SB4251E00 May.
Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Index Inspect Battery System................................. 23 Inspect Ignition System................................. 23 Inspection of Ignition Timing ......................... 23 Chapter 1. GENERAL INFORMATION Inspection of Spark Plug ............................... 24 Fuel System Maintenance ................................. 26 Precautions before Service ................................. 7 Tightening Torque ............................................. 10 Replace LP Fuel Filter Element...........
Crankshaft Accessory Pulley ............................ 57 Diagnosis Procedure ...................................116 Timing Belt Rear Cover ..................................... 57 Start Relay Tests .........................................118 Rocker Arms, Linkage, Valve Lifters With Troubleshooting...........................................119 Cylinder Head and Eegine............................... 59 Cooling System.................................................. 60 Chapter 5.
EMS Inspection and Repair ............................. 161 N-2001 Regulator Service Testing ........198 Engine Control Module (SECM) .................. 161 AVV (Air Valve Vacuum) Testing ..........200 Camshaft Position Sensor........................... 163 Connection of the MI-07 Service Tool ...200 IAT (Intake Air Temperature) Sensor........... 167 Idle Mixture Adjustment ........................201 Oxygen Sensor (Pre-Catalyst)..................... 168 Parts Description ..........................
Appendix Acceleration................................................ 237 Detonation / Spark Knock............................ 239 Backfire ...................................................... 240 Service Tool Software (MotoView)...................279 Dieseling, Run-on ....................................... 240 Introduction .................................................279 Rough, Unstable, Incorrect Idle, or Stalling.. 241 Connection of the Service Tool ....................280 Cuts Out, Misses.
Chapter 1. GENERAL INFORMATION Precautions before Service Tightening Torque Removal and Disassembly Tighten the part properly to specified torque. Sealant 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 Use specified brand of sealant. Use of sealant other than specified sealant may cause water or oil leaks. Be sure to use Special Tools when their use is specified for the operation.
Replacement Part Genuine Part When oil seal, O-ring, packing and gasket have been removed, be sure to replace them with new parts. However, rocker cover gasket may be reused if it is not damaged. 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 Rubber Parts 1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery. Do not stain timing belt and V-belt with oil or water.
Precautions for catalytic Converter CAUTION If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. 1. Use only unleaded gasoline. 2. Do net run the engine while the truck is at rest for a long time. Avoid running the engine at fast idle for more than 5 minutes and at idle speed for more than 10 minutes. 3. Avoid spark-jump tests.
Tightening Torque Tightening Torque Table of Standard Parts Torque (kg·m) Bolt nominal diameter (mm) Pitch (mm) M5 Head mark 4 Head mark 7 0.8 0.3 ~ 0.4 0.5 ~ 0.6 M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1 M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5 M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0 M12 1.25 3.5 ~ 4.5 6~8 M14 1.2 7.5 ~ 8.5 12 ~ 14 M16 1.5 11 ~ 13 18 ~ 21 M18 1.5 16 ~ 18 26 ~ 30 M20 1.5 22 ~ 25 36 ~ 42 M22 1.5 29 ~ 33 48 ~ 55 M24 1.5 37 ~ 42 61 ~ 70 M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6 M6 1.0 0.
Recommended Lubricants and Capacities Recommended Lubricants Lubricant Specification Remarks Engine Oil API Classification SJ or above SAE 10W30 or SAE 5W30 Coolant (Antifreeze) Automotive antifreeze suitable for gasoline engines having aluminum alloy parts Concentration level 50%(normal) Concentration level 40%(tropical) Lubricant Capacities Description Engine Oil (liters) Coolant (liters) G(C)20/25/30/33P-5 Oil Pan 4.25 Oil Filter 0.3 Total 4.5 Engine 3.0 Radiator & Hoses 6.
Engine Model and Engine Serial Number Engine Model G424FE G424F Emission Regulation Fuel Type LP/Dual Fuel Indication of Engine Model and Serial Number EPA/CARB* 2007 Compliant LP * EPA: Environmental Protection Agency * CARB: California Air Resources Board G424FE Engine Engine Model • Comply with EPA 2007 Emission Regulation G424FE/G424F • Electronic Control by ECM • Certified LP/Dual Fuel System available Engine Serial Number 30700001 to 39999999 Features and Benefits of G424FE/G424F Engine –
General Specification G424FE Engine G424F Engine GENERAL DESCRIPTION ENGINE TYPE: Water-cooled, Inline 4-Cycle, 4-Cylinders COMBUSTION SYSTEM: INTAKE MANIFOLD Squish Combution Chamber Cast Aluminum (with injector ports) EXHAUST MANIFOLD Cast Iron (dual channel) VALVE CONFIGURATION: VALVE LIFTER/LASH ADJUSTER SOHC, 2 Valves per Cylinder Stationary Hydraulic Lash Adjusters VALVE ROTATOR Exhaust Rotator CAMSHAFT DRIVE Timing belt system (20 mm Toothed Belt) DISPLACEMENT: 2,405 cc (147 cid) BORE
G424FE Engine G424F Engine COOLING SYSTEM WATER PUMP ROTATION: THERMOSTAT: Toothed Timing Belt Drive- Clockwise from front of engine Opening Temperature: 82°C (180°F) Fully Open Temperature: 95°C (203°F) COOLING WATER CAPACITY: 3.
G424F/G424FE Engine Power and Torque G424FE ENGINE MODEL unit G424F 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 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 rpm 2,200 2,200 2,200 GOVERNED SPEED rpm 2,600 2,600 2,600 LOW IDLE rpm 750 750 750 RATED POWER MAX TORQUE G424F(FE) Service Manual 15 Chapter 1.
Chapter 2. RECOMMENDED MAINTENANCE Suggested maintenance requirements for an engine equipped with an MI-07 fuel system are contained in this section. The operator should, however, develop a customized maintenance schedule using the requirements listed in this section and any other requirements listed by the engine manufacturer. General Maintenance Inspect Engine for Fluid Leaks Test Fuel System for Leaks • Start the engine and allow it to reach operating temperatures. • Turn the engine off.
Engine Oil Classification Recommended API classification: Above SJ Recommended SAE viscosity classification *1. 10W-30 engine oil is recommended If 10W-30 is not applicable, proper engine oil will be possible according to temperature ranges. The following lubricants should be selected for all 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.
Checking Engine Oil Level Replacing Engine Oil and Filter CAUTION Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine 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.
3. Refill with engine oil filter. CAUTION 1) Clean and install the oil drain plug with a new gasket. Torque At this time, necessarily screen the spark plug hole with a rag. Because hot coolant, oil, fuel, and other 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 open the throttle valve before cranking. 40~70 N·m 2)Fill with fresh engine oil.
Antifreeze Cooling System Maintenance DOOSAN recommends selecting automotive antifreeze suitable for gasoline engines using aluminum alloy parts. The antifreeze should meet ASTM-D3306 standard. Coolant Recommendation The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water (For the vehicles of tropical area, the engine cooling system is provided with a mixture of 40% ethylene glycol anti-freeze and 60% water at the time of manufacture.
Checking coolant leaks 1. After the coolant temperature drops below 38°C loosen the radiator cap. 2. Check that the coolant level reaches filler neck. 3. Install the radiator cap tester to the radiator filler neck and apply a pressure of 1.4kg/cm2 . While maintaining it for 2 minutes, check the radiator, hose, and connecting part for leak. CAUTION Because the coolant in the radiator is too hot, never open the cap when it hot, or injury may occur due to an outburst of hot water. Dry out the inspection part.
3. Tighten the bolt “A” and then tighten “B” to the specified torque. Checking and Adjusting Drive Belt 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 become inefficient and finally engine is overheated or damaged. 1.
Ignition System Maintenance CAUTION Inspect Battery System Because ignition timing is fixed by set data value in ECU, it is impossible to control on purpose. Fist, check that sensors send output properly to help determine ignition timing control. • Clean battery outer surfaces with a mixture of baking soda and water. • Inspect battery outer surfaces for damage and replace as necessary.
Inspection of Spark Plug Inspection and clean 3. Check the spark plug as below. 1) Insulator broken 1) Ignition cable 2) Terminal worn 2) Ignition coil 3) Carbon deposit 1. Disconnect the ignition cables from ignition coil ass’y. 4) Gasket damaged or broken 2. Remove all spark plugs from the cylinder head using a sparkplug wrench. 5) Porcelain insulator of spark plug clearance CAUTION Take care not to come foreign materials into spark-plug mounting hole. 4.
Spark Plugs 5. Install the spark plug and tighten it to the specified torque. Take 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 G424F(FE) Service Manual 25 Chapter 2.
Fuel System Maintenance 8. Re-assemble the filter assembly aligning the scribe lines on the top and bottom covers. Replace LP Fuel Filter Element 9. Install the cover retaining screws, tightening the screws in an opposite sequence across the cover. Park the lift truck in an authorized refueling area with the forks lowered, parking brake applied and the transmission in Neutral. 10. Open the fuel valve by slowly turning the valve counterclockwise. 11.
Pressure Regulator/Converter Inspection Checking the TMAP Sensor • Verify that the TMAP sensor (F) is mounted tightly into the manifold or manifold adapter (E), with no leakage. • Visually inspect the pressure regulator/converter (B) housing for coolant leaks. • If the TMAP is found to be loose, remove the TMAP retaining screw and the TMAP sensor from the manifold adapter. • Refer to Chapter 5 if the pressure regulator/converter requires replacement.
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. G424F(FE) Service Manual 28 Chapter 2.
G424F(FE) Service Manual 29 Chapter 2.
Chapter 3. ENGINE MECHANICAL SYSTEM General Information Engine Outline G424F(FE) Service Manual 30 Chapter 3.
Technical Specifications CRANKSHAFT Maximum saddle taper..................................................................................................................... 0.005 mm Maximum saddle out-of-roundness .................................................................................................. 0.004 mm Crankshaft maximum warping ............................................................................................................ 0.03 mm Trunnion diameter............................
CYLINDER HEAD Valve seat angle (all) .......................................................................................................................... 90° ± 1° INTAKE AND EXHAUST VALVES Seat angle ........................................................................................................................................ 92° ± 15° Stem lash in the guides........................................................................................... 0.015 a 0.042 mm (intake) e 0.030 a 0.
Shells Selection Table MAIN BEARINGS – STANDARD SIZE (*) (*) ALL MEASURES ARE IN MILLIMETERS G424F(FE) Service Manual 33 Chapter 3.
MAIN BEARINGS – 0.50 UNDERSIZE (*) G424F(FE) Service Manual 34 Chapter 3.
CONNECTING ROD BEARINGS 0.25 UNDERSIZE G424F(FE) Service Manual CONNECTING ROD BEARINGS 0.50 UNDERSIZE 35 Chapter 3.
