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Doosan G643, Service Manual

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G643(E) Service Manual 

Chapter 1. General Information 

7

Chapter 1. GENERAL INFORMATION 

 

Precautions before Service 

 

Removal and Disassembly 

 
 
 
 
 
 
 
 
 
 
 
 
 
For prevention of wrong installation or reassembly 
and for ease of operation, 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 or oil leaks. 
 

Summary of Contents for G643

Page 1: ...Service Manual G643E LP Engine G643LP Engine G35S 5 G40S 5 G45S 5 G50C 5 G55C 5 GC35S 5 GC40S 5 GC45S 5 GC50C 5 GC55C 5 G40SC 5 G45SC 5 G50SC 5 G55SC 5 G50S 5 G60S 5 G70S 5 SB4263E01 Dec 2008...

Page 2: ......

Page 3: ...ollowing 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...

Page 4: ......

Page 5: ...on Timing 24 Inspection of Spark Plug 25 Fuel System Maintenance 27 Replace LP Fuel Filter Element 27 Testing Fuel Lock off Operation 27 Pressure Regulator Converter Inspection 28 Inspect Air Fuel Val...

Page 6: ...earings 91 Crankshaft Runout 93 Crankshaft End Play 93 Connecting Rod Bearings 93 Connecting Rod Side Clearance 94 Assembly of Engine 95 Prior to Assembly 95 Crankshaft And Crankshaft Bearing Installa...

Page 7: ...Shaft Position Sensor G643E 182 IAT Intake Air Temperature Sensor G643E and G643 184 OxygenSensor Pre Catalyst G643E 185 Oxygen Sensor Post Catalyst G643E 186 ECT Engine Coolant Temperature Sensor G64...

Page 8: ...ck of Power Slow to Respond Poor High Speed Performance Hesitation During Acceleration 238 Detonation Spark Knock 240 Backfire 241 Dieseling Run on 241 Rough Unstable Incorrect Idle or Stalling 242 Cu...

Page 9: ...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 ma...

Page 10: ...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...

Page 11: ...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 eng...

Page 12: ...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 w...

Page 13: ...5 8 3 4 7 8 1 1 1 8 1 1 4 1 3 8 1 1 2 9 3 18 5 32 5 50 10 75 20 110 15 150 20 265 35 420 60 640 80 800 100 1000 120 1200 150 1500 200 12 4 25 7 45 7 70 15 100 15 150 20 200 25 360 50 570 80 875 100 1...

Page 14: ...ation 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...

Page 15: ...Standard LP System available Open loop LP Carburetion system Muffler is standard Indication of Engine Model and Serial Number Engine Model Engine Serial Number G643E G643 30700001 to 39999999 Feature...

Page 16: ...s Wet ENGINE ROTATION Counter Clockwise CCW when viewed from Flywheel End FUEL TYPE LPG CRANK VENTILATION PCV System IGNITION SYSTEM IGNITION TYPE Distributor System IGNITIOIN TIMING Electronic contro...

Page 17: ...ute Press Sensor Intake Air Temp Manifold Absolute Press Sensor PEDAL ANGLE SENSOR Two Output Signals Installed on Accelerator Pedal Two Output Signals Installed on Accelerator Pedal OXYGEN SENSOR Hea...

Page 18: ...G643 G643E Engine Power and Torque ENGINE MODEL unit G643E LP G643 LP kW 69 4 69 4 hp 93 0 93 0 PS 94 3 94 3 RATED POWER rpm 2 450 2 450 N m 284 294 lbf ft 210 217 kgf m 29 0 30 0 MAX TORQUE rpm 1600...

Page 19: ...e 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...

Page 20: ...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 th...

Page 21: ...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 en...

Page 22: ...r foreign material being penetrated in the cylinder through cracks can come into the spark hole during checking compressed pressure When cranking the engine to test compressed pressure necessarily ope...

Page 23: ...sphates 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 espec...

Page 24: ...ster 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 Measu...

Page 25: ...s out of the standard Inspect the belt tensioner The belt tensioner is pre set and spring loaded Standard Item New belt Used belt Drive belt deflection L 4 0 4 4mm 5 1 5 7mm Checking Belt for Damage C...

Page 26: ...n In neutral position Parking brake ON 2 Inspection 1 Connect the timing light 2 Measure RPM RPM Low Idle 750 15 rpm NOTE If RPM is not normal it is impossible to measure the proper ignition timing so...

Page 27: ...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 clea...

Page 28: ...e care not to over tighten it to prevent cylinder head threads from damage Tightening torque 25 30 N m SPARK PLUG ANALYSIS State Contact point is black Contact point is white Description Density of th...

Page 29: ...mage 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 ac...

Page 30: ...ng cracks and missing cover retaining clips Repair and or replace as necessary NOTE Refer to Chapter 6 for procedures on removing the mixer and inspecting the throttle plate Checking the TMAP Sensor G...

