness connector 8 8 Loosen the four bolts 4 that secure the mixer adapter throttle body assembly to the intake manifold 9 ...

Page 696: ...on the throttle body Be careful not to pinch the O ring See Figure 31 4 Attach the mixer throttle body assembly to the intake manifold making sure gasket is in place Tighten the four mounting bolts 5 Connect the wiring harness 8 to the throttle body 6 Install the vapor fuel inlet line 3 to the mixer 7 Install the vacuum line 2 to the mixer 8 Install the air cleaner hose 1 NOTE A plastic O ring spa...

Page 697: ...Break Off Test Secondary Stage Test Hardware 1 Hand vacuum pump 2 Regulator vapor outlet test fitting 3 4 NPT x 1 4 hose barb 3 Union Tee 1 4 NPT with three 1 4 NPT x 1 4 hose barb 4 Vacuum hose 5 0 3 WC Magnehelic gauge inches of water column Secondary Stage Break Off Test 1 Connect the vacuum pump the Magnehelic gauge and the regulator vapor outlet to the Union Tee fitting Figure 30 Make sure th...

Page 698: ...uum hose or vinyl tubing This prevents the gauge from reading maximum pressure due to the large velocity of compressed air entering the primary chamber 4 Make sure there is no leakage at any of the fittings The static pressure should read between 40 60 WC on the Magnehelic gauge and maintain a constant pressure for 60 seconds 5 If the pressure reading begins to increase a leak is most likely prese...

Page 699: ...check for vacuum leaks in the manifold throttle mixer TMAP sensor and attached hoses Figure 37 Magnehelic Gauge Connection Ignition Timing Adjustment With the MI 07 system ignition timing advance is controlled by the SECM Connection of the MI 07 Service Tool To use the Service Tool a USB Universal Serial Bus to CAN Controller Area Network communica tion adapter by KVaser will be required along wit...

Page 700: ...2 Apply a load to the engine while the engine is operating above idle speed Torque converter stall is the preferred operating mode for this test If a torque converter speed test cannot be performed the engine can be run at another speed max governor but a load must be applied by using hydraulics NOTE While adjusting the power valve do not hold engine at load point for longer than 5 10 seconds Hold...

Page 701: ...If a torque converter speed test cannot be performed the engine can be run at another speed max governor but a load must be applied by using hydraulics The power valve should be adjusted to obtain maximum torque converter stall speed NOTE While adjusting the power valve do not hold engine at load point for longer than 5 10 seconds Holding for a longer period of time will cause the fuel temperature...

Page 702: ...loded view on facing page REF NO DESCRIPTION QTY 1 Screws 10 24 x 5 8 T 25 Button Head SEMS 4 2 Mixer Cover 1 3 Mixer Spring 1 4 Diaphragm 1 5 Gas Valve Cone part of air valve assembly 1 6 Mixer 1 7 Throttle Body Gasket 1 8 Screws 12 24 x 5 8 Fillister Head SEMS 8 9 Air Horn Adapter 1 10 Air Horn Gasket 1 Parts List for CA100 Mixer ...

Page 703: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 203 Exploded View CA100 Mixer Figure 44 CA100 Non Certified Mixer Exploded View ...

Page 704: ...er assembly removed from the engine and the throttle adapter removed from the mixer remove the four cover retaining screws from the top of the mixer Figure M4 2 Gently remove the diaphragm cover from the top of the mixer Take care not to loose the air valve spring shown in Figure M5 3 Remove the air valve assembly from the mixer as shown in Figure M6 Figure M5 Figure M6 3 6 5 4 14 9 2 8 7 15 1 10 ...

Page 705: ... M8 6 Tighten the cover fastners and reinstall the mixer on the engine Figure M9 CA100 Disassembled Service 1 Clean the air valve assembly with soap and warm water to remove heavy end deposits Inspect the fuel metering valve and sealing ring for wear Replace worn components as necessary Replace all gaskets before assembly Clean the mixer body casting with a parts cleaning solvent Be sure to remove...

Page 706: ...econdary Lever 1 8 Secondary Valve 1 9 Secondary Lever Fulcrum Pin 1 10 Red Secondary Spring 1 11 Pilot Valve Lever 1 12 Pilot Valve Lever Fulcrum Pin 1 13 Internal Hex Head Set Screw 8 32 x 1 4 1 14 Cover Screws 12 24 x 5 8 SEMS 6 15 Primary Diaphragm Cover 1 16 Primary Regulator Springs 2 17 Primary Diaphragm Assembly 1 18 1 8 NPT Hex Pipe Plug Fitting 1 19 Body Assembly 1 20 Body Seal O ring 1 ...

Page 707: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 207 Exploded View N 2001 RSA Regulator Figure 47 N 2001 Regulator Exploded View ...

Page 708: ... and the secondary diaphragm 3 2 Remove the six primary diaphragm cover screws 4 and the primary cover assembly 5 Remove the six primary diaphragm cover screws 4 and the primary cover assembly 5 Remove the primary diaphragm by sliding the diaphragm to one side releasing the primary valve pin Figure R6 Figure R3 Figure R4 1 2 3 Figure R5 4 5 Figure R5 Figure R6 ...

Page 709: ... is retained by the primary diaphragm Figure R9 6 Remove the body gasket 10 body o ring seal 11 and the fuel inlet plate exposing the fuel inlet expansion chamber and the coolant passage NOTE For re assembly of the N2001 regulator converter reverse the steps for disassembly Tighten all fasteners to recommended torque values and test the regulator before installing in the vehicle Torque primary cov...

Page 710: ...rm water Inspect for wear tears or pinholes and deformations that may cause leaks or poor performance of the regulator converter 3 Replace the body gasket of the coolant chamber and body o ring seal when servicing the N2001 to avoid coolant leaks from the fuel expansion chamber to the coolant passage 4 Clean the regulator body casting with a parts cleaning solvent Be sure to remove all seals and g...

Page 711: ...UEL DELIVERY SYSTEM Specification Items Specification Fuel Retrun System Type Returnless Fuel Filter Type High pressure type built in Fuel Pump Assembly Type Built in fuel pump assembly Fuel Pressure Regulator Regulated Fuel Pressure 350 kPa 3 5kg cm 49 8psi Fuel Pump Type Electrical in tank type ...

Page 712: ...424F FE Service Manual 212 Chapter 7 MPI Gasoune Fuel Delivery System Components Location 1 Fuel Tank 2 Fuel Pump Including full pressure regulator and fuel filter 3 Fuel Hose Assy 4 Fuel Rail 5 Injector ...

Page 713: ...connecting the fuel feed hose otherwise fuel will spill out Install Service Tool For Measuring The Fuel Pressure 1 Disconnect the fuel feed hose from the delivery pipe CAUTION Cover the hose connection with a shop towel to prevent splashing of fuel caused by residual pressure in the fuel line 2 Install the Fuel Pressure Gage Adapter between the delivery pipe and the fuel feed hose 3 Connect the Fu...

Page 714: ...pump because of poor seating of the fuel pressure regulator Fuel Pressure Regulator Fuel Pressure too High Sticking fuel pressure regulator Fuel Pressure Regulator 5 Stop the engine and check for a change in the fuel pressure gauge reading After engine stops the gage reading should hold for about 5 minutes Observing the declination of the fuel pressure when the gage reading drops and perform the n...

Page 715: ...o the fuel pump terminal and activate the fuel pump With fuel pressure applied check that there is no fuel leakage from the fuel pressure gauge or connection part 3 If the vehicle is normal connect the fuel pump connector Injector Component Location Description Based on information from various sensors the ECM measures the fuel injection amount The fuel injector is a solenoid operated valve and th...

Page 716: ...o vibrations are felt check the wiring connector injector or injection signal from ECM Resistance Measurement Between Terminals 1 Disconnect the connector at the injector and measure the resistance between the two terminals Standard value 12 14Ω at 20 68 2 Re connect the connector to the injector Removal 1 Release residual pressure from the fuel line to prevent fuel from spilling CAUTION Cover the...

Page 717: ...pecifications replace the injector Installation 1 Install a new grommet and O ring to the injector 2 Apply a coating of solvent spindle oil or gasoline to the O ring of the injector 3 While turning the injector to the left and right fit it on to the delivery pipe 4 Be sure the injector turns smoothly NOTE If it does turn smoothly the O ring may be jammed Remove the injector and re insert it into t...

Page 718: ...ly harness connector A b Start the engine and wait until fuel in fuel line is exhausted After the engine stalls turn the ignition switch to OFF position c Disconnect the negative terminal from the battery 2 Disconnect the fuel feed line CAUTION Cover the hose connection with a shop towel to prevent splashing of fuel caused by residual pressure in the fuel line 3 Unfasten the fuel pump cap D counte...

Page 719: ...main on until the engine is started Once the engine is started the MIL lamp will go out unless one or more fault conditions are present If a detected fault condition exists the fault or faults will be stored in the memory of the small engine control module SECM Once an active fault occurs the MIL will illuminate and remain ON This signals the operator that a fault has been detected by the SECM 2 D...

Page 720: ...her_______________________________________________ Others Poor driving Surge Knocking Poor fuel economy Back fire After fire Other____________________________ 3 Environment Problem frequency Constant Sometimes _________________ Once only Other___________________________________________ Weather Fine Cloudy Rainy Snowy Other__________________ Outdoor temperature Approx _____ Place Suburbs Inner City...

Page 721: ...check terminal for poor connections loose wires bent broken or corroded pins and then verify that the connectors are always securely fastened 3 Slightly shake the connector and wiring harness vertically and horizontally 4 Repair or replace the component that has a problem 5 Verify that the problem has disappeared with the road test SIMULATING VIBRATION 1 Sensors and Actuators Slightly vibrate sens...

Page 722: ...3 Listen for a click when locking connectors This sound indicates that they are securely locked 4 When a tester is used to check for continuity or to measure voltage always insert tester probe from wire harness side 5 Check waterproof connector terminals from the connector side Waterproof connectors cannot be accessed from harness side NOTE Use a fine wire to prevent damage to the terminal Do not ...

Page 723: ...erminal Repair Method of Connector Terminal 1 Clean the contact points using air gun and or shop rag NOTE Never uses and paper when polishing the contact points otherwise the contact point may be damaged 2 In case of abnormal contact pressure replace the female terminal Wire Harness Inspection Procedure 1 Before removing the wire harness check the wire harness position and crimping in order to res...

Page 724: ...hown in FIG 2 In FIG 2 the measured resistance of line1and 2 is higher than 1 and below 1Ω respectively Specifically the open circuit is line 1 Line 2 is normal To find exact break point check sub line of line 1as described in next step b Disconnect connector B and measure for resis tance between connector C and B1 and between B2 and A as shown in FIG 3 In this case the measured resistance between...

Page 725: ...round Circuit 1 or Higher Normal Circuit a Disconnect connectors A C and measure for resistance between connector A and Chassis Ground as shown in FIG 6 The measured resistance of line 1 and 2 in this example is below 1Ω and higher than 1 respectively Specifically the short to ground circuit is line 1 Line 2is normal To find exact broken point check the sub line of line1 as described in the follow...

Page 726: ...G424F FE Service Manual 226 Chapter 8 Basic Troubleshooting Symptom Troubleshooting Guide Chart for MPI Gasoline System Engine Is Not Starting Engine Is Difficult To Start Cranking OK ...

Page 727: ...G424F FE Service Manual 227 Chapter 8 Basic Troubleshooting Irregular Idling Or Engine Is Suddenly Stopped ...

Page 728: ...G424F FE Service Manual 228 Chapter 8 Basic Troubleshooting Engine Hesitation Or Insuffient Accelelation ...

Page 729: ...G424F FE Service Manual 229 Chapter 8 Basic Troubleshooting ...

Page 730: ...G424F FE Service Manual 230 Chapter 8 Basic Troubleshooting Troubleshooting Guide for MPI Gasoline System The following number represents inspection order ...

Page 731: ...G424F FE Service Manual 231 Chapter 8 Basic Troubleshooting ...

Page 732: ...ontact tension Loose connections or broken wires Poor terminal to wire connection crimp If a visual physical check does not find the cause of the problem perform the following 1 Drive the vehicle with a voltmeter or Service tool connected to a suspected circuit Check if circuit is active and signal is reasonable 2 Using the Service tool monitor the input signal to the SECM to help detect intermitt...

Page 733: ...he complaint Monitoring pre catalyst O2 adapts dither valve duty cycle or mechanical injector pulse width will help identify problem Check fuel supply while condition exists Check in line fuel filter Replace if dirty or plugged Check fuel pressure Ignition system malfunction Check for proper ignition voltage output using spark tester Check spark plugs Remove spark plugs check for wet plugs cracks ...

Page 734: ... valve Propane excess flow valve closed Reset excess flow valve in LPG tank Close liquid valve Wait for a click sound slowly open liquid valve Plugged fuel line Remove obstruction from the fuel line Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve Leak test Clogged fuel fi...

Page 735: ...ltage with the throttle closed Fuel system malfunction Check fuel lock off propane or fuel pump relay gasoline operation actuator should turn ON for 2 seconds when ignition is turned ON Check fuel pressure Check for contaminated fuel Check both gasoline injector and lock off fuses visually inspect Check propane tank valve pickup A faulty in tank fuel pump check valve will allow the fuel in the lin...

Page 736: ... tank Check for contaminated fuel Check for clogged fuel filter and repair or replace as required See Chapter 4 Fuel Filter replacement Check for plugged fuel line and remove any obstruction from the fuel line Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve and leak test ...

Page 737: ...st system for possible restriction Refer to Chart T 1 on later pages Inspect exhaust system for damaged or collapsed pipes Inspect muffler for heat distress or possible internal failure Check for possible plugged catalytic converter by comparing exhaust system backpressure on each side at engine Check backpressure by removing Pre catalyst O2 sensor and measuring backpressure with a gauge Engine me...

Page 738: ...ify problem Cooling system malfunction Check for obvious overheating problems Low engine coolant Loose water pump belt Restricted air flow to radiator or restricted water flow through radiator Inoperative electric cooling fan Correct coolant solution should be a mix of anti freeze coolant or equivalent and water High coolant temperature Ignition system malfunction Check ignition timing See applica...

Page 739: ...spark plug wires and proper routing of plug wires Check ignition timing Refer to application manual Engine mechanical Check compression look for sticking or leaking valves Check intake and exhaust manifold for casting flash and gasket misalignment Refer to Chapter 3 Engine Mechanical System Related MIL Faults EST faults ETC faults Encoder error Pre catalyst O2 sensor faults Dieseling Run on Engine...

Page 740: ...ne pressure regulator hose If fuel is present replace regulator assembly The pre catalyst oxygen O2 sensor should respond quickly to different throttle positions If it does not then check the pre catalyst O2 sensor for contamination If the pre catalyst O2 sensor is aged or contaminated the SECM will not deliver correct amount of fuel resulting in a drivability problem Fuel container empty Check fo...

Page 741: ...uid fuel valve leak test Fuel lock off malfunction Repair replace fuel lock off See Chapter 4 Fuel Lock Off Faulty vapor connection between the pressure regulator converter and the mixer Check connection Verify no holes in hose Clamps must be tight Look for kinked pinched and or collapsed hose Pressure regulator freezes Check level in cooling system Must be full check coolant strength 35 F 37 C mi...

Page 742: ...r intermittent operation or miss If there is a spark remove spark plug s in these cylinders and check for cracks wear improper gap burned electrodes heavy deposits Check spark plug wires by connecting ohmmeter to ends of each wire in question If meter reads over 30 000 ohms replace wire s Visually inspect distributor cap rotor and wires for moisture dust cracks burns etc Spray cap and plug wires w...

Page 743: ...ositive pressure Monitor Pre catalyst O2 sensor with Service Tool Cooling system malfunction Check engine coolant level Check engine thermostat for faulty part always open or for wrong heat range Ignition system malfunction Check ignition timing Refer to application manual Check for weak ignition and or spark control Check spark plugs Remove spark plugs and check for wet plugs cracks wear improper...

Page 744: ...vacuum leaks See Chapter 8 Advanced Diagnostics Chapter 6 Tests and Adjustments Throttle sticking Replace throttle See Fault Code 461 ETC_Sticking Foot pedal sticking or incorrect pedal signal Check pedal return spring travel for binding Check APP function with Service Tool Verify smooth change of APP reading with pedal movement See Chapter 8 Advanced Diagnostics Engine mechanical Check for vacuum...

Page 745: ...art always open or for wrong heat range Check fan operation Fuel system malfunction If the system is running rich refer to Diagnostic Aids chart on the next page If the system is running lean refer to Diagnostic Aids chart on the next page Check for properly installed fuel system components Check fuel pressure Ignition system malfunction Check ignition timing Refer to application manual Check spar...

Page 746: ...lve duty cycle 90 Inspect hoses from AVV port port on bottom of mixer to trim valves and regulator for leaks or blockages replace as necessary Inspect in line orifices for blockages in wye replace as necessary Check trim valves for proper operation replace as necessary Check regulator out pressure replace if out of spec Gasoline Iniector Pulse Width 1 0 msec Inspect fuel cone for damage replace mi...

Page 747: ...sor with anti seize compound prior to re installation Illustration Notes 1 Backpressure gage 2 Pre catalyst Oxygen O2 sensor 3 Exhaust manifold Diagnosis 1 With the engine idling at normal operating temperature observe the exhaust system backpressure reading on the gage Reading should not exceed 1 25 psig 8 61 kPa 2 Increase engine speed to 2000 rpm and observe gage Reading should not exceed 3 psi...

Page 748: ...which is the ETCSticking fault If any additional faults were stored the SECM would again have a long pause then display the next fault by flashing each digit Since no other faults were stored there will be a long pause then one flash 1 pause then two flashes 2 This identifies a twelve signifying the end of the fault list This list will then repeat Displaying Fault Codes DFC from SECM Memory To ent...

Page 749: ...s Level4 Power Limit Level3 Power Limit Level2 Power Limit Level1 Power Limit The maximum engine power output will be limited to one of four possible levels The engine power is calculated from measured engine parameters e g MAP rpm fuel flow etc Disable Gas O2 Control In LPG mode closed loop correction of air fuel ratio based on the Pre catalyst O2 sensor is disabled Disable Liquid O2 Control In G...

Page 750: ...mally set if the APP1 signal has shorted to power or the ground for the sensor has opened 611 61 APP2AdaptHiMax Learned full pedal end of APP2 sensor range higher than expected 642 68 APP2AdaptHiMin Learned full pedal end of APP2 sensor range lower than expected 652 APP2AdaptLoMax Learned idle end of APP2 sensor range higher than expected 662 APP2AdaptLoMin Learned idle end of APP2 sensor range lo...

Page 751: ...ensor 193 CrankSyncFault Loss of synchronization on the crankshaft sensor normally due to noise on the signal or an intermittent connection on the crankshaft sensor 194 ECTOverTempFault Engine Coolant Temperature is High The sensor has measured an excessive coolant temperature typically due to the engine overheating 161 16 ECTRangeHigh Engine Coolant Temperature Sensor Input is High Normally set i...

Page 752: ...possibly open EST4 signal or defective spark module 424 EST4_Short EST4 output shorted high or low EST4 signal shorted to ground or power or defective spark module 434 EST5_Open EST5 output open possibly open EST5 signal or defective spark module 425 EST5_Short EST5 output shorted high or low EST5 signal shorted to ground or power or defective spark module 435 EST6_Open EST6 output open possibly o...

Page 753: ...ore is sticking The plate sticking can be due to some type of obstruction a loose throttle plate or worn components shaft bearings NOTE Throttle assembly is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly 461 26 FuelSelectConflict Conflict in fuel select signals normally set if one or both of the fuel select signals are shorted to ground 181 FuelTempRangeHi...

Page 754: ...atalyst failure sensor failure or wiring relay failure causing the sensor to not be properly heated If any Pre O2 sensor faults are set diagnose these first and after correcting these faults recheck if this fault sets 772 GasPostO2FailedLean Post catalyst O2 sensor control on LPG has reached lean limit and sensor still reads to rich This could be caused by catalyst failure sensor failure or wiring...

Page 755: ...injector 1 wire or defective injector 131 Inj2Open Gasoline Injector 2 open circuit broken injector 2 wire or defective injector 132 Inj3Open Gasoline Injector 3 open circuit broken injector 3 wire or defective injector 133 Inj4Open Gasoline Injector 4 open circuit broken injector 4 wire or defective injector 134 Inj5Open Gasoline Injector 5 open circuit broken injector 5 wire or defective injecto...

Page 756: ...ine mode system had to adapt rich more than expected 821 LiqFuelAdaptRangeLow In Gasoline mode system had to adapt lean more than expected 831 LiqO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on gasoline 851 LiqO2FailedRich Pre catalyst O2 sensor indicates extended rich operation on gasoline 871 LiqO2NotActive Pre catalyst O2 sensor inactive on gasoline open O2 sensor signa...

Page 757: ...CM 332 MAPTimeRangeHigh Manifold Absolute Pressure Sensor Input is High normally set if the TMAP pressure signal wire has become shorted to power shorted to the IAT signal the TMAP has failed or the SECM has failed 341 34 MAPTimeRangeLow Manifold Absolute Pressure Sensor Input is Low normally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the circuit has opened ...

Page 758: ...han expected 251 25 TPS1AdaptHiMin Learned WOT end of TPS1 sensor range lower than expected 271 TPS1AdaptLoMax Learned closed throttle end of TPS1 sensor range higher than expected 281 TPS1AdaptLoMin Learned closed throttle end of TPS1 sensor range lower than expected 241 24 TPS1RangeHigh TPS1 sensor voltage out of range high normally set if the TPS1 signal has shorted to power or ground for the s...

Page 759: ...r voltage out of range low normally set if TPS2 signal has shorted to ground circuit has opened or sensor has failed 222 TPS_Sensors_Conflict TPS sensors differ by more than expected amount NOTE The TPS is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly 291 TransOilTemp Excessive transmission oil temperature 933 ...

Page 760: ... B Check Injector 3 Resistance 12 to14 ohms cold 134 Inj4Open Gasoline Injector 4 open circuit broken injector 4 wire or defective injector 1 TurnOnMil 2 DisableLiquid O2Ctrl 3 DelayedEngine Shutdown Check INJ4 wiring for an open circuit SECM Signal A7 to Injector 4 Pin A Switched 12V to Injector 4 Pin B Check Injector 4 Resistance 12 to14 ohms cold 135 Not Used Inj5Open Gasoline Injector 5 open c...