Recommended Torque Values nuts N•m Starter to cylinder block 45 Exhaust manifold to cylinder head 18-22 1) Dipstick oil tube to cylinder block 20-30 DIS Ignition Module to camshaft housing carrier 8 Throttle body to intake manifold 11-13 Pressure plate to camshaft housing 8 Intake manifold to cylinder head 18-22 1) Crankshaft position sensor 6 Rear toothed belt cover bolts 8 Rear toothed belt cover nuts 7 Heat shield to exhaust manifold 6-8 bolts N•m V–belt tensioner to alternator
bolts N•m Oil pan to cylinder block 18-22 Con–rod bearing cap to con–rod 30-40+40°+45° Flywheel to crankshaft 35 + 30 ° + 15° 2) Coolant temperature sensor to thermostat housing 20 Thermostat housing to cylinder head 15 Carrier plate (DIS ignition 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 c
Troubleshooting Symptom Possible cause Remedy Cylinder head gasket damaged Worn or damaged piston ring Worn piston or cylinder Worn or damaged valve seat Insufficient engine oil Oil pressure switch defective Oil filter clogged Worn oil pump gear or cover Thin or diluted engine oil Oil relief valve clogged(Open) Excessive bearing clearance Oil relief valve clogged(Closed) Replace gasket Replace ring Repair or replace piston and cylinder block Repair or replace valve and seat ring Check engine oil level R
Engine Exploded View (1 of 2) 1) RING KIT 13) INDICATORK,OIL LVL 21) ENGINE 26) SEAL 47) CAP 61) KEY 87) SENSOR 98) BEARING KIT 103) SEAL 108) SEAL 113) BAFFLE 120) SPRING 125) GASKET 132) PLATE 139) BOLT 2) PISTON 14) HOSE 22) SEAL 27) COVER 57) BEARING 62) BEARING KIT 90) BOLT 99) PLATE 104) PIN 109) SEAL 114) SEAL 121) PLUG 126) PIN 133) BOLT 143) BOLT G424F(FE) Service Manual 3) BEARING KIT 16) GASKET 23) BOLT 28) BOLT 58) BOLT 80) FILTER 91) BOLT 100) CAP 105) GASKET 110)PIPE 115) PLUG 122) SEAL 12
Engine Exploded View (2 of 2) 1) ENGINE 8) CAP 29) NUT 36) SEAT 67) HOUSING 75) SEAL 81) BRACKET 89) SEAL 95) WIRE 104) COIL 116) BOLT 122) WASHER 129) KEY 135) HOUSING 143) INJECTOR 150) CLIP 161) TUBE 168) VALVE 174) BOLT 183) STUD 3) SPARK PLUG 9) SPRING 31) MANIFOLD 37) GASKET 69) WASHER 76) COVER 82) BRACKET 90) BOLT 96) WIRE 105) BOLT 117) ADAPTER 123) BOLT 130) SEAL 136) SENSOR 144) SEAL 151) BOLT 162) FITTING 169) HOSE 175) PIPE 184) NUT G424F(FE) Service Manual 4) ARM 10) SEAL 32) GASKET 38) HE
Intake manifold and gasket Components 1) Gasket 6) Tmap 11) Washer 16) Hose 21) Clamp 26) Block 2) Intake Manifold Assy 7) Bolt 12) Bolt 17) Clamp 22) Washer 27) Bracket G424F(FE) Service Manual 3) Stud Bolt 8) Bracket-Stay 13) Pipe 18) Washer 23) Bolt 28) Fitting 41 4) Nut 9) Washer 14) Plug 19) Bolt 24) Hose 29) Plug 5) Fitting 10) Bolt 15) Hose 20) Hose 25) Clamp Chapter 3.
Removal Remove or Disconnect 1. Relieve of fuel line pressure: • Fuel-off solenoid valve disconnect. • Run the engine and leave it running until stopping by lack of fuel. • Run the engine for about 5 seconds so as to fully depressurize the fuel system. 10. If necessary, remove the fuel rain from intake manifold by using 12mm socket wrench and extension. • Fuel pump electric connection, from the tank upper area 11.
Installation 7. Put the pipe on the manifold. Install or connect 8. With a 10-mm socket wrench, extension and proper torque wrench; tighten. 1. Coolant pipe attaching bolt with cylinder block in its place. Tighten • Bolts: 5 – 6 N·m (3.7 – 4.4 lb·ft.). 9. Insert the TMAP onto manifold with greased oring. 10. With an E-8 socket wrench, extension and proper torque wrench; tighten. Tighten • Bolts: 6– 7 N·m (4.4 – 5.2 lb·ft.). 2. With 13mm torque spanner, proper torque; tighten.
14. Connect wiring to the injectors. 15. Connect the PCV hose between PCV and fitting. 16. Hose clamp with torque driver; tighten. 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.
Exhaust Manifold and Gasket Components 1) Gasket 4) Washer 7) Washer 10) Shield G424F(FE) Service Manual 2) Adapter-Exhaust Manifold 5) O2 Sensor 8) Bolt 11) Gasket 45 3) Bolt 6) Stud Bolt 9) Exhaust Manifold Chapter 3.
Removal Installation Remove or disconnect Install or connect 1. Spark plug cable terminals; 1. New gasket between the exhaust manifold and cylinder head. 2. Exhaust manifold heat shield and remove dipstick tube (to allow removal of #3 plug wire). 2. Exhaust manifold and attaching nuts, without tightening. 3. Oxygen sensor (O2) electric connection. 3. With a 13-mm socket wrench, extension and torque wrench; tighten. 4. Adapter-Manifold 5. Remove attaching bolts of adapter with 6 mm hex – bit socket.
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 G424F(FE) Service Manual 47 Chapter 3.
Removal Timing Belt Remove or disconnect Inspection 1. Crankshaft pulley; see “Crankshaft Pulley – Removal”, in this section. 2. V pulley belt automatic Tensioner; see “V Pulley Belt Automatic Tensioner – Removal”, in this section. 3. Timing belt front cover attaching bolt, with an E10 Torx socket wrench, extension and handle 4. Timing belt front cover. Important 1. Check the belt for oil or dust deposit and replace it if necessary.
Description 1. Back side rubber is hardened Specification Glossy back side. Due to non-elasticity and hardening, when pressing it with the tip of a finger, there is no sign of it. 2. Back side rubber is cracked 3. Canvas is cracked or detached 4. Tooth is excessively worn out (initial step) 5.
Installation Install or connect Important • Align the camshaft timing pulley mark with the timing belt rear cover mark. • Align the crankshaft timing pulley mark with the oil pump case flange, in the no. 1 cylinder combustion stroke. 1. Timing belt 2. Belt Tensioner adjustment: with a 6-mm Allen wrench, so as to keep steady the Tensioner shaft, loosen the Tensioner shaft attaching bolt until the same becomes steady.
Timing Belt Tensioner Removal Remove or disconnect 1. Timing belt; see instructions under “Timing Belt – Removal”, in 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.
PCV Valve Outline and Operation Principle Engine condition PCV valve Vacuum path No operating No operating Clogged Engine condition PCV valve Vacuum path At idle or deceleration Full operating Small Engine condition PCV valve Vacuum path Proper operating Proper operating Big Engine condition PCV valve Vacuum path High speed and overload Light operating Very big G424F(FE) Service Manual 52 Chapter 3.
Crankcase Ventilation Oil Fill Cap Secondary Vent (Fresh Air Port) Primary Vent to PCV Hi C/C Pressure “Herringbone separator” lies on horizontal. Shown here in vertical for viewing ease.
TROUBLESHOOTING Service Procedure REMOVAL 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. 1. After disconnecting the vacuum hose (A), remove the PCV valve (B). 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. INSTALLATION Install the PCV valve and connect the vacuum hose. INSPECTION 1. Remove the PCV valve. 2.
Camshaft Timing Pulley and/or Seal Installation Removal 1. New seal in the camshaft case, with the aid of tool KM-422, camshaft pulley washer and bolt. Install or connect Remove or disconnect 1. Timing belt; see “Timing Belt – Removal”, in this section. 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. 2. Camshaft case cover; see “Camshaft Case Cover – Removal”, in this section.
• Install the seal in the protecting sleeve. • Place installer KM-417 and bolt and install the seal in its lodging. 2. Remove tool and protecting sleeve. 3. Timing pulley in the crankshaft; see “Crankshaft Timing Pulley – Installation”, in this section. 4. Timing belt; see “Timing Belt – Installation”, in this section. Crankshaft Front Seal Removal Remove or disconnect 1. Timing belt; see “Timing Belt – Removal”, in this section. 2.
Camshaft Case Cover and Gasket Crankshaft Accessory Pulley Removal Removal Remove or disconnect Remove or disconnect 1. V pulley belt; see “V Pulley Belt – Removal”, in this section. 1. Spark plug cables from the support. 2. Breather hose from the valve cover. 2. Crankshaft accessory pulley attaching bolt, with a 13-mm socket wrench and handle. 3. Camshaft case cover attaching bolts, with a 10mm socket wrench and handle. 3. Crankshaft pulley. 4. TDC sensor and CAS sensor. 4.
Timing Belt Rear Cover Removal Remove or disconnect 1. Timing belt; See “Timing Belt – Removal”, in this section. 2. Camshaft timing pulley; see “Camshaft Timing Pulley – Removal”, in this section. 3. Crankshaft timing pulley; see “Crankshaft Timing Pulley – Removal”, in this section. 4. Timing belt rear cover attaching bolts and nuts, with a T30 Torx socket wrench; extension and handle. 5. Timing belt rear cover. Installation Install or connect 1.
Rocker Arms, Linkage, Valve Lifters With Cylinder Head and Engine Removal Remove or disconnect 1. Camshaft case cover; see “Camshaft Cover – Removal”, in this 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.
Cooling System General Description Water Outlet Assy (attaches to cyl head) Upper outlet to ancillary device Lower outlet to water pump inlet Cam Carrier Cylinder Head (1) Coolant Sensor (2) Blocking t/stat (bypass open cold) Note: Cylinder head gasket orifices control water flow from block to head.
The thermostat 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. G424F(FE) Service Manual 61 Chapter 3.
Testing and Adjusting 5. Inspect the drive belts for the fan. Adhere to the following warnings when performing any tests or adjustments while the engine is running: 6. Check for damage to the fan blades. 7. Look for air or combustion gas in the cooling system. WARNING Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. 8. Inspect the filler cap and the surface that seals the cap. This surface must be clean. 9.
Cooling System Leak Check Pressure Cap Test 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 pressure cap from the radiator. Pressure Cap Diagram (A) Sealing surface of cap and radiator. 2. Make sure the radiator is full (hot) or nearly full (cold) of coolant.