Page 31: ...fluid leaks X Inspect all vacuum lines and fittings X Inspect electrical system check for loose dirty or damaged wires and connections X Inspect isolation mounts on engine control module for cracks an...

Page 32: ...r cracks or deterioration X Ensure valve seals in the closed position when the engine is off X Replace FTV When indicated by MIL Carburetor Mixer Check air filter indicator X Check for air leaks in th...

Page 33: ...G643 E Service Manual Chapter 3 Engine Mechanical System 31 Chapter 3 ENGINE MECHANICAL SYSTEM General Information Engine Outline...

Page 34: ...m 010 in MAX Cylinder Head Surface Flatness 0 1016 mm 004 in MAX Crankshaft Crankshaft Journal Diameter 1 62 199 62 217 mm 2 4488 2 4495 in Diameter 2 3 62 192 62 215 mm 2 4485 2 4494 in Diameter 4 62...

Page 35: ...s 10 N m 89 lb ft Final Pass 25 N m 18 lb ft EGR Valve Pipe Bracket Bolt 25 N m 18 lb ft EGR Valve Inlet Pipe Nut 35 N m 26 lb ft Engine Block Drain Plug 20 N m 15 lb ft Engine Block Oil Gallery Plug...

Page 36: ...m 18 lb ft Oil Pump Tightening Specifications for Oil Pump to Main Bearing Cap Bolt 1 Oil Pump 2 Torque for bolt 90 N m 66 lb ft Oil Filter Tightening Specifications for Oil Filter 1 Wipe clean the f...

Page 37: ...ifold tighten bolts in two steps begin with the center bolts 1 Torque for exhaust manifold bolts 15 N m 11 lb ft 2 Torque for exhaust manifold bolts second pass 30 N m 22 lb ft Intake Manifolds Tighte...

Page 38: ...ng Flywheel 1 Torque for the bolts that hold the flyweel to the crankshaft100 N m 74 lb ft 2 Use a torch Heat the ring around the entire circumference then drive the gear off the flywheel using care n...

Page 39: ...e flywheel 0 19 mm 0075 in Outside Diameter Runout Radial Eccentricity Outside Diameter Runout Check Maximum permissible outside diameter runout of the flywheel 0 1 mm 004 in Pressure Cap For testing...

Page 40: ...urnals for the camshaft bearings new 51 03 to 51 05 mm 2 009 to 2 010 in Balance Shaft 1 Front Bearing Journal Diameter 55 985 to 55 001 mm 2 1648 to 2 1654 in 2 Rear Bearing Journal Diameter 38 084 t...

Page 41: ...ecified lobe lift 0 05 mm 022 in See procedure under Testing And Adjusting section of manual on to due measurements Front Gear Cover 1 The front gear cover 1 of the engine must be replaced if it is re...

Page 42: ...l bolts are torqued to a torque of 30 N m 22 lb ft On the second pass a tool A degree wheel must be used Bolts in sequence 1 Short length bolts 11 7 3 2 6 10 55 degrees 2 Medium length bolts 12 13 65...

Page 43: ...G643 E Service Manual Chapter 3 Engine Mechanical System 41 Engine Exploded View...

Page 44: ...GASKET KIT 95 GUIDE VALVE LIFTER PUSH ROD 17 BOLT VALVE ROCKER ARM COVER 96 BOLT VALVE LIFTER GUIDE 19 NUT VALVE ROCKER ARM 97 NIPPLE HTR INL HOSE 21 ARM VALVE ROCKER 99 HOSE WATER PUMP INLET INCL CLA...

Page 45: ...G643 E Service Manual Chapter 3 Engine Mechanical System 43...

Page 46: ...AL OIL PAN DRAIN PLUG O RING 20 SPROCKET CM SHF SEE ITEM 2A END 78 PLUG OIL PAN DRAIN W MAGNET SEAL 21 SPROCKET CR SHF SEE ITEM 2A END 79 BOLT OIL PAN HFH 5 16 18 X 7 8 22 BOLT CM SHF SPROCKET 80 NUT...

Page 47: ...ance Shaft A cast iron balance shaft is mounted in the crankcase above and in line with the camshaft A camshaft gear drives the gear attached to the balance shaft The front end of the balance shaft is...

Page 48: ...as to prevent distortion of parts RTV is weaker in shear lateral strength than in tensile vertical strength NOTICE Attempting to pry or pull components apart may result in damage to the part 3 Surface...

Page 49: ...tch and depth of damaged thread If necessary adjust stop collars on cutting tool and tap to required depth IMPORTANT Refer to the kit manufacturer s instructions regarding the size of drill and tap to...

Page 50: ...per Puller and Installer J 5239 Connecting Rod Guide Set J 5590 Crankshaft Sprocket Installer J 5715 0 0762 mm 0 003 in Reamer J 5825 A Crankshaft Sprocket Puller J 5830 02 Reamer Set J 5830 1 5830 2...

