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G424F(FE) Service Manual

Chapter 9. Advanced Diagnostics

261

Table 2. Diagnostic Fault Codes (Flash Codes)

DFC

PROBABLE FAULT

FAULT ACTION*

CORRECTIVE ACTION

FIRST CHECK

12

NONE

Signifies the end of one pass
through the fault list

NONE

None, used as end of the fault list
identification

131

Inj1Open

Gasoline Injector 1 open
circuit, broken injector 1 wire
or defective injector

TurnOnMil

Check INJ1 wiring for an open circuit
SECM (Signal) A5 to Injector 1 Pin A
Switched 12V to Injector 1 Pin B
Check Injector 1 Resistance, 12 to14 ohms
(cold)

132

Inj2Open

Gasoline Injector 2 open
circuit, broken injector 2 wire
or defective injector

TurnOnMil

Check INJ2 wiring for an open circuit
SECM (Signal) A8 to Injector 2 Pin A
Switched 12V to Injector 2 Pin B
Check Injector 2 Resistance, 12 to14 ohms
(cold)

133

Inj3Open

Gasoline Injector 3 open
circuit, broken injector 3 wire
or defective injector

TurnOnMil

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

TurnOnMil

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
circuit, broken injector 5 wire
or defective injector

None N/A

136

Not Used

Inj6Open

Gasoline Injector 6 open
circuit, broken injector 6 wire
or defective injector

None N/A

137

Not Used

Inj7Open

Gasoline Injector 7 open
circuit, broken injector 7 wire
or defective injector

None N/A

138

Not Used

Inj8Open

Gasoline Injector 8 open
circuit, broken injector 8 wire
or defective injector

None N/A

141

(14)

ECTRangeLow

Coolant Sensor failure or
shorted to GND

TurnOnMil

Check ECT sensor connector and wiring
for a short to GND
SECM (Signal) Pin B15 To ECT Pin 3
SECM (Sensor GND) Pin B1 to
ECT Pin 1
SECM (Sensor GND) Pin A16, B17

151

(15)

ECTRangeHigh

Coolant sensor disconnected
or open circuit

(1) TurnOnMil
(2) Delayed Engine

Shutdown

(3) CheckEngineLight

Check if ECT sensor connector is
disconnected or for an open ECT circuit
SECM (Signal) Pin B15 to ECT Pin 3
SECM (Sensor GND) Pin B1 to
ECT Pin 1

(*) Fault actions shown are default values specified by the OEM.

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Summary of Contents for G20P-5

Page 1: ...Service Manual G424FE LP Dual Fuel Engine G424F LP Engine G20P 5 G25P 5 G30P 5 G33P 5 G35C 5 GC20P 5 GC25P 5 GC30P 5 GC33P 5 SB4251E00 May 2007 ...

Page 2: ......

Page 3: ...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 4: ......

Page 5: ...y 21 Checking and Adjusting Drive Belt 22 Adjusting 22 Checking Belt for Damage 22 Ignition System Maintenance 23 Inspect Battery 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 Asse...

Page 6: ...ug Wire Replacement 104 Spark Plug Replacement 105 Spark Plug Inspection 105 Charging System 107 General Description 107 Troubleshooting Procedure 110 STARTING SYSTEM 115 General Description 115 Diagnosis Procedure 116 Start Relay Tests 118 Troubleshooting 119 Chapter 5 ENGINE MANAGEMENT SYSTEM EMS General Information 121 Specifications 121 Service Standard 126 Component Location 127 G424FE EMS En...

Page 7: ... and Installation 193 G424F Fuel System Connections 194 Removal and Installation of N 2001 LP Regulator Converter 195 Removal and Installation of CA100 Mixer for G424F 196 Tests and Adjustments 198 N 2001 Regulator Service Testing 198 AVV Air Valve Vacuum Testing 200 Connection of the MI 07 Service Tool 200 Idle Mixture Adjustment 201 Parts Description 203 CA100 Mixer for G424F Engine 203 CA100 Di...

Page 8: ...k248 Chapter 9 ADVANCED DIAGNOSTICS Reading Diagnostic Fault Codes 249 Displaying Fault Codes DFC from SECM Memory 249 Clearing Fault DFC Codes 249 Fault Action Descriptions 250 Fault List Definitions 250 Table 1 Fault List Definitions 251 Table 2 Diagnostic Fault Codes Flash Codes 261 Appendix Service Tool Software MotoView 279 Introduction 279 Connection of the Service Tool 280 MotoView Display ...