Thermostat Cooling System Heat Problems The thermostat is the wax pellet type. A jiggle valve (which improves air bleeding during water supply) is provided on the flange part. When the thermostat is closed, the circulation of coolant is stopped, thereby making warm-up faster. 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.
Filling at over 20 liters per minute can cause air pockets in the cooling system. NOTE: Another condition that can cause heat problems is the ignition timing. Retarded (late) timing causes the engine to send more heat to the cooling system. Advanced (early) timing causes the engine to send less heat to the cooling system.
Make proper antifreeze additions. 9. Thermostat housing. Adding pure antifreeze as a makeup 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 chemical inhibitors in the cooling system. Add antifreeze mixed with water to the same freeze protection as your cooling system. Installation Thermostat Housing 3.
6. Timing belt rear cover; see “Timing Belt Rear Cover – Installation”, in this section. Water Pump Removal Remove or disconnect 1. Drain the coolant loosening the radiator lower hose. 2. Timing belt rear cover; see “Timing Belt Rear Cover – Removal”, in this section. 3. Timing belt Tensioner attaching bolt, with a 13mm combination wrench. 4. Mark the water pump regarding the cylinder block so as to identify the assembly position. 5. Water pump attaching pump, with a 6-mm Allen wrench and handle. 6.
Lubrication System General Description Lubricating system is the full-flow filtered pressurefeed 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. G424F(FE) Service Manual OIl Filter 68 Chapter 3.
Testing and Adjusting Adhere to the following warnings when performing any tests or adjustments while the engine is running. WARNING Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. WARNING Engine Oil Viscosity Recommendation Exhaust fumes contain carbon monoxide (CO) which can cause personal injury or death. Start and operate the engine in a well ventilated area only. In an enclosed area, vent the exhaust to the outside.
Too Much Oil Consumption the engine’s internal parts. • Engine outside oil leakage If the oil light comes on, indicating the pressure is low, check for the causes that follow: Check for leakage at the seals at each end of the crankshaft. Look for leakage at the oil pan gasket and all lubrication system connections. Check to see if oil comes out of the crankcase breather. This can be caused by combustion gas leakage around the pistons.
Installation Oil Pan Install or connect Removal 1. Adhesive sealant in the oil pan. Remove or disconnect 2. Oil pan-to-engine attaching bolts, without tightening. 1. Drain the oil on a proper container, removing the oil pan drain plug, with Torx T45 wrench. 3. Transmission flange-to-oil pan attaching bolts, without tightening. 2. Position the vehicle on an elevator and raise it. 3. Oil pan guard attaching bolts; with a 13-mm socket wrench, extension and handle, remove the guard. 4.
Oil Pump Removal Remove or disconnect 1. Timing pulley rear cover; see “Timing Pulley Rear Cover – Removal”, in this section. 2. Crankshaft timing pulley, use a 17-mm socket wrench and handle to remove the attaching bolt. 3. Oil filter. Installation 4. Position the vehicle on an elevator and raise it. Install or connect 5. Engine oil pan; see “Oil Pan – Removal”, in this Section. 1. Oil pump new gasket to the cylinder block. 2. Oil pump to the cylinder block and attaching bolts, without tightening. 6.
8. Sealing washer. Important 9. Spring. • The Tensioner roller lug (1) should be positioned in the guide housing (2) of the oil pump case. 10. Valve plunger. 12. Crankshaft timing pulley and attaching bolt, without tightening. Clean 13. With a 17-mm socket and torque wrench. • All pump parts. Tighten Inspect • Bolts: 135 + 30° + 15° (99 lb·ft. + 30° + 15°). • Parts for wear. 14. Timing pulley rear cover; see “Timing Pulley Rear Cover – Installation”, in this section.
Camshaft Case Assembly Tighten • Switch: 30 – 50 N·m (22 – 36,7 lb·ft) Removal 10. Install the oil pump; see “Oil Pump – Installation”, in this section. Remove or disconnect 1. Depressurize the fuel system: • Fuel-off solenoid valve disconnect. • Run the engine and leave it running until stopping by lack of fuel. • Run the engine for about 5 seconds so as to fully depressurize the fuel system.
21. Hot air pipe hose clamp-to-radiator lower hose attaching bolt, with a 7-mm socket wrench and handle. 22. Hot air pipe hose. 23. Thermostat pipe; see “Thermostat Pipe – Removal”, in this Section. 24. Cylinder head-to-cylinder block bolts, with a Torx T-55 wrench, extension and handle; for the front bolts, use a 19-mm socket wrench, extension and handle. 8. Camshaft cover-to-cylinder block breather hose, with special clamp pliers. Obs.
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 socket wrench and torque wrench, give the final tightening. 28. Attach the camshaft case on a vise. Obs.: Use protecting jaws in the vise. Tighten 29. Camshaft rear cover attaching bolt, with a 10mm wrench combination wrench.
10 6 2 3 7 9 5 1 4 8 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. 11.
Tighten 40. Battery negative cable. • Bolt: 18 – 28 N·m (13 – 20.5 lb·ft.) 41. Change the engine oil, in view of possible water contamination. 26. With a 15-mm socket wrench and torque wrench, tighten the nuts attaching the upper support to the cylinder head. Cylinder Head Tighten Removal • Nuts: 25 – 30 N·m (18 – 22 lb·ft.) Remove or disconnect 27. Timing belt rear cover; see “Timing Belt Rear Cover – Installation”, in this section. 1.
Tighten • 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. Camshaft case assembly; see “Camshaft Case Assembly – Installation”, in this section. Valve, Spring or Seal Removal Remove or disconnect 1. Camshaft case assembly, as per instructions under “Camshaft Case Assembly – Removal”, in this section. 2. Intake manifold-to-cylinder head nuts, with a 13mm socket wrench, extension and handle and remove the manifold. 3.
Important Important • If necessary use a 45° ± 3° Valves for corrosion. Corroded valves, once not excessively worn, can be refaced by special equipment, as follows: Reface them until obtaining a 92 ° ± 15° angle. The face angle can also be considered regarding the valve head, which should be 44°. • If the lash is out of the specification, which is 0.015 – 0.042 mm (intake) and 0.038 – 0.072 mm (exhaust), ream the guide to install an oversize valve.
9. Timing pulley front cover attaching bolts, with a 10- mm socket wrench, extension and handle; remove the front cover. 10. Timing belt Tensioner bolt, to relieve the tension of the belt, with a 13-mm combination wrench; remove the timing belt. Obs.: Turn the crankshaft 45° clockwise, so as to prevent 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.
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. 22. Spark plugs, with a proper wrench. 23. Clutch assembly attaching bolts, with a 10-mm socket wrench, extension and handle. Remove the whole clutch assembly. 24. Flywheel attaching bolt, with a 17-mm socket wrench and handle; remove the flywheel. 1 5 9 8 3 2 6 10 7 4 Obs.: Remove tool S-9407182 with a 19-mm combination wrench. 25.
34. Install two flywheel attaching bolts in the crankshaft, to rotate the latter and ease the access to the connecting rod attaching bolts. 35. With a punch, identify the connecting rod bearing and connecting rod, according to the cylinder regarding the connecting rod. 36. Turn the crankshaft until the first and four th connecting rods remain with their attaching bolts turned upward. 37.
G424F(FE) Service Manual 84 Chapter 3.
Tighten Important: • Bolts: 50 N·m + 45° + 15°. • Whenever the crankshaft is removed, it should be positioned standing up in the flywheel, to prevent it from warping. 6. Crankshaft seal, with tool KM-658. Engine Assembly Installation Install or connect 1. Upper shells in the block; lubricate the surface turned toward the saddle with engine oil. 2. Crankshaft in the cylinder block. 3. Main bearing caps with the shells lubricated on the surfaces turned to the saddle.
Tighten • Bolts: 4 – 10 N·m (3 – 7 lb·ft.). 13. Balancer and baffle plate and attaching bolts, with a Torx E12 wrench and torque wrench. Tighten • 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.
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.). 21. Camshaft case. 22. New cylinder head attaching bolts, in the indicated sequence, with a Torx E55 wrench and torque wrench. Tighten • Bolts: 25 N·m (18 lb·ft.) + 180° + 10°. 23. A new “O” ring in the water pump. 24.
34. Remove tool S-9406182 from the flywheel with a 17-mm combination wrench. Tighten • Bolts: 6 – 10 N·m (4.4 – 7 lb·ft.). 35. Belt expander with attaching bolt, without tightening. • Nut: 6 – 8 N·m (4.4 – 5.8 lb·ft.). 28. Flywheel and bolts, without giving the final tightening; use a 17-mm socket wrench and handle. 36. Camshaft timing pulley and attaching bolt, with a 22-mm wrench to lock the camshaft and a 17mm socket wrench with torque wrench. Obs.: Use new bolts.
43. Exhaust manifold in the cylinder head and attaching nuts, with a 13-mm socket wrench and torque wrench. Tighten • Nuts: 18 – 22 N·m (13 – 16 lb·ft.). 44. A new “O” ring in the crankcase breather tube. 45. Crankcase breather tube and dipstick oil tube in the cylinder block and attaching bolts, with a 13mm 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.
54. Engine assembly; see “Engine Assembly – Installation”, in this section. Cylinder Honing Note: Some of the services that are next presented are not necessarily performed when reconditioning an engine. The performance should depend on the inspections to which the engines will be submitted before reconditioning. Cylinder Block Removal Remove or disconnect 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.
Crankshaft Removal Remove or disconnect 1. Engine assembly, as per instructions under “Engine and Transmission Assembly – Removal”, in this section. 2. Install the engine on the engine stand. 3. Disassemble 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.
• Note the trunnions and journals maximum concentricity, which could be 0.005 mm. • Note the maximum out-of-rounds, which could be 0.004 mm. • Note the trunnions and journals diameter and check in the shell table that should be used. If the diameters are not between those indicated in the table, the crankshaft should be rebored or replaced. Installation Install or connect 1. Upper shells in the block; lubricate the surface turned toward the saddle with engine oil. 2. Crankshaft. 3.
5. Tighten the main bearing attaching bolts, with a Torx E12 wrench, extension and torque wrench. Tighten • Bolts: 50 N·m + 45° + 15°. Measure Crankshaft end clearance, as follows: • Install a dial gauge so that the probe touches the crankshaft end. 6. A new seal in the crankshaft, with tool KM-658. • With the aid of a screwdriver, displace the crankshaft to and fro and read the dial gauge 7.