Page 761: ... to be rotating broken crankshaft sensor leads or defective CAM sensor None Check CAM sensor connections SECM SIGNAL Pin B10 to CAM sensor Pin 2 SECM Sensor GND Pin B1 to CAM sensor Pin 3 Switched 12V to CAM sensor Pin 1 Check for defective CAM sensor 192 CamSyncFault Loss of synchronization on the CAM sensor normally due to noise on the signal or an intermittent connection on the CAM sensor None ...

Page 762: ...ensor voltage out of range high normally set if the TPS1 signal has shorted to power or the ground for the sensor has opened 1 TurnOnMil 2 CutThrottle Check throttle connector and TPS1 sensor wiring for a shorted circuit SECM Pin B23 signal to ETC Pin 6 SECM Pin B1 sensor GND to ETC Pin 2 232 TPS2RangeHigh TPS2 sensor voltage out of range high normally set if the TPS2 signal has shorted to power o...

Page 763: ...mally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the circuit has opened to the SECM TurnOnMil Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP Pin ...

Page 764: ...shorted circuit TMAP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP Pin 1 GND to Pin 4 pressure signal KPA 2 4kΩ 8 2kΩ TMAP Pin 3 power to Pin 4 pressure signal KPA 3 4kΩ 8 2kΩ 351 MAP_IR_HI MAP sensor indicates higher pressure than expected TurnOnMil C...

Page 765: ...oil driver wiring and connector for open circuit SECM Pin A9 EST1 to OEM ignition system See application note Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details 422 EST2_Open EST2 output open possibly open EST2 signal or defective spark module TurnOnMil Check coil driver wiring and...

Page 766: ...dc on ignition module Pin B of both connectors Refer to application manual for specific engine details 425 EST5_Open EST5 output open possibly open EST5 signal or defective spark module None N A 426 EST6_Open EST6 output open possibly open EST6 signal or defective spark module None N A 427 EST7_Open EST7 output open possibly open EST7 signal or defective spark module None N A 428 EST8_Open EST8 ou...

Page 767: ...t shorted high or low EST3 signal shorted to ground or power or defective spark module None N A 434 EST4_Short EST4 output shorted high or low EST4 signal shorted to ground or power or defective spark module None N A 435 EST5_Short EST5 output shorted high or low EST5 signal shorted to ground or power or defective spark module None N A 436 EST6_Short EST6 output shorted high or low EST6 signal sho...

Page 768: ...ing the motor drive resistance at the throttle TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0 471 ETC_Open_Fault Electronic Throttle Control Driver has failed normally set if driver signals have failed open or become disconnected electronic throttle or SECM is defective 1 TurnOnMIL 2 CutThrottle Check the ETC driver wiring for an open circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18 to ETC Pin 4 Check the...

Page 769: ...lectrical connection to the oil pressure switch SECM Pin B9 to Oil Pressure Switch 531 53 SysVoltRangeLow System voltage too low TurnOnMil Check battery voltage Perform maintenance check on electrical connections to the battery and chassis ground Check battery voltage during starting and with the engine running to verify charging system and alternator function Measure battery power at SECM with a ...

Page 770: ...R to ETC Pin 2 XDRG GND Verify transducer power to the foot pedal with a multimeter 571 57 HardOverspeed Engine speed has exceeded the third level 3 of 3 of overspeed protection 1 TurnOnMil 2 HardRevLimit 3 EngineShutdown Usually associated with additional ETC faults Check for ETC Sticking or other ETC faults Verify if the lift truck was motored down a steep grade 572 MediumOverspeed Engine speed ...

Page 771: ...urnOnMil Check APP connector and pins for corrosion Cycle the pedal several times and check APP1 signal at SECM Pin B7 642 68 APP2AdaptHiMax Learned full pedal end of APP2 sensor range higher than expected TurnOnMil Check APP connector and pins for corrosion Cycle the pedal several times and check APP2 signal at SECM Pin B16N A 651 APP1AdaptHiMin Learned full pedal end of APP1 sensor range lower t...

Page 772: ... or signal shorted to GND FTV2 Pin 1 signal to SECM Pin A2 FTV2 Pin 2 power to SECM DRVP Pin A23 Check FTV1 for an open coil by disconnecting the FTV connector and measuring the resistance 26 Ω 2 Ω 713 LSDFault_CSValve None N A 714 LSDFault_CheckEngine Check Engine Lamp Fault signal has opened or shorted to ground or power or defective check engine lamp None Check Check Engine Lamp for an open wir...

Page 773: ...ck off valve for an open coil by disconnecting the lock off valve connector and measuring the resistance 26 Ω 3 Ω Check for 12V to lock off valve 718 LSDFault_MIL Malfunction Indicator Lamp Fault signal has opened or shorted to ground or power or defective MIL lamp None N A 721 72 GasFuelAdaptRangeLo In LPG mode system had to adapt rich more than expected 1 TurnOnMil 2 DisableGasO2Ctrl 3 DisableGa...

Page 774: ...t catalyst O2 sensor connections are OK O2 signal Pin 3 to SECM Pin B19 O2 Pin 2 HEATER GND to SECM DRVG GNG Pins A16 B17 O2 Pin 1 HEATER PWR to Post O2 Heater Relay Relay pin 87 This relay only turns on after engine has been running for some time and SECM has calculated that water condensation in exhaust has been removed by exhaust heat Post O2 Heater Relay has SECM DRVP 12V applied to the relay ...

Page 775: ...ed 1 TurnOnMil 2 DisableLiquidO2Ctrl 3 DisableLiqPostO2Ctrl Check for vacuum leaks Low gasoline fuel pressure perform gasoline pressure test Injector problems e g plugged defective injector 822 LiqDesEquivHi None N A 831 LiqFuelAdaptRangeLow In Gasoline mode system had to adapt rich more than expected 1 TurnOnMil 2 DisableLiquidO2Ctrl 3 DisableLiqPostO2Ctrl Low gasoline fuel pressure perform gasol...

Page 776: ...lean operation on gasoline 1 TurnOnMil 2 DisableLiquidO2Ctrl 3 DisableLiqPostO2Ctrl Check for vacuum leaks Low gasoline fuel pressure perform gasoline pressure test Injector problems e g plugged defective injector 852 LiqPostO2FailedLean Pre catalyst O2 sensor indicates extended lean operation on gasoline 1 TurnOnMil 2 DisableLiqPostO2Ctrl Correct other faults that may contribute to 852 e g faults...

Page 777: ...l shorted to ground 1 TurnOnMil 2 DisableGasPostO2Ctrl 3 DisableLiqPostO2Ctrl Check if O2 sensor installed after catalyst is shorted to 5Vdc or battery O2 signal Pin 3 to SECM Pin B19 Possible voltage sources SECM XDRP 5V Pin B24 and SECM DRVP 12V Pin A23 931 FuelTempRangeLow Fuel Temperature Sensor Input is Low normally set if the fuel temperature sensor wire has shorted to chassis ground or the ...

Page 778: ...o Service Interval 1 determined by OEM 992 ServiceFault2 Service Interval 2 has been reached None Perform service procedure related to Service Interval 2 determined by OEM 993 ServiceFault3 Service Interval 3 has been reached None Perform service procedure related to Service Interval 3 determined by OEM 994 ServiceFault4 Service Interval 4 has been reached replace HEGO sensors TurnOnMil Replace Pr...

Page 779: ... section Once MotoView is connected to the SECM through the CAN cable a display file is opened MI_07RevL dis to display the available diagnostic features The use of these features is described in Appendix Figure 1 Opening MotoView Software Figure 2 Display File of Available Diagnostic Features Service Tool Software Kit Service tool software kit consists of USB CAN converter Service tool software M...

Page 780: ... an available USB port in the computer Figure 4 2 With the ignition key in the OFF position connect the KVaser communication cable from a second USB port on the computer to the CAN communications cable on the engine If your laptop computer does not have a second USB port an appropriate USB hub will need to be used 3 Connect a timing light to the engine 4 Turn the ignition key to the ON position Do...

Page 781: ...This category displays the engine RPM one of three engine states Stall Crank Run and the selected fuel type Engine run hours are also displayed in this category directly below the engine state If the LPG fuel lock off or liquid fuel pump is active the adjacent data box will display a 1 meaning the device is on and the data box will turn green Brief parameter notes are listed to the right of the pa...

Page 782: ...stored faults of the ten possible fault stored record are displayed by the three digit fault codes Definitions of these fault codes can be located on the DFC screens Fault States Suspected possible faults are displayed here These may be redundant of the occurred fault list All faults can be cleared from the Clear Faults pull down parameter Place your mouse pointer over the Clear Fault parameter bo...

Page 783: ...cated on the DFC screens Fault States Suspected possible faults are displayed here These may be redundant of the occurred fault list All faults can be cleared from the Clear Faults pull down parameter Place your mouse pointer over the Clear Fault parameter box then simply click the pull down arrow and select the Arm option Figure 7 You have now armed the clear fault function Using your mouse click...

Page 784: ...p computer These values will be saved and used by the SECM even after disconnecting from the SECM and closing the display screen If the ground switch input is closed grounded the Switched MAX RPM value will be used by the SECM as the maximum RPM If the ground switch is open or not used the High MAX RPM value will be used by the SECM as the maximum RPM There is a limit placed on these values the ra...

Page 785: ...12 through 353 are defined on this display for quick reference Faults that are displayed in yellow have been enabled on the MI 07 system Faults that appear in grey are included for future use but are not enabled Refer to the service manual or the Advanced Diagnostics section of this manual for repair steps and further troubleshooting ...

Page 786: ...371 through 641 are defined on this display for quick reference Faults that are displayed in yellow have been enabled on the MI 07 system Faults that appear in grey are included for future use but are not enabled Refer to the service manual or the Advanced Diagnostics section of this manual for repair steps and further troubleshooting ...

Page 787: ...642 through 995 are defined on this display for quick reference Faults that are displayed in yellow have been enabled on the MI 07 system Faults that appear in grey are included for future use but are not enabled Refer to the service manual or the Advanced Diagnostics section of this manual for repair steps and further troubleshooting ...

Page 788: ...puts to the various system sensors solenoids relays and drivers Components are listed in categories with the signal names values and SECM pin location A pin out of each sensor is given along with the signal type and the corresponding SECM pin connection System power and sensor power is actively displayed in red or orange Ground connections are displayed in grey Figure 13 Signal I O Screen 1 ...

Page 789: ...occurred faults are displayed on each override screen for quick reference along with the ability to clear all faults Manual Override Screen 1 Components that can be overridden on override screen 1 include the Main Power Relay LP fuel Lock off Fuel Select Switch Electric Fuel Pump Bi Fuel Units Fuel Trim Valves O2 Sensor and the Cold Start Valve Figure 14 Manual Override Screen 1 CAUTION Be aware o...

Page 790: ...x then simply click the pull down arrow and select the Locked option Enter the desired duty cycle in percent 0 100 in the DC Offset box This offset value will be added to the Status DC value For example when locked the status value is 30 If you wish to drive the component at 50 you would enter 20 in the DC Offset box 30 20 50 The SECM will now be overridden and the manual value will be used to dri...

Page 791: ...ocked the TDC value is 8 0 If you wish to advance the spark to 10 degrees BTDC you would enter 2 0 in the Spark Offset box 8 0 2 0 10 0 The SECM control will now be overridden and the manual value will be used to set the spark advance through the SECM at the fixed value The Lock Spark Adv box will turn red when in manual override or locked To stop the override mode simply click the pull down arrow...

Page 792: ...reen 2 include the Low Oil Pressure Switch Transmission Temperature Switch Ground Speed Switch Spark Advance and the Malfunction Indicator Light MIL Figure 18 Manual Override Screen 2 CAUTION Be aware of fuel flow and ignition when performing any manual override of a system component as engine damage may result ...

Page 793: ...Current SECM software version VARSPEDDRAAF 01 2 5 D 000 000 siz calibration ID Upgrade to software version VARSPEDDRAAG 01 2 5 D 000 000 siz calibration ID Using field update file VARSPEDDRAAG 01 1 5 D 000 mfu NEW Corresponding DLL file VARSPEDDRAAG dll STEP1 LOAD UPDATE FILES INTO THE APPROPRIATE DIRECTORY Software upgrade packages include an upgrade file mfu and translation file dll The mfu file...

Page 794: ...s on the update computer A second available USB port will be used by the USB to CAN converter The USB to CAN coverter must then be connected to the SECM A USB hub must be used with computers that do not have two USB ports STEP 3 LAUNCH THE MOTOUPDATE APPLICATION Launch the MotoUpdate application You will see a Welcome scree Select PCM 1 in the location field then select Next ...

Page 795: ...he ON position In general it is usually best to see the latest revision e g 001 is later than 000 in situations where multiple revisions are available Additional information is provided in the revision matrix and or service bulletins No Upgrader Available for this Engine No Upgrader Available for this Engine This Upgrade Options screen shows that there are no upgrades available for the listed Cali...

Page 796: ...e process as shown below Once the upgrade process is complete a complete message will appear and will give the operator the option of upgrading another module If another module is to be upgraded select the Upgrade again button and select next If another upgrade is not required select finish Note 1 After successfully upgrading the SECM MotoViewer software will not function without the appropriate t...

Page 797: ...tch assy onto the main pressure port of transmission using elbow and o ring like Figure 1 2 Assemble the harness assy between the pressure switch and engine wiring harness Figure 1 Speed control option How To Set New Speed Limit Default Engine Maximum Speed Once speed control option is assembled the default engine maximum speed is as followed Engine max speed rpm Forklift Model Engine Model HIGH M...

Page 798: ...e SECM as the maximum RPM If the ground switch is open or not used the HIGH MAX RPM value will be used by the SECM as the maximum RPM The pressure switch state is displayed at the middle of the screen and labeled Ground Speed Switch For example as Figure 2 depicts With pushing of inching pedal the maximum RPM for normal speed governing is set at 2600 Please refer below the pressure switch state Wi...

Page 799: ... at 212 deg F 100 deg C If an engines operating temperature is approximately 230 deg F 110 deg C then the water in an open un pressurized cooling system would simply boil off into steam eventually leaving the cooling system empty and over heating the engine If we install a 10 PSIG cap on the radiator pressurizing the cooling system to 10 PSIG the boiling point of the water increases to 242 deg F 1...

Page 800: ... of the vehicle to prevent damage to the valves when maneuvering in tight spaces Horizontal tanks must be installed on the saddle that contains an alignment pin which matches the hole in the collar of the tank When the pin is in the hole the liquid withdrawal tube is positioned to the bottom of the tank A common problem is that often these guide pins are broken off allowing the tank to be mounted ...

Page 801: ...ders In order for this type of gauge to be accurate the tank must be positioned properly When full 80 LPG the valve is closed by turning the knurled knob clockwise Typically a warning label surrounds the fixed tube gauge which reads STOP FILLING WHEN LIQUID APPEARS Service Valve The service valve is a manually operated valve using a small hand wheel to open and close the fuel supply to the service...

Page 802: ...he other coupling and the flat washer seals when the coupler is fully connected NOTE The flat seal and or the o ring will sometimes pop off when disconnecting and slide up the shaft of the mating connector causing the valve not to open when fully mated The extra washer or o ring must be removed from the shaft and the coupling reconnected Filler Valve The liquid filler valve Figure 9 has a male thr...

Page 803: ...rtified to IEC standard with a SELV Safety Extra Low Voltage classified output SECM 48 inputs and outputs may only be connected to other circuits certified as SELV Safety Extra Low Voltage WARNING EXPLOSION HAZARD Do not connect or disconnect while circuit is live unless area is known to be non hazardous Substitution of components may impair suitabil ity for Class I Division 2 or Zone 2 applicatio...

Page 804: ...uel while compression ignition engines are dual fuel Engine control module Foot pedal position Fuel primer valve Fuel temperature sensor Fuel trim valve Gallons per minute of flow Heated exhaust gas oxygen sensor Limited angle torque motor Liquified petroleum gas Manifold absolute pressure Manifold air temperature Malfunction indicator lamp Manufacturer of record for emissions certification on the...

Page 805: ...ification System Operation Testing Adjusting Disassembly Assembly D20G D25G D30G with B3 3 Engine D20G D25G D30G with 4TNE98 Engine G20G G25G G30G with G424F Engine G20G G25G G30G with G424FE Engine SB4218E01 Jan 2008 ...

Page 806: ......

Page 807: ...following symbol WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on t...

Page 808: ......

Page 809: ...11 Transmission Power Flow 12 Transmission Hydraulic System 13 Differential and Drive Axle 21 Testing and Adjusting Troubleshooting 22 Visual Checks 22 Checks During Operation 22 Differential 24 Transmission Tests and Adjustments 25 Transmission Pressure Tests 25 Converter Stall Test 27 Disassembly Assembly Instruction 28 Drive Axle 43 Special Service Tools and Jigs 47 ...

Page 810: ......

Page 811: ...Train Specification 5 Specification Torque Converter 1 Torque for bolts plate to torque converter Apply Loctite No 242 or 243 60 5 N m 44 4 3 7 lb ft 2 Torque for bolts plate to flywheel 25 7 N m 18 5 5 lb ft ...

Page 812: ... bolts that hold cap Apply Loctite No 242 or 243 140 to 165 N m 104 to 122 lb ft 4 Torque for bolts that hold case 100 L 20 N m 72 14 8 lb ft 5 Ring gear runout measured on back 0 1 0 2 mm 0 0039 0 0078 in T I R 6 Backlash of spiral bevel gear 0 15 to 0 23 mm 0 006 to 0 009 in 7 Rolling torque of ring gear for complete assembly 50 5 N m 37 3 7 lb ft See Transaxle in Testing and adjusting for the c...

Page 813: ...ut slowly until torque required to 200 L 10 N m 148 L 7 4 lb ft and release the insidenut by 1 8 1 10 circle Bearing rolling Torque 10 30 N m 7 4 21lb ft 3 Torque for bolts that hold drive shaft to hub 70 to 75 N m 51 8 to 55 5 lb ft 4 Torque for wheel mounting bolts Apply Loctite No 262 420 10 N m 310 7 4 lb ft 5 Torque for Drum mounting bolts 460 20 N m 340 14 8 lb ft ...

Page 814: ...erential Two axle shafts connect the differential to two final drives The drive wheels are mounted to the final drives Power from the engine flywheel goes from the torque converter to the input shaft of the transaxle The transaxle has two hydraulically operated clutch packs that are released by spring The transaxle has one speed in forward and one speed in reverse Power from either clutch pack is ...

Page 815: ...ally connects the engine to the transaxle There is no direct mechanical connection between the engine and the transaxle When the machine works against a load the torque converter can multiply the torque from the engine and send a higher torque to the transaxle The torque converter has four main parts housing 5 impeller 6 turbine 4 and stator 3 The housing 5 and impeller 6 turn with the engine The ...

Page 816: ...rbine blades makes turbine 4 and the transmission input shaft turned This gives power to the transaxle After the oil hits the turbine blades it goes toward the inside of the turbine 4 As the oil goes from the turbine 4 it moves opposite to the direction of impeller rotation When the truck is moved at low speed the torque converter one way clutch holds the stator 3 in place The stator 3 causes the ...

Page 817: ...ransaxle The forward and reverse directional controls are changed by directional switch Power is transmitted by constant mesh helical gears and multiple disc clutch packs In forward power is sent from a gear 6 at the forward clutch 5 to an output gear 9 which is on the pinion shaft In reverse power is sent from a gear 13 at the reverse clutch 12 to idle gear and then to the output gear 9 The trans...

Page 818: ... 6 and output gear 9 Output gear 9 is splined to pinion 10 Pinion 10 is in mesh with ring gear 15 Spur gear 16 is splined to shaft with ring gear 15 Spur gear 16 is in mesh with spur gear ring 17 witch is mounted to the differential Power will flow through spur gear 16 spur gear ring 17 differential to the final drives and wheels The truck will move in a forward direction Reverse Direction With th...

Page 819: ...utlet port and flows to the torque converter outlet The torque converter outlet acts to raise the pressure within the torque converter approx min 200 Kpa 29 psi and it is regularly opened after the engine is started 5 The oil pressure passing through the torque converter outlet port goes towards the torque converter cooler 10 lubricates all parts then returns to the transmission case Main Relief V...

Page 820: ...Power Train System Operation 14 Hydraulic System ...

Page 821: ...ter 9 flows to oil cooler 10 Oil then flows through passage to cool and lubricate the clutches and shaft bearings Pump pressure is directed to the inching valve 4 which reduces pressure prior to being fed to the modulating valve 5 With the inching valve 4 not in use inching pedal up oil from inching valve 4 flows through passage to modulating valve 5 In NEUTRAL position pump oil flow is blocked at...

Page 822: ...Power Train System Operation 16 Hydraulic System ...

Page 823: ... and oil cooler 10 circuits will be the same as explained in NEUTRAL position Oil will flow from the inching valve 4 through passage and modulating valve 5 to directional valve 6 In FORWARD the directional spool in the directional valve 6 is in the position shown Oil flows through passage to forward clutch 13 Forward clutch 13 will fill with pump oil ...

Page 824: ...Power Train System Operation 18 Hydraulic System ...

Page 825: ...9 and oil cooler 10 circuits will be the same as explained in NEUTRAL position Oil will flow from the inching valve 4 through passage and modulating valve 5 to directional valve 6 In REVERSE the directional spool in the directional valve is in the position shown Oil flows through passage to reverse clutch 12 Reverse clutch 12 will fill with pump oil ...

Page 826: ...Power Train System Operation 20 Hydraulic System ...

Page 827: ... the axle shafts 9 When the lift truck moves in a forward direction and there is same traction under each wheel there is also the same torque on each axle and pinions 2 are stopped This gives the same effect as if both wheels were on the same axle During a turn the force traction that is on the drive wheels is different These different forces are also felt on opposite sides of the differential and...

Page 828: ...on 4 Check the oil in the transmission for loose particles a Bronze colored particles give an indication of a clutch failure b Shiny steel particles in the filter give an indication of a pump failure c Rubber particles give an indication of a seal failure or hose failure If you find metal or rubber particles all components of the hydraulic and lubrication systems must be washed clean Do not use pa...

Page 829: ...se direction clutch 2 Leakage at the seals 3 Reverse clutch components have damage 4 Control linkage has damage or wrong adjustment Problem Transmission operates in reverse only Probable Cause 1 Discs and plates have too much wear in forward direction clutch 2 Leakage at the seals 3 Forward clutch components have damage 4 Control linkage has damage or wrong adjustment Problem Low stall speed Proba...