Page 51: ...J 3049 A Valve Lifter Remover J 5715 or J 6036 Rocker Stud Hole Reamer J 6098 01 Camshaft Bearing Remover Installer J 5239 Connecting Rod Bolt Guide Set J 8062 Valve Spring Compressor J 8087 Cylinder...

Page 52: ...037 Piston Ring Compressor J 9290 01 Valve Lifter Remover Slide Hammer Type J 24086 C Piston Pin Remover Installer Set J 24270 Ridge Reamer J 24420 C Universal Crankshaft Pulley Remover J 21882 Oil Su...

Page 53: ...system If the coolant is cold cool the thermostat will be closed The coolant circulates makes a complete circuit from the water pump and through the cylinder block until the temperature of the coolan...

Page 54: ...de 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 h...

Page 55: ...s 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 WARNIN...

Page 56: ...e 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...

Page 57: ...otection 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 recommen...

Page 58: ...solution for cooling system top up is an unacceptable practice It increases the concentration of antifreeze in the cooling system which increases the concentration of dissolved solids and undissolved...

Page 59: ...e adequate oil supply in the event the filter becomes plugged or develops excessive pressure drop Figure 12 1 Engine Lubrication Flow Filtered oil flows into the main gallery and then to the camshaft...

Page 60: ...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 G643 E E...

Page 61: ...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 ope...

Page 62: ...have been removed These accessories may include one or more of the following Hydraulic Pump Drive Belt Tensioner Alternator Cooling Fan Distributor Accessory Mounting Brackets Starter Motor Carbureto...

Page 63: ...n Drain plug to 25 N m 18 lb ft Engine Flywheel Removal Figure 12 3 Remove or Disconnect 1 Engine flywheel bolts 2 Engine flywheel Figure 12 3 Engine Flywheel Exhaust Manifold Removal Figure 12 4 Figu...

Page 64: ...ket 2 Remove the bracket assembly Note For installation of the fan bracket reverse the removal steps and torque mounting bolts to 50 N m 37 lb ft Coolant Pump Removal Remove or Disconnect Start By a D...

Page 65: ...Rocker Arm Cover Thermostat Removal Start By a Draining coolant from radiator b Removing upper radiator hose from thermostat housing Components 1 Gasket Thermostat Housing 2 Thermostat Housing Spacer...

Page 66: ...res 12 6 through 12 8 Remove or Disconnect IMPORTANT Store all reusable components in an exact order so they can be reassembled in the same wear pattern location from which they were removed Mark the...

Page 67: ...ad Removal Remove or Disconnect Start By a Removing high mounted fan bracket b Remove distributor from intake manifold c emove intake manifold assembly d Remove exhaust manifold assemblies e Remove ro...

Page 68: ...vement of the inertia weight section of the hub will destroy the tuning of the torsional damper and the engine timing reference 1 Torsional damper bolt 2 Torsional damper using J 39046 figure 12 12 3...

Page 69: ...posite cover is removed DO NOT reinstall it Always install a new engine front cover Start By a Removing crankshaft pulley b Remove crankshaft balancer 1 Remove bolts from cover 2 Remove cover from eng...

Page 70: ...and camshaft retainer 2 Camshaft A Install three 5 16 18 bolts 100 125 mm 4 5 in long into the camshafts threaded holes Use these bolts to handle the camshaft figure 12 14 B Pull the camshaft out from...

Page 71: ...r nicks and burrs Piston and Connecting Rod Removal Figures 12 18 and 12 19 Tools Required J 24270 Ridge Reamer J 5239 Guide Set Remove or Disconnect 1 Ridge or deposits from the upper end of the cyli...

Page 72: ...ich they were removed 4 Connecting rod cap 5 Connecting rod and piston Figure 12 19 Removing Piston and Connecting Rod IMPORTANT Attach J 5239 to the connecting rod bolts figure 12 19 Use the long gui...

Page 73: ...ssembly Remove or Disconnect Notice Be sure to mark bearings rod and piston assemblies so when they are installed they will be in the correct location 1 Remove crankshaft bearing cap bolts 2 Remove th...

Page 74: ...not be expected to perform properly if the parts are worn beyond acceptable limits are reused NOTICE Use only a razor blade type scraper on engine component surfaces Use extreme care so sealing surfac...

Page 75: ...spected Take the feeler gage and at various locations check the gap between the straightedge and the sealing surface Figure 12 25 Measuring Cylinder Block Surface Flatness If the gap is greater than 0...

Page 76: ...nd measure across the gage contact points with an outside micrometer with the gage at the same zero setting when removed from the cylinder figure 12 28 Figure 12 27 Typical Cylinder Wear Pattern Figur...

Page 77: ...etal so that all stone marks may be removed with the fine stones used for finishing to provide proper clearance 2 Occasionally during the honing operation the cylinder bore should be thoroughly cleane...

Page 78: ...aring and cap need to be stored together as mating parts so they may be reassembled in the same position from which they were removed Figures 12 29 through 12 31 Tool Required J 24086 B Piston Pin Rem...