Page 9: ...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 10: ...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 11: ... 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 12: ...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 13: ...ssification 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 G C 20 25 30 33P 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 14: ...onic Control by ECM Standard LP System available Open loop LP Carburetion 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 El...

Page 15: ... 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 16: ...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 17: ...G424F ENGINE MODEL unit G424FE LP G424FE DF LP G424FE DF GAS G424F LP kW 46 2 44 7 46 2 hp 62 60 62 PS 62 9 60 8 62 9 RATED POWER rpm 2 550 2 550 2 550 N m 181 172 181 ibf ft 134 127 134 Kgf m 18 5 17 5 18 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 18: ...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 19: ...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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...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 31: ...G424F FE Service Manual Chapter 2 Recommended Maintenance 29 ...

Page 32: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 30 Chapter 3 ENGINE MECHANICAL SYSTEM General Information Engine Outline ...

Page 33: ...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 34: ...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 35: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 33 Shells Selection Table MAIN BEARINGS STANDARD SIZE ALL MEASURES ARE IN MILLIMETERS ...

Page 36: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 34 MAIN BEARINGS 0 50 UNDERSIZE ...

Page 37: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 35 CONNECTING ROD BEARINGS CONNECTING ROD BEARINGS 0 25 UNDERSIZE 0 50 UNDERSIZE ...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ... 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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ... 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 53: ...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 54: ...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 55: ... 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 56: ...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 57: ... 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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ... 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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ... 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 84: ...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 85: ... 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 86: ...G424F FE Service Manual Chapter 3 Engine Mechanical System 84 ...

Page 87: ... 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 88: ...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 89: ... 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 90: ... 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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ... 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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ... 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 105: ...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 106: ... 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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...G424F FE Service Manual Chapter 4 Engine Electrical System 110 Troubleshooting Procedure Inspection before Starting 1 Alternator and drive belt tension inspection ...

Page 113: ...G424F FE Service Manual Chapter 4 Engine Electrical System 111 2 Alternator and outer terminal connection inspection ...

Page 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...underhood automotive Camshaft Position Sensor 0 LP 1 Dual Fuel None 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 O...

Page 124: ...tuation Pressure Normal Open 145 28 kPa 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 ...

Page 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...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 option ...

Page 131: ...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 132: ...G424F FE Service Manual Chapter 5 Engine Management System EMS 130 Gasoline Injectors and fuel rail Gasoline Fuel Pump Ass y ...

Page 133: ...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 The SECM controller has full adaptive learning capabilities allowing it to adapt control function as operating conditions change Factors such as ambient temperature fuel variations...

Page 134: ... used for G424FE dual fuel engine On gasoline the camshaft sensor along with the crankshaft sensor is used to control the fuel injectors and feedback from oxygen sensor is used by the SECM to adjust the gasoline delivery based on the exhaust emissions Crank Sensor Throttle body CAM sensor Dual Fuel Only TMAP sensor Coolant Temp EG oil pressure switch T M Temp switch Accel pedal angle sensor Thrott...

Page 135: ...ctuators Ignition system including spark plugs cables coils and drivers Gasoline injectors and fuel pressure regulator dual fuel systems only 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 and gasoline MPI fuels Speed load s...

Page 136: ...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 137: ...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 138: ...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 139: ...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 140: ...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 141: ... 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 142: ...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 143: ... 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 ...

Page 144: ...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 145: ...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 146: ... 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 147: ...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 148: ...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 149: ...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 150: ...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 151: ... 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 21 Dual fuel certified system Figure 22 LP certified system ...

Page 152: ...G424F FE Service Manual Chapter 5 Engine Management System EMS 150 Figure 21 SECM Wiring Diagram for G424FE Dual Fuel System ...

Page 153: ...G424F FE Service Manual Chapter 5 Engine Management System EMS 151 Figure 22 SECM Wiring Diagram for G424FE LP System ...

Page 154: ... throttle 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 LP System The LPG regulator and the mixer operate as an open loop system since no mixture adjustments are ...

Page 155: ...153 LP System of G424F INPUT OUTPUT Crank Sensor Throttle body T M Inching pressure switch option 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 ...