Page 830: ...e direction and creeps in that direction in neutral Engine stalls when shifted to the other direction Probable Cause 1 Failure of direction clutch in the direction the vehicle will move Problem Transmission does not operate in forward or reverse Probable Cause 1 Clutch discs and plates have too much wear 2 Leakage at the seals 3 Forward and reverse clutch components have damage Differential Proble...

Page 831: ... clear area that is level Keep all other personnel away from the lift truck Use lifting equipment or a safe method to lift the front of the lift truck until the drive wheels are off the floor Put wood blocks or jack stands of the correct capacity under it to hold it in this position while pressure tests are performed When the transmission test is made the transmission oil must be at the correct ra...

Page 832: ...o show engine speed during the test 3 Put a thermistor probe in place of the dipstick in the transaxle oil reservoir 4 Remove each of the following pressure tap plugs in the order shown and install the pressure gauge After the pressure check is done remove the gauge and install the plug again Front Side Rear Side Pressure Tap Location 1 Converter Out Pressure Tap 2 Main Line Pressure Tap 3 Clutch ...

Page 833: ...e ground speed was modified in the field other than 2 450 50 rpm the high idle rpm should be changed to this range with the engine service tool before measuring the stall speed After check and repair the ground speed needs to be returned to the original range with the engine service tool 1 Connect a tachometer to the engine start the engine and move the control lever to the FORWARD direction In ca...

Page 834: ...bolt 2 and removing washer 3 and shim 5 with a wrench Precautions a Tightening torque for bolt 2 shall be 55 65 N m 40 48 lb ft for reassembling Apply LOCTITE 242 or 243 cohering agent b During the reassembly while pushing the converter 1 to the opposite direction of the arrow turn it in order to insert it into the driving gear 6 of oil pump c When converter 1 is put in place the dimension A of mo...

Page 835: ...id of two threaded hole A on stator seat 3 Take the pump ass y off Precautions Tightening torque for bolts 2 and 4 shall be 25 32 N m 18 24 lb ft for reassembling Apply LOCTITE 242 or 243 cohering agent 3 Disassembly Oil pump ass y Take stator seat 1 out of pump ass y together with driving gear 2 and driven gear 3 Take the oil seal 5 out from pump case 4 Precautions Dering the disassembly the oil ...

Page 836: ...e and paper gasket 8 Dismantle gears 5 6 and bearings 4 7 with drawing tool Precautions a Apply some amount of lubricant oil on the surface of the bearings and the case in assembling b When assembling tightening is bolt 1 tightening torque is 55 65 N m 40 48 lb ft and apply LOCTITE 242 or 243 locking agent c Assemble bearings 4 and 7 with a pressing tool Jig A Pressing tool use when assembling bea...

Page 837: ...ng the assembly Take care not to damage seal ring B Jig A Pressing tool use when reassembling bearings 6 Disassembly Clutch ass y Take off seal rings 1 and 11 Remove gears 4 and 8 using a drawing tool together with bearing 2 10 thrust rings 3 6 9 12 needle bearings 5 7 Precautions a Apply suitable amount of lubricating oil on the surface of bearings 2 and 10 b Use pressing tool to assemble bearing...

Page 838: ...ve by means of pressing tool Then remove the elastic retainer ring 5 and other parts in clutch ass y Precautions When assembling install the seal ring 9 into piston 8 and apply suitable amount of lubricant oil on clutch drum Push the piston into the drum Jig A Pressing tool use when reassembling bearings 8 Disassemble idle shaft Remove the idle shaft 2 together with the bearings Precautions Use pr...

Page 839: ...l use when reassembling bearings 9 Disassemble bearing 1 from idler shaft 2 by means of drawing tool Precautions Use pressing tool to assemble bearings 10 Disassemble Strainer 1 Remove cover 2 and take out the strainer 1 Item 5 is gasket 35 5mm 100mm 46mm ...

Page 840: ...bent area of locking plate 2 and unscrew bolt 1 to remove bearing seat 3 Take out the differential ass y 4 Precautions a Tightening torque for bolt 1 shall be 140 165 N m 103 120 lb ft for reassembling Apply LOCTITE 242 or 243 cohering agent b After the bolt being screwed in bend the locking plate 2 ...

Page 841: ... parts out Straighten the bent area of locking plate 12 and unscrew nut 13 to remove the plate 12 and bolt 14 Dismantle gear 2 from L H differential case 3 Precautions a Tightening torque for nuts 13 and 17 shall be 45 55 N m 33 40 lb ft for reassembling Apply LOCTITIE 242 or 243 cohering agent b Replace locking plates 12 and 16 After nuts 13 and 17 being tightend bend the locking plates 12 and 16...

Page 842: ...e new ones be careful to adjust the shim 4 The improper shimming would cause the noise 14 Tap with a copper hammer on reduction gear 2 along the direction as indicated by arrow to dismantle bearing 1 gear shaft 2 spacer 3 and bevel gear 4 Precautions a Remember not to mix the inner and outer rings of upper and lower bearings up in disorder b The bevel gear 4 must be mounted in it s position Axial ...

Page 843: ...ide A of output shaft 7 gently to remove the shaft together with the bearings and nut on it Precautions a Tightening torque for bolt 1 shall be 25 32 N m 18 24 lb ft for reassembling Apply LOCTITE 242 or 243 cohering agent b Use pressing tool for reassembling Jig D Pressing tool use when assembling and disassembling bearings on output shaft 116mm 75 4mm ...

Page 844: ... arrow to remove all the parts on the shaft Precautions a To reassemble replace the nut first and screw it in When the axial clearnace on bearings 2 and 6 is diminished releasse the nut Apply tightening torque of 10 15 N m 7 11 lb ft to the nut and then strike the nut end flat for locking purpose b Use pressing tool for reassembling Jig D Pressing tool use when assembling and disassembling bearing...

Page 845: ...om the case Remove elastic retainer 11 by pliers Take out Oring 12 sleeve 13 spring 14 inching piston 15 shaft 16 and spring 17 successively Dismantle oil seal 21 retainer 20 by pliers and remove cap 19 from the valve body 18 Precautions Tightening torque for reassembling bolts 1 and 4 shall be 25 32 N m 18 24 lb ft for reassembling Apply LOCTITE 242 or 243 cohering agent ...

Page 846: ... and remove bolt 1 and 4 washer 2 and 3 to separate control valve 6 from cover 7 Precautions a Tightening torque for reassembling bolt 1 as shown in L H fig shall be 45 55 N m 33 40 lb ft for reassembling b Tightening torque for reassembling bolts 1 and 4 as shown in R H fig shall be 25 32 N m 18 24 lb ft for reassembling c Apply LOCTITE 242 or 243 cohering agent ...

Page 847: ...ke out the pins 1 and 2 Unscrew and remove threaded plug 3 spring 4 and steel ball 5 And then take out control valve and all the rest parts Precautions Tightening torque for plug 3 when reassembling shall be 40 55 N m 30 40 lb ft Apply LOCTITE 242 or 243 cohering agent ...

Page 848: ... take off all the rest parts on valve cover Precautions a Tightening torque for bolt 3 when reassembling shall be 25 32 N m 18 24 lb ft b Tightening torque for cover 10 of release valve shall be 50 65 N m 37 48 lb ft c Tightening torque for pipe adapter shall be 55 65 N m 40 48 lb ft d Apply LOCTITE 242 or 243 cohering agent NOTE Reverse the disassembling procedures for reassembling ...

Page 849: ...xample 3 Remove the drive shaft 2 Typical Example 4 Loosen the bolts from the lock nut 3 Typical Example 5 Loosen lock nut and remove the plate 4 Tool Ref No Jig H Typical Example 6 Remove bearing cone 5 from the hub Typical Example 7 Remove the hub and drum 6 from the drive axle IBPD183P IBPD185P IBPD184P IBPD186P IBPD187P IBPD185P ...

Page 850: ...emove brake assembly 9 11 Loosen the bolts 12 and remove the drive axle housing by using lifting device Assembly The assembly procedure is the reverse order of removal but requires additional care as noted below 1 Install bearing cup and oil seal Typical Example 2 Fill 50 70 of space between bearings with Lithium grease IBPD191P IBPD190P IBPD189P IBPD195P IBPD196P IBPD194P ...

Page 851: ...Coat rib of oil seal with lithium grease Install the hub and drum NOTE Remove dirt or oil in the inside surface of the brake drum completely 6 After installing plate and lock inner nut tighten then release by 1 8 1 10 circle Next tighten the outer nut at a torque of 200 10 N m 148 7 lb ft Check bearing rolling torque The torque valve is 10 30 N m 7 22 lb ft IBPD191P IBPD190P IBPD188P IBPD200P IBPD...

Page 852: ...ace of hub with liquid gasket Typical Example 8 Install the drive shaft and tighten the bolts to a torque of 110 to 120 N m 81 to 88 lb ft 9 Fill the drive axle housing with oil NOTE All bolts should be coated with Loctite 271 thread lock when installing IBPD185P IBPD203P ...

Page 853: ...A Pressing tool for assembling bearing 35 5 mm 100 mm 46 mm Locally Manufactured Jig B Pressing tool for disassembling clutch ass y 90mm 51 5mm Locally Manufactured Jig C Pressing tool for assembling bearing 25mm 52mm Locally Manufactured Jig D Pressing tool for bearing of clutch 116mm 75 4mm Locally Manufactured ...

Page 854: ... 48 Ref No Tool Jig Name Illustration Jig E Drive Axle Pinion Bearing Adjustment Jig Locally Manufactured Jig F Drive Axle Pinion Bearing Adjustment Jig Locally Manufactured Jig G Drive Axle Pinion Depth Check Jig Locally Manufactured ...

Page 855: ...Power Train Disassembly Assembly 49 Ref No Tool Jig Name Illustration Jig H Drive Axle Hub Nut Installer 90 0 8 0 4 109 0 0 5 55 0 2 0 4 30 0 0 8 Locally Manufactured ...

Page 856: ......

Page 857: ... System Specification System Operation Testing Adjusting D20G D25G D30G with B3 3 Engine D20G D25G D30G with 4TNE98 Engine G20G G25G G30G with G424F Engine G20G G25G G30G with G424FE Engine SB4219E01 Jan 2008 ...

Page 858: ......

Page 859: ...ollowing symbol Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on the produc...

Page 860: ......

Page 861: ...ing 32 Visual Checks 32 Performance Tests 32 Hydraulic Oil Temperature Too Hot 32 Hydraulic System and Mast 33 Hydraulic Pump 36 Hydraulic Control Valve 37 Steering System 38 Brake System 39 Parking Brake 40 Hydraulic System 41 Relief Valve Pressure Check 41 Lift Cylinder Air Removal Only FFT FFL Mast 43 Delayed Engine Shutdown System 44 Operation 44 Diagram of Delayed Engine Shutdown System 45 Tr...

Page 862: ...System 64 Steer Wheel Bearing Adjustment 64 Steering Axle Stop Adjustment 65 Steering Knuckle Bearing Preload Adjustment 65 Steering System Pressure Check 66 66 Brake System 67 Brake System Air Removal 67 Brake Adjustment 67 Parking Brake Test 71 Parking Brake Adjustment 71 ...

Page 863: ... shown above See Relief valve pressure check in Testing Adjusting 4 Torque for screws 6 2 N m 53 20 lb in CONTROL VALVE ITEM psi kPa bar Kgf EU USA LIFT TILT 2 630 35 18 100 250 181 2 5 185 2 5 2 0t NON EU NON USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 EU USA LIFT TILT 2 840 35 19 500 250 195 2 5 199 2 5 2 5t NON EU NON USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 EU USA LIFT TILT 3 13...

Page 864: ...E98 Engine Displacement 26 5 rev Rotation is counter clockwise when seen from drive end Type of pump Gear A601502 for G20 25 30G Rotation is counter clockwise when seen from drive end Type of pump Gear Displacement 29ml rev Lift Cylinder Flow rate of flow protector FFL and FFT Mast D700495 45 to 53 liter min A215044 90 to 106 liter min STD Mast A371156 85 to 90 liter min Standard 1 Put pipe sealan...

Page 865: ...Lift Primary 1 Put pipe sealant on the last three threads of cap NOTE All seals to be lubricated with hydraulic oil Full Free Triple Lift And Full Free Lift Secondary 1 Put pipe sealant on the last three threads of cap NOTE All seals to be lubricated with hydraulic oil ...

Page 866: ...282 6 12 167 6 57 514 20 24 A375322 6 6 110 4 33 571 22 48 A375324 6 4 92 3 62 589 23 19 D20G G20G D25G G25G D30G G30G A375335 6 10 148 5 83 533 20 98 Permissible tolerance of 1 2 1 Adjust pivot eye to dimension Z with cylinder closed 2 Torque for bolt 95 15 N m 70 10 lb ft 3 Torque for head 270 30 N m 200 22 lb ft 4 Torque for piston nut 270 30 N m 200 22 lb ft ...

Page 867: ...60mm 4 315in D581816 Oversize 110 70mm 4 358in Permissible tolerance of 0 08 mm 003 in Carriage 1 Select bearings from the chart to obtain minimum clearance C between bearings and channel leg for full channel length Use same bearing at all six locations 2 Equally shim both sides until contact A is made zero clearance between bearings and inner mast at narrowest point 3 Shim bolt as needed to obtai...

Page 868: ... 2 or more could cause damage or injury to persons 1 Put LOCTITE NO 242 Thread Lock on the threads of the relay group locknuts after adjustment of the lift chains is completed 2 Maximum chain wear Less than 2 See Chain Wear Test in TESTING ADJUSTING 3 Distance from bottom of inner mast to bottom of lower bearing on carriage must be even flush with the inner mast ...

Page 869: ...s until contact is made with guard 2 Put LOCTITE NO 242 Thread Lock on the threads of the relay group locknuts after adjustment of the lift chains is completed 3 Maximum chain wear Less than 2 See Chain Wear Test in TESTING ADJUSTING 4 Distance from bottom of inner mast to bottom of lower bearing on carriage must be 41 1 5 mm 1 61 0 6 in Bottom of inner mast must be even flush with bottom of stati...

Page 870: ...ain wear Less than 2 See Chain Wear in TESTING ADJUSTING 2 Put LOCTITE NO 242 Thread Lock on the threads of the relay group locknuts after adjustment of the lift chains is completed 3 Tighten bolts until contact is made with guide assembly 4 Distance from bottom of inner mast to bottom of lower bearing on carriage must be 41 1 5 mm 1 61 0 6 in Bottom of inner mast be even flush with bottom of stat...

Page 871: ...tal shim pack must not be more than three shims maxi mum 2 Install bearing outer race to a depth of F 4 5 0 8 mm 177 031 in 3 Tilt cylinder installation shown 4 Install bearing outer race to a depth of G 4 5 0 8 mm 177 031 in 5 Std Mast Only Tighten the bolt until the middle plastic shim touches the cylinder slightly 6 Std Mast Only Tighten the nut until the U Bolt touches the cylinder slightly Re...

Page 872: ...ick move to one side hold lift cylinder tube on that side and loosen bearing 1 4 turn and check mast again Loosen bearing until kicking movement stops or gap H reaches 3 0 mm 12 in approximately 1 5 turns whichever is less Insert shims 11 under bearing it may be necessary to loosen bearing an additional amount of turns to install shims Tighten bearing again 12 Tighten the bolt of mounting mast the...

Page 873: ...th internal pump gear gerotor 2 and drive 3 as shown 4 Tighten bolts in sequence shown Tighten to a first torque of 14 1 2 8 N m 125 25 lb in Tighten to a final torque of 28 2 2 8 N m 250 25 lb in 5 Torque for plug 11 3 N m 100 lb in Plug to be flush even with or below mounting surface ...

Page 874: ...t 1 completely Tighten it again to 50 5 N m 37 4 lb ft c Insert the pin 2 into lock nut 1 and bend it over nut 3 Torque for bolt that holds pin 11 1 N m 100 9 lb ft 4 6 Loosen nuts 5 on both sides Adjust bolts 4 to get steering knuckle turning angle A of 76 to 77 5 See Steering Axle Stop Adjustment in Testing And Adjusting section 8 Tapered Roller Bearing Axles Only Torque for bolts that hold stee...

Page 875: ...uts that hold steer wheel 120 20 N m 90 15 lb ft Shoe Brake 1 Axle shaft bolt 110 10N m 81 7 4 lb ft 2 Nut 200 10N m 148 7 4 lb ft 3 Torque for bolts that hold plate to final drive cover 180 30N m 133 22 lb ft 4 Torque for nuts that hold brake drum to hub 460 20N m 339 15 lb ft ...

Page 876: ...3 Lift Cylinder Primary 4 Flow Protector Secondary 5 Side Shfit Cylinder 6 Tilt Cylinder 7 Control Valve 8 Hydraulic Line To Steering Unit 9 Relief valve Auxiliary 10 Relief Valve Main 11 Gear Pump 12 Suction Filter 13 Return Filter 14 Hydraulic Tank 15 21 Hydraulic Line 22 Flow Regulator Valve FFT mast 12 Engine 1 6 5 3 1 2 4 STD mast 4 7 11 13 14 8 9 10 15 18 19 20 21 16 22 ...

Page 877: ...turn 13 and back to a hydraulic tank 14 The relief valve main 10 releases the excessive pressure to the hydraulic tank when the pressure in the lift circuit or tilt circuit goes higher than setting pressure shown at CONTROL VALVE SECTION of SPECIFICATION The relief valve auxiliary 9 releases the excessive pressure to the hydraulic tank when the pressure in auxiliary circuit goes higher than settin...

Page 878: ...inder 6 Tilt Cylinder 7 Control Valve 8 Hydraulic Line To Steering Unit 9 Relief valve Auxiliary 10 Relief Valve Main 11 Gear Pump 12 Suction Filter 13 Return Filter 14 Hydraulic Tank 15 24 Hydraulic Line 25 Flow Regulator Valve 26 Solenoid Block 27 Lift Lock Solenoid 28 Unload Solenoid 29 Emergency Manual Over Ride Valve FFT mast 12 Engine 1 6 5 3 1 2 4 STD mast 4 7 11 13 14 8 9 10 15 16 18 19 20...

Page 879: ...n 3 seconds or a start key is off The solenoid valve 27 for lift lock is electrically connected to the electric on off switch beneath a seat When the operator leaves a seat for more than 3 seconds or a start key is off the solenoid valve become off This leads to block the lowering flow passage Once the operator sits on seat and a start key is on the solenoid valve becomes on and immediately loweri...

Page 880: ...ns to control the loading Oil from Port P goes from throttle hole check valve PF throttling part inside of spool FD into PF port If oil from port P is increased pressure difference will be generated in front and back of throttle hole Because of the pressure difference on ends of FD spool the spool goes toward the part to shut the PF throttle part And then pressure difference goes down as well as P...

Page 881: ... the tank Meanwhile oil from Port Are turns to tank through the back flow path open by the spool And the spool comes back to the neutral position by reset spring Working principle of tilting valve 1 Neutral Position Oil from the pump returns to the tank through unload path 2 Tilting up of spool While unload path is closed oil from pump opens a load check through parallel path and flow out from Por...

Page 882: ...r doesn t work even spool down is performed When spool is down with no coming oil tank path from Port A is closed since no pressure to open pilot spool Therefore no action is done by a tilt cylinder which is in a lock condition Working Principle of Accessory Valve Section 1 Neutral Position Oil from the pump returns to tank through unload path 2 Spool up When unload path is closed oil opens a load...

Page 883: ...Relief Valve 1 Free Action Condition of relief valve When the circuit pressure is lower than the rated values relief valve keeps balance Pressure at Port P is filled in the spring chamber through poppet throttle hole By the work of spring force and oil pressure main poppet is squashed into the seat of slip while the pilot poppet is also in the condition of close by the force of spring Therefore al...

Page 884: ... omitted here Over load Relief Valve Port Over flow Valve Working principle is same as main relief valve Below is only the description of cavitation proof When working port pressure is lower than that off low back port main poppet is open and flow back oil goes into working port to play the function of cavitation ...

Page 885: ...rainer to hydraulic pump 8 The pump sends the oil through hose 11 to prioriey valve 12 The priority valve 12 supplies 12 Lpm of all pump flow to steering gear 1 and make it s remaider flow go to the sections of control valve 6 Check valve 5 in priority valve 12 is in hose 10 near the steering gear to prevent oil flow back to priority valve 12 priority which could cause a sudden jerk of the steerin...

Page 886: ... are met The steering gear has two main sections control section A and pump or metering section B These two sections work together to send oil to the steering cylinder Oil from the priority valve goes through inlet 4 into the control section of the steering gear When the steering wheel is turned the control section sends the oil to and from the metering section and also to and from the steering cy...

Page 887: ...uses a rotation of gear 5 inside gear 6 This rotation of the gear sends a controlled metered flow of pilot oil back through body 11 This oil flows to port 9 or 10 and then to the steering cylinder Port 9 or 10 that is not used for pressure oil to the steering cylinder is used for return oil from the other end of the steering cylinder Pump Gears In Metering Section 5 Internal pump gear 6 External p...

Page 888: ...ton moves into the master cylinder and push brake liquid through outlet into the brake lines When floating piston seats on seal the liquid that is pushed by piston goes around cup seal out through loading piston and outlet This action continues until the liquid pressure in piston bore reaches the pressure that opens relief valve The liquid being pushed by piston now returns to reservoir 1 Cup seal...

Page 889: ... automatic adjustment are adjusted on the reverse braking action In this example the drum rotation is counterclockwise in reverse which causes a counterclockwise rotation of the brake shoes Secondary shoe 4 moves away from cylinder 2 that causes link 1 to move toggle lever 6 in a clockwise rotation Link 8 is connected to the lower part of toggle lever 6 and to adjustment lever 9 By this connection...

Page 890: ...lug line or component is removed make sure all hydraulic pressure is released Visual Checks A visual inspection of the hydraulic system and its components is the first step when a diagnosis of a problem is made Lower the carriage to the floor and follow these inspections 1 Measure the oil level Look for air bubbles in the oil tank 2 Remove the filter element and look for particles removed from the...

Page 891: ...en the relief valve Relief valve pressures that are too low will cause a decrease in the lift and tilt characteristics of the lift truck Pressures that are too high will cause a decrease in the life of hoses and components 2 Drift rates in the cylinders Cylinder drift is caused by a leakage past cylinder pistons O ring seals in the control valve check valves that do not seat correctly or poor adju...