9. Connecting rod cap bolts, without fully tightening, with a 14-mm socket wrench and handle. 18. A new cylinder head gasket, with the TOP mark turned upward and toward the engine front side. Important Obs.: Whenever is necessary to remove the cylinder head, a new gasket should be used. • Rotate the crankshaft some turns, so that the connecting rods are properly seated. 19. Cylinder head in the engine. 10. Tighten the connecting rod cap bolts, with a 14mm socket wrench and torque wrench. 20.
34. Remove tool S-9406182 from the flywheel with a 17-mm combination wrench. 22. New cylinder head attaching bolts, in the indicated sequence, with a Torx E55 wrench and torque wrench. 35. Belt expander with attaching bolt, without tightening. Tighten • Bolts: 25 N·m (18 lb·ft.) + 180° + 10°. 23. A new “O” ring in the water pump. 24. Water pump and attaching bolts, with a 6-mm Allen wrench and torque wrench. Tighten • Bolts: 20 – 30 N·m (14,7 – 22 lb·ft.). 25. A new “O” ring in the thermostat housing.
Tighten • Bolts: 4 – 10 N·m (3 – 7 lb·ft.). 38. Timing belt. 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 oil pump case flange mark, on the no. 1 cylinder combustion stroke.
47. A new seal ring in the crankcase phase and reference sensor. 5. Cylinder head; see “Cylinder Head – Removal”, in this section. 48. Crankshaft phase and reference sensor in the cylinder block and attaching bolt; use a Torx E10 wrench and torque wrench to tighten. 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. Tighten • Bolt: 4 – 8 N·m (3 – 5.8 lb·ft.). 8.
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 280° C to 320° C, in the piston pin hole area. The heating should be made preferably in oil bath. Cool the pin with dry ice. Attach the warmed connecting rod in the vise, this with aluminum jaws.
D. Oil control ring. Obs.: This procedure should be performed with protecting gloves. These procedures should be followed so that the connecting rod projection is located opposite the arrow in the piston head. E. Lower compression ring. F. Upper compression ring. Rings Measure Gap between the tips of the selected ring, according to the piston size; install the ring into the cylinder and push it with a piston so that it stays flush with the cylinder wall. The gap should be: • Compression ring: ...........
• Install the connecting rod upper shell lubricated only in the face turned toward the journal and pull the connecting rod until it touches the journal. 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 upward. 10.
Chapter 4. ENGINE ELECTRICAL SYSTEM Specifications Ignition Coil 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 Item Specification Rated output 13.5V - 80A RPM 1,000 ~ 18,000rpm Voltage regulator type Electronic, Built-in type Alternator G424F(FE) Service Manual 101 Chapter 4.
Ignition System Wasted Spark DIS Ignition System Spark-ignited engines require accurate control of spark timing and spark energy for efficient combustion. The MI-07 ignition system provides this control. The system consists of the following components: The G424F and G424FE engine has a wasted spark ignition system (2 cylinders per coil). Wasted spark ignition is a type of distributor-less ignition system where a pair of multi tower coils is mounted near the spark plugs.
Magnetic crankshaft position sensors can be tested with an ohmmeter, and the sensor output voltage and waveform can be read with an oscilloscope. The output voltage of a Hall Effect crankshaft position sensor can be checked with a voltmeter. On most vehicles, a defective crank position sensor will usually set a fault code that can be read with the Service Tool. MISFIRES DIS problems can include many of the same ailments as other ignition systems such as misfiring, hard starting, or a no start.
Spark Plug Wire Inspection a. Twist each spark plug boot 1/2 turn. Sparking plug wire integrity is vital for proper engine operation. A Thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following condition: b. Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the coil pack. Installation 1. Correct routing of the spark plug wires.
Spark Plug Replacement CAUTION Removal 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. Remove or disconnect 1. Remove the spark plug wires. Refer to spark Plug Wire Replacement. 2. Loosen each spark plug 1 or 2 turns. 4. Tighten the spark plug to 20 N•m (15 Ibf ft) 3.
b. Best for a loose terminal post by twisting and pulling the post. The terminal post should NOT move. c. Inspect for sign of tracking that occurred near the insulator tip instead of the center electrode (4). 2. Inspect the insulator for flashover or carbon tracking soot. See Figure 84. This is caused by the electrical charge traveling across the insulator between the terminal post and ground. Inspect for the following conditions: d. Inspect for a broken or worn side electrode (3). e.
Charging System • Reduced ignition system voltage output - Weak coil pack - Worn ignition wires - Incorrect combustion - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. General Description The alternator is an electrical and mechanical components driven by a belt from engine rotation. It is used to charge the storage battery during the engine operation.
Alternators Troubleshooting The alternators used on these engines have three phase, full-wave, rectified output. They are the brush type. Refer to the Alternator Coverage chart for detailed systems operation information Charging system defect is almost caused 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.
Refer to the following troubleshooting table Symptom With ignition switch ON, charging warning lamp does not illuminate With the engine started, warning lamp is not turned off (Battery needs often charging) Possible cause Remedy Fuse cut off Replace Bulb burnt out Replace Loose wiring connection Retighten Bad connection of L terminal Inspect and replace wiring Loose or worn drive belt Correct or replace Fuse cut off Replace Circuit breaker cut off Reset or replace Faulty voltage regulator
Troubleshooting Procedure Inspection before Starting 1. Alternator and drive belt tension inspection. G424F(FE) Service Manual 110 Chapter 4.
2. Alternator and outer terminal connection inspection. G424F(FE) Service Manual 111 Chapter 4.
3. Battery outer terminal inspection. Inspection after Starting 1. When starting, belt slip and noise inspection 13.2~15.4V 2. Inspection of battery voltage at idling (At this time charge battery only) G424F(FE) Service Manual 112 Chapter 4.
Drop of Electric Pressure Test of Alternator Output Wire Test 1. Start the engine. This test is to check that wiring is correctly connected between the alternator “B“ terminal and battery (+) terminal. 2. Repeating ON and OFF of headlight and small light, adjust the engine speed until an ammeter 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.
3. With the engine running at 2,500 rpm, turn ON the high beam headlights, place the heater blower switch at ”HIGH” measure the maximum output current using a ammeter. 2. Turn the ignition switch OFF. 3. Disconnect the battery ground cable. 4. Disconnect the alternator output wire from the alternator “B” terminal. 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.
STARTING SYSTEM General Description The starting motor is used to turn the engine flywheel lfast enough to make the engine run. The starting motor has a solenoid. When the ignition switch is activated, voltage from the electrical system will cause the solenoid to move the pinion toward the flywheel ring gear of the engine. The electrical contacts in the solenoid close the circuit between the battery and the starting motor just before the pinion engages the ring gear.
Diagnosis Procedure The starting motor solenoid has two functions: 1. Engages the pinion with flywheel. The following simplified procedure is intended to help the serviceman determine if a starting motor needs to be removed and replaced or repaired. It is not intended to cover all possible problems and conditions, but to serve only as a guide. The most common 12 volt circuit is shown and discussed. 2. Is a high current switch rated about 1000 amps that actually turns on the starting motor.
The result of these switches and relays is to permit a 5 amp dash-mounted switch to turn on a 500 to 1000amp motor used to crank an engine. Battery voltage (power) available during cranking varies according to the temperature of the batteries. The following chart is a guide as to what to expect from a normal system. NOTICE Do not operate the starting 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.
Start Relay Tests 5. Is voltage equal to or greater than shown in Figure1? Relay • If the starting motor voltage is correct, the battery and starting motor cables down to the motor are within specifications. Go to Step 8. 1. Put the multimeter on the 200 ohm scale. 2. Put the multimeter lead to the 85 and 86 terminals. • If the starting motor voltage is low, the voltage drop between the battery and the starting motor is too great. Go to Step 6. 3. The indication on the meter must be 82 5 ohms.
Troubleshooting Starting system problem can be classified into “Start motor is not operating”, “Start motor is operating but engine is not starting” , and “There is a lot of time taken to start engine”. When the starting system has problems, before removing the start motor, find where the problem happens. Generally if it is difficult to start, there are problems in ignition system, fuel system, and electrical system. In this case, necessarily inspect and repair step by step, or the same problem will happen.
Starter Repair Removal Remove or disconnect WARNING Always disconnect the cable at the battery before you make repairs to the engine. Disconnect the cable at the negative terminal first. Install a tag on the battery terminals first. Install a tag on the battery terminals so that no one connects the cable on the terminal. 1. Discount battery negative cable at negative terminal. 2. Disconnect the battery positive cable at positive terminal. 3.
Chapter 5.
Q’ty Components Items G424FE G424F Transmission Oil Temperature Switch 1 1 Ground speed limit switch option option Specifications Actuation Temperature 125°C Type Actuation Pressure Normal Open 145 ± 28 kPa Electronic Throttle System Q’ty Components Electronic Throttle System Items G424FE G424F 1 1 Minimum Electrical Resistance of Throttle Actuator Specifications 1.
LP Fuel Components Specification Q’ty Components G424FE Items Specifications G424F LP Fuel System Requirements Operating Temperature -20 °F to 221°F [-29 °C to 105 °C] - - LPG Composition Requirements HD5 / HD10 LPG. Failure to use fuel compliant with HD5 or HD10 standards will void the user warranty. LP Fuel Filter 1 1 Fuel Filter Micron Size 40 micron LP Fuel Lock-off 1 1 Electrical Resistance 20~25Ω Fuel Supply Pressure 10 psi to 250 psi (68.95 kPa to 1723.
Q’ty Components G424FE Items N-2001 LP Regulator For G424F None 1 CA100 Mixer For G424FE 1 G424F(FE) Service Manual Specifications G424F None Fuel Supply Pressure 10 psi to 250 psi (69 kPa to 1724 kPa) Fuel Inlet Fitting 1/4” NPT Fuel Outlet Fitting One 3/4” NPT and one 1/8” NPT fitting with plug Fuel Supply Temperature At Tank Outlet -20 °F to 120 °F [-29 °C to 49 °C] Primary Pressure Tap 1/8” NPT with plug Max Flow 50 lbm/hr LPG Coolant Flow to Vaporizer >1.
Q’ty Components G424FE Items CA100 Mixer For G424F None Fuel Trim Valve (FTV) Specifications G424F 1 2 None Fuel LPG Fuel Inlet Fitting 1/2” NPT Fuel inlet fitted with Delphi temperature sensor Air Intake Flange 2.25” (57.15mm) ID inlet, four #1024 screws in 1.94” (49.28mm) square pattern Mixer Mounting Flange 1.87” (47.49mm ID outlet, four #1224 screws arranged in a rectangular pattern Reference Pressure Ports 1/4-1/8 NPT ports. Pressure readings must be identical within 0.25 inH2O (0.
Service Standard Basic Idle rpm (After warm up) No Load Ignition Timing (After warm up, at idle) 750±15 rpm 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.