Page 79: ...uring Piston Pin To Piston Clearance Figures 12 32 and 12 33 Measure 1 Piston pin diameter Check against Specifications 2 Piston pin to piston clearance A Measure the piston pin hole diameter B Subtra...

Page 80: ...termine if a new piston will fit the cylinder bore 3 If a new piston does not bring the clearance within tolerances the cylinder bore must be reconditioned 4 Mark the piston to identify the cylinder f...

Page 81: ...with a feeler gage D Refer to Specifications in the proper Section for correct gap E If the gap between the ends of the ring is not as specified remove the ring and try another for fit Figure 12 37 Me...

Page 82: ...arped and should be replaced Figure 12 40 Checking Manifold Flange Alignment Camshaft Figures 12 41 and 12 42 Tool Required J 7872 Dial Indicator or Equivalent IMPORTANT Do not attempt to repair the c...

Page 83: ...in their bores Replace the camshaft bearings if necessary Camshaft lobes and journals for scratches pitting scoring and wear Minor irregularities may be cleaned up with emery cloth Camshaft Bearing I...

Page 84: ...the specifications Refer to Specifications Rear sleeve bearing journal clearance Replace the balance shaft if the clearance exceeds the specification Refer to Specifications Timing Chain and Sprockets...

Page 85: ...Covers Figure 12 45 Clean Parts in solvent Remove all sludge and varnish Old gaskets from the gasket surfaces Inspect Gasket flanges for bending or damage Rubber grommets and parts on the valve rocke...

Page 86: ...embly must be replaced Inspect Oil pump screen damage or loose fit of the pipe Pressure regulator valve for fit The regulator valve should slide freely in its bore without sticking or binding Install...

Page 87: ...g J 21882 and a hammer E The pump screen must be parallel with the bottom of the oil pan when installed 9 Oil pump drive shaft and connector Valve Train Components IMPORTANT Store all reusable compone...

Page 88: ...t reassembly Figure 12 48 Compressing Valve Springs Figure 12 49 Valves and Components Cleaning Inspection and Measurement Figures 12 50 through 12 54 Tool Required J 8089 Wire brush Clean Carbon from...

Page 89: ...gasket rail B Observe dial indicator movement while moving valve from side to side crosswise to the head The dial indicator measurement must be taken just above the valve guide bore C Drop the valve h...

Page 90: ...argin may result because of the amount of metal that must be removed Undersize valve margins lead to breakage burning or preignition due to heat localizing on this knife edge figure 12 55 Refer to Spe...

Page 91: ...a valve with an oversize stem installed Oversize valves are available Refer to Specifica tions Select a reamer that will provide a straight clean bore through the entire length of the valve guide fig...

Page 92: ...60 Measuring Valve Spring Installed Height Thermostat and Coolant Outlet Remove or Disconnect 1 Bolts 2 Stud 3 Coolant outlet 4 Gasket 5 Thermostat with gasket Inspect Coolant outlet for cracks Instal...

Page 93: ...rsize Selective fitting of crankshaft bearings is necessary in production to obtain close tolerances For example you may find one half of a standard crankshaft bearing with one half of an undersize cr...

Page 94: ...e figure 12 63 Figure 12 63 Measuring Gauging Plastic c If the flattened plastic tapers toward the middle or ends there is a difference in clearance indicating taper low spot or other irregularity of...

Page 95: ...bolts b Tighten bolts to specification c Firmly thrust end of the crankshaft first rearward then forward This will line up the rear main bearing and crankshaft thrust surfaces d With the crankshaft we...

Page 96: ...al Chapter 3 Engine Mechanical System 94 Connecting Rod Side Clearance Figure 12 66 Measure Connecting rod side clearance as shown in figure 12 66 Refer to Specifications Figure 12 66 Measuring Connec...

Page 97: ...herwise specified during assembly This will provide initial lubrication when the engine is started Crankshaft And Crankshaft Bearing Installation Install or Connect IMPORTANT If any undersized bearing...

Page 98: ...r Oil Seal Installation Figure 12 68 Tool Required J 35621 Seal Installer Install or Connect 1 Crankshaft rear oil seal A Lubricate the inner and outer diameter of the seal with engine oil B Install t...

Page 99: ...engine oil 4 Piston and connecting rod into the proper bore A With the connecting rod cap removed install J 5239 onto the connecting rod bolts figure 12 69 B Locate the piston ring end gaps figure 12...

Page 100: ...nnecting rod bolt nuts an additional 70 using J 36660 Measure Connecting rod side clearance as outlined previously Balance Shaft Installation Figures 12 72 through 12 76 NOTICE Refer to Notice on page...

Page 101: ...alance shaft drive gear and driven gear line up figure 12 76 6 Balance shaft drive gear bolt Tighten Bolt to 16 N m 12 lb ft Figure 12 75 Installing Balance Shaft Figure 12 76 Balance Shaft Drive Gear...

Page 102: ...linder is at top dead center of the compression stroke with the timing marks in this position 2 Camshaft sprocket bolts and nut Tighten Camshaft sprocket bolts and nut to 28 N m 21 lb ft Figure 12 78...