Page 892: ...lt spool has a restriction 7 The priority valve does not work correctly 8 Seals in tilt cylinder worn or damaged 9 Unload function doesn t work correctly Probable Mechanical Cause 1 Damage or failure of the tilt cylinders 2 Mast mounting pins seized Problem The carriage will not lower correctly Probable Cause 1 There are restrictions in the lift line 2 The lift spool in the control valve has a res...

Page 893: ... and twisted 180 degree clockwise Probable Electric Cause 1 Not to supply the electric power to solenoid valve in solenoid block Probable Hydraulic cause 1 A broken lift lock solenoid valve in solenoid block Probable Mechanical Cause 1 Lift cylinder damaged or bent 2 Load roller defective bearing or not adjusted correctly 3 Not enough lubricant on the parts of mast which that moves Problem Safety ...

Page 894: ... valve setting is too low 4 The oil is too thin 5 There is air leakage in the system 6 The pump has too much wear 7 The system operates at too high a pressure a Relief valve setting too high b Attachment components cause a restriction during movement c Restrictions in flow control valve load check valve and in oil lines 8 Severe hydraulic usage Problem Leakage on the shaft seal Probable Cause 1 Th...

Page 895: ...d check valve and seat show wear 3 Sudden loss of pump oil pressure 4 Damage to the relief valve which causes low oil pressure Problem Spools do not return to neutral Probable Cause 1 The springs are broken 2 The spool is bent 3 The system or valve has foreign particles in it 4 The control linkage is not in alignment 5 The fastening bolts of the valve have too much torque Problem No motion or slow...

Page 896: ...alve check valve permits lift and tilt hydraulic oil to affect steering hydraulic circuit Problem Oil leakage at the pump Probable Cause 1 Loose hose connections 2 Detective shaft seal Problem Low oil pressure Probable Cause 1 Low oil level 2 Priority valve relief valve spring weak 3 Relief valve priority valve will not move from the open position 4 Oil leakage inside or outside of the system 5 De...

Page 897: ... shoe adjustment not correct 2 Brake pedal adjustment not correct 3 Mechanical resistance at the pedal or shoe 4 Restriction in the brake line 5 Defective wheel cylinder Problem Pedal resistance is not solid spongy Probable Cause 1 Leakage or low fluid level 2 Air in the brake hydraulic system 3 Loose master cylinder mounting Problem Hard pedal Probable Cause 1 Mechanical resistance on the pedal o...

Page 898: ... adjustment or is bent Problem Not braking evenly or rough feeling of braking chatter Probable Cause 1 Lining surface looks like glass glazed or worn 2 Oil or brake fluid is on the lining 3 Defective contact between the lining and drum 4 Loose lining 5 Brake drum out of round 6 Loose wheel bearing 7 Defective wheel cylinder Parking Brake Problem Brake will not make application Probable Cause 1 Par...

Page 899: ...sure is released before any fitting plug hose or component is loosened tightened removed or adjusted Always move the lift truck to a clean and level location away from the travel of other machines Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are made Pressure Tap Location 1 Pressure tap With the engine off remove cap 1 from nipple assemb...

Page 900: ... control lever in the full tilt back position and watch the gauge The gauge indication is the pressure that opens the relief valve 3 The correct pressure setting is shown in the chart 4 If an adjustment to the relief valve setting is necessary loosen nut 5 Relief Valve Adjustment 5 Locknut 6 Stud 5 Turn setscrew 6 clockwise to increase or counterclockwise to decrease the pressure setting of the re...

Page 901: ... high enough to put a load on all stages of the lift cylinders Typical example Setscrew Locations Standard Cylinders NOTE The Full Free and Full Free Triple Lift mast has one primary and two secondary cylinders 5 Locate the setscrew on each lift cylinder Slowly open setscrews no more than one turn The weight of the carriage will force air and hydraulic oil out of the cylinders through the setscrew...

Page 902: ...engine shutdown system will interrupt the fuel supply to the engine thereby saving the engine from the critical damage 1 Low engine oil pressure The warning MIL lamp will turn on when the oil pressure drops to approximately 28KPa 4 psi and the delayed engine shutdown System will interrupt the fuel supply to the engine after thirty seconds 2 Hot engine coolant The warning MIL lamp will turn on when...

Page 903: ...Vehicle System Testing and Adjusting 45 Diagram of Delayed Engine Shutdown System G20 25 30G G424F E ENGINE LP TRUCK G20 25 30G G424F E ENGINE GAS TRUCK ...

Page 904: ... 161 15 Low Oil Pressure Fault Low engine oil pressure 521 52 Transmission Oil Temperature Excessive transmission oil temperature 933 Diagnostic Fault Codes DFC PROBABLE FAULT FAULT ACTION CORRECTIVE ACTION FIRST CHECK 151 15 ECT Range High Coolant sensor disconnected or open circuit 1 Turn on MIL 2 Delayed Engine Shutdown 3 Check Engine Light Check if ECT sensor connector is disconnected or for a...

Page 905: ...Vehicle System Testing and Adjusting 47 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G20 25 30G G424F E LP ...

Page 906: ...Vehicle System Testing and Adjusting 48 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN G20 25 30G G424F E GAS ...

Page 907: ...utral shift feature Transmission is automatically shifted to the neutral when the operator leaves the seat with the engine running and the direction lever in forward or reverse To restore the lift truck return the directional lever to the neutral position and then reselect a direction of travel either forward or reverse The transmission will then re engage 4 Water separator sediment warning only d...

Page 908: ...em Schematic SOL_VALVE_UNLOAD SOL_VALVE_LIFT LOCK INDICATOR AS SEAT BELT SWITCH SEAT SWITCH AIR CLEANER SWITCH FUSE CIRCUIT BREAKER IGNITION SW DIR SWITCH RELAY CREEPING SPEED PILOT BUZZER FWD BATTERY FUSE PARKING BRAKE SW REV LP PR SW SEDIMENT SW CONTROLLER VCS ...

Page 909: ...een controller SW3 and GND 12V is no problem 1 Buzzer warning 2 Neutral light 3 No drive operation 1 Seat switch open 2 Relay REV FWD Creep speed defect 3 Directional switch defect 4 Wiring defect 5 FWD REV Solenoid defect 6 Controller defect 1 Check seat switch 2 Check relay REV FWD Creep speed 3 Check FWD REV Solenoid 4 Check continuity of wire from relay creeping speed 85 to controller C RELAY ...

Page 910: ...lock Unload Solenoid 3 Check continuity of wire from solenoid lift lock 2 or solenoid unload 2 to controller ISO3691 VALVE 4 Check continuity of wire from solenoid lift lock 1 or solenoid unload 1 to controller IGN 5 Measure the voltage between controller IGN and controller ISO3691 VALVE 12V is no problem 1 Air cleaner light 1 Air cleaner switch short 2 Wiring defect 1 Check air cleaner switch 2 C...

Page 911: ...arings A Lower Bearing Adjustment of Intermediate Mast Mast Adjustment Lower Bearings A Zero clearance B Minimum clearance C Zero clearance 3 Bearing 4 Bearing 5 Shims 6 Shims 1 Select lower bearings 3 and 4 from the chart to obtain minimum clearance B between bearing and channel leg for full channel length Use same bearing on left and right side Mast And Carriage Bearings Part No Bearing Size Bea...

Page 912: ...ually when positioned behind each bearing 4 Mast Adjustment Lower Bearings A Zero clearance B Minimum clearance C Zero clearance 3 Bearing 4 Bearing 5 Shims 6 Shims 4 Make surer intermediate mast lower bearings are properly shimmed in the stationary mast by rolling up and down and moving intermediate mast to right and left If clearance between both masts can be detected pull out the intermediate m...

Page 913: ...ermediate lower bearings Repeat same procedure of above until properly shimmed There is to be contact zero clearance C between intermediate lower bearings and stationary channel at approximately 475 mm 18 7 in channel lap B Upper Bearing Adjustment of Stationary Mast 1 Lift by crane and pull out intermediate mast from stationary mast Install 1 mm shim to each bearing of stationary mast upper Beari...

Page 914: ...tationary mast and remove shim 0 5 mm to both stationary upper bearings Repeat same procedure of above until properly shimmed There is to be contact zero clearance C between stationary upper bearings and the widest point of intermediate mast to be checked before C Upper Pad Adjustment Mast Adjustment Upper Bearings D Zero clearance E 0 80 mm 031 in Clearance maximum F Zero clearance 7 Pads 8 Shims...

Page 915: ... right side Mast And Carriage Bearings Part No Bearing Size Bearing O D D581814 Under Size 108 6 mm 4 276 in D581815 Standard 109 6 mm 4 135 in D581816 Over Size 110 7 mm 4 358 in Permissible tolerance 0 08mm 003in 2 Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 475 mm 18...

Page 916: ... There is to be contact zero clearance C between inner lower bearings and intermediate channel at narrowest point E Upper Bearing Adjustment of intermediate Mast Follow same procedure with above B F Upper Pad Adjustment of Intermediate Mast Follow same procedure with above C Carriage Adjustment NOTE The standard Full Free Lift and Full Free Triple Lift carriage load bearings are all adjusted the s...

Page 917: ...3 Install enough shims 4 that have been divided into two equal groups behind bearings 3 At installation there is to be contact zero clearance A between the bearings and the narrowest point of inner mast 4 Do step 2 through 3 for other sets of bearings 5 Tighten screw 5 that holds the top bearings to the carriage to a torque of 34L7 N m 25L5 lb ft Chain Adjustment Chain Adjustment Check Chain Adjus...

Page 918: ... 1 or bolts 2 for equal tension of the mast and carriage chains 3 Put LOCTITE NO 242 Thread Lock on the threads of the locknuts after the adjustment is completed Outer Lift Chains 2 Chain Anchor Bolts Chain Wear Test Chain wear test is a measurement of wear of the chain links and pins Do the steps that follow to check chain wear 1 Lift the mast and carriage enough to put tension on the lift chains...

Page 919: ...he bearing must be even flush with the inner mast If the above measurements are not correct make adjustments to the chains to get the correct measurement See Chain Adjustments in TESTINGAND ADJUSTING Forks Parallel Check 1 Lift the mast and operate the tilt control lever until the top surface of the forks is parallel with the floor Place two straight bars that are the same width as the carriage ac...

Page 920: ... sure that the mast is not twisted The tilt angle is determined by the tilt cylinders used See tilt cylinders in specifications to determine the tilt angle from the cylinder being used Tilt Cylinder Length Check Tilt Cylinder Length Check 1 Tilt the mast to full forward position Measure the extended length of the cylinder rods from the cylinder housing to the mast The difference of length between ...

Page 921: ... cylinders or control valve Before testing the drift WARNING Personal injury can be caused by sudden movement of the mast or carriage Use woodblocks and clamps to hold the mast in this position Keep hands and feet clear of any parts that can move 1 Check the chain adjustment and tilt cylinder alignment and make necessary adjustments 2 Lift the mast approximately 762 mm 30 in Use wood blocks and cl...

Page 922: ...height extension raise the load to the truck s maximum height Tilt Drift Check 3 The tilt drift is measured as the charge in the tilt cylinder stroke Measure any drift of the mast for ten minute period Drift for shall not exceed 35 5 mm 1 40 in Steering System Steer Wheel Bearing Adjustment Bearing Adjustment 1 Nut 2 Lock 1 Tighten nut 1 slowly to 135 N m 100 lb ft while the wheels is rotated in b...

Page 923: ...ection and do the same procedure for the opposite stop bolts This will give a maximum cramp angle of 76 Steering Knuckle Bearing Preload Adjustment Steering Knuckle Bearing Preload Adjustment 4 Steering link 5 Shims 6 Bearing 1 During assembly of the steering knuckle install the thrust bearing and bushing without shims 2 Measure the clearance between bearing 6 and the axle beam 3 Take an average o...

Page 924: ...ition for operation start the engine and activate the hydraulic controls until the oil is at a temperature for normal operation 4 Turn the steer wheels to the left or right against the stops and make a note of the indication on the pressure gauge 5 The indication on the pressure gauge must be the priority valve relief setting of 9 000 0 300 kPa 1 305 0 43 psi If the indication is correct and a pro...

Page 925: ...screw 5 Fill remote reservoir 1 again with the correct fluid to the level explained in Step 1 Brake Adjustment The brakes make an adjustment automatically when an application is made in reverse but only after an application has been made in the forward direction With each reverse brake application there happens an adjustment until the lining to drum clearance is made small enough to stop the movem...

Page 926: ...red conduct the burning on the brake shoes and linings for 5 10 minutes Pedal Adjustment The brake pedal must have proper free play to let the master cylinder piston return to the release position and open the relief outlet Approximately 5 mm of free play on the pedal is required Hydraulic pressure in the brake lines goes back through the relief opening and releases the brakes If there is no pedal...

Page 927: ...per bolt for the brake pedal to meet 130 135 mm A between end of pedal floor plate For reference the distance B between the top of transmission and pedal shown below is about 353 mm 3 After finish the adjustment tighten the bolt with nut 130 135 mm 353 mm ...

Page 928: ... height of Inching Pedal with the brake pedal s by inching rod 6 Adjust the engaging point of inching pedal to the brake pedal when the stroke of inching spool becomes 2 mm 7 Make sure the same level of 2 pedals 8 Finally check the distance between floor plate end of brake pedal should be 130 mm 9 Test the brake performance and adjust once again if required additionally ...

Page 929: ...brakes Apply the parking brake 3 If the parking brake has the correct adjustment the lift truck can be held in this position 4 If the parking brake does not hold do the steps in parking Brake Adjustment Parking Brake Adjustment 1 Put the control lever in the released position 2 Turn the screw 1 on the lever in clockwise direction to tighten the cable assembly with driver 3 Turn the screw 1 on the ...

Page 930: ......

Page 931: ...Vehicle System Disassembly Assembly D20G D25G D30G with B3 3 Engine D20G D25G D30G with 4TNE98 Engine G20G G25G G30G with G424F Engine G20G G25G G30G with G424FE Engine SB4220E01 J a n 2 0 0 8 ...

Page 932: ......

Page 933: ... by the following symbol Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on t...

Page 934: ......

Page 935: ... Cylinder 31 Primary Lift Cylinder 34 Tilt Cylinder 37 Hydraulic Pump 42 Steering Wheel 51 Steering Unit 52 Brake Master Cylinder 62 Steer Wheel Bearing 64 Steering Knuckle Kingpin And Bearing 66 Steer Axle 67 Steering Cylinder 69 Hydraulic Control Valve 73 Counterweight 80 Engine 81 WARNING Disconnect batteries before performance of any service work ...

Page 936: ......

Page 937: ...mbly before removing nut 1 1 Raise the hood Support the hood with a hoist 2 Remove nut 1 from the support cylinder Remove the cylinder rod from the bracket 3 Lower the hood 4 Remove the bolts 2 from the cover Remove cover 5 Remove the washers and four bolts 3 6 Release latch Use the hoist to remove hood and seat assembly 4 The hood and seat assembly weighs approximately 52 kg 115 lb 7 Install the ...

Page 938: ...aps and a hoist 2 Remove the washers nuts and bolts 2 3 Remove the washers nuts and two bolts 3 4 Remove front overhead guard 1 Front over head guard 1 weighs approximately 30 kg 66 lb 5 Remove the washers nuts and four bolts 4 6 Remove rear Leg 5 7 Install front overhead guard 1 and rear leg 5 in the reverse order of removal ...

Page 939: ... 7 Install the forks in the reverse order of removal 8 Put the forks in position Lower both fork pins 1 to lock the forks in position 9 Install stopper bolt and washer 3 Be careful not to miss this step Backrest Remove Install Backrest 1 Fasten a hoist to the backrest Remove bolts 2 that fasten the backrest to the carriage 2 Remove backrest 1 Backrest 1 weighs about 40 kg 90 lb 3 install backrest ...

Page 940: ...any hydraulic lines Slowly loosen the cap of the hydraulic tank to release any pressure in the tank Be cautious of hot hydraulic coil when any lines are disconnected in the hydraulic system NOTE For purposes of reassembly identify and mark all hydraulic lines and connectors before removing or disconnecting Typical Example 3 Remove four bolts 8 from the chain guard hose support assembly 6 Set the h...

Page 941: ... 12 from the shaft Typical Example 7 Raise the inner mast to pull out carriage as shown 8 Remove carriage 14 from bottom of inner mast 15 Carriage 14 weighs 116kg 255 lb NOTE Use the following steps to install the carriage 9 Raise the inner mast to put in the carriage onto the mast and lower the inner mast to cover carriage 1 bearing fully ...

Page 942: ...70 40 N m 200 30 lb ft Install bolts 10 onto the hose mounting bracket Typical Example 12 Install chain guard hose support assembly 6 and four bolts 8 to a torque of 8 2 N m 6 1 5lb ft Typical Example 13 Connect two hydraulic line 4 in their original positions End By a Install backrest b Install forks Disassemble Carriage Start By a Remove carriage Typical Example 1 Remove the roll pins and pins 2...

Page 943: ...djustments carriage must be removed from the mast Use the procedure that follows to adjust carriage load bearings Carriage adjustment 3 Upper bearings 4 Shims 5 Bolt 6 Screw 7 Middle bearings 8 Lower bearings A Zero clearance B 6 0 to 9 0 mm 236 to 354 in clearance C Minimum clearance 1 Select lower bearings from the chart to obtain minimum clearance B between bearings and channel leg for full cha...

Page 944: ... contact zero clearance A between the bearings and the narrowest point of inner mast 4 Do step 2 through 3 for other sets of bearings 8 9 Typical Example Typical Example 5 Tighten screw 5 that holds the top bearings to the carriage to a torque of 34 7 N m 25 5 lb ft Typical Example 6 Position chains 6 on the carriage Install pins 7 and the roll pins End By a Install carriage raise the inner mast a...

Page 945: ...l hydraulic connectors and hoses to avoid debris and contamination from entering the system 2 Disconnect hose 3 3 Disconnect the hydraulic return lines not shown WARNING Tilt cylinders 7 can drop when pin 6 is removed To avoid component damage or personal injury support tilt cylinder 7 while removing pin 6 4 Remove bolt 5 from each side of mast assembly 2 5 Remove pin 6 from the tilt cylinders on ...

Page 946: ... remove mast assembly 2 from the machine 8 Install the mast in the reverse order of removal End By a Install forks b Fill hydraulic oil to tank Refer to the Operation and Maintenance Manual for further information Disassemble Mast Start By a Remove primary lift cylinder b Remove mast NOTE The following disassembly and assembly procedure is for a full free triple lift mast Typical Example 1 Remove ...

Page 947: ... 3 3 Remove chain nut 4 from the top of the mast each side Typical Example 4 Disconnect and remove chains 5 from the bottom of the mast STD Mast FFT Mast 5 Remove top cylinder retainer bolt 6 from each side of the mast 6 Disconnect lift hose 7 and return hose 8 ...

Page 948: ...tainer bolt 9 from each side of mast STD mast only STD Mast FFT Mast 8 Remove cylinder retainer brackets 10 from each cylinder STD Mast FFT Mast 9 Fasten a nylon strap and hoist to lift cylinder as shown Hoist and remove lift cylinder 11 Each cylinder weighs about 50 kg 110 lb ...

Page 949: ... the bearings 13 with new if worn or damaged Typical Example 12 Fasten nylon straps and hoist to inner channel 14 Remove inner channel 14 The weight of the inner channel is approximately 150kg 330 lb Typical Example 13 Remove rollers 15 and the shims from the inner channel mast Typical Example 14 Fasten nylon straps and a hoist to the intermediate mast channel 16 Remove mast channel 16 The interme...

Page 950: ...xample 15 Remove rollers 17 and the shims from the intermediate mast channel FFT mast only 16 Remove nylon pads 18 and the shims Typical Example 17 Remove rollers 19 and the shims from the stationary mast channel 18 Remove nylon pads 20 and the shims ...

Page 951: ...ct lower bearings 3 and 4 from the chart to obtain minimum clearance B between bearing and channel leg for full channel length Must use same bearing on left and right side Mast And Carriage Bearings Part No Bearing Size Bearing O D D581814 Under Size 108 6 mm 4 276 in D581815 Standard 109 6 mm 4 135 in D581816 Over Size 110 7 mm 4 358 in Permissible tolerance 0 08 mm 003in 4 Find narrowest point b...

Page 952: ...m the upper side NOTE When installing shims 5 behind bearings 4 make sure the amount of shim is divided equally when positioned behind each bearing 4 Mast Adjustment Lower Bearings A Zero clearance B Minimum clearance C Zero clearance 3 Bearing 4 Bearing 5 Shims 6 Shims Typical Example 7 Make sure intermediate mast lower bearings are properly shimmed in the stationary mast by rolling up and down a...

Page 953: ... channel at approximately 475 mm 18 7 in channel lap B Upper Bearing Adjustment of Stationary Mast Typical Example 9 Lift by crane and pull out intermediate mast from stationary mast Install 1 mm shim to each bearing of stationary mast upper basically Bearing should be selected D581814 under size bearing Mast Adjustment Upper Bearings D Zero clearance E 0 80 mm 031 in Clearance maximum F Zero clea...

Page 954: ...arance C between stationary upper bearings and the widest point of intermediate mast to be checked before C Upper Pad Adjustment Mast Adjustment Upper Bearings D Zero clearance E 0 80 mm 031 in Clearance maximum F Zero clearance 7 Pads 8 Shims 9 Shims 10 Shims Typical Example 12 Install shims 8 behind each pad 7 until there is 0 80 mm 031 in maximum clearance E between the pads and the inner and i...

Page 955: ... And Carriage Bearings Part No Bearing Size Bearing O D D581814 Under Size 108 6 mm 4 276 in D581815 Standard 109 6 mm 4 135 in D581816 Over Size 110 7 mm 4 358 in Permissible tolerance 0 08 mm 003in Typical Example 14 Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 475 mm ...

Page 956: ... stuck and cannot move by rolling up and down there might be excessive shim Pull out the inner mast from the intermediate mast and remove shim 0 5 mm to both inner lower bearings Repeat same procedure of above until properly shimmed There is to be contact zero clearance C between inner lower bearing sand intermediate channel at narrowest point E Upper Bearing Adjustment of intermediate Mast Follow...

Page 957: ...d nylon strap to secondary cylinder 11 Install secondary cylinders 11 into the stationary mast STD Mast FFT Mast 21 Install secondary cylinder mounting brackets 10 over the secondary cylinders STD Mast 22 Install cylinder bottom retainer bolt 9 to each side of mast STD mast only ...