Component Location Engine Control Module (SECM48) Camshaft Position Sensor Crankshaft Position Sensor TMAP Sensor LP Fuel Temperature Sensor Coolant Temperature Sensor G424F(FE) Service Manual 127 Chapter 5.
Pre-Catalyst Oxygen Sensor Post-Catalyst Oxygen Sensor Pedal Angle Sensor Engine Oil Pressure Switch Transmission Oil Temperature Switch Ground speed limit switch (option) G424F(FE) Service Manual 128 Chapter 5.
Electronic Throttle Body Fuel Trim Valve(FTV) Ignition Coil LP Fuel Lock-off N-2007 LP Regulator CA100 Mixer G424F(FE) Service Manual 129 Chapter 5.
Gasoline Fuel Pump Ass'y Gasoline Injectors and fuel rail G424F(FE) Service Manual 130 Chapter 5.
G424FE EMS (Engine Management System) Overview General Description MI-07 is a closed loop system utilizing a catalytic muffler to reduce the emission level in the exhaust gas. In order to obtain maximum effect from the catalyst, an accurate control of the air fuel ratio is required. A small engine control module (SECM) uses two heated exhaust gas oxygen sensors (HEGO) in the exhaust system to monitor exhaust gas content.
Dual Fuel System of G424FE (certified engine system) INPUT OUTPUT Crank Sensor Throttle body CAM sensor (Dual Fuel Only) lgnition coil TMAP sensor 2 Fuel trim valves Coolant Temp LP fuelock valve EG oil pressure switch T/M Temp switch 4 Injectors SECM Fuel Pump Accel pedal angle sensor CAN communication Throttle position sensor Pre Oxygen sensor Post Oxygen sensor LP fuel temp sensor T/M Inching pressure switch (Optional) MPI (multi-point injection) system is used for G424FE dual fuel engine
• LPG pressure regulator • Fuel trim valves • Fuel trim orifices • Small engine control module (SECM), firmware and calibration † • Fuel system sensors and actuators • Ignition system including spark plugs, cables, coils and drivers • Gasoline injectors and fuel pressure regulator (dual-fuel systems only) MI-07 System Components The MI-07 control system provides electronic control to the following subsystems on mobile industrial engines: • Fuel delivery system • Spark-ignition control system • Air throttle
LPG Fuel System Operation Other system features include: The principles outlined below describe the operation of MI-07 on an LPG fuel system. Tamper-Resistance Special tools, equipment, knowledge, and authorization are required to effect any changes to the MI-07 system, thereby preventing unauthorized personnel from making adjustments that will affect performance or emissions.
pressure regulator outlet pressure changes 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 major benefit of this trim system results from the use of mixer inlet pressure and AVV as the reference pressure extremes. The pressure differential across the mixer fuel valve is related to these same two pressures, and thus so is fuel flow.
the propane is reduced, the liquid propane vaporizes and refrigeration occurs inside the regulator due to the vaporization of liquid propane. To replace heat lost 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.
A higher flow mixer is required on larger engines. A lower flow mixer is required on smaller engines. Figure 6. Parts View of N-2007 Regulator Because vapor propane has now left the expansion chamber, the pressure in the chamber will drop, causing the primary diaphragm spring force to reopen the primary valve allowing liquid propane to enter the regulator, and the entire process starts again.
and air valve spring (6). The gas-metering valve is permanently mounted to the air valve diaphragm assembly with a face seal mounted between the two parts. When the engine is not running this face seal creates a barrier against the gas discharge jet, preventing fuel flow with the aid (downward force) of the air valve spring. When the engine is cranked over it begins to draw in air, creating a negative pressure signal. This negative pressure signal is transmitted through four vacuum ports in the air valve.
exists across the diaphragm, reducing fuel flow and leaning the air/fuel mixture. Figure 12. Idle Mixture Adjustment Screw (with tamper proof cap removed) Fuel Trim Valve (FTV) The Fuel Trim Valve (FTV) is a two-way electric solenoid valve and is controlled by a pulse-width modulated (PWM) signal provided by the SECM.
Branch-Tee Fitting 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. Increasing the amount of time the FTVs remain open (modulation or duty cycle) causes the air/fuel mixture to become leaner; decreasing the modulation (duty cycle) enriches the mixture.
exactly calculated fuel as a spray to engine to best combustion under the condition of various engine load and speed. MPI Gasoline System Operation MPI (multi-point injection) system is used for G424FE dual fuel engine. An electric fuel pump in gasoline fuel tank supplies the fuel and generates the injection pressure. The gasoline fuel pressure regulator is a one-way, non-return configuration. All gasoline specific components are automotive production parts and validated to strict automotive standards.
Electronic Throttle System MI-07 Electronic Throttle Conventional throttle systems rely on 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.
There are multiple limp-home modes available with electronic throttle control: 1. If the throttle itself is suspected of being inoperable, the SECM will remove the power to the throttle motor. When the power is removed, the throttle blade returns to its “default” position, approximately 7% open. 2. If the SECM can still control the throttle but some other part of the system is suspected of failure, the SECM will enter a “Reduced Power” mode.
and length. There are fewer parts to malfunction on the DIS system when compared to a distributor type system. 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 in the exhaust stream and is considered the primary control point. Based upon the O2 sensor feedback, the MI-07 system supplies a stoichiometric air-fuel ratio to the catalytic converter.
converter. It reduces the unburned hydrocarbons and carbon monoxide by burning (oxidizing) them over a platinum and palladium catalyst. Cerium is also used to promote oxygen storage and improve oxidation efficiency. The HEGO stoichiometric air-fuel ratio voltage target is approximately 500 mV and changes slightly as a function of speed and load. When the pre-catalyst HEGO sensor sends a voltage signal less than 450 mV the SECM interprets the air-fuel mixture as lean.
The SECM provides a transducer ground for all the sensors, and a low side driver signal controlling the fuel lock-off, MIL, gasoline injectors, gasoline fuel pump, and FTVs. SECM General Description The Small Engine Control Module (SECM) controller has full authority over spark, fuel and air. Utilizing a Freescale micro controller, the SECM has 48 pins of I/O and is fully waterproof and shock hardened.
NOTE : The DV-E5 throttle is not a serviceable assembly. If a TPS sensor fails, the assembly should be replaced. Speed Management Drive-by-wire refers to the fact that the MI-07 control system has no throttle cable from the foot pedal to the throttle body. Instead, the SECM is electronically connected both to the foot pedal assembly and the throttle body. The SECM monitors the foot pedal position and controls the throttle plate by driving a DC motor connected to the throttle.
Ignition Management In the normal course of events, with the engine operating at the correct temperature in defined conditions, the SECM will use load and engine speed to derive the correct ignition timing. In addition to load 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 Wiring Diagrams for G424FE CAUTION—PROPER WIRING To prevent system faults be sure to follow good wiring practices. Poor wiring may cause unexpected or intermittent failures not related to MI-07 components. The schematics on the next pages are wiring diagrams for G424FE engines. Figure 21: Dual fuel certified system Figure 22: LP certified system G424F(FE) Service Manual 149 Chapter 5.
Figure 21. SECM Wiring Diagram for G424FE Dual Fuel System. G424F(FE) Service Manual 150 Chapter 5.
Figure 22. SECM Wiring Diagram for G424FE LP System. G424F(FE) Service Manual 151 Chapter 5.
G424F EMS (Engine Management System) Overview General Description Engine speed is monitored by the SECM through a variable reluctance (VR) sensor. Intake manifold air temperature and absolute pressure are monitored with a TMAP sensor. MI-07 is a drive-by-wire (DBW) system connecting the accelerator pedal to the electronic throttle through the electrical harness; mechanical cables are not used.
LP System of G424F INPUT OUTPUT Crank Sensor Throttle body TMAP sensor lgnition coil Coolant Temp EG oil pressure switch T/M Temp switch LP fuelock valve SECM CAN communication Accel pedal angle sensor Throttle position sensor T/M Inching pressure switch (option) G424F(FE) Service Manual 153 Chapter 5.
MI-07 System Components The MI-07 control system provides electronic control to the following subsystems on mobile industrial engines: 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. • Fuel delivery system • Spark-ignition control system • Air throttle • Sensors/Switches/Speed inputs The chart below lists the MI-07 components required for a G424F engine operating on LP fuel.
Other system features include: LPG Fuel System Operation Tamper-Resistance Special tools, equipment, knowledge, and authorization are required to effect any changes to the MI-07 system, thereby preventing unauthorized personnel from making adjustments that will affect performance or emissions. The principles outlined below describe the operation of MI-07 on an LPG fuel system.
stage) valve closes. Unlike most other regulator/converters, the N-2001 primary valve closes with fuel pressure rather than against pressure, extending primary seat life and adding additional safety. N-2001 Operation Refer to Figure 6. Liquid propane, at tank pressure, enters the N-2001 through the fuel inlet port (1). Propane liquid then flows through the primary valve (2).
imbalance on the secondary diaphragm, which overcomes the secondary spring force, opening the secondary valve and allowing vapor propane to flow out of the expansion chamber, through the secondary chamber to the 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 inside the mixer.
Figure 9. Parts View of CA100 Mixer Figure 11. CA100 Mixer Installed with Electronic Throttle A pressure/force imbalance begins to build across the air valve diaphragm between the air valve vacuum (AVV) chamber (above the diaphragm) and atmospheric pressure below the diaphragm. Approximately 6 inH2O (14.945 mbar) of negative pressure is required to overcome the air valve spring force and push the air valve assembly upward off the valve seat. Approximately 24 inH2O (59.
Electronic Throttle System The electronic throttle system of G424F engine is the same as that of G424FE engine. See, “Electronic 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 overview” G424F(FE) Service Manual 159 Chapter 5.
SECM Wiring Diagrams for G424F LP Engine G424F(FE) Service Manual 160 Chapter 5.
• Fuel Temperature Sensor (FTS) -40°F to 266°F (-40ºC to 130ºC) range, 48K ohm to 57 ohm sensor range EMS Inspection and Repair Engine Control Module (SECM) • HEGO (3) 0 to 1 V The 48-pin Small Engine Control Module (SECM) and sensors provide the computational power, algorithm logic, sensor inputs and control outputs to control the system.
Outputs • Saturated injector drivers (4) 10A peak, 45 V max, 1 injector per channel capable of continuous on-time Driver circuit designed for minimum turn-on/turnoff delay Minimum pulse width resolution of 1 usec • FTV drivers (2) 10A peak, 45V max.