Page 103: ...read the stud fully into the tapped hole in the crankshaft 4 Torsional damper over the end of the stud Align the keyway in the torsional damper shaft with the crankshaft key 5 Bearing washer and nut A...

Page 104: ...gure 12 83 Installing Oil Pan to Engine Block 2 Oil pan gasket onto pan 3 Oil pan to cylinder block figure 12 83 4 Slide oil pan back against straightedge using J 34673 or equivalent 5 Oil pan bolts a...

Page 105: ...G643 E Service Manual Chapter 3 Engine Mechanical System 103 Figure 12 84 Oil Pan Tightening Sequence Figure 12 85 Oil Filter Adapter Installation With Oil Cooler Typical...

Page 106: ...ertight Tighten A Bolts to 30 N m 22 lb ft B Bolts in sequence using J 36660 to Short length bolt 11 7 3 2 6 10 55 Medium length bolt 12 13 65 Long length bolt 1 4 8 5 9 75 4 Spark plugs Tighten Spark...

Page 107: ...with positive stop shoulders no valve adjustment is necessary When the valve train requires service you simply tighten the rocker arm nuts to 25 N m 18 lb ft Intake Manifold Installation Figures 12 8...

Page 108: ...3 E Service Manual Chapter 3 Engine Mechanical System 106 Figure 12 89 Intake Manifold Sealer Application Figure 12 90 Intake Manifold Tightening Sequence Figure 12 91 Valve Rocker Arm Cover Installat...

Page 109: ...en Bolts in two steps beginning with the two center bolts A Bolts to 15 N m 11 lb ft B Bolts to 30 N m 22 lb ft Figure 12 92 Exhaust Manifold Flywheel Housing Installation 1 Place the flywheel housing...

Page 110: ...or Connect 1 Flywheel 2 Flywheel bolts Tighten Bolts to 100 N m 74 lb ft 3 Check flywheel runout using a dial indicator If runout is excessive remove flywheel check and clean mounting surfaces and ins...

Page 111: ...parts are binding If parts are binding disassemble engine to determine the source 1 Install oil filter if not already installed 2 Fill the crankcase with the proper quantity and grade of engine oil IM...

Page 112: ...t with the correct timing mark on the timing plate Ignition Sequence Firing Order Engine firing order 1 6 5 4 3 2 Ignition Coil Rating 12 Volts Resistance between B and ground coil mounting bracket in...

Page 113: ...o 7 80 in The distributor end play will be checked with the distributor in an inverted position from normal Measure from the mounting surface to the face of the gear Sensor Gap The Air gap X between t...

Page 114: ...the ignition system These components must have closed current connections to complete the operation of the ignition circuit Coil 3 and spark plugs 5 are of the standard type The ignition coil changes...

Page 115: ...the SECM consistent authority over ignition timing The spark is sent to the appropriate cylinder in the conventional way via the rotor arm and spark plug wires The SECM uses the signal from the GM Ge...

Page 116: ...hapter 4 Engine Electrical System 114 lgnition System Schematic for G643E lgnition System Schematic for G643 V SECM24 IGNITION COIL DISTRIBUTOR SPARK PLUGS CONNECTION CLOSE TO THE MODULE ECUP_AN1 EST1...

Page 117: ...Use these procedures to find possible solutions for ignition problems Tools Needed Digital Mutimeter or Equivalent 1 1 Inspect distributor cap 1 Look for breaks cracks or dirt inside and on the outsid...

Page 118: ...mely important that the spark plug cables be handled with care They should be routed so as not to cross each other or be in contact with other parts of the engine to prevent rubbing NOTICE For proper...

Page 119: ...ance 4 Check the plug clearance using a plug clearance auge and if the value is not within the specified values adjust it by bending the ground clearance When installing a new sparkplug install it aft...

Page 120: ...quivalent 1 Remove module from distributor 2 Connect red battery cable clamp to positive terminal and black battery cable clamp to negative terminal of a fully charged 12V battery 3 Connect the adapte...

Page 121: ...coil leads from the module 3 Connect an ohmmeter between the pickup coil lead and housing test 1 IAGS059S Reding should be infinite no continuity 4 Connect an ohmmeter to both pickup coil leads test 2...

Page 122: ...004S 3 Connect ohmmeter between B or C terminals and coil high voltage tower On high scale reading should be approximately 8000 ohms Reading should not be infinite test 3 IAGS004S NOTICE On tests 2 an...

Page 123: ...distributor and intake manifold to show the position of the rotor 4 Remove the bolt distributor clamp and distributor Install Distributor 1 Install the distributor 1 in position in the intake manifold...

Page 124: ...her and remove retainer 8 7 Unplug and remove the pickup coil 9 8 Remove two screws 10 and remove pickup module 11 Assemble Distributor 9 Wipe distributor base and module clean apply silicone lubrican...