Page 958: ...ose 7 and return hose 8 STD Mast FFT Mast 24 Install top retainer bolt 6 to the secondary cylinders 25 Install hydraulic steel tube to each secondary cylinder When install the steel tube assembling angle should be kept as shown in above figure FFT mast only ...

Page 959: ...per 28 Install sheave of lift hose FFT mast only 29 Install the lift hose support bracket 3 and hoses FFT mast only 30 Install primary lift cylinder 2 FFT mast only Typical Example 31 Install carriage assembly from the bottom of inner mast Typical Example 32 Install cross head 21 and retainer ring 24 and install chain sheave 23 and retainer ring 22 FFT mast only ...

Page 960: ...T mast only Typical Example 34 Install hydraulic hose 25 of side shifter to side shifter cylinder 26 35 Install mast to lift truck Standard Lift Cylinder Disassembly Start By a Remove standard lift cylinders 1 Put standard lift cylinder 1 in position on vise A 2 Loosen set screw 2 with wrench B ...

Page 961: ...mbly 29 3 Remove bearing 3 with wrench C 4 Remove rod 4 from the cylinder body 5 Remove split rings 5 from the cylinder rod 6 Remove O ring seal 6 and back up ring 7 from the bearing 7 Remove wiper seal 8 and seal 9 from the bearing ...

Page 962: ...ith the lip toward the outside NOTE Install back up ring 4 with the curved side contacting the O ring seal 3 Install O ring seal 3 and back up ring 4 into the bearing 4 Install split rings 5 on the cylinder rod 5 Install cylinder rod 6 in the cylinder body 6 Install bearing 7 on the cylinder rod and tighten using wrench C ...

Page 963: ...6 1 N m 53 9 lb in End By a Install standard lift cylinders Secondary Lift Cylinder Disassembly Tools Needed A B Hydraulic Cylinder Repair Stand 1 Wrench Assembly 1 Start By a Remove standard lift cylinders 1 Put standard lift cylinder 1 in position on tool A 2 Remove bearing 2 with tool B ...

Page 964: ...e stop ring 4 from the cylinder rod 5 Remove wear ring 5 U packing 6 and backup ring 7 6 Remove retaining ring 8 spacer 9 and check valve 10 7 Remove ring 11 wear ring 12 and O ring 13 from the bearing 8 Remove wiper seal 14 and retaining ring 15 from the bearing 9 Remove U packing 16 ...

Page 965: ...outside 3 Install O ring 4 wear ring 5 and ring 6 in the bearing 4 Install check valve 7 retaining ring 8 and spacer 9 5 Install stop rings 10 on the cylinder rod 6 Install wear ring 11 U packing 12 and backup ring 13 7 Install cylinder rod 14 in the cylinder body 8 Install bearing 15 on the cylinder rod and tighten using tool B End By a Install secondary lift cylinders ...

Page 966: ...any pressure in the tank Be cautious of hot hydraulic oil when any lines are disconnected in the hydraulic system 1 Fasten nylon straps and hoist to the primary lift cylinder 2 Remove bolts 1 3 Pull the cylinder out far enough to disconnect elbow 3 Remove primary lift cylinder 4 Weight is 27 kg 60 lb NOTE The following steps are for the installation of the primary lift cylinder 4 Put primary lift ...

Page 967: ...1 Wrench Assembly 1 Start By a Remove primary lift cylinder 1 Remove flow protector valve 1 from the cylinder body 2 Remove bearing 2 with tool A 3 Remove rod 3 from the cylinder body 4 Remove wear ring 4 U packing 5 and backup ring 6 5 Remove retaining ring 7 spacer 8 and check valve 9 6 Remove O ring 10 and two rings 11 ...

Page 968: ...eded A B Hydraulic Cylinder Repair Stand 1 Wrench Assembly 1 1 Install U packing 1 in the bearing 2 Install wiper seal 2 and retaining ring 3 Install the seal with the lip toward the outside 3 Install O ring seal 4 and two rings 5 4 Install check valve 6 retaining ring 7 and spacer 8 5 Install wear ring 9 U packing 10 and back up ring 11 on the cylinder rod ...

Page 969: ...ng the tilt cylinders is the same for both cylinders WARNING If both tilt cylinders are removed at the same time the mast can fall To avoid possible personal injury make sure the mast is securely held in place or supported by a hoist before removing the tilt cylinders WARNING To prevent personal injury move the control levers backward and forward to release any pres sure in hydraulic system Slowly...

Page 970: ...olt 6 from pin 5 Remove pin 5 3 Remove tilt cylinder 4 4 Install the tilt cylinder in the reverse order of removal 5 Adjust the tilting angle Be sure to engage the rod into the anchor more than 32min Also inspect if both tilt cylinders have the uneven tilting ...

Page 971: ... 1 there will be contact zero clearance between the rollers and the inner mast at most narrow point of mast refer to step 4 2 Remove rod assembly 2 from the cylinder body 3 Remove nut 3 from the cylinder rod 4 Remove piston and seal assembly 4 from the cylinder rod 5 Remove head assembly 5 Typical Example 6 Remove spacer 6 from the cylinder rod 7 Loosen the nut and bolt on the rod eye Remove cylin...

Page 972: ...lt cylinder 12 Install seal 14 in the head Position the lip of the seal toward the inside of the head 13 Install seal 15 14 Install seal 16 in the cylinder head Position the lip of seal 16 toward the outside of the cylinder head NOTE The curved side of back up ring 13 should contact O ring seal 12 15 Install O ring seal 12 and back up ring 13 Make sure the curved side of back up ring 13 is in cont...

Page 973: ...ten the bolt on rod eye 2 to a torque of 95 15 N m 70 11 lb ft 19 Install seals 10 and O ring seal 9 on the piston 20 Install head assembly 5 on the cylinder rod 21 Install piston assembly 4 onto the cylinder rod 22 Install nut 3 Tighten nut 3 to a torque of 270 30 N m 200 22 lb ft Typical Example 23 Install the rod assembly in the cylinder body ...

Page 974: ...Pump a Start by remove hydraulic pump 1 Remove four cap screws 1 and washers 2 Remove shaft seal 2 and washer from the housing 3 Remove hydraulic pump part 3 from pump assembly 4 Remove Seal 6 and 4 from pump part 5 5 Remove wear plate 7 from pump assembly 4 6 Remove gear assemblies 8 from the body 9 ...

Page 975: ...oon cavities in the body NOTE The smaller half moon port cavity must be on the pressure side of the pump The side of wear plate with midsection cut out must be on suction side of pump Suction side of back plate is always side with larger port boss 2 Install seal 1 and 2 in groove of front plate 3 3 Apply a thin coat of petroleum jelly or hydraulic oil to both milled gear pockets of body Slip body ...

Page 976: ...d section cut away must be on the suction side of pump 5 Place body 5 onte the body 6 Dip gear assemblies 6 into oil and slip into front plate bushings and gears into pockets of body 7 Install wear plate 7 into housing 8 Install seal 11 and 10 to pump part 9 9 Install hydraulic pump part 12 to pump assembly ...

Page 977: ...Disassembly Assembly 45 10 Place washer over drive shaft into housing Liberally oil shaft seal 13 and install over driveshaft carefully so that rubber sealing lips are not cut 11 Install four cap screws 14 and washers ...

Page 978: ... 46 Hydraulic Pump D514289 for EM0QM EM0QN Disassemble Hydraulic Pump A Start by removing the hydraulic pump 1 Remove snap ring 1 from pump assembly 2 2 Remove four cap screws 3 3 Remove hydraulic pump cover part from pump assembly 1 2 3 ...

Page 979: ...Vehicle System Disassembly Assembly 47 4 Remove a plate seal and Back up 4 from pump cover part 5 Remove the side plate 5 from the body 6 Remove gear assemblies 6 from the body 4 5 6 6 ...

Page 980: ...Vehicle System Disassembly Assembly 48 7 Remove the side plate 7 from the body 8 Remove the body 8 from pump assembly 9 Finished 7 8 ...

Page 981: ...ow photo of the description 4 and please prepare a set of repair kit 1 It is important that the relationship of the pump cover part body and two side plates is correct 2 Install new plate seal and Back up 1 to pump cover part 3 Install the body 2 to pump cover part 3 4 Install the side plate 4 into the body 5 Install gear assemblies 5 into the body 6 Install the side plate 6 into the body 1 2 3 4 ...

Page 982: ... Assembly 50 7 Install new plate seal and Back up 7 to pump cover part 7 8 Install pump cover part 8 to pump assembly 9 9 Install four cap screws 10 10 Install a new snap ring 11 into pump assembly 11 Finished 7 9 8 8 9 10 11 11 ...

Page 983: ...ocation marks on the steering wheel and the steering wheel shaft for installation purposes 3 Use a rubber hammer to remove the steering wheel from the shaft NOTE Use the following steps to install the steering wheel 4 Put the steering wheel on the steering wheel shaft on its original position 5 Install cup 3 and nut 2 Tighten nut 2 to a torque of 80 7 N m 60 5 lb ft 6 Install cap 1 ...

Page 984: ...lic tank to release any pressure in the tank Be cautious of hot hydraulic oil when any lines are disconnected in the hydraulic sys tem NOTE Identify and mark all hydraulic hoses for purposes of reassembly 4 Remove two bolts 4 NOTICE Steering unit 6 and column 3 can separate after bolts 4 have all been removed causing unit 6 to fall To avoid damaging components support the steering pump while remov...

Page 985: ...awings show the unit in a vise we recommend that you keep the unit in the vise during disassembly Follow the clamping procedures explained throughout the manual 1 Clamp unit in vise meter end up Clamp lightly on edges of mounting area Use protective material on vise jaws Housing distortion could result if jaws are over tightened 2 Remove 5 16 inch cap screws and washers if applicable 7 each 3 Remo...

Page 986: ...ousing from vise Place housing on a clean soft cloth to protect surface finish Use a thin bladed screwdriver to pry retaining ring from housing 12 Rotate spool and sleeve until pin is horizontal Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing Remove bushing ...

Page 987: ...ry dust seal from seal gland bushing Do not damage bushing 15 Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly 16 Remove spool and sleeve assembly from 14 hole end of housing ATTENTION Identify and mark all hydraulic hoses for purposes of reassembly 17 Push pin from spool and sleeve assembly ...

Page 988: ...om control end of sleeve then remove 4 centering springs from spool carefully by hand 19 Push spool back through and out of sleeve Rotate spool slowly when removing from sleeve 20 Remove seal from housing 21 Remove check ball seat 22 Tip housing to remove check ball ...

Page 989: ...heck ball seat in housing insert open end of seat first Push check ball seat to shoulder of hole 5 Install set screw Use a 1 4 inch hex key to torque set screw to 11 N m 100 lb in To prevent interference make sure top of set screw in slightly below housing mounting surface 6 Assemble spool and sleeve carefully so that the spring slots line up at the same end Rotate spool while sliding parts togeth...

Page 990: ...ool assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the housing With the spool assembly in this flush position check for free rotation with in the housing by turning with light finger tip force at the splined end 12 Place housing on clean lint free cloth Install 47 5mm 1 86 in ID seal in housing 13 Install 2 bearing races and the needle thrust bearing...

Page 991: ...n groove 18 Clamp housing in vise Clamp lightly on edges of mounting area Do not over tighten jaws NOTE Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing ATTENTION Clean the upper surface of the housing by wiping with the palm of clean hand Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly Do...

Page 992: ...er alignment mark drive as shown Note relation ship between slotted end of drive to splined end of drive when marking 22 Install 73 5 mm 2 89 in ID seal in spacer plate or gerotor meter 23 With seal side of meter toward spacer plate align star valleys on drive Note the parallel relation ship of reference lines A B C and D Align bolt holes without disengaging meter from drive ...

Page 993: ...l 7 dry cap screws in end cap Pretighten screws to 11 17 N m 100 150 lb in then torque screws to specifications Spacer Actual Displacement cm r in r Length mm in 45 2 8 None 60 3 6 None 75 4 5 None 95 5 9 3 56 140 120 7 3 6 10 240 145 8 9 10 29 405 160 9 7 12 19 480 185 11 3 15 62 615 230 14 1 21 97 865 295 17 9 28 45 1 120 370 22 6 41 15 1 620 460 28 2 53 67 2 113 590 35 9 66 37 2 613 740 45 1 91...

Page 994: ...4 Remove clamps and disconnect hoses 4 5 Support the brake master cylinder Remove two bolts 6 6 Remove the brake master cylinder 7 Install the brake master cylinder in the reverse order of removal 8 Bleed the brake system Refer to the Testing and Adjusting Manual for further information End By Disassemble Assemble Brake Master Cylinder Start By a Remove brake master cylinder 1 Slip boot 4 off of b...

Page 995: ...al 18 when disassembling the brake master cylinder For purposes of reassembly position seal 18 into the bore of body 8 Remove the components from body 5 as follows a Remove piston 17 and cup 18 b Remove cup primary 19 c Remove spring 20 and spring seat 21 d Remove check valve 22 e Check the condition of the seals Replace the seals with new if worn or damaged 9 Assemble the brake master cylinder in...

Page 996: ... left steer wheel 1 Support the steer axle with a floor jack or a wood block under the frame A 2 Remove wheel nuts 1 and wheel assembly 2 Steer wheel 2 weighs approximately 34kg 75Ib 3 Remove wheel cap 3 4 Straighten and remove split pin 4 5 Remove nut 5 and washer 6 6 Remove wheel hub assembly 7 Tools Needed A B C Floor Jack 1 Driver Set 1 Lock Nut Installer 1 ...

Page 997: ... contact surfaces of the bearing cups with Multipurpose Grease 10 Reverse the procedures and steps 2 through 9 to install the steer wheels and bearings 11 Adjust the steer wheel bearings as follows a Use tool C to tighten nut 5 to a torque of 135 N m 100 lb ft while slowly rotating steer wheel 5 b Use tool C to loosen nut 5 completely c Use tool C to tighten nut 5 again to a torque of 50 5 N m 37 ...

Page 998: ...procedure to remove and install the steering knuckle kingpin and bearing is the same for both sides of the lift truck 1 Remove two bolts 2 and pin retaining plate 3 2 Remove tie rod pin 1 and separate tie rod 4 from knuckle 5 3 Remove the top grease nipple 6 4 Remove the king pin retaining bolt 7 and nut 8 For purposes of reassembly the torque for bolt 7 is 11 1 N m 8 9 lb ft 5 Remove the king pin...

Page 999: ...g pins and bearings 11 Install the steering knuckle kingpins and bearings in the reverse order of removal End By a Install steer wheels Steer Axle Remove Install Steer Axle Tools Needed A Jack Stand 4 WARNING Be sure the pressure in the hydraulic system is released before any lines or hoses have been disconnected 1 Put the lift truck on the plain ground 2 For purposes of reassembly put identificat...

Page 1000: ...e the following steps to install the steer axle 8 Use a floor jack to position steer axle 4 NOTE Use bolts 2 and cap 3 to align steer axle 4 with the mounting bosses while raising steer axle 4 into position with the floor jack 9 Seat steer axle 4 as follows a Install bolts 2 through cap 3 and into the mounting bosses approximately two bolt threads b Use the floor jack to raise steer axle 4 into th...

Page 1001: ... Remove steer axle 1 Remove the pin retaining bolt and pin 2 from the tie rod at each end of steering cylinder 1 2 Remove four bolts 3 For installation purposes the torque for bolts 3 is 250 40 N m 184 29 lb ft 3 Remove steering cylinder 1 4 Install steering cylinder 1 in the reverse order of removal ...

Page 1002: ...aps with nuts at each end Remove the nuts and rods before removing the cylinder end caps from the cylinder tube 1 Put location marks on end caps 1 as to their position on the steering cylinder tube 2 Remove end caps 1 from the steering cylinder 3 Remove bolts 2 and mounting caps 3 from the steer axle 4 Use tool A to remove retaining rings 4 and rings 3 from the cylinder rod 5 Remove piston 5 from ...

Page 1003: ...each end cap as follows a Remove O ring seal 10 b Remove wear ring 8 c Remove u cup seal 9 d Remove wiper seal 11 Assemble Steering Cylinder Tools Needed A Pliers 1 1 Assemble each end cap as follows a Install O ring seal 2 b Install wear ring 1 c Install u cup seal 3 d Install wiper seal 4 2 Install seal 5 on the piston ...

Page 1004: ...nder rod 5 Install rings 8 6 Use tool A to install retaining rings 9 on each side of the piston 7 Install cylinder tube 10 on the rod assembly 8 Install end caps 11 on cylinder tube 10 NOTE Install the nuts and rods on steering cylinder rafter installing the cylinder end caps End By a Install the steering cylinder ...

Page 1005: ...ased before any fitting plug hose or component is loosened tightened removed or adjusted Always move the lift truck to a clean and level location away from the travel of other machines NOTE For purposes of reassembly put identification marks on all lines tubes and hoses before any disconnections are made 1 Disconnect seven lines 4 from control valve 3 2 Remove the cotter pins washers and pins 1 fr...

Page 1006: ...trol valve PF relief valve and port relief valve 2 remove bolts to separate the valve sections when separating the valve section make sure that the O ring and load check incorporated into the lateral face are not damaged and injured b disassembly of front cover 1 remove O ring 11 from the lateral face 2 remove hex plug 6 and priority connector 5 3 remove FD sleeve 4 ball retainer 7 steel ball 8 sp...

Page 1007: ...h dust seal 4 slowly smoothly to prevent spool damage 6 loose bolts 11 take out seal plate 8 and dust seal 4 from body 7 Loose hex bolt 14 d disassembly of tilt section 1 remove O ring 15 poppet 11 and spring from lateral face 2 Loose bolts 14 and remove cap 7 3 after fixing the end of spool 2 not to be rotated remove a set screw 9 4 remove retainer spring 8 spring 10 seal plate 5 5 take out spool...

Page 1008: ...ut seal plate 3 and dust seal 4 from body 7 Loose hex bolt 14 Assemble Hydraulic Control Valve Start by NOTE make sure all valve parts are clean and free of dirt a disassembly of auxiliary section 1 fix section by using a vice for lateral machined faces not to be damaged 2 install O ring And install priority connector 5 into the front cover by tightening toque 60 3 incorporate ball retainer 7 stee...

Page 1009: ... ring by 35N m 8 release a section from a vise and install O ring 13 poppet 9 and spring 10 into lateral face c assembly of tilt section 1 fix section by using a vice for lateral machined faces not to be damaged 2 Install spool 2 into body 1 smoothly and slowly A direction of spool access to body is same as that of spool disassembly 3 dust seals 6 put on the end of spool by using a tool Note be ca...

Page 1010: ...n two hex bolts 11 by 14N m 6 install cap 7 and tighten two hex bolts 14 by14N m 7 release a section from a vise and install O ring 13 poppet 9 and spring 10 into lateral face e assembly of section place each section in a row insert tie rod and tight en nut by 27 4 31 4N m NOTE in case of excessive torque it could make as pool sticking In case of insufficient torque it could make an external leaka...

Page 1011: ...gh oil temp 6 low oil temp Measure 1 take spool out and clean it 2 exchange valve section ass y 3 exchange valve section ass y 4 tighten cap boly by standard torque 5 Use in normal temperature 6 Use in normal temperature Problem large drift of cylinder Cause 1 internal leakage of spool damage 2 leakage of port relief valve and shut off plug 3 bias of spool position not neutal position 4 leakage of...

Page 1012: ... A as shown 3 Remove towing pin 7 4 Remove the washer plate and bolts 8 5 Use the hoist and tooling A to remove counterweight 6 The weight of the counterweight is approximately 1753 kg 3865 lb NOTE The following steps are for installation of the counterweight 6 Put counterweight 6 in position on the frame and install bolt 8 and bolts 9 Tighten the bolts to a torque of 400 50 N m 300 37 lb ft 7 Ins...

Page 1013: ...B3 3 engine Start by a Remove Overhead guard b Remove counterweight c Remove hood assembly Refer to the topics Overhead guard Counterweight and hood assembly in this module 1 Remove two bolts 1 and floor plate 2 2 Disconnect the two battery cables 1 Remove the washers two bolts 2 and battery assembly 3 3 Loosen the clamps and disconnect air cleaner hoses 4 4 Remove mounting bracket 5 and air clean...

Page 1014: ... bolts and muffler assembly 8 Loosen cock drain from the radiator and drain coolant 9 Loosen clamps and disconnect two radiator hoses 13 10 Loosen the clamp and disconnect radiator overflow hose 14 11 Loosen clamps and disconnect the two transmission cooler hoses 15 12 Remove eight bolts 16 and baffle assembly 17 if equipped ...

Page 1015: ...loosen four bolts 19 and remove radiator 20 Typical Example 15 Disconnect wires 21 from starter assembly 22 16 Disconnect wires 23 from alternator 24 NOTICE Place identification marks on all wires and connectors to assure proper assembly 17 Disconnect connector 25 from transmission switch 18 Disconnect engine wire harness 26 ...

Page 1016: ... 21 Remove two bolts 31 Push wiring 32 back toward the engine Remove cover 33 Typical Example 22 Remove the six bolts 34 that hold the converter to the flywheel During the reassembly the tightening torque is 28 7 N m 40 10 lb ft NOTE At this point make a final check to be sure all removals and disconnections have been made from the engine Typical Example 23 Support engine with a hoist and tooling ...

Page 1017: ...reassembly the tightening torque is 200 25 N m 147 18 lb ft NOTICE Make sure the engine is supported underneath by suitable wooden blocks Failure to support the engine will result in possible clamage 26 Remove the engine with a hoist as shown The engine weighs about 215 kg 27 Install the engine in the reverse order of removal End By a Install overhead guard b Install counterweight c Install hood a...

Page 1018: ......

Page 1019: ...Hydraulic Schematic D20G D25G D30G with B3 3 Engine D20G D25G D30G with 4TNE98 Engine G20G G25G G30G with G424F Engine G20G G25G G30G with G424FE Engine SB4321E00 Jan 2008 ...

Page 1020: ...5 t NON EU NON USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 EU USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 3 0 t NON EU NON USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 0 43 0 300 90 0 3 92 0 3 ALL ALL Aux 2 040 35 14 000 250 140 2 5 143 2 5 A375417 01 1 305 9 000 HYDRAULIC SCHEMATIC STANDARD MODEL D20G D25G D30G G20G G25G G30G Steer unit Hyd Pump Steer cylinder Lift cylinder Tilt ...