Camshaft Position Sensor (G424FE- Dual Fuel Only) Sensor Inspection Component Location CAM shaft Position Sensor 3 2 1 1. Turn ignition switch to OFF position and then disconnect CMPS connector. 2. Remove the CMPS from the engine. Description 3. Turn ignition switch to ON position. The Camshaft Position Sensor (CMPS) is a sensor that detects the compression TDC of the NO.1 cylinder. The CMPS consists of a hall type sensor and a target on the end of the in take camshaft.
Installation 1. Install new O-ring on CMP sensor. 2. Lubricate O-ring with clean engine oil. 3. Install 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.
Crankshaft Position Sensor Removal Component Location 1. Remove the timing belt front cover. See Timing 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. Crank Position Sensor 2. Install the capscrew to retain the crankshaft/rpm sensor. Tighten capscrew to 8 N◦m (71 lbf ft). 3.
Sensor Inspection MAP (Manifold Absolute Pressure) Sensor 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 Ignition SW. ON At idle Test specification 4~5V 0.5~2.0V 2. If the voltage deviates from the standard value, replace the MAP sensor assembly. Removal MAP sensor 1. Disconnect the negative battery cable. The manifold absolute pressure (MAP) sensor is a pressure sensitive variable resistor.
IAT (Intake Air Temperature) Sensor Sensor Inspection 1. Using a multimeter, measure the IAT sensor resistance between terminals 3 and 4. IG.SW.ON Temperature ℃ (°F) MAP sensor Resistance(kΩ) 0 (32) 4.5 ~ 7.5 20 (68) 2.0 ~ 3.0 40 (104) 0.7 ~ 1.6 80 (176) 0.2 ~ 0.4 2. If the resistance deviates from the standard value, replace the intake air temperature sensor assembly.
Oxygen Sensor (Pre-Catalyst) Schematic Diagram Component Location [CIRCUIT DIAGRAM] HO2S (B1/S1) ECM 4 3 1 2 Pre - Catalyst Oxygen Sensor Description A23 - HO2S HEATER (B1/S1) B13 - HO2S SIGNAL B1 - HO2S GND After Main Relay [HARNESS CONNECTORS] The heated oxygen sensor is mounted on the front side of Catalytic Muffler, which detects the oxygen concentration in the exhaust gas. The heated oxygen sensor produces a voltage that varies between 0V and 1V.
Oxygen Sensor (Post-Catalyst) Signal Wave Form Component Location The amplitude of the signal output of the rear HO2S is small compared to the front HO2S because the rear HO2S detects emission gas purified by the catalytic converter. This illustration is the normal signal waveform of the rear HO2S at idle. Description The rear heated oxygen sensor is mounted on the rear side of the Catalytic Muffler, which detects the catalyst efficiency.
ECT (Engine Coolant Temperature) Sensor Sensor Inspection Component Location ECT Senser 1. Remove the engine coolant temperature sensor from the intake intake manifold. Description The Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting the engine coolant temperature. The ECTS uses a thermister whose resistance changes with the temperature.
Schematic Diagram [CIRCUIT DIAGRAM] ECM 1 B15_ECT_SIGNAL B1_GND 2 [HARNESS CONNECTORS] 1 2 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. G424F(FE) Service Manual 171 Chapter 5.
LP Fuel Temperature Sensor [Harness Connectors] Location Inspection 1. Remove the LP fuel temperature sensor from the adapter connected to LP mixer. Description The LP Fuel Temperature Sensor (FTS) is located in the LP fuel passage of the LP mixer for detecting the LP fuel temperature. The FTS uses a thermistor whose resistance changes with the temperature. The electrical resistance of the FTS decrease as the temperature increase, and increase as the temperature decrease.
Angle Sensor-Accelerator [Harness Connectors] Location Inspection 1. Disconnect the Accelerator Pedal’s connector from the main engine harness. Description Angle Sensor-Accelerator is located in the accelerator pedal assembly. The engine speed management deals with a Drive-by-wire system. Drive-by-wire refers to the fact that the MI-07 control system has no throttle cable from the foot pedal to the throttle body.
Transmission Oil Temperature Switch Location [Harness Connectors] Description Transmission Oil Temperature Switch is located in the adapter on transmission (T/M) for operating by the transmission (T/M) oil temperature change. This switch is normally open, and then it is closed as the T/M oil temperature Increases to the 125±3°C. Actually if the switch is closed by high T/M oil temperature, the ECM makes engine shutdown with fault set.
Ground Speed Limit Switch (optional) [Harness Connectors] Location Description Ground Speed Limit Switch is located in the pressure port on transmission (T/M) for operating by the transmission (T/M) oil pressure change. This switch is normally opened, and then it is closed as the T/M oil pressure increases. Actually the switch is closed by increasing of the T/M oil pressure after engine cranking.
Electronic Throttle Body Location [Harness Connectors] Description The MI-07 system uses electronic throttle control (ETC). The SECM controls the throttle valve based on engine RPM, engine load, and information received from the foot pedal. Two potentiometers on the foot pedal assembly monitor accelerator pedal travel. The electronic throttle used in the MI-07 system is a Bosch 32mm electronic throttle body DV-E5.
Chapter 6. LPG FUEL DELIVERY SYSTEM G424FE LP System Inspection and Repair Removal and Installation WARNING - PROPER USE • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. • Gas vapor may reduce oxygen available for breathing, cause headache, nausea, dizziness and unconsciousness and lead to injury or death.
Hose Connections Proper operation of the closed loop control greatly depends on the correct vacuum hose routing and fuel line lengths. Refer to the 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.
DIAGRAM NOTES Trim valves must be positioned 1 shown 2 3 1 vertically with flow arrows in position 2 Fuel outlet must be min 15° below horizontal position Only one 90° fitting permissible on 3 4 sensor adaptor is considered the one 90° fitting.) Vapor fuel fittings (regulator and 4 8 for 7/32” (5.56mm) ID Tube 9 Valve (TEV Bosch Canister) Plastic WYE Fitting (blue color) 10 11 for 7/32” (5.56mm) ID Tube Brass Tee Fitting.
N-2007 Installation Steps Removal and Installation of N-2007 LP Regulator Refer to Figure 28. Follow the procedures below for removal and reinstallation of the N-2007 regulator in certified systems. 1. Install the nipple extension (6) with the lock-off to the regulator. N-2007 Removal Steps 2. Install the fuel vapor outlet hose (5) to the regulator. Refer to Figure 28. 3. Install the two cooling lines (4) to the regulator. 1.
2. Purge the system of fuel by starting the engine and running until all trapped fuel in the system is exhausted and the engine shuts down. Removal and Installation of CA100 Mixer for G424FE Follow the procedures below for removal and reinstallation of the CA100 mixer in certified systems. 3. Key switch in “OFF” position. CA100 Certified Mixer Removal Steps 4. Remove the air cleaner hose (1). 5 5.
NOTE : A plastic O-ring spacer and an O-ring are inside the mixer/adapter assembly. Be careful not to lose these items when removing the assembly from the throttle (Figure 31). CA100 Certified Mixer Installation Steps Refer to Figure 30. 1. Install the vacuum port barb onto the mixer (9). 2. Install the fuel temperature sensor fitting (4) onto the mixer. 3. Install the fuel temperature sensor into the fitting. 4. Ins tall the four mounting screws that attach the throttle adapter (7) to the mixer.
N-2007 Regulator Service Testing Tests and Adjustments For checking the N-2007 regulator/converter operation, the following tests can be performed (See Chapter 5 for removal/installation of the N-2007 regulator). To check the secondary regulation (output) a 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. WARNING—PROPER USE • LP gas is highly flammable.
3. Apply compressed air, wait for air to exit the hose barb in the test port, and then connect the Magnehelic gauge (Figure 36) to the hose barb using the vacuum 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” of water column on the Magnehelic gauge and maintain a constant pressure for 60 seconds.
5. If the measured pressure drop is low, check for vacuum leaks in the manifold, throttle, mixer, TMAP sensor and attached hoses. CAUTION • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. • Gas vapor may reduce oxygen available for breathing, cause headache, nausea, dizziness and unconsciousness and lead to injury or death.
Idle Mixture Adjustment The CA100 mixer requires adjustment of the idle mixture screw to assure optimal emissions and performance. This adjustment accounts for minor part-to-part variations in the fuel system and assures stable performance of the engine at idle. Once adjusted, the idle mixture screw is sealed with a tamper proof cap, after which it need not be adjusted for the life of the vehicle.
measurement at Closed Loop Idle of 25-60% is acceptable if the optimum range of 35-55% cannot be reached through adjustment. If the FTV duty cycle cannot be adjusted below 60%, the mixer is faulty and should be replaced. Factory Adjustment Procedure: NOTE : Be sure engine is fully warm (ECT>167°F [75°C]) before performing the idle mixture adjustment. NOTE : If the FTV Duty Cycle reading is NOT between 25-60%, check for possible vacuum leaks, manifold leaks, or a faulty mixer. 1.
8. If the FTV duty cycle reading is above 55% adjust the idle adjustment screw outward and re-check the duty cycle reading. Continue to do this until the FTV duty cycle reading is within the optimum range (35-55%). DO NOT adjust the screw so far outward that the tamper proof cap cannot be installed. A duty cycle measurement at Closed Loop Idle of 25-60% is acceptable if the optimum range of 35-55% cannot be reached through adjustment.
Parts Description CA100 Mixer for G424FE Engine Parts List of CA100 Mixer (Certified) REF NO DESCRIPTION QTY 1 Torx Screws (T-25) #10-24 x 5/8” 4 2 Lockwashers (T-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.
Exploded View of CA100 Mixer (Certified) Figure 44. CA100 Certified Mixer Exploded View G424F(FE) Service Manual 190 Chapter 6.
N-2007 Regulator for G424FE Engine Parts List of N-2007 Regulator (Certified) REF NO DESCRIPTION QTY 1 N-2007 Body 1 2 Diaphragm, Primary Assembly 1 3 Springs, Primary Assembly 2 4 Cover, Primary Assembly 1 5 Spring, Secondary Seat, Red 1 6 Dowel Pin Ø 0.094” x 1” L (Ø 2.39mm x 25.
Exploded View of N-2007 Regulator (Certified) Figure 46. N-2007 Certified Regulator Exploded View G424F(FE) Service Manual 192 Chapter 6.
G424F LPG System Inspection and Repair Removal and Installation WARNING – PROPER USE • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. • Gas vapor may reduce oxygen available for breathing, 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.
G424F Fuel System Connections 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) DWG NO 5555-1243 Figure 27. Hose Connections for Non-Certified Systems DIAGRAM NOTES 1 Only one 90° fitting permissible on vapor fuel line between mixer and regulator 3 Vapor fuel fittings (regulator and mixer) must have minimum ID of 0.46” (11.