Page 156: ...ntrol Module SECM 48 pin None None Camshaft Position Sensor 1 1 Crankshaft Position Sensor 1 1 TMAP Sensor 1 None Fuel Temperature Sensor 1 1 Transmission Oil Temperature Switch 2 None Oxygen Sensors 1 1 Coolant Temperature Sensor 1 1 Engine Oil Pressure Switch 2 None Fuel Trim Valve 1 1 Ignition Coils 1 1 Fuel Lock Off Solenoid N 2007 N 2001 LP Regulator CA 100 Certified CA 100 LP Mixer 1 1 Elect...

Page 157: ...o 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 supplied by customer El...

Page 158: ... 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 secondary valve 6 The seconda...

Page 159: ...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 160: ...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 161: ...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 162: ...G424F FE Service Manual Chapter 5 Engine Management System EMS 160 SECM Wiring Diagrams for G424F LP Engine ...

Page 163: ...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 164: ...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 165: ...tion 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 st...

Page 166: ...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 167: ...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 168: ...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 169: ...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 170: ... 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 171: ... 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 172: ... 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 173: ...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 174: ... 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 175: ...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 176: ...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 177: ... decreasing 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...

Page 178: ...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 179: ... 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 180: ...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 181: ...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 182: ...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 183: ... 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 184: ...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 185: ...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 186: ...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 187: ...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 188: ...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 189: ...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 190: ... 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 191: ...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 192: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 190 Exploded View of CA100 Mixer Certified Figure 44 CA100 Certified Mixer Exploded View ...

Page 193: ...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 194: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 192 Exploded View of N 2007 Regulator Certified Figure 46 N 2007 Certified Regulator Exploded View ...

Page 195: ...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 196: ...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 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 202: ...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 203: ...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 204: ...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 205: ...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 206: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 204 Exploded View CA100 Mixer Figure 44 CA100 Non Certified Mixer Exploded View ...

Page 207: ...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 208: ... 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 209: ...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 210: ...G424F FE Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 208 Exploded View N 2001 RSA Regulator Figure 47 N 2001 Regulator Exploded View ...

Page 211: ... 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 212: ... 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 213: ...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 214: ...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 215: ...424F FE Service Manual 213 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 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ...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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...G424F FE Service Manual 227 Chapter 8 Basic Troubleshooting Symptom Troubleshooting Guide Chart for MPI Gasoline System Engine Is Not Starting Engine Is Difficult To Start Cranking OK ...

Page 230: ...G424F FE Service Manual 228 Chapter 8 Basic Troubleshooting Irregular Idling Or Engine Is Suddenly Stopped ...

Page 231: ...G424F FE Service Manual 229 Chapter 8 Basic Troubleshooting Engine Hesitation Or Insuffient Accelelation ...

Page 232: ...G424F FE Service Manual 230 Chapter 8 Basic Troubleshooting ...

Page 233: ...G424F FE Service Manual 231 Chapter 8 Basic Troubleshooting Troubleshooting Guide for MPI Gasoline System The following number represents inspection order ...

Page 234: ...G424F FE Service Manual 232 Chapter 8 Basic Troubleshooting ...

Page 235: ...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 236: ...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 237: ... 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 238: ...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 239: ... 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 240: ...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 241: ...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 242: ...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 243: ...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 244: ...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 245: ...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 246: ...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 247: ...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 248: ...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 249: ...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 250: ...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 251: ...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 252: ...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 253: ...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 lower than expected 632 67 APP2RangeHigh APP2 sensor voltage out of range high normally set if the APP2 signal has shorted to power or the ground for the sensor has opened 622 66 APP2Ran...

Page 254: ...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 255: ...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 256: ... SECM is defective 471 ETC_Sticking Electronic Throttle Control is Sticking This can occur if the throttle plate butterfly valve inside the throttle bore 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 ...

Page 257: ...e 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 relay failure...

Page 258: ...ssis ground or the sensor has failed 371 37 IAT_IR_Fault Intake Air Temperature not changing as expected 391 Inj1Open Gasoline Injector 1 open circuit broken 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 ...

Page 259: ...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 260: ... the SECM 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 ...

Page 261: ...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 262: ...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 263: ...ld 134 Inj4Open Gasoline Injector 4 open circuit broken injector 4 wire or defective injector TurnOnMil 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 circuit broken injector 5 wire or defective injector None N A 136 Not Used Inj6Open Gasoline Inje...