Page 1021: ... 21 550 250 216 2 5 220 2 5 EU USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 3 0 t NON EU NON USA LIFT TILT 3 130 35 21 550 250 216 2 5 220 2 5 0 43 0 300 90 0 3 92 0 3 ALL ALL Aux 2 040 35 14 000 250 140 2 5 143 2 5 1 305 9 000 HYDRAULIC SCHEMATIC with LOCKING SYSTEM MODEL D20G D25G D30G G20G G25G G30G A602000 Control Valve Steer Cylinder Tilt Cylinder Lift Cylinder Hyd Pump P A P4 P2 P3 P1 C...

Page 1022: ...Electric Schematic D20G D25G D30G with B3 3 Engine D20G D25G D30G with 4TNE98 Engine G20G G25G G30G with G424F Engine G20G G25G G30G with G424FE Engine SB4322E00 Jan 2008 ...

Page 1023: ...A374081 01 ELECTRIC SCHEMATIC MODEL D20 25 30G EM0K2 EM0K3 Cummins B3 3 ...

Page 1024: ...A654030 00 ELECTRIC SCHEMATIC MODEL D20 25 30G EM0QM EM0QN Yanmar 4TNE98 Tier 3 ...

Page 1025: ...A604500 00 ELECTRIC SCHEMATIC MODEL G20 25 30G EM0QF EM0QG GM G424F Non Certi LP ...

Page 1026: ...A604510 00 ELECTRIC SCHEMATIC MODEL G20 25 30G EM0QH EM0QJ GM G424F Non Certi GAS ...

Page 1027: ...A604516 00 ELECTRIC SCHEMATIC MODEL G20 25 30G EM0QY EM0QZ GM G424FE Tier 3 LP ...

Page 1028: ......

Page 1029: ...SB2360E00 Operation Maintenance Manual LIFT TRUCKS D20G D25G D30G Tier 3 G20G G25G G30G LP Non Certi G20G G25G G30G GAS Non Certi G20G G25G G30G LP Tier 3 0801 ...

Page 1030: ......

Page 1031: ... Engine 58 Lift Truck Operation 61 Operating Techniques 97 Parking the Lift Truck 101 Lift Fork Adjustment 102 Storage Information 103 Transportation Hints 104 Towing Information 105 Maintenance Section Inspection Maintenance and Repair of Lift Truck Forks 106 Tire Inflation Information 110 Torque Specifications 111 Cooling System Specifications 113 Fuel Specification 115 Lubricant Information 117...

Page 1032: ...ly be replaced with another DOOSAN operator restraint system Photographs or illustrations guide the operator through correct procedures of checking operation and maintenance of the DOOSAN operator restraint system SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness on the part of the operator To develop this skill the operator should read and understan...

Page 1033: ...erform service on items at multiples of the original requirement For example at Every 500 Service Hours or 3 Months also service those items listed under Every 250 Service Hours or Monthly and Every 10 Service Hours or Daily Environment Management Note that DOOSAN INFRACORE is ISO 14001 certified which is harmonized with ISO 9001 Periodic ENVIRONMENTAL AUDITS ENVIRONMENTAL PERFORMANCE EVALUATIONS ...

Page 1034: ...f this safety alert symbol is as follows Attention Become Alert Your Safety is involved The message that appears under the warning explaining the hazard can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication DOOSAN cannot anticipate every possible circumstance that might involve a potential haza...

Page 1035: ...n of the lift truck to be alert and to avoid actions or conditions which can result in an accident Do not operate a lift truck if in need of repair defective or in any way unsafe Report all defects and unsafe conditions immediately Do not attempt any adjustments or repairs unless trained and authorized to do so Warning Signs and Labels There are several specific safety signs on your lift truck The...

Page 1036: ... load interferes with visibility travel with load trailing 6 On grade operations travel with load up grade 7 Watch out for pedestrians and obstructions Check overhead clearances 8 Do not permit riders on forks or machine at any time 9 Do not allow anyone to stand or pass under the elevated portion of any machine 10 Be sure operating surface can safely support machine 11 Operate machine and attachm...

Page 1037: ... touch lean on or reach through the mast or permit others to do so Located on the mast No Standing On Fork Warning No Standing Under Fork Warning WARNING Do not stand or ride on the forks Do not stand or ride on a load or pallet on the forks Do not stand or walk under the forks Located on the oil cylinder Load Backrest Must Be In Place Warning WARNING Operation without this device in place may be ...

Page 1038: ...ted with an impact of appropriate valve Located on the Overhead Guard No Riders Warning WARNING To avoid personal injury allow no riders A lift truck is designed for only one operator and no riders Located beside the operator s station STD or on front of the hood Convenience Package Moving Fan Warning WARNING To avoid personal injury stay clear of moving fan Located inside the engine compartment c...

Page 1039: ...applying the parking brake an audible alarm will sound If Equipped WARNING When leaving machine apply parking brake Parking brake is not automatically applied Alarm will sound if parking brake is not applied If Equipped WARNING Correct adjustment is necessary to provide adequate braking See the MAINTENANCE section for adjustment procedures The lift truck may creep at engine idle and can cause dama...

Page 1040: ...perated without the overhead guard in place due to low overhead clearance use extreme care Make sure there is no possibility of falling objects from any adjacent storage or work area Make sure the load is stable and fully supported by the carriage and the load backrest extension if equipped Do not raise loads any higher than necessary and never raise a load higher than 1830 mm 72 in with the overh...

Page 1041: ... dealer We would like to draw your attention to the fact that any secondary damages due to improper handling insufficient maintenance wrong repairs or the use of other than original DOOSAN spare parts waive any liability by DOOSAN Operation Information Mounting and Dismounting Mount and dismount the lift truck carefully Clean your shoes and wipe your hands before mounting Use both hands and face t...

Page 1042: ...r lift truck operates Know its safety devices Know how the attachments work Before moving the lift truck look around Start turn and brake smoothly An operator must constantly observe his lift truck for proper operation Operating the Lift Truck Always keep the lift truck under control Obey all traffic rules and warning signs Never leave the lift truck with the engine operating or with the parking b...

Page 1043: ...extension and overhead guard Refer to the topic Operation Techniques in the Operation Section of this manual Loading or Unloading Trucks Trailers Do not operate lift trucks on trucks or trailers which are not designed or intended for that purpose Be certain truck or trailer brakes are applied and wheel chocks in place or be certain unit is locked to the loading dock before entering onto trucks or ...

Page 1044: ... fan blades They will throw or cut any object or tool that falls or is pushed into them Do not use a kinked or frayed wire rope cable Wear gloves when handling the wire rope cable Retainer pins when struck with force can fly out and injure nearby persons Make sure the area is clear of people when driving retainer pins Wear protective glasses when striking a retainer pin to avoid injury to your eye...

Page 1045: ...on All fuels most lubricants and some coolant mixtures are flammable Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling area Do not smoke in areas where batteries are charged or where flammable materials are stored Batteries in series can be located in separate compartments When using jumper cables always connect positi...

Page 1046: ... use your bare hand to check for leaks Use a board or cardboard to check for leaks See Fluid Penetration in the Safety Section for more details Tighten all connections to the recommended torque Replace if any of the following conditions are found End fittings damaged or leaking Outer covering chafed or cut and wire reinforcing exposed Outer covering ballooning locally Evidence of kinking or crushi...

Page 1047: ... the assemblies could burst with explosive force and cause serious personal injury or death Follow carefully the specific information provided by your tire or rim servicing personnel or dealer Operator Restraint System If Equipped Warning Signs and Labels Your DOOSAN lift truck has the following tipover warning decals Make sure that you can read all safety signs Clean or replace these if you canno...

Page 1048: ... adjusting set the seat to make sure it is properly locked DO NOT adjust the seat while the truck is in motion WARNING Do NOT place your hand or fingers under the seat Injury may occur as the seat suspension mechanism moves up and down NOTICE Before getting on the truck adjust the level of the suspension using the grip in the rear of the seat WARNING When raising and lowering the seat backrest avo...

Page 1049: ... into the buckle properly replace the seat belt assembly 2 Belt Maintenance Every 500 service hours Check that the belt fastening works properly and that winding device is free from run lock when jerked Check that the belt is suitably fastened to the seat Check that the seat is correctly secured to the hood and the chassis On visual inspection fastenings must be intact otherwise contact the safety...

Page 1050: ...asten the Seat Belt 1 Grip the plate connector of the belt and pull the belt from the retractor Then insert the plate into the slot of the buckle until a snap is heard Pull on the belt to confirm it is latched 2 Make sure the belt is not twisted WARNING If you fasten the belt across your abdomen the belt may injure your abdomen in an accident 3 Be sure to fasten the belt across your hips not acros...

Page 1051: ... outside of the object When the lift truck picks up a load the truck and load have a new combined CG Stability and Center of Gravity The stability of the lift truck is determined by the location of its CG or if the truck is loaded the combined CG of the truck and load The lift truck has moving parts and therefore has a CG that moves The CG moves forward or backward as the mast is tilted forward or...

Page 1052: ...ad face of an attachment to the CG of the load The location of the CG in the vertical direction is the same as the horizontal dimension Remember that unless otherwise indicated the capacity load shown on the nameplate is for a standard lift truck with standard backrest forks and mast and having no special purpose attachment In addition the capacity load assumes that the load center is no further f...

Page 1053: ... all safety rules and read all warning signs Do not operate a lift truck unless you are in the operator s seat Keep hands and feet inside the operator s compartment Do not put any part of the body outside of the operator s compartment Never put any part of body into the mast structure or between the mast and the truck Do not start stop turn or change direction suddenly or at high speed Sudden move...

Page 1054: ...ross both forks Always use the proper size pallet Position the forks as wide as possible under the load Position loads evenly on the forks for proper balance Do not lift a load with one fork Do not overload Always handle loads within the rated capacity shown on the capacity plate Do not add extra counterweight to the truck An overload can cause the truck to roll over and cause injury to personnel ...

Page 1055: ...or falling loads when stacking Travel with the load tilted back and the forks as low as possible This will increase stability to the truck and load and permit better visibility for you Do not elevate the load with the mast tilted forward Do not tilt the elevated loads forwards This will cause the lift truck to tip over forward Do not jump off if your truck starts to tip over Stay in your seat to s...

Page 1056: ... for other persons or obstructions in your path of travel An operator must be in full control of his lift truck at all times Do not drive in forward direction when loads restrict your visibility Operate your lift truck in reverse to improve visibility except when moving up a ramp Be careful when operating a lift truck near the edge of a loading dock or ramp Maintain a safe distance from the edge o...

Page 1057: ...gas tank Mop up spilt fuel and do not forget to close the fuel tank before restarting the engine Park your lift truck in authorized areas only Fully lower the forks to the floor put direction lever in NEUTRAL position engage the parking brake and turn the key to the OFF position Remove the key and put blocks behind the wheels to prevent the truck from rolling Shut off your forklift truck when leav...

Page 1058: ...pover the risk of serious injury or death will be reduced if the operator is using the operator restraint system and follows the instructions provided Always use operator restraint system Don t jump Hold on tight Brace your feet and keep them within the operator s compartment ...

Page 1059: ...Safety Section 29 Lean away from the direction of fall Lean forward ...

Page 1060: ...4 travel loaded unloaded km hr 19 5 21 19 5 21 25 lift loaded unloaded mm s 520 570 510 570 26 SPEED lowering loaded unloaded mm s 510 460 510 460 27 DRAWBAR PULL loaded at 1 6km hr kg 1840 1820 28 GRADEABILITY loaded at 1 6km hr 35 29 29 ACCELERATION time reached at max speed loaded unloaded sec WEIGHT 30 TOTAL WEIGHT at unloaded kg 3570 3940 31 at loaded front rear kg 4900 670 5650 790 32 AXLE L...

Page 1061: ... 4280 18 2160 19 1185 20 2375 21 482 22 2857 23 2290 23a 20 21 5 24 490 570 25 510 460 26 1750 27 24 28 29 4460 30 6560 900 31 1750 2710 32 2 2 33 28x9x15 12PR 34 6 50x10 10PR 35 1650 36 1000 980 37 118 38 132 39 40 hand mech 41 12 90 42 YANMAR 4TNE98 43 43 7 58 6 2300 44 181 1600 45 4 4 3319 46 powershift 47 1 1 48 49 50 SIP 16 17 19 9 10 18 38 20 15 22 13 13 14 2 3 a 23 21 ...

Page 1062: ...aded km hr 19 20 19 20 25 lift loaded unloaded mm s 500 550 500 550 26 SPEED lowering loaded unloaded mm s 560 580 560 580 27 DRAWBAR PULL at 1 6km hr loaded unloaded kg 1650 1590 1625 1580 28 GRADEABILITY at 1 6km hr loaded unloaded 31 50 26 44 29 ACCELERATION time reached at max speed loaded unloaded sec WEIGHT 30 TOTAL WEIGHT at unloaded kg 3480 3850 31 at loaded front rear kg 4660 820 5400 950...

Page 1063: ...60 19 1185 20 2375 21 482 22 2857 23 2290 23a 19 5 20 5 24 500 550 25 550 580 26 1465 1450 27 20 35 28 29 4320 30 6210 1110 31 1680 2640 32 2 2 33 28x9 15 12 34 6 50 10 10 35 1650 36 1000 980 37 118 38 132 39 foot hyd 40 hand mech 41 12 65 42 G424F 43 46 2 62 2550 44 181 2200 45 4 4 2405 46 powershift 47 1 1 48 210 160 49 50 SIP 16 17 19 9 10 18 38 20 15 22 13 13 14 2 3 a 23 21 ...

Page 1064: ... 19 5 20 5 19 5 20 5 25 lift loaded unloaded mm s 500 550 500 550 26 SPEED lowering loaded unloaded mm s 560 580 560 580 27 DRAWBAR PULL at 1 6km hr loaded unloaded kg 1750 1685 1730 1680 28 GRADEABILITY at 1 6km hr loaded unloaded 34 55 5 28 48 5 29 ACCELERATION time reached at max speed loaded unloaded sec WEIGHT 30 TOTAL WEIGHT at unloaded kg 3480 3850 31 at loaded front rear kg 4660 820 5400 9...

Page 1065: ...60 19 1185 20 2375 21 482 22 2857 23 2290 23a 20 21 24 500 550 25 550 580 26 1640 1615 27 23 40 28 29 4320 30 6210 1110 31 1680 2640 32 2 2 33 28x9 15 12 34 6 50 10 10 35 1650 36 1000 980 37 118 38 132 39 foot hyd 40 hand mech 41 12 65 42 G424FE 43 47 7 64 2550 44 182 2200 45 4 4 2405 46 powershift 47 1 1 48 210 160 49 50 SIP 16 17 19 9 10 18 38 20 15 22 13 13 14 2 3 a 23 21 ...

Page 1066: ...mm MFH MAST E 5990mm MFH MAST D25G G25G A 2500 4000mm MFH MAST B 4250mm MFH MAST C 4500mm MFH MAST D 4750mm MFH MAST E 5000mm MFH MAST A 2500 3880mm MFH MAST B 4270mm MFH MAST C 4710mm MFH MAST D 5540mm MFH MAST E 5990mm MFH MAST D30G G30G A 2500 4000mm MFH MAST B 4250mm MFH MAST C 4500mm MFH MAST D 4750mm MFH MAST E 5000mm MFH MAST A 2500 4270mm MFH MAST B 4710mm MFH MAST C 5540mm MFH MAST D 5990...

Page 1067: ...0mm MFH MAST D 5990mm MFH MAST D25G G25G A 2500 4250mm MFH MAST B 4500mm MFH MAST C 47500mm MFH MAST D 5000mm MFH MAST A 2500 3880mm MFH MAST B 4270mm MFH MAST C 4710mm MFH MAST D 5540mm MFH MAST E 5990mm MFH MAST D30G G30G A 2500 4500mm MFH MAST B 4750mm MFH MAST C 5000mm MFH MAST A 2500 3880mm MFH MAST B 4270mm MFH MAST C 4710mm MFH MAST D 5540mm MFH MAST E 5990mm MFH MAST ...

Page 1068: ...ST D 5540mm MFH MAST E 5990mm MFH MAST D25G G25G A 2500 4000mm MFH MAST B 4250mm MFH MAST C 4500mm MFH MAST D 4750mm MFH MAST E 5000mm MFH MAST A 2500 3880mm MFH MAST B 4270mm MFH MAST C 4710mm MFH MAST D 5540mm MFH MAST E 5990mm MFH MAST D30G G30G A 2500 4000mm MFH MAST B 4250mm MFH MAST C 4500mm MFH MAST D 4750mm MFH MAST E 5000mm MFH MAST A 2500 4270mm MFH MAST B 4710mm MFH MAST C 5540mm MFH MA...

Page 1069: ...40mm MFH MAST D 5990mm MFH MAST D25G G25G A 2500 4250mm MFH MAST B 4500mm MFH MAST C 4750mm MFH MAST D 5000mm MFH MAST A 2500 3880mm MFH MAST B 4270mm MFH MAST C 4710mm MFH MAST D 5540mm MFH MAST E 5990mm MFH MAST D30G G30G A 2500 4500mm MFH MAST B 4750mm MFH MAST C 5000mm MFH MAST A 2500 3880mm MFH MAST B 4270mm MFH MAST C 4710mm MFH MAST D 5540mm MFH MAST E 5990mm MFH MAST ...

Page 1070: ...ce record your lift truck s serial numbers in the spaces provided below the photographs Lift Truck Serial Number 3 3 liter Diesel Engine 4TNE98 Serial Number 2 4 Liter Spark Ignition Engine Serial Number G424F E Power Shift Transmission Serial Number Drive Axle Serial Number ...

Page 1071: ...General Section 41 Typical Example Side Shifter Serial Number If Equipped ...

Page 1072: ...k type Sideshift Carriage ITA CW Counterweight SF Special Forks SWS Swing Shift Sideshift RAM Ram or Boom DBCBH Double Cube Block Handler HFP Hydraulic Fork Positioner CR Crane Arm or Crane Boom TH Tire Handler CTH Container Handler LPP Load Push Pull Device CC Carton Clamp RC Roll Clamp LS Load Stabilizer PWH Pulp Wood Handler SS ST Sideshift Side Tilt Carriage ...

Page 1073: ...Capacity and Attachment Plate Located on the cowl to the right side of the steering column Below are abbreviations that may appear on the IDENTIFICATION LIFT CAPACITY and ATTACHMENT PLATES and their meanings Mast Abbreviations STD Standard Mast single inner member low free lift FF Full Free Lift Mast single inner member with high free lift duplex cylinder FFT Triple Lift Mast two inner members wit...

Page 1074: ...llustrations Due to the various options available typical instrument panels are shown However the symbols on the indicators and lights on your panel identify what those particular items are Also the symbol for each of the items is identified and an explanation of their function and location is described on the following pages Diesel Engine 12V LPG 12V GAS 12V ...

Page 1075: ...an fuel flows from the filter which approximately takes 5 to 6 seconds 5 Fuel Level Gauge Indicates fuel level Gas Diesel Fuel Trucks Only 6 Engine Coolant Temperature Gauge Indicates coolant temperature If the pointer point to outside of green band while operating the lift truck overheating is indicated Park the lift truck and stop the engine Check the cooling system for a malfunction The pointer...

Page 1076: ...ill come on When the body leave the seat seat switch is turned off Mast lift and title is locked 14 Horn Switch Push on the horn button to sound the horn Engine Compartment 1 The engine compartment is accessible by pushing down the lever located at cowl and raising the hood and seat assembly 2 The hood and seat assembly is held up by a support cylinder Make certain the air cylinder is operating pr...

Page 1077: ...ARNING Engine stop start switch stop at 0 postion Engine run it is prohibited to turn the switch at START positon otherwise start motor will be damaged Start time should not more than 15 second restart should be after 20 second Light Switch NOTE Lamp switch has 2 shifts Each lamp has individual switch regardless with the position of the start switch shift lamp O OFF 1shift 2shift Width lamp and pa...

Page 1078: ... with an alarm that will sound if the parking brake is not applied when leaving the machine NOTICE 1 Prior to operating the lift truck be sure to understand and check the SEAT SWITCH SYSTEM 2 While in normal operation and on level ground select a direction with the derectional lever and with the park brake released You will note that the truck will move slowly in the selected direction If you lift...

Page 1079: ...ent should be checked at the beginning of each shift and when operators change Lock the seat into position before operating to prevent an unexpected seat change Adjust seat to allow full brake pedal travel with operator s back against seat back NOTE The seat can only be correctly adjusted with the operator fully seated Tilt Steering Column To adjust the steering column push down the lever and move...

Page 1080: ...ermitting disc slippage Further pushing on the pedal completely relieves clutch pack pressure and applies the service brakes to stop and hold the lift truck NOTE The purpose of the inching control pedal is to provide precise inching control at slow travel speed with high engine rpm This is used for fast hydraulic lift during load approach pickup or positioning Service Brake Pedal Push DOWN on the ...

Page 1081: ... will stop 3 Lift Position Pull the lever BACK smoothly to lift the load Tilt Control 1 Mast Tilt Forward Push the lever FORWARD smoothly to tilt the mast forward 2 Mast Hold When the lever is released it will return to the HOLD or center position Tilting action will stop 3 Mast Tilt Back Pull the lever BACK smoothly to tilt the mast backward Sideshift Attachment If Equipped 1 Sideshift Left Push ...

Page 1082: ...h down the clutch pedal to separate the eninge and transimission drive release the clutch pedal the drive is transfer from engine to transmission by clutch pedal WARNING The clutch is not allow to operate the lift truck at half on and half off position ...

Page 1083: ...moisture laden air and to prevent condensation In the cold weather the moisture condensation can cause rust in the fuel system and hard starting due to its freezing Do not fill the tank to the top Fuel expands when it gets warm and may overflow 1 Park the lift truck only at a designated safe location Place the transmission in NEUTRAL Lower the forks to the ground Engage the parking brake Stop the ...

Page 1084: ...ring refueling Do not smoke in refueling areas Lift truck should be refueled only at designated safe locations Safe outdoor locations are preferable to indoor locations Stop the engine and get off the lift truck during refueling The careless handling of LP containers can result in a serious accident Use extreme care when transporting containers to prevent damage to them 1 Park the lift truck on le...

Page 1085: ...egible 7 Check to be sure the replacement tank is of the correct type 8 Inspect the replacement tank for damage such as dents scrapes or gouges and for indication of leakage at valves or threaded connections 9 Check for debris in the relief valve for damage to various valves and liquid level gauge 10 Inspect the quick disconnect couplings for deterioration damage or missing flexible seals ...