Removal and Installation of N-2001 LP Regulator/Converter Follow the procedures below for removal and reinstallation of the N-2001 regulator. N-2001 Removal Steps Refer to Figure 29. 1. Close the liquid outlet valve in the forklift cylinder or fuel storage container. 2. Purge the system of fuel by starting the engine and running until all trapped fuel in the system is exhausted and the engine shuts down. 3.
Removal and Installation of CA100 Mixer for G424F 1. Close the liquid outlet valve in the forklift cylinder or fuel storage container. Follow the procedures below for removal and reinstallation of the CA100 mixer in non-certified systems. 2. Purge the system of fuel by starting the engine and running until all trapped fuel in the system is exhausted and the engine shuts down. CA100 Mixer Removal Steps 3. Key switch in “OFF” position. 1 4. Remove the air cleaner hose (1). 5.
NOTE : A plastic O-ring spacer and an O-ring are inside the mixer/adapter assembly. Be careful not to lose these items when removing the assembly from the throttle (Figure 31). CA100 Mixer Installation Steps 1. Install the vapor fuel inlet fitting onto the mixer. 2. Install the four mounting screws that attach the throttle adapter (5) to the mixer. (See Figure 32). Torque bolts to 30-40 lbf-in (3.39-4.52 N-m). 3.
Secondary Stage (Break-Off) Test Tests and Adjustments 1. Connect the vacuum pump, the Magnehelic gauge and the regulator vapor outlet to the Union Tee fitting (Figure 30). Make sure there is no leakage at any of the fittings. WARNING – PROPER USE • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. 2. Using the vacuum pump slowly apply enough vacuum to measure above -2” WC on the gauge.
Pressure Test Primary Stage Pressure Test Primary Stage Test Hardware 1. Remove the primary test port plug from the side of the regulator and install the 1/16” NPT hose barb fitting (Figure 31). 1. Hand vacuum pump 2. Connect a compressed air line (shop air ~100 psi) to the liquid propane fuel inlet of the N-2001 regulator (Figure 31). 2. Regulator fuel inlet test fitting 1/4 NPT standard air coupling) 3. Test gauge fitting (1/4” NPT X 1/4” hose b) 4. Vacuum hose or vinyl tubing 5.
AVV (Air Valve Vacuum) Testing Connection of the MI-07 Service Tool Purpose of Test To use the Service Tool, a USB (Universal Serial Bus) to CAN (Controller Area Network) communication adapter by KVaser will be required along with a Crypt Token (Figure 38). The Crypt Token acts as a security key allowing the laptop to retrieve the necessary data from the SECM. Check for excessive or inadequate pressure drop across CA100 mixer. AVV Test Hardware 1. Union Tee fitting, 1/4” (6.35mm) NPT with three 1/4” (6.
Power Valve Adjustment 1. The power valve should only be adjusted after the idle screw has been adjusted properly. The engine and vehicle drive train and hydraulics should also be at normal operating temperatures. 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.
Power Valve Adjustment 1. The power valve should only be adjusted after the idle screw has been adjusted properly. The engine and vehicle drive train and hydraulics should also be at normal operating temperatures. 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.
Parts Description CA100 Mixer for G424F Engine Refer to Figure 45 exploded 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 G424F(FE) Service Manual 203 Chapter 6.
Exploded View CA100 Mixer Figure 44. CA100 Non-Certified Mixer Exploded View G424F(FE) Service Manual 204 Chapter 6.
CA100 Disassembly and Service 6 5 Figure M4 4 1. With the mixer/adapter 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). 9 14 2 3 8 7 Figure M5 1 15 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).
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 all seals and gaskets before cleaning the casting with solvent. Make sure all parts are completely dry before re-assembly. Figure M7 4.
N-2001 Regulator for G424F Engine Refer to Figure 47 exploded view on facing page. Parts List N-2001-RSA Regulator REF NO.
Exploded View N-2001-RSA Regulator Figure 47. N-2001 Regulator Exploded View G424F(FE) Service Manual 208 Chapter 6.
N2001 Regulator Disassembly Steps: 4 Figure R5 1 Figure R3 5 2 3 Figure R5 Remove the six primary diaphragm cover screws (4) and the primary cover assembly (5). Figure R4 1. Remove the six secondary cover screws (1), the secondary cover (2) and the secondary diaphragm (3). 2. Remove the six primary diaphragm cover screws (4) and the primary cover assembly (5). Figure R6 Remove the primary diaphragm by sliding the diaphragm to one side, releasing the primary valve pin (Figure R6).
10 3 11 Figure R7 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 cover screws to (40-50 inch lbs.), secondary cover screws to (1518 inch lbs.).
N2001 Disassembled Service 1. Clean the primary and secondary valves with soap and warm water to remove heavy-end deposits. Inspect the valve seats and o-rings for wear. Replace worn components as necessary. 2. Clean the primary and secondary diaphragms with soap and warm water. Inspect for wear, tears or pinholes and deformations that may cause leaks or poor performance of the regulator/converter. . 3.
Chapter 7. MPI GASOLINE FUEL 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 Regulated Fuel Pressure 350 kPa (3.5kg/cm², 49.8psi) Fuel Pressure Regulator Fuel Pump G424F(FE) Service Manual Type Electrical, in-tank type 212 Chapter 7.
Components Location 1. Fuel Tank 2. Fuel Pump (Including full pressure regulator and fuel filter) 3. Fuel Hose Assy 4. Fuel Rail 5. Injector G424F(FE) Service Manual 213 Chapter 7.
Fuel Pressure Test Install Service Tool For Measuring The Fuel Pressure Release The Internal Pressure 1. Disconnect the fuel pump connector (1). 2. Start the engine and wait until fuel in fuel line is exhausted. 3. After the engine stalls, turn the ignition switch to OFF position and diconnect the negative (-) terminal from the battery. NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel feed hose, otherwise fuel will spill out. 1.
Inspect Fuel Leakage On Connection • Observing the declination of the fuel pressure when the gage reading drops and perform the necessary repairs using the table below. 1. Connect the battery negative (-) terminal. 2. Apply battery voltage to 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. Fuel Pressure Test 1. Diconnect the negative (-) terminal from the battery. 2.
Remove Service Tool And Connect the Fuel Line Description Based on information from various sensors, the ECM measures the fuel injection amount. The fuel injector is a solenoid-operated valve and the fuel injection amount is controlled by length of time the fuel injector is held open. The ECM controls each injector by grounding the control circuit. When the ECM energizes the injector by grounding the control circuit, the circuit voltage should be low (theoretically 0V) and the fuel is injected.
Injector Inspection Resistance Measurement Between Terminals Operation check Operation Sound Check 1. Disconnect the connector at the injector and measure the resistance between the two terminals. 1. Using a stethoscope, check the injectors for a clicking sound at idle. Check that the sound is produced at shorter intervals as the engine speed increases. Standard value : 12-14Ω [at 20℃ (68℉)] 2. Re-connect the connector to the injector.
Inspection 1. Measure the resistance of the injectors between the terminals using an ohmmeter. Resistance : 12-14Ω [at 20℃ (68℉)] 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 the delivery pipe and recheck. 2. If the resistance is not within specifications, replace the injector. Installation 1. Install a new grommet and O-ring to the injector. 2.
Fuel Pump Removal (Including Fuel Filter And Fuel Pressure Regulator) A 1. Release the internal pressure of the fuel lines and hoses as following : a. Disconnect the fuel pump assembly 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. 4. Remove the fuel pump assembly. c. Disconnect the negative (-) terminal from the battery. 2. Disconnect the fuel feed line.
Chapter 8. BASIC TROUBLESHOOTING Preliminary Checks Visual/Physical check MI-07 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) and are covered in Chapter 9, Advanced Diagnostics. However, items such as fuel level, plugged fuel lines, clogged fuel filters, and malfunctioning pressure regulators may not set a fault code and usually can be corrected with the basic troubleshooting steps described on the following pages.
Basic Troubleshooting Guide Customer Problem Analysis Sheet 1. Forklift Information (I) VIN: (II) ProductionDate: (III) Hour meter Reading: (hrs) 2.
4. Repair or replace the component that has a problem. Basic Inspection Procedure Measuring Condition Of Electronic Parts Resistance 5. Verify that the problem has disappeared with the road test. The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient temperature (20℃, 68 ℉), unless there is any notice. ● SIMULATING VIBRATION NOTE: The measured resistance in except for ambient temperature (20℃, 68℉) is reference value.
Connector Inspection Procedure Handling of Connector 4. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side. 1. Never pull on the wiring harness when disconnecting connectors. 5. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side. 2. When removing the connector with a lock, press or pull locking lever. NOTE: Use a fine wire to prevent damage to the terminal.
Wire Harness Inspection Procedure Checking Point for Connector 1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part. 1.
normal). To find exact break point, check sub line of line 1as described in next step. Electrical Circuit Inspection Procedure ● Check Open Circuit 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 connector (C) and (B1) is higher than 1㏁ and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). 1.
● Check Short Circuit b. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground as shown in [FIG.7]. 1. Test Method for Short to Ground Circuit • Continuity Check with Chassis Ground The measured resistance between connector (B1) and chassis groundis1Ω or less. The short to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). If short to ground circuit occurs as shown in [FIG.
Symptom Troubleshooting Guide Chart for MPI Gasoline System Engine Is Not Starting Engine Is Difficult To Start (Cranking OK) G424F(FE) Service Manual 227 Chapter 8.
Irregular Idling Or Engine Is Suddenly Stopped G424F(FE) Service Manual 228 Chapter 8.
Engine Hesitation Or Insuffient Accelelation G424F(FE) Service Manual 229 Chapter 8.
G424F(FE) Service Manual 230 Chapter 8.
Troubleshooting Guide for MPI Gasoline System • The following number represents inspection order. G424F(FE) Service Manual 231 Chapter 8.
G424F(FE) Service Manual 232 Chapter 8.
Basic Troubleshooting An intermittent “Service Engine Soon” light with no stored diagnostic code may be caused by: Intermittents • Ignition coil shortage to ground and arcing at spark plug wires or plugs An intermittent fault is the most difficult to troubleshoot since the MIL flashes on at random, causing uncertainty in the number of flashes or the conditions present at the time of the fault. Also, the problem may or may not fully turn “ON” the MIL light or store a code.
Surges and/or Stumbles Engine power varies under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the acceleration pedal. Preliminary Checks Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Be sure driver understands vehicle operation as explained in the operator manual.
Engine Cranking but Will Not Start / Difficult to Start Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies. Preliminary Checks Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Be sure driver is using correct method to start engine as explained in operator’s manual. Use “clear flood” mode during cranking by fully depressing the pedal and cranking the engine. If engine does not start, continue troubleshooting.