Page 264: ... 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 Check ...

Page 265: ...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 the sensor has opened TurnOnMil Check throttle connector and TPS1 sensor wiring for a shorted circuit SECM Pin B4 signal to ETC Pin 5 SECM Pin B1 sensor GND to ETC Pin 2 241 24 TPS1AdaptLoMin Learned closed throttle e...

Page 266: ...he circuit has opened to the SECM None 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 pressure signal KPA 2 4kΩ 8 2k TMAP Pin 3 power to Pin 4 pressure signal KPA 3 4...

Page 267: ...r a 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 None Ch...

Page 268: ...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 269: ...bly 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 open EST8 signal or defective spark module None N A 431 EST1_Short EST1 output shorted high or low EST1 signal shorted t...

Page 270: ...r shorts SECM Pin A3 EST3 to ignition module Pin D 4 pin connector 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 434 EST4_Short EST4 output shorted high or low EST4 signal shorted to ground or power or defective spark module TurnOnMil Check coil driver wiring and connector for...

Page 271: ...e throttle connector and measuring 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 either of the ETC driver signals have opened or become disconnected electronic throttle or SECM is defective None Check the ETC driver wiring for an open circuit SECM Pin A17 to ETC Pin 1 SECM Pin A18...

Page 272: ...il level 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 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...

Page 273: ...PWR 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 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 has exceeded th...

Page 274: ...edal several times and check APP1 signal at SECM Pin B7 632 67 APP2AdaptLoMin Learned idle end of APP2 sensor range lower than expected None Check APP connector and pins for corrosion Cycle the pedal several times and check APP2 signal at SECM Pin B16 641 64 APP1AdaptHiMax Learned full pedal end of APP1 sensor range higher than expected None N A 642 68 APP2AdaptHiMax Learned full pedal end of APP2...

Page 275: ...gine 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 wire or shorted to GND 715 LSDFault_CrankDisable Crank Disable Fault signal has opened or shorted to ground or power or defective crank disable relay None N A 717 LSDFault_LockOff Fuel lock off Valve Fault signal has opened or shorted to ground or pow...

Page 276: ... 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 coil power The relay coil ground is controlled by SECM ...

Page 277: ...uelAdaptRangeHi In Gasoline mode system had to adapt lean more than expected TurnOnMil Check for vacuum leaks Low gasoline fuel pressure perform gasoline pressure test Injector problems e g plugged defective injector 831 LiqFuelAdaptRangeLow In Gasoline mode system had to adapt rich more than expected TurnOnMil Low gasoline fuel pressure perform gasoline pressure test Injector problems e g leaking...

Page 278: ...ates extended lean operation on gasoline 1 TurnOnMil 2 DisableLiquid O2Ctrl 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 DisableLiqPost O2Ctrl Correct other faults that may contribute to 852 e g faults pertai...

Page 279: ...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_PostCatRangeHigh Post catalyst O2 sensor voltage out of range low sensor signal shorted to ground 1 TurnOnMil 2 Disable Gasoline Post catalyst O2Ctrl 3 Disable LPG Post catalyst O2Ctrl Check if O2 sensor installed after catalyst is shorted to 5Vdc or b...

Page 280: ...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 281: ... section Once MotoView is connected to the SECM through the CAN cable a display file is opened MI_07RevJ 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 282: ... 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 283: ...ine 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 parameter filed throughout the display screens The indic...

Page 284: ...lt 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 You have now armed the clear fault function Using your mouse click the pull down arrow again and select...

Page 285: ...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 286: ...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 287: ...2 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 288: ...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 289: ...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 290: ...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 291: ...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 292: ...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 293: ...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 294: ...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 295: ...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 296: ...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 297: ...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 298: ...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 299: ...ring 1 Assemble the pressure switch 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 Fo...

Page 300: ...MAX RPM Setpoint The pressure switch state is displayed at the bottom of the screen and labeled NEUTRAL SWITCH STATE For example as Figure 2 depicts With pushing of inching pedal the maximum RPM for normal speed governing Neutral State is set at 2600 With release of inching pedal the maximum RPM for limited speed governing In Gear State is set at 2000 Allowable Range of RPM Limits Software limits ...

Page 301: ... 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 302: ... 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 303: ...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 304: ...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 305: ...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 306: ...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...

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