Page 125: ...lt value not controlled by the SECM 5 Connect standard inductive timing light Figure 36 to the 1 cylinder 6 Manually bar the engine so that the timing indicator on the crankshaft pulley lines up to 0...

Page 126: ...ue is added to the value displayed in the Spark Advance parameter NOTE You must always return the Spark Offset value to 0 00 before closing the Service Tool or the offset will be applied during engine...

Page 127: ...ect on ignition timing 1 degree of the distributor rotation would produce a 2 degree change in spark timing G643E engine senses crank position from the crank position sensor and the target wheel Rotat...

Page 128: ...t and voltage generated by the stator are changed to direct current by a three phase full wave rectifier system using six silicone rectifier diodes Some alternators have three exciter diodes or a diod...

Page 129: ...ing 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 Fau...

Page 130: ...set 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 b...

Page 131: ...G643 E Service Manual Chapter 4 Engine Electrical System 129 Troubleshooting Procedure Inspection before Starting 1 Alternator and drive belt tension inspection...

Page 132: ...G643 E Service Manual Chapter 4 Engine Electrical System 130 2 Alternator and outer terminal connection inspection...

Page 133: ...r 4 Engine Electrical System 131 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 cha...

Page 134: ...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 insp...

Page 135: ...itch 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 starti...

Page 136: ...s 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 pos...

Page 137: ...es 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...

Page 138: ...rting 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 ex...

Page 139: ...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 s...

Page 140: ...ptom 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...

Page 141: ...tive 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...

Page 142: ...ition Sensor 1 None Type Tooth wheel VR sensor 3X 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...

Page 143: ...Manual Chapter 5 Engine Management System EMS 141 Electronic Throttle System Q ty Components G643E G643 Items Specifications Electronic Throttle System 1 1 Minimum Electrical Resistance of Throttle Ac...

Page 144: ...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 kP...

Page 145: ...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 G643 1 None Fuel Fuel Inlet Fitting Air Intake...

Page 146: ...1 2 NPT Fuel inlet fitted with Delphi temperature sensor 2 25 57 15mm ID inlet four 10 24 screws in 1 94 49 28mm square pattern 1 87 47 49mm ID outlet four 12 24 screws arranged in a rectangular patte...

Page 147: ...ice Manual Chapter 5 Engine Management System EMS 145 Component Location Engine Control Module SECM48 Crankshaft Position Sensor LP Fuel Temperature Sensor LP Fuel Lock off TMAP Sensor Coolant Tempera...

Page 148: ...ual Chapter 5 Engine Management System EMS 146 Pre Catalyst Oxygen Sensor Pedal Angle Sensor Ground Speed limit option Sensor Post Catalyst Oxygen Sensor Engine Oil Pressure Switch Ground speed limit...

Page 149: ...G643 E Service Manual Chapter 5 Engine Management System EMS 147 Electronic Throttle Body Ignition Coil N 2007 LP Regulator Fuel Trim Valve FTV Distributor CA100 Mixer...

Page 150: ...atalytic muffler Figure 1 MI 07 LP Fuel System for G643E Engine The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air fuel mixer by modulatin...

Page 151: ...Crank Sensor Throttle body TMAP sensor Coolant Temp EG oil pressure switch T M Temp switch Accel pedal angle sensor Throttle position sensor Pre Oxygen sensor Post Oxygen sensor LP fuel temp sensor Gr...

Page 152: ...iming and lift Intake Exhaust manifold design Catalytic converter and exhaust system Throttle body Air intake and air filter LPG mixer LPG pressure regulator Fuel trim valves Fuel trim orifices Small...

Page 153: ...nd the operator initiates a diagnostic request sequence such as repeated actuations of the pedal within a short period of time following reset Limp Home Mode The system is capable of limp home mode in...

Page 154: ...anges by the same amount and in the same direction The end result is that a change in FTV modulation changes the outlet pressure of the regulator fuel inlet pressure of the mixer and thus the AFR A ma...

Page 155: ...k off outlet to the pressure regulator converter 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 wh...

Page 156: ...alve Since the fuel pressure has been reduced from tank pressure to 1 5 psig 10 3 kPa the liquid propane vaporizes As the propane vaporizes it takes on heat from the expansion chamber This heat is rep...

Page 157: ...tive pressure vacuum signal from a cranking or running engine to open This is the third of the three safety locks in the MI 07 system If the engine stops or is turned off the air valve assembly closes...

Page 158: ...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 In...

Page 159: ...nsor 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 amoun...

Page 160: ...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 leanin...

Page 161: ...n 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...

Page 162: ...gure 15 Throttle Body Assembly Exploded View Ignition System Control Spark ignited engines require accurate control of spark timing and spark energy for efficient combustion The MI 07 ignition system...

Page 163: ...sor This falling edge signal provides a stable engine position reference at all engine speeds for the SECM Exhaust System Heated Exhaust Gas Oxygen Sensors HEGO The MI 07 system utilizes two HEGO O2 s...

Page 164: ...us 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...