Page 1086: ...nt panel for broken or damaged indicator lights or gauges 3 Test the horn and other safety devices for proper operation 4 Inspect the mast and lift chains for wear broken links pins and loose rollers 5 Inspect the carriage forks or attachments for wear damage and loose or missing bolts 6 Inspect the tires and wheels for cuts gouges foreign objects inflation pressure and loose or missing bolts 7 In...

Page 1087: ...ches on the dip stick 12 Observe the fuel level gauge after starting the truck Add fuel if necessary WARNING Personal injury may occur from accidents caused by improper seat adjustment Always adjust the operator s seat before starting the lift truck engine Seat adjustment must be done at the beginning of each shift and when operators change 13 Push the control lever off the seat rail and move the ...

Page 1088: ...ase the ignition switch 3 If the engine does not start repeat step 1 4 If engine coolant is cold engine speed could be higher than low idle speed Don t drive forklift until engine speed becomes nomal low idle speed NOTICE If the inside of engine cylinder is wet by gasoline the engine could not start In this case press accelerator pedal fully and turn the ignition switch to ON position for 10 secon...

Page 1089: ...the key when the engine starts and release the accelerator pedal to a low idle position 4 If the engine stalls or does not start turn the key to the OFF position then repeat steps 1 thru 3 Starting a Warm Diesel Engine 1 Turn the key to the ON position and then to START position without waiting for the preheat light to go OFF At the same time fully depress the accelerator 2 Release the key when th...

Page 1090: ...will not come ON with the engine running unless the fault or faults are stored in the memory of the engine control module ECM Stop the engine and check the electric engine control system if the light comes ON Refer G424F E Engines of this section 4 The diesel engine water in fuel filter indicator light 4 will not come ON with the engine running unless water in fuel filter exceeds 100cc Stop the en...

Page 1091: ...lace the transmission control lever in the NEUTRAL center position and apply the parking brake before dismounting the lift truck 5 Release the service brake 6 Push down on the accelerator pedal to obtain the desired travel speed Release the pedal to decrease travel speed WARNING Sudden reversal of a loaded lift truck traveling forward can cause the load to fall or the lift truck to tip over Stop t...

Page 1092: ... to the desired direction of travel Slowly push down on the accelerator pedal as the lift truck changes direction 10 When the direction change is completed continue to push down on the accelerator pedal to obtain the desired travel speed 11 To stop the lift truck when traveling in either direction release the accelerator pedal 12 Push down on the service brake pedal and bring the lift truck to a s...

Page 1093: ...y to stop and hold the lift truck This will provide full engine power for fast hydraulic lift WARNING Do not use inching pedal instead of brake pedal It will give wearing to transmission clutch disc Steering Knob If Equipped There is a steering knob available for inclusion with new truck deliveries This option is solely intended for slow travel situations when two handed steering is not possible d...

Page 1094: ...formance Engine speed is monitored by the SECM through a variable reluctance VR or Hall Effect sensor Intake manifold air temperature and absolute pressure are monitored with a TMAP sensor MI 07 is a drive by wire DBW system connecting the accelerator pedal to the electronic throttle through the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle posi...

Page 1095: ...his system LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM Manifold pressure from the TMAP rpm from the crank position sensor and throttle position is used by the SECM to calculate load Feedback from the electronic throttle is still provided to the SECM by the throttle position sensors TPS EMS schematic of G424F Dual Fuel engine ...

Page 1096: ...e closed Reset excess flow valve z Close liquid valve z Wait for a click sound z Slowly open liquid valve Plugged fuel line Remove obstruction from the fuel line z Close liquid fuel valve z Using caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Broken Fuse SECM Replace Fuse for SECM z...

Page 1097: ...ne may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and or collapsed hose Pressure regulator converter malfunction Test pressure regulator converter operation z...

Page 1098: ...z Re connect fuel line z Slowly open liquid fuel valve Leak test Pressure regulator freezes Check level in cooling system z Must be full check coolant strength z 35F minimum Check coolant hoses z Watch for kinks and or pinched hoses z Verify one pressure hose and one return hose Fuel Lock off malfunction Repair replace Fuel Lock off z See Engine Service Manual Incorrect idle speed or ignition prob...

Page 1099: ...nostics Will Not Accelerate Hesita tion During Acceleration Engine Mechanical See Engine Service Manual Fuel container almost empty LPG Vapor from liquid outlet z Fill fuel container z Do not exceed 80 of liquid capacity Excess flow valve closed Reset excess flow valve z Close liquid valve z Wait for a click sound Slowly open liquid valve Clogged fuel filter Repair replace as required z See Mainte...

Page 1100: ...e Service Manual Vacuum leak Check for vacuum leaks z Between mixer and throttle body z Between throttle body and intake manifold z Between intake manifold and cylinder head Air Fuel Mixer malfunction Check mixer z See Engine Service Manual Engine Stalls Engine Mechanical See Engine Manufacturers Service Manual Faulty vapor connection between the pressure regulator converter and the mixer Check co...

Page 1101: ...el valve z Using caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve Leak test Air filter clogged Check air filter z Clean replace as required Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify no holes in hose z Clamps must be tight z Look for k...

Page 1102: ...lator malfunction fuel pressure too high Test pressure regulator operation z See Engine Service Manual Faulty FTV Check FTV for housing cracks or obstructions z See Advanced Diagnostics FTV operation z Repair and or replace as necessary Weak ignition and or spark control See Advanced Diagnostics Incorrect air fuel control See Advanced Diagnostics Exhaust system leaks Repair exhaust system Excessiv...

Page 1103: ... the mixer LPG Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and or collapsed hose Electric Fuel Pump malfunction GAS Check electrical connection z Check Relay and fuse Turn key ON and verify pump is operating Fuel Pressure regulator malfunction Test pressure regulator operation z See Engine Service Manual Fuel Injector malfunction Test Injector operat...

Page 1104: ...n z See Engine Service Manual Air filter clogged Check air filter z Clean replace as required Incorrect air fuel or ignition control See Advanced Diagnostics Difficult to Start Gas Engine Mechanical See Engine Service Manual Isolate the gasoline system by running the lift truck on LPG Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the correctiv...

Page 1105: ...by running the lift truck on LPG Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in LPG mode then the root cause is most likely to be something other than the fuel system z See Advanced Diagnostics Fuel tank almost empty Fuel Pump Cavitations z The tank should be at least full to prope...

Page 1106: ...eps below If the problem also exists in LPG mode then the root cause is most likely to be something other than the fuel system z See Advanced Diagnostics Service Manual Pressure regulator malfunction Test pressure regulator operation z See Engine Service Manual Clogged fuel filter Repair replace as required z See Maintenance section Primary and Secondary Fuel Filter replacement Pressure regulator ...

Page 1107: ...Advanced Diagnostics Engine Service Manual Rough Idle Gas Engine Mechanical See Engine Service Manual Incorrect Idle speed control Throttle sticking See Advanced Diagnostics Engine Service Manual High Idle Speed Gas Foot pedal sticking or incorrect pedal signal Check pedal return spring travel for binding See Advanced Diagnostics ...

Page 1108: ...opane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve Leak test Air filter clogged Check air filter z Clean replace as required Faulty vapor connection between the pressure regulator converter and the mixer Check connection z Verify no holes in hose z Clamps must be tight z Look for kinked pinched and or collapsed hose Poor High Speed Perfo...

Page 1109: ... of the code list EXAMPLE A code 461 ETCSticking has been detected and the engine has shut down and the MIL has remained ON When the codes are displayed the MIL will flash four times 4 pause then flash six times 6 pause then flash one time 1 This identifies a four sixty one 461 which is the ETCSticking fault If any additional faults were stored the SECM would again have a long pause then display t...

Page 1110: ... injector 3 wire or defective injector 1 TurnOnMil 2 Disable LiquidO2Ctrl 3 Delayed EngineShutdown Check INJ3 wiring for an open circuit SECM Signal A4 to Injector 3 Pin A Switched 12V to Injector 3 Pin B Check Injector 3 Resistance 12 to14 ohms cold 134 Inj4Open Gasoline Injector 4 open circuit broken injector 4 wire or defective injector 1 TurnOnMil 2 Disable LiquidO2Ctrl 3 Delayed EngineShutdow...

Page 1111: ...broken crankshaft sensor leads or defective CAM sensor None Check CAM sensor connections SECM SIGNAL Pin B10 to CAM sensor Pin 2 SECM Sensor GND Pin B1 to CAM sensor Pin 3 Switched 12V to CAM sensor Pin 1 Check for defective CAM sensor 192 CamSyncFault Loss of synchronization on the CAM sensor normally due to noise on the signal or an intermittent connection on the CAM sensor None Check CAM sensor...

Page 1112: ...t of range high normally set if the TPS1 signal has shorted to power or the ground for the sensor has opened 1 TurnOnMil 2 CutThrottle Check throttle connector and TPS1 sensor wiring for a shorted circuit SECM Pin B23 signal to ETC Pin 6 SECM Pin B1 sensor GND to ETC Pin 2 232 TPS2RangeHigh TPS2 sensor voltage out of range high normally set if the TPS2 signal has shorted to power or the ground for...

Page 1113: ...P pressure signal wire has been disconnected or shorted to ground or the circuit has opened to the SECM TurnOnMil Check TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP Pin 1 GND to Pin 4 press...

Page 1114: ...AP Pin 4 to SECM Pin B18 signal TMAP Pin 1 to SECM Pin B1 sensor GND TMAP Pin 3 to SECM Pin B24 XDRP 5 Vdc Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP Pin 1 GND to Pin 4 pressure signal KPA 2 4kΩ 8 2kΩ TMAP Pin 3 power to Pin 4 pressure signal KPA 3 4kΩ 8 2kΩ 351 MAP_IR_HI MAP sensor indicates higher pressure than expected TurnOnMil Check for vacuum le...

Page 1115: ...nd connector for open circuit SECM Pin A9 EST1 to OEM ignition system See application note Verify GND on ignition module Pin A of both connectors Verify 12 Vdc on ignition module Pin B of both connectors Refer to application manual for specific engine details 422 EST2_Open EST2 output open possibly open EST2 signal or defective spark module TurnOnMil Check coil driver wiring and connector for open...

Page 1116: ...le Pin B of both connectors Refer to application manual for specific engine details 425 EST5_Open EST5 output open possibly open EST5 signal or defective spark module None N A 426 EST6_Open EST6 output open possibly open EST6 signal or defective spark module None N A 427 EST7_Open EST7 output open possibly open EST7 signal or defective spark module None N A 428 EST8_Open EST8 output open possibly ...

Page 1117: ...ow EST3 signal shorted to ground or power or defective spark module None N A 434 EST4_Short EST4 output shorted high or low EST4 signal shorted to ground or power or defective spark module None N A 435 EST5_Short EST5 output shorted high or low EST5 signal shorted to ground or power or defective spark module None N A 436 EST6_Short EST6 output shorted high or low EST6 signal shorted to ground or p...

Page 1118: ... A18 to ETC Pin 4 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS Pin 1 DRIVER to Pin 4 DRIVER 3 0 4 0Ω 471 ETC_Open_Fault Electronic Throttle Control Driver has failed normally set if driver signals have failed open or become disconnected electronic throttle or SECM is defective 1 TurnOnMil 2 CutThrottle Check...

Page 1119: ...vel Check electrical connection to the oil pressure switch SECM Pin B9 to Oil Pressure Switch 531 53 SysVoltRangeLow System voltage too low TurnOnMil Check battery voltage y Perform maintenance check on electrical connections to the battery and chassis ground y Check battery voltage during starting and with the engine running to verify charging system and alternator function y Measure battery powe...

Page 1120: ... Verify transducer power to the foot pedal with a multimeter 571 57 HardOverspeed Engine speed has exceeded the third level 3 of 3 of overspeed protection 1 TurnOnMil 2 HardRevLimit 3 EngineShutdown Usually associated with additional ETC faults y Check for ETC Sticking or other ETC faults Verify if the lift truck was motored down a steep grade 572 MediumOverspeed Engine speed has exceeded the seco...

Page 1121: ... APP connector and pins for corrosion Cycle the pedal several times and check APP1 signal at SECM Pin B7 642 68 APP2AdaptHiMax Learned full pedal end of APP2 sensor range higher than expected TurnOnMil Check APP connector and pins for corrosion Cycle the pedal several times and check APP2 signal at SECM Pin B16 651 APP1AdaptHiMin Learned full pedal end of APP1 sensor range lower than expected Turn...

Page 1122: ... ground or power or defective crank disable relay None N A 716 LSDFault_FuelPump Fuel pump fault signal has opened shorted to ground or power or defective fuel pump TurnOnMil Check fuel pump for an open wire or connector being disconnected or signal shorted to GND Fuel Pump Pin B signal from SECM Pin A13 Fuel Pump Pin A power from main relay 1 Pin A23 Check Fuel Pump for an open coil by disconnect...

Page 1123: ...er Relay Relay pin 87 This relay only turns on after engine has been running for some time and SECM has calculated that water condensation in exhaust has been removed by exhaust heat Post O2 Heater Relay has SECM DRVP 12V applied to the relay coil power The relay coil ground is controlled by SECM Pin A20 to activate the relay to flow current through the post O2 heater Verify O2 sensor heater circu...

Page 1124: ...alyst O2 sensor connections are OK O2 signal Pin 3 to SECM Pin B13 O2 Pin 2 HEATER GND to SECM DRVG GNG Pins A16 B17 O2 Pin 1 HEATER PWR to SECM DRVP 12V PIN A23 Verify O2 sensor heater circuit is operating by measuring heater resistance 2 1Ω 0 4Ω O2 Pin 2 HEATER GND to Pin 1 HEATER PWR 842 LiqPostO2NotActive Post catalyst O2 sensor inactive on gasoline open O2 sensor signal or heater leads defect...

Page 1125: ...alyst O2 sensor voltage out of range low sensor signal shorted to ground None N A 921 O2RangeHigh Pre catalyst O2 sensor voltage out of range high sensor signal shorted to power 1 TurnOnMil 2 DisableLiquid O2Ctrl 3 DisableGas O2Ctrl Check if O2 sensor installed before catalyst is shorted to 5Vdc or battery O2 signal Pin 3 to SECM Pin B13 SECM XDRP 5V Pin B24 SECM DRVP 12V Pin A23 922 O2_PostCatRan...

Page 1126: ...1 determined by OEM 992 ServiceFault2 Service Interval 2 has been reached None Perform service procedure related to Service Interval 2 determined by OEM 993 ServiceFault3 Service Interval 3 has been reached None Perform service procedure related to Service Interval 3 determined by OEM 994 ServiceFault4 Service Interval 4 has been reached replace HEGO sensors TurnOnMil Replace Pre catalyst HEGO sen...

Page 1127: ...art as load permits Typical Example 2 Move the lift truck FORWARD until the load touches the carriage Lifting the Load 1 Lift the load carefully and tilt the mast back a short distance Typical Example 2 Tilt the mast further back to cradle the load Typical Example 3 Operate the lift truck in reverse until the load is clear of the other material 4 Lower the cradled load to the travel position NOTE ...

Page 1128: ...ill on upgrades and downgrades Typical Example 2 For better vision travel in reverse with bulky loads Unloading Typical Example 1 Move the lift truck into the unloading position Typical Example 2 Tilt the mast FORWARD only when directly over the unloading area WARNING Do not tilt the mast forward with the load unless directly over the unloading area even if the power is off ...

Page 1129: ...ple 4 Lower the carriage and forks to the travel position or to the park position Turning 1 When turning sharp corners keep close to the inside corner Begin the turn when the inside drive wheel meets the corner 2 In narrow aisles keep away from the stockpile when turning into the aisle Allow for counter weight swing ...

Page 1130: ...in hot weather Keep the following points in mind when you operate the lift truck in hot weather 1 Check the radiator Clogging can cause overheating Clean them out regularly with a blast of compressed air also check for leakage of water 2 Check the fan belt tension and adjust to proper tension 3 Even if the engine overheats and the coolant boils over let the engine idle for a while with opening eng...

Page 1131: ...he ignition switch to the OFF position or the battery will continue to discharge and remove the key WARNING Blocking the wheels will prevent unexpected lift truck movement which could cause personal injury NOTE If a LP equipped lift truck is stopped or parked for an indefinite or prolonged period of time shut off the LP fuel tank valve 6 Actuate each loading lever several times to remove the resid...

Page 1132: ... position 2 Raise the hook pin in each fork to side the fork on the carriage bar 3 Adjust the forks in the position most appropriate for the load and as wide as possible for load stability 4 When adjusting the forks make sure that the weight of the load is centered on the truck 5 After adjustment set the fork locks to keep the forks in place WARNING Make sure the forks are locked before carrying a...

Page 1133: ...ummer y Dismount the battery from the machine Even though the machine is parked indoors if the place is hot or humid the battery should be kept in a dry cool place Charge the battery once a month y Apply antirust to the exposed parts which tend to rust y Cover components such as the breather and air cleaner which may be caught with humidity y The machine should be operated at least once a week Fil...

Page 1134: ...uck on the truck bed or the rail car Apply the parking brake and place the transmission control in NEUTRAL Tilt the mast forward and lower forks to the floor Turn the ignition switch to the OFF position and remove the key If LP Gas equipped shut off the LP Gas fuel tank Block the wheels and secure the lift truck with tiedowns Machine Lifting and Tiedown Information NOTICE Improper lifting or tiedo...

Page 1135: ... as low as possible on the lift truck that is being towed Quick lift truck movement could overload the tow line or bar and cause it to break Gradual and smooth lift truck movement will work better Normally the towing lift truck should be as large as the disabled lift truck Satisfy yourself that the towing lift truck has enough brake capacity weight and power to control both lift trucks for the gra...

Page 1136: ...is equal to or greater than the Standard or rated Capacity of the lift truck The individual load rating in most cases will be stamped on the fork in a readily visible area This is generally on the top or side of the fork shank y A fork rated at 1500 pounds at 24 inch load center will be stamped 1500x24 y A fork rated at 2000 kg at 600 mm load center will be stamped 2000x600 The manufacturer identi...

Page 1137: ...ad bearing cross section of the remaining metal is decreased in size until it becomes insufficient to support the load and complete failure occurs Fatigue failure is the most common mode of fork failure It is also one which can be anticipated and prevented by recognizing the conditions which lead up to the failure and by removing the fork service prior to failing y Repetitive Overloading Repetitiv...

Page 1138: ...f the forks First Installation 1 Inspect forks to ensure they are the correct size for the truck on which they will be used Make sure they are the correct length and type for the loads to be handled If the forks have been previously used perform the 12 Month Inspection If the forks are rusted see Maintenance and Repair 2 Make sure fork blades are level to each other within acceptable tolerances Se...

Page 1139: ...with a carbon stone to remove minor surface cracks or defects Polish the inside radius of the heel section to increase the fatigue life of the fork Always grind or polish in the direction of the blade and shank length y Repair or replace the positioning locks on hook type forks y Repair or replace most fork retention devices used with other fork types 4 A fork should be load tested before being re...

Page 1140: ...he following chart are cold inflation shipping pressures Shipping Pressure Size Ply Rating or Strength Index kPa psi 6 0X9 10 790 115 6 5X10 10 790 115 7 0X12 12 825 120 28X9 15 12 825 120 1 Standard tire ply rating and inflation pressures The operating inflation pressure is based on the weight of a ready to work machine without attachments at rated payload and in average operating conditions Pres...

Page 1141: ... 1 lb in 16 mm 625 in 7 5 0 5 65 5 13 5 mm 531 in 4 5 0 5 40 5 8 mm 312 in 0 9 0 2 8 2 Reassembly or Retightening Torque On Existing Hose Clamp Width N m 1 lb in 16 mm 625 in 4 5 0 5 40 5 13 5 mm 531 in 3 0 0 5 25 5 8 mm 312 in 0 7 0 2 6 2 1 Newton meter N m is approximately the same as 0 1 kg m Torque for Standard Bolts Nuts and Taperlock Studs NOTICE The two charts below give general torques for...

Page 1142: ...ven result in personal injury Original fasteners removed from the lift truck should be saved for reassembly whenever possible If new fasteners are needed they must be of the same size and grade as the ones that are being replaced The material strength identification is usually shown on the bolt head by numbers 8 8 10 9 etc This chart gives standard torques for bolts and nuts with Grade 8 8 Metric ...

Page 1143: ...r shipped to an area with freezing temperatures the cooling system must be protected to the lowest expected outside ambient temperature The engine cooling system is normally protected to 28 C 20 F with antifreeze when shipped from the factory unless special requirements are defined Check the specific gravity of the coolant solution frequently in cold weather to ensure adequate protection Clean the...

Page 1144: ...by a reliable maker and never use it mixed with antifreeze of different brand DOOSAN recommends that the coolant mix contain 50 commercially available automotive antifreeze or equivalent and acceptable water to maintain and adequate water pump cavitation temperature for efficient water pump performance Premix coolant solution to provide protection to the lowest expected outside ambient temperature...

Page 1145: ...duced engine service life Crude oil is used to describe oils fuels that are not refined and are in the original state as when pumped from the ground Certain types of crude oils can be burned in DOOSAN Engines PREFERRED DISTILLATE FUEL FOR DISEL ENGINES Specifications Requirements Aromatics AST D1319 35 Max Ash ASTM D482 0 02 Weight Max Cetane Number ASTM D613 35Min for 45 max 40 Min for DI Engines...

Page 1146: ... Specifications Only unleaded gasoline should be used for DOOSAN forklift trucks The gasoline in which methanol or ethanol is contained is not recommended It is recommended to use gasoline fuel that has octane number 87 to prevent knocking trouble LP Specifications LP is liquefied petroleum gas The exact composition of LP varies slightly between different parts of the country and different refiner...

Page 1147: ...cts the Infrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of engine oil The sulfur products formation depends on the fuel sulfur content oil formulation crankcase blow by engine operating conditions and ambient temperature Hydraulic Oil HYDO The following commercial classifications can be used in the hydraulic system y ISO 6743 4 HM y AFNO...

Page 1148: ...grease can not be used multipurpose type grease which contains 3 to 5 molybdenum disulfide can be used NLGI No 2 grade is suitable for most temperatures Use NLGI No 1 or No 0 grade for extremely low temperature Transmission Oil NOTICE This oil is formulated for transmissions and drive trains only and should not be used in engines Shortened engine life will result NOTE Multi grade oils are not blen...