Page 165: ...gasoline fuel pump and FTVs Fuel Management During engine cranking at startup the SECM provides a low side driver signal to the fuel lock off which opens the lock off allowing liquid propane to flow t...

Page 166: ...throttle position sensors TPS1 and TPS2 which are integral to the drive by wire DBW throttle assembly provide feedback for position control by monitoring the exact position of the throttle valve See F...

Page 167: ...lerator 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 assembly A demand position for the throttl...

Page 168: ...gnition coils distributors spark plug wires etc It is recommended that the SECM be mounted at least 29 5 749 mm away from the distributor and ignition coil and at least 20 508 mm from the nearest plug...

Page 169: ...BLACK COLOR COLOR COLOR COLOR COLOR CONNECTOR CONNECTOR A B COLOR MAP MAT COLOR B5_CRNK B10_CAM A24_LSO9_MIL B2_AN6_TOTS B9_AN13_OPS B21_CAN1 B20_CAN1 A15_EST8_FSS LIQ B7_AN4_APP1 B16_AN5_APP2 B14_AN...

Page 170: ...absolute pressure are monitored with a TMAP sensor MI 04 is a drive by wire DBW system connecting the accelerator pedal to the electronic throttle through the electrical harness mechanical cables are...

Page 171: ...S 169 LP System of G643 INPUT OUTPUT Throttle body Ground speed limit Device SECM lgnition Module LP fuelock valve CAN communication TMAP sensor Coolant Temp EG oil pressure switch Accel pedal angle s...

Page 172: ...able speeds Spark timing modifiers for temperature and fuel type Input sensor selection and calibration Auxiliary device control for fuel pump fuel lock off solenoid tachometer MIL interlocks vehicle...

Page 173: ...lock off solenoid valve The lock off solenoid is energized when fueling with LPG and the engine is turning The lock off is de energized when engine rpm is not detected MI 07 LP Fuel Filter The LP fuel...

Page 174: ...ed by engine coolant which is pumped through the coolant passage of the regulator At this point vapor propane will not flow past the expansion chamber of the regulator until the secondary valve is ope...

Page 175: ...m If the engine stops or is turned off the air valve assembly closes the gas metering valve stopping fuel flow past the mixer The gas metering valve controls the amount of fuel to be mixed with the in...

Page 176: ...i 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 o...

Page 177: ...her a distributor based ignition system or a distributorless ignition system The current application uses a distributor based ignition system The distributor will have no internal advance mechanisms g...

Page 178: ...communication link Battery power 12 Vdc is supplied through the fuse block to the main power relay The ignition key switch is used to energize the main power relay A main power relay supplies 12 Vdc...

Page 179: ...sition sensor a temperature manifold air pressure sensor TMAP is used to monitor intake manifold temperature and pressure Figure 19 This enables the SECM full control capabilities monitoring actual ai...

Page 180: ...as a throttle position sensor demand TPSd This signal will be processed through a PID Proportional Integral Derivative controller in the SECM to achieve the appropriate motor current response then pas...

Page 181: ...G643 E Service Manual Chapter 5 Engine Management System EMS 179 SECM Wiring Diagrams for G643 LP Engine...

Page 182: ...G643 E Service Manual Chapter 5 Engine Management System EMS 180...

Page 183: ...to 5 V Coolant Temperature Sensor CTS 40 F to 266 F 40 C to 130 C range 48K ohm to 85 ohm sensor range Fuel Temperature Sensor FTS 40 F to 266 F 40 C to 130 C range 48K ohm to 57 ohm sensor range HEG...

Page 184: ...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...

Page 185: ...and G643 MAP sensor The manifold absolute pressure MAP sensor is a pressure sensitive variable resistor It measures changes in the intake manifold pressure which result from engine load and speed cha...

Page 186: ...old 4 Remove MAP MAT sensor Installation 1 Place the MAP MAT Sensor in position on the intake manifold and install the two retaining screws Tighten retaining screws to 6 N m 53 lbf ft 2 Connect the el...

Page 187: ...concentration in the exhaust gas The heated oxygen sensor produces a voltage that varies between 0V and 1V When the air fuel ratio is lean the oxygen concentration in the exhaust gas increases and the...

Page 188: ...on the rear side of the Catalytic Muffler which detects the catalyst efficiency The rear heated oxygen sensor HO2S produces a voltage between 0V and 1V This rear heated oxygen sensor is used to estima...

Page 189: ...the cylinder head for detecting the engine coolant temperature The ECTS uses a thermister whose resistance changes with the temperature The electrical resistance of the ECTS decreases as the temperatu...

Page 190: ...Diagram G643E HARNESS CONNECTORS Schematic Diagram G643 Installation 1 Install engine coolant temperature sensor and tighten it to specified torque Tightning torque Engine coolant temperature sensor...

Page 191: ...TS 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...

Page 192: ...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...

Page 193: ...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 l...

Page 194: ...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 condi...

Page 195: ...use 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 direc...

Page 196: ...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...