Page 1149: ...43 4 HM ISO VG 68 0 50 32 122 Drive Axle Housing API GL 5 SAE 80W90 20 50 4 122 The SAE grade number indicates the viscosity of oil A proper SAE grade number should be selected according to ambient temperature Refill Capacities REFILL CAPACITIES APPROXIMATE Compartment or System Liters U S Gal Engine Crankcase w Filter G424F G424F E 2 4 liter LP 4 5 1 19 Engine Crankcase w Filter 4TNE98 Diesel 9 2...

Page 1150: ...t Adjust 140 First 250 Service Hours or a Month Hydraulic Return Filter Change 141 Every 250 Service Hours or Monthly Air Intake System Check Clean 142 Hydraulic Oil Level Check 144 Drive Axle Oil Level Check 145 Mast Carriage Lift Chains Attachments Inspect Lubricate 145 Steering Mechanism Check Lubricate 145 Battery Terminal Clean Inspect 146 Engine Oil Filter LP Gasoline Engine Only Change 146 ...

Page 1151: ...ly 163 Fuel Injectors Diesel Engine Only Inspect Clean Test 164 Every 2000 Service Hours or Yearly Engine Valve Lash 4TNE98 Diesel Engine Only Check Adjust 165 Steer Wheel Bearings Reassemble 165 Drive Wheel Bearing Power Shaft and Drive Wheel Reassemble 167 Cooling System Clean Change 168 Forks Inspect 170 Every 2500 Service Hours or 15 Months Inspect Battery System 172 Hydraulic Oil Check Clean ...

Page 1152: ...e Wheel Reassemble 167 O Engine Oil Filter Diesel Engine Only Change 136 152 O O Engine Oil Filter LP Gasoline Engine Only Change 146 O Engine Oil Level Check 131 O Engine Valve Lash Diesel Engine Only Check Adjust 161 165 O O Forks Inspect 170 O Fuel Filter Diesel Engine Only Change 154 O Fuel Filter LP Engine Only 163 O Fuel Injectors Diesel Engine Only Inspect Clean Test 164 O Fuel Lines Fittin...

Page 1153: ... Mast Carriage Lift Chains Attachments Inspect Lubricate 145 O Overhead Guard Inspect 150 O Parking Brake Inspect 135 O Parking Brake Test Adjust 140 151 O O Replace LP Fuel Filter Element LP Engine Only 163 O Replace Oxygen Sensor G424F E Engine Only 173 O Replace Spark Plugs G424F E LP Gosoline Engine Only 162 O Priming the Fuel System Diesel Engine Only 128 O Seat Hood Latch Support Cylinder Ch...

Page 1154: ...nt 2 Dry cap assembly 3 Install filler cap assembly WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire 4 Drain moisture and sediment from fuel tank as required by prevailing conditions Seat Hood Latch Support Cylinder Check Lubricate 1 Check the operation of the seat adjuster rod Make sure that the seat slides freely on its track Lightly oil the seat slider ...

Page 1155: ...ordance with the note on the tags of fuses box Fuses are identified as follows 1 Nuetral Start Solenoid 10 amps 2 Lamp Relay 15 amps 3 Horn 15 amps 4 Start Relay Start 30 amps 5 Head Rear Lamp 15 amps 6 Fwd Rev Solenoid lamp Relay Back up Lamp alarm 15 amps G30G Typical Example D30G Typical Example Remove the front cover from the fuse box located under the cowl Fuse Protects an electrical circuit ...

Page 1156: ...holds the hood open G30G Typical Example D30G Typical Example 2 The main circuit breaker is located on the front of battery compartment NOTE To reset circuit breakers push in on the button The button should stay in if the breaker is reset If the button will not stay in or comes out shortly after reset have the circuits checked ...

Page 1157: ...Section 127 Fuses and Relay D20 25 30G Located inside of electrical component box Located on the right side of the frame G20 25 30G Located inside of electrical component box Located on the right side of the frame ...

Page 1158: ...in Drain the fuel filter water separator whenever there are contaminants such as water collected in the bottom of the cup NEVER wait until the scheduled periodic maintenance if contaminants are discovered The cup of the separator is made from semi transparent material In the cup is a red colored float ring The float ring will rise to the surface of the water to show how much needs to be drained Al...

Page 1159: ...LP Engines Only 1 Obtain a leak check squirt bottle or pump spray bottle 2 Fill the bottle with an approved leak check solution 3 Spray a generous amount of the solution on the fuel system fuel lines and connections starting at the storage container 4 Wait approximately 15 60 seconds then perform a visual inspection of the fuel system 5 Repair any leaks before continuing 6 Crank the engine through...

Page 1160: ...ire that has been run while flat or underinflated without first checking to make sure the locking ring on the rim is not damaged and is in the correct position When tires are changed be sure to clean all rim parts and if necessary repaint to stop detrimental effects of corrosion Sand blasting is recommended for removal of rust Check all components carefully and replace any cracked badly worn damag...

Page 1161: ...in oil level between the MAX and MIN marks on the dipstick Coolant Level Check WARNING At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the filter cap is cool enough to touch with your bare hand Remove the filter cap slowly to relieve pressure Cooling system conditioner contains ...

Page 1162: ...r leaks hose cracks or loose connections WARNING Pressure air can cause personal injury When using pressure air for cleaning wear a protective face shield protective clothing and protective shoes Maximum air pressure must be less than 205 kPa 30 psi for cleaning purposes 6 Blow any dust and lint from the radiator fins Inspect Foot Pedal Operation G424F E Only 1 Verify foot pedal travel is smooth w...

Page 1163: ... leaks on the lift truck and on the ground 5 Inspect the operator s compartment for loose items and cleanliness 6 Inspect the instrument panel for broken gauges and indicator lights 7 Test the horn and other safety devices for proper operation 8 Inspect the cooling system for leaks worn hoses and debris buildup 3 3 liter Diesel Engine 4TNE98 G424F E Engine 9 Inspect engine compartment for oil cool...

Page 1164: ...to contact skin 1 Start and operate the lift truck until the engine reaches normal operating temperature 2 Park the lift truck level with the forks lowered parking brake applied and the transmission controls in NEUTRAL 3 With the service brake applied and the engine at low idle shift the directional control lever to forward and then to reverse to fill the clutches 4 Shift the direction control lev...

Page 1165: ... in REVERSE Report truck movement or tendency to move under power with the parking brake engaged PARKING BRAKE NOTE The parking brake is required to be adjusted to hold the lift truck with capacity load on a 15 grade If there is a 15 grade in your workplace engage a capacity load and drive over to the grade If the maximum grade in your workplace is less than 15 or if the maximum load carried by th...

Page 1166: ...crankcase and allow the engine oil to drain more easily 5 Position a container under the engine to collect waste oil Figure 5 1 6 Remove the oil drain plug Figure 5 2 1 from the engine oil pan Allow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain plug Figure 5 2 1 and tighten to 139 8 47 0 ft lb 53 9 63 7 N m 5 5 6 5 kgf m 8 Dispose of used oil properly Remove...

Page 1167: ...nutes 7 Recheck the engine oil level 8 Add engine oil Figure 5 3 5 as needed until the level is between the upper Figure 5 3 2 and lower lines Figure 5 3 3 shown on the dipstick Figure 5 3 1 Figure 5 3 9 Reinstall the oil filler cap Figure 5 3 4 If any engine oil is spilled wipe it away with a clean cloth NOTICE Servicing of the engine oil and oil filter element will largely affect the engine perf...

Page 1168: ...ed 4 Apply clean oil on new filter sealing slightly 5 Install the filter with hand when the filter contact with the base retighten an additional 3 4 turn 6 Remove the dip stick filler cap Refill the tank with oil Refer to Refuel capacities Install dip sticke filler cap 7 Start the engine 8 With the service brake applied and engine at low idle shift the direction control lever to forward and revers...

Page 1169: ...n plug 2 Install the drain plug 3 Remove the dip stick filler cap Fill the drive axle housing with oil See Refill Capacities 4 Start the lift truck With the engine at low idle place the directional control lever to the NEUTRAL 5 Remove the drain plug Maintain the oil level until the oil flows out 6 Install the drain plug 7 Install the dip stick filler cap NOTE Tighten the dipstick plug fully not t...

Page 1170: ...ve in reverse down the grade with the parking brake engaged stop it with the service brakes disengage the parking brake and reverse slowly down the grade controlling your speed with the service brakes WARNING To prevent personal injury the operator MUST be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move Parking Brake Adjusting 1 Park ...

Page 1171: ...el with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped 1 Loosen the bolts of the hydraulic tank top plate assembly 2 Remove the return filter from tank top plate assembly 3 Change the return filter 4 Install the tank top plate assembly and fasten the bolts 5 Start the engine and operate the hydraulic controls and the steering system through a few cycles to f...

Page 1172: ...r latches and remove the cover 2 Rotate the element slightly to separate it from its base and remove it from the air cleaner housing 3 Clean and inspect the element or replace with a new element See topic Cleaning Primary Filter Element 4 Clean the inside of air cleaner housing and the cover Inspect all connections between the air cleaner and egine Check intake hose for cracks damage necessary to ...

Page 1173: ...n hand to use while cleaning used elements The primary element should be replaced after 6 months service or after cleaning no more than 3 times Air 205 kPa 30 psi Maximum Pressure Direct air on the inside and outside of the element along the length of the pleats Check the element for any tears rips or damage Water 280kPa 40 psi Maximum Pressure Direct water on the inside and outside of the element...

Page 1174: ... hand Remove the filter cap slowly to relieve pressure 1 Operate the lift truck for a few minutes to warm the oil Park the lift truck on a level surface with the forks lowered mast tilted back parking brake engaged transmission in NEUTRAL and the engine stopped 2 Raise the hood and seat assembly Make sure the support cylinder securely holds the hood open 3 Remove the dip stick filler cap Maintain ...

Page 1175: ...or free operation and damage Have repairs made if necessary 4 Brush a film of oil on all links of the chain 5 Raise and lower the carriage a few times to allow lubricant to enter into the chain links NOTICE Lubricate chains more frequently than normal in applications where the lift truck is operating in an atmosphere which could cause corrosion of components or when lift truck must work in rapid l...

Page 1176: ...gine Only Change Gasoline LP Engine Crankcase 1 Operate lift truck a few minutes to warm oil Park the lift truck with the forks lowered parking brake applied transmission in neutral and the engine stopped 2 Raise rear of lift truck off ground and block securely WARNING Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 3 Remove the crankcase drain p...

Page 1177: ...crankcase See Refill Capacities 11 Start the engine and allow the oil to fill the filter and passages 12 Check for oil leaks 13 Stop the engine and measure the oil level Maintain the oil level to the FULL mark on the dip stick 14 Close hood and seat assembly Wheel Bolts Nuts Inspect Inspect Tightness Steer Wheels Typical Example 1 Inspect tightness of wheel bolts in a sequence opposite each other ...

Page 1178: ...adjustment allows 10 mm 3 8 inch deflection under 110 N 25 lb of force NOTICE Failure to loosen the alternator mounting bolt 2 will cause excessive stress and break the alternator mounting ear 2 To adjust the alternator drive belt loosen adjusting bracket bolt 1 and mounting bolt 2 Move the alternator in or out as required Tighten bolts 1 and 2 Mast Hinge Pin Lubricate Typical Example 1 Lower the ...

Page 1179: ...cylinder continues to move after the other oil cylinder has stopped in full forward or backward tilt an adjustment must be made to one oil cylinder 3 To adjust the cylinder rod extending part move the spacer at the rear and loosen the tightening bolt on liner 4 Turn the cylinder rod in or out of the liner to obtain the proper adjustment Turning the rod into the liner shortens the stroke Turning th...

Page 1180: ... direction control lever to forward and reverse to fill the clutches 7 Shift the direction control lever into NEUTRAL Engage the parking brake 8 Remove the dip stick filter cap Observe the oil level 9 Maintain the oil level between the Min and Max marks on the dip stick filter cap When the oil temperature is 40 C approximately the cold side mark on the dipstick is applicable When the oil temperatu...

Page 1181: ... with engine at low idle place the directional control lever to the NEUTRAL 6 Check the driven axle oil level is lower than the lower edge of screw plug with light Add oil if necessary 7 Install the dip stick filler cap Steer Suspension Inspect 1 Inspect the suspension mounting bolts Tighten suspension mounting bolts if necessary to 240 30 N m 180 20 lb ft 2 Look for leaks at the power steering ho...

Page 1182: ...d replace all defective gauges 3 Check all lights such as warning directional backup driving and flood lights for correct operation Replace all burned out bulbs Have repairs made if needed Engine Oil Filter Diesel Engine Only Change See topic Engine Oil Filter Diesel Engine Only Change in First 50 100 Service Hours or a Week ...

Page 1183: ...ng Replace as necessary 2 To ensure the valve is not leaking a blow by test can be performed 3 With the engine off disconnect the electrical connector to the FTV 4 Disconnect the vacuum lines form the FTV to the pressure regulator converter at the converter s tee connection 5 Lightly blow through the vacuum line connected to the FTV Air should not pass through the FTV when de energized If air leak...

Page 1184: ...r carefully hold it to prevent the fuel from spilling Wipe up all spilled fuel Figure5 13 4 Clean the filter mounting surface and apply a small amount of diesel fuel to the gasket of the new fuel filter 5 Install the new fuel filter Turn to the right Figure5 13 2 and hand tighten it only until it comes in contact with the mounting surface Tighten to 14 17 ft lb 19 6 23 5 N m 2 0 2 4kgf m or one ad...

Page 1185: ...g the cup 5 Carefully hold the cup to prevent fuel from spilling If you spill any fuel clean up the spill completely 6 Remove the float ring Figure5 15 8 from the cup Pour the contaminants into the container and dispose of it properly 7 Clean the element Figure5 15 9 and inside cup Replace the element if it is damaged 8 Install the element and O ring in the bracket 9 Position the float ring in the...

Page 1186: ...nd the engine stopped 1 Loosen the bolts of the hydraulic tank top plate assembly 2 Remove the return filter from tank top plate assembly 3 Install new return filter by hand 4 Remove the suction strainer from the tank 5 Install the new strainer by hand 6 Install the tank top plate assembly and fasten the bolts Typical Example 7 Remove and discard the air breather 8 Install a new air breather 9 Sta...

Page 1187: ...g steps to check chain wear 1 Lift the mast and carriage enough for getting tension on lift chains Typical example 2 Measure precisely ten links of chain distance at the center of pins in millimeter 3 Calculate chain wear rate 4 If the chain wears rate is 2 or more replace the lift chain Chain wear rate Actual measurement Pitch X 10 Pitch X 10 Chain Pitch 19 05mm 0 75in Check for Equal Tension Typ...

Page 1188: ...in tension If not equal repeat the same procedure as step 1 through step 3 5 Put LOCTITE No 242 Tread lock on the threads of the anchor nuts 1 2 after the adjustment is completed Mast Chain Adjustment FF FFT Mast Typical example for FF mast Typical example for FFT mast Make sure that mast height is correct If correct adjust chain for equal tension If not adjust mast chain for correct mast height b...

Page 1189: ... between the air cleaner housing and the engine inlet Replace the gasket if it is damaged NOTICE Always replace the secondary element Do not attempt to reuse it by cleaning 3 Install a new secondary element Install a new or cleaned primary element Install the cover Tighten the latches 4 Start the engine and observe the air cleaner service indicator If the indicator shows RED after installing a new...

Page 1190: ...nce is required NOTE For pressure testing and internal inspection of the pressure regulator converter refer to the pressure regulator converter section of the service manual Fuel Lines Fittings Check Visually inspect fuel lines and fittings for physical damage Replace as required Inspect Mixer Assembly G424F E Engine Only Refer to the LP mixer section of the engine service manual for procedures In...

Page 1191: ...ngine components can cause burns Allow additional time for the engine to cool before measuring valve clearance NOTICE Measure the valve lash with the engine stopped To obtain an accurate measurement allow at least 20 minutes to cool the engine cylinder head and block temperature Set the clearance to the nominal appropriate clearance given in the Valve Clearance Setting shown below Valve Clearances...

Page 1192: ... and rotor 5 Inspect the ignition coil for cracks and heat deterioration Visually inspect the coil heat sink fins If any fins are broken replace as required G424F E Engine 1 Spark Plug Cables 2 Ignition Coil Replace Spark Plugs G424F E LP Gasoline Engine Only 1 Disconnect Battery Cables 2 Using a gentle twisting motion remove the high voltage cables from the spark plugs Replace any damaged cables ...

Page 1193: ... lines on the top and bottom covers 5 Install the cover retaining screws tightening the screws in an opposite sequence across the cover 6 Open the fuel valve by slowly turning the valve counterclockwise 7 Crank the engine several revolutions to open the fuel lock off DO NOT START THE ENGINE Turn the ignition key switch to the off position 8 Check the filter housing fuel lines and fittings for leak...

Page 1194: ...sure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar industrial engine dealer or distributor repair the damage Failure to comply could result in death or serious injury Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance The E...

Page 1195: ...Only Check Adjust See topic Engine valve Lash 4TNE98 Engine Only Check Adjust In First 250 Service hours Steer Wheel Bearings Reassemble Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped Typical Example 1 Lift the steer wheels off the ground Place stands or blocking under the frame and steer axle to support the lift truck Typical ...

Page 1196: ...er and outer bearing cones 7 Install the inner bearing Lubricate the seal and install the wheel assembly on the knuckle 8 Install the outer wheel bearing and the out washer Install a new lock washer and fit the locknut Typical Example 9 Tighten the locknut to 135 N m 100 lb ft while turning wheel hub to seat the bearing 10 Loosen the locknut Retorque it to 50 5N m 37 4 lb ft Bend the lock washer t...

Page 1197: ... valve casing on driven axle housing and then install the wheel bearing Torque for bolt 2 that hold braking assembly and drive axle housing is 200 10N m 148 10 lb ft Tighten wheel bearing 3 and loosen 7 8 1 10 turns Tighten the wheel bearing nut 4 with 300 10N m 220 10 lb ft and confirm the torque for wheel bearing is 10 30N m 7 22 lb ft Bend the lock washer tab into a groove of the nut Torque for...

Page 1198: ...p slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury Use all cleaning solutions with care The lift truck must be level the forks lowered the parking brake engaged the transmission in NEUTRAL and the engine stopped and cool 1 Turn the radiator cap slowly to relieve the pressure and then remove the cap Typical Example...

Page 1199: ... cooling water is drained Fill the engine and radiator with cleaner clean the engine and radiator 5 Start and run the engine for 30 minutes 6 Stop the engine and drain the neutralizing solution into a suitable container 7 Flush the system with clean water until draining water is clear 8 Close the drain valve and install the block drain plug Add coolant to the top of the filter neck 9 Start and run...

Page 1200: ... fork should be withdrawn from service if angle C exceeds 93 degrees or deviates by more than 3 degrees from an original angle other than 90 degrees as may be found in some special application forks 3 Check the straightness of the upper face of blade D and the front face of shank E with a straight edge The fork should be withdrawn from service if the deviation from straightness exceeds 0 5 percent...

Page 1201: ...prevented from sliding off the end of the carriage by stop blocks These stop blocks are at both ends of the carriage and in the path of the bottom fork hook The load backrest extension may be used in place of the stop blocks in some cases Shaft mounted forks may use set collars or spacers on the shaft to either side of the fork They may also use U bolts pins or similar devices which engage the for...

Page 1202: ... cause personal injury Do not allow hot oil or components to contact skin Park the lift truck level with the forks lowered parking brake engaged transmission in NEUTRAL and the engine stopped 1 Remove the hydraulic tank drain plug Allow the oil to drain into a suitable container Clean and install the plug 2 Remove the dipstick filler cap assembly 3 Fill the hydraulic tank See topic Refill Capaciti...

Page 1203: ...ector of oxygen sensor WARNING When assembling the filters check the arrow mark on the filter surface The arrow mark position is same as fuel flow direction Checking the TMAP Sensor G424F E Engine Only 1 Verify that the TMAP sensor F is mounted tightly into the manifold adapter E with no leakage 2 If the TMAP is found to be loose remove the TMAP retaining screw and the TMAP sensor from the manifol...

Page 1204: ...ake manifold throttle assembly 2 and manifold adapters 3 for looseness and leaks Repair as necessary Replace PCV Valve and breather element Change LP Gasoline Engines only G424F E Engine 1 Loosen the hose clamps and remove the PCV valve 2 Assemble new PCV valve and hose 3 Tighten the hose clamps ...

Page 1205: ...ust read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures Timing Belt G424F E LP Gasoline Engine Only Change See the Service manual for the procedure and specification ...

Page 1206: ...ng System Clean Change 168 Cooling System Specifications 113 Crosshead Rollers Inspect 149 Crushing or Cutting Prevention 14 Cylinder Rod Extension Adjust 149 D D20 25 30G 127 Daily Inspection 108 Detergent 143 Diesel Engine 12V 44 Diesel Engine 59 Diesel Engines 131 Diesel Specifications 115 Diesel 12V 60 Disassembly 163 Displaying Fault Codes DFC from SECM Memory 79 Drain the fuel filter water s...

Page 1207: ...onvenience Package Equipped 43 If Optional Suspension Seat weight adjusting type Equipped 19 Important Safety Information 4 Improper Modification or Repair 107 Inching into Loads 97 Inching 63 Index 176 Inspect Battery System 172 Inspect Coolant Hoses LP Engine Only 160 Inspect Electrical System G424F E Engine Only 153 Inspect Engine for Fluid Leaks 131 Inspect Foot Pedal Operation G424F E Only 13...

Page 1208: ... 61 Precleaner If Equipped 142 Preheat Start Switch 47 Pressure Air 14 Pressure Warning 7 Prestart Conditions 58 Priming the Fuel System Diesel Engine Only 128 R Reading Diagnostic Fault Codes 79 Refill Capacities 119 Refueling 53 Replace LP Fuel Filter Element LP Engine Only 163 Replace Oxygen Sensor G424F E Engine Only 173 Replace PCV Valve and breather element Change LP Gasoline Engines only 17...

Page 1209: ...dard Threads 111 Torques for Taperlock Studs 112 Towing Information 105 Traing Required To Operate or Service Warning5 Transmission Inching Control Pedal 50 Transmission Oil Filter Change 150 Transmission Oil Level Check 134 Transmission Oil 118 Transmission Oil Oil Filter Strainer Check Clean Change 138 157 Transportation Hints 104 Traveling With the Load 98 Turning 99 U Unloading 98 W Walk Aroun...

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