Page 197: ...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 Tub...

Page 198: ...oling lines 4 and a thermostat 7 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...

Page 199: ...ing 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 F...

Page 200: ...on the mixer adapter assembly 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 rin...

Page 201: ...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...

Page 202: ...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 pressu...

Page 203: ...O 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...

Page 204: ...duty cycle turning the screw out counter clockwise should decrease the duty cycle 7 Adjust the idle mixture screw on the mixer until a reading of 40 45 is reached for the FTV Duty Cycle in Closed Loop...

Page 205: ...ignal wire For the Fluke 87 press the RANGE button until 4 or 40 appears in the lower right hand corner of the display Press the Hz button twice so that the percent sign appears on the right hand side...

Page 206: ...cycle measurement at Closed Loop Idle of 40 60 is acceptable if the optimum range of 45 55 cannot be reached through adjustment If the FTV duty cycle cannot be adjusted below 60 the mixer is faulty an...

Page 207: ...10 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 1 2 x 1 16 thick 12 7mm x 27mm 1 10...

Page 208: ...G643 E Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 206 Exploded View of CA100 Mixer Certified Figure 44 CA100 Certified Mixer Exploded View...

Page 209: ...gm 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...

Page 210: ...G643 E Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 208 Exploded View of N 2007 Regulator Certified Figure 46 N 2007 Certified Regulator Exploded View...

Page 211: ...ea 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 sk...

Page 212: ...ne 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 DWG NO 5555 1236 Figure 25 Hose Connection...

Page 213: ...s 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...

Page 214: ...ted and the 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 t...

Page 215: ...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 Co...

Page 216: ...eak 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 W...

Page 217: ...m 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 fitt...

Page 218: ...uge Connection Ignition Timing Adjustment With the MI 07 system ignition timing advance is controlled by the SECM The initial ignition timing setting of the distribytor is described in chapter 4 Ignit...

Page 219: ...tment 1 After the mixer is installed start and warm up the engine to normal operating temperature ECT 167 F 75 C Also ensure that the vehicle drive train and hydraulic systems are at normal operating...

Page 220: ...ded 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 Thr...

Page 221: ...G643 E Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 219 Exploded View CA100 Mixer Figure 44 CA100 Non Certified Mixer Exploded View...

Page 222: ...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 th...

Page 223: ...8 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 t...

Page 224: ...ondary 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 Co...

Page 225: ...G643 E Service Manual Chapter 6 LPG FUEL DELIVERY SYSTEM 223 Exploded View N 2001 RSA Regulator Figure 47 N 2001 Regulator Exploded View...

Page 226: ...nd 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...

Page 227: ...s 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 ass...

Page 228: ...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 whe...

Page 229: ...in 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 s...

Page 230: ...r_______________________________________________ Others Poor driving Surge Knocking Poor fuel economy Back fire After fire Other____________________________ 3 Environment Problem frequency Constant So...

Page 231: ...eck 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...

Page 232: ...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...

Page 233: ...minal 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 damage...

Page 234: ...wn in FIG 2 In FIG 2 the measured resistance of line1and 2 is higher than 1 and below 1 respectively Specifically the open circuit is line 1 Line 2 is normal To find exact break point check sub line o...

Page 235: ...ound 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...

Page 236: ...tact 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...

Page 237: ...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 Re...

Page 238: ...ve 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...

Page 239: ...stem 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 Chec...

Page 240: ...ank 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 fu...

Page 241: ...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 possib...

Page 242: ...elp identify 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 radiato...

Page 243: ...ributor cap spark plug wires and proper routing of plug wires Check ignition timing Engine mechanical Check compression look for sticking or leaking valves Check intake and exhaust manifold for castin...

Page 244: ...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 cataly...

Page 245: ...d fuel valve leak test Fuel lock off malfunction Repair replace fuel lock off See Chapter 2 Fuel Lock Off Faulty vapor connection between the pressure regulator converter and the mixer Check connectio...

Page 246: ...eck 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 bu...

Page 247: ...itive 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 Igniti...

Page 248: ...cuum 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 ped...

Page 249: ...t 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 D...

Page 250: ...nctioning properly If the sensor is not operating properly the criteria may be reversed Rich Operation LP Trim valve duty cycle 90 Inspect hoses from AVV port port on bottom of mixer to trim valves an...

Page 251: ...r 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 tem...

Page 252: ...been detected ETCSticking and the engine has shutdown and the MIL has remained ON When the codes are displayed the MIL will flash one time 1 pause then flash two times 2 This identifies a twelve 12 wh...

Page 253: ...various sequences to bring engine speed back to acceptable levels Level4 Power Limit Level3 Power Limit Level2 Power Limit Level1 Power Limit The maximum engine power output will be limited to one of...

Page 254: ...il 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 l...

Page 255: ...f 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 t...

Page 256: ...rs 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 th...

Page 257: ...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 connec...

Page 258: ...ified 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 EXPLO...

Page 259: ...l 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 oxy...

Page 260: ......

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