Engine Cranking but Will Not Start / Difficult to Start (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION SECM / control system malfunction Check Coolant Temperature Sensor using the Service Tool; compare coolant temperature with ambient temperature on cold engine. If coolant temperature reading is 5° greater than or less than ambient air temperature on a cold engine, check resistance in coolant sensor circuit or sensor itself. Compare CTS resistance value to “Diagnostic Aids” chart at end of this section.
Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During Acceleration Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part way. Momentary lack of response as the accelerator is pushed down. Can occur at all vehicle speeds. Usually most severe when first trying to make vehicle move, as from a stop. May cause engine to stall.
Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During Acceleration (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION Component malfunction Check SECM grounds for cleanliness and secure connection. See SECM wiring diagrams. Check alternator output voltage. Repair if less than 9 volts or more than 16 volts. Check for clogged air filter and clean or replace as required. Check exhaust system for possible restriction. Refer to Chart T-1 on later pages.
Detonation / Spark Knock A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with throttle opening (similar to the sound of hail striking a metal roof). PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. PROBABLE CAUSE CORRECTIVE ACTION Fuel system malfunction Check for proper fuel level: • Check for LPG vapor from LPG liquid outlet valve on tank. • Fill fuel container.
Backfire Fuel ignites in intake manifold or in exhaust system, making loud popping noise. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Simulate condition by reviewing operation procedure practiced by vehicle operator.
Rough, Unstable, Incorrect Idle, or Stalling Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies. PRELIMINARY CHECKS Perform the visual checks as described at start of “Basic Troubleshooting” chapter. Check for vacuum leaks. Check that SECM grounds are clean and tight. See SECM wiring diagram PROBABLE CAUSE CORRECTIVE ACTION Fuel system malfunction Monitor oxygen feedback to help identify the cause of the problem.
Rough, Unstable, Incorrect Idle, or Stalling (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION Excess flow valve closed Reset excess flow valve. • Close liquid valve. • Wait for a “click” sound. Slowly open liquid valve. Clogged fuel filter Repair/replace as required See Chapter 4 Fuel Filter Replacement 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.
Cuts Out, Misses Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases, sometimes above 1500 rpm. The exhaust has a steady spitting sound at idle or low speed. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. PROBABLE CAUSE CORRECTIVE ACTION Fuel system malfunction Check fuel system specifically for plugged fuel filter, low pressure. Check for contaminated fuel. Check injector drivers.
Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell Fuel economy, as measured during normal operation, is noticeably lower than expected. Also, economy is noticeably lower than what it has been in the past. Propane fuel smell near vehicle sets off carbon monoxide sensors. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Verify operator complaint: identify operating conditions.
High Idle Speed Engine idles above the range of 750-1100 rpm. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. PROBABLE CAUSE Incorrect idle speed control Throttle sticking Foot pedal sticking or incorrect pedal signal Engine mechanical CORRECTIVE ACTION Check all hoses and gaskets for cracking, kinks, or leaks. Verify that there are no vacuum leaks. See Chapter 8 Advanced Diagnostics & Chapter 6 Tests and Adjustments Replace throttle.
Excessive Exhaust Emissions or Odors Vehicle has high CO emissions. NOTE: Excessive odors do not necessarily indicate excessive emissions. PRELIMINARY CHECKS Verify that no stored codes exist. If emission test shows excessive CO and HC, check items that cause vehicle to run rich. If emission test shows excessive NOx, check items that cause vehicle to run lean or too hot.
Diagnostic Aids for Rich / Lean Operation SERVICE TOOL ITEM RICH LEAN Pre-catalyst O2 A/ D counts Consistently > 250 Consistently < 170 Pre-catalyst O2 sensor switching between high and low Always high ADC Always low ADC Trim valve duty cycle > 90% < 10% Fuel injector pulse width at idle * < 1.0 msec. > 8 msec.
Diagnosis: Chart T-1 Restricted Exhaust System Check Proper diagnosis for a restricted exhaust system is essential before replacement of any components. The following procedures may be used for diagnosis, depending upon engine or tool used. Check Atpre - Catalystoxygen (O2) Sensor 1. Carefully remove pre-catalyst oxygen (O2) sensor. 2. Install exhaust backpressure tester or equivalent in place of O2 sensor using Snap-On P/N EEVPV311A kit and YA8661 adapter or Mac tool (see illustration). 1.
Chapter 9. ADVANCED DIAGNOSTICS MI-07 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) as Diagnostic Fault Codes (DFC) or flash codes, and viewed in detail with the use of the Service Tool software. When the ignition key is turned on, the MIL will illuminate and remain 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.
Fault Action Descriptions Fault List Definitions Each fault detected by the SECM is stored in memory (FIFO) and has a specific action or result that takes place. Listed below are the descriptions of each fault action. All the analog sensors in the MI-07 system have input sensor range faults. These are the coolant temperature sensor, fuel temperature sensor, throttle position sensors, pedal position sensors, manifold pressure sensor, HEGO sensors, and intake air temperature sensor.
Table 1.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.) FAULT ETCSpringTest CODE (MI04 CODE) DESCRIPTION Electronic Throttle Control Spring Return Test has Failed. The SECM will perform a safety test of the throttle return spring following engine shutdown. If this spring has become weak the throttle will fail the test and set the fault. 481 (28) NOTE: Throttle assembly is not a serviceable item and can only be repaired by replacing the DV-EV throttle assembly.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.) FAULT CODE (MI04 CODE) DESCRIPTION HbridgeFault_ETC (Electronic Throttle Control Driver has Failed) Indeterminate fault on Hbridge driver for Electronic Throttle Control.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) Post-catalyst O2 sensor control on gasoline has sensed the O2 sensor is not responding as expected. If any Pre-O2 sensor faults are set, diagnose these first and after correcting these faults recheck if this fault sets. Possible causes for this fault are sensor disconnected, sensor heater failed, sensor element failed, heater relay, or SECM control of heater relay is disconnected or failed.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) TPS2 sensor voltage out of range low, normally set if TPS2 signal has shorted to ground, circuit has opened or sensor has failed 222 FAULT TPS2RangeLow TPS sensors differ by more than expected amount. TPS_Sensors_Conflict TransOilTemp NOTE: The TPS is not a serviceable item and can only be repaired by replacing the DV-EV throttle assembly Excessive transmission oil temperature G424F(FE) Service Manual 260 291 933 Chapter 9.
Table 2.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT 161 (16) ECTOverTempFault Engine coolant temperature is high. The sensor has measured an excessive coolant temperature typically due to the engine overheating.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * 341 (34) 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.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT 381 (38) IATRangeHigh Intake Air Temperature Sensor Input is High normally set if the IAT temperature sensor wire has been disconnected or the circuit has opened to the SECM.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT ACTION * CORRECTIVE ACTION FIRST CHECK 424 EST4_Open EST4 output open, possibly open EST4 signal or defective spark module TurnOnMil Check coil driver wiring and connector for open circuit SECM Pin A6 (EST4) to OEM ignition system. See application manual. 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.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TurnOnMil Check coil driver wiring and connector for shorts SECM Pin A10 (EST2) 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.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC 437 438 PROBABLE FAULT EST7_Short EST7 output shorted high or low, EST7 signal shorted to ground or power or defective spark module EST8_Short EST8 output shorted high or low, EST8 signal shorted to ground or power or defective spark module FAULT ACTION * CORRECTIVE ACTION FIRST CHECK None N/A None N/A 461 (26) ETC_Sticking Electronic Throttle Control is sticking.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT 491 (29) HbridgeFault_ETC Electronic Throttle Control Driver has failed. Indeterminate fault on Hbridge driver for electronic throttle control.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * 731 (73) GasFuelAdaptRangeHi In LPG mode, system had to adapt lean more than expected TurnOnMil 741 (74) GasO2NotActive Pre-catalyst O2 sensor inactive on LPG, open O2 sensor signal or heater leads, defective O2 sensor (1) TurnOnMil (2) DisableGas O2Ctrl 742 GasPostO2NotActive Post-catalyst O2 sensor inactive on LPG, open O2 sensor signal or heater leads, defective O2 sensor.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION FIRST CHECK DFC PROBABLE FAULT FAULT ACTION * 771 (77) GasO2FailedRich Pre-catalyst O2 sensor indicates extended rich operation on LPG (1) TurnOnMil (2) DisableGas O2Ctrl Check fuel trim valves, e.g. plugged valve or hose. Check for plugged orifice(s). (1) TurnOnMil (2) DisableGasPostO2Ctrl Correct other faults that may contribute to 772 (e.g.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. PROBABLE FAULT 842 LiqPostO2NotActive Post-catalyst O2 sensor inactive on gasoline, open O2 sensor signal or heater leads, defective O2 sensor.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT ACTION * CORRECTIVE ACTION FIRST CHECK DFC PROBABLE FAULT 911 O2RangeLow Pre-catalyst O2 sensor voltage out of range low, sensor signal shorted to ground (1) TurnOnMil (2) DisableLiquid O2Ctrl (3) DisableGas O2Ctrl Check if O2 sensor installed before the catalyst is shorted to GND or sensor GND.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Appendix Service Tool Software Kit Service Tool Software (MotoView) Service tool software kit consists of USB-CAN converter, Service tool software (MotoView) and Extension cable. Introduction The MI-07 Service Tool is a graphic interface to the SECM (Small Engine Control Module) and is made up of several screens to aid the technician in system diagnostics using a personal computer. The software application that is used to connect to the SECM is MotoView and is described in the next section.
Figure 4. Crypt Token Installed on Laptop A334071 Extension Cable (L=200 cm) A334082 Extension Cable (L=20 cm) Connection of the Service Tool To use the Service Tool, a USB (Universal Serial Bus) to CAN (Controller Area Network) communication adapter by KVaser will be required along with a Crypt Token (Figure 3). The Crypt Token acts as a security key allowing the laptop to retrieve the necessary data from the SECM. Figure 5. Opening the Service Tool Display 1.
MotoView Display Screens Service Screen Tab The first screen displayed when connecting to the SECM-48 is the Main Service Screen. The screen format is designed to give the technician a quick reference to the state of the MI-07 system and the engine. Main sections of this screen include the Engine category, Faults, Fault States, AFR Control, Sensors, Throttle, Accelerator Pedal, and Ignition.
AFR (Air Fuel Ratio) Control The AFR Control category is divided into two separate sections, one for LP and a second for Gasoline, (active on bi-fuel units). Key parameters for AFR Control include the “Open-Loop”/ “ClosedLoop” control listing. This description informs the technician whether the emission system is using closed loop feedback from the oxygen sensors to control the AFR delivered to the exhaust catalyst or using tables in the engine control module for AFR control in open loop mode.
Faults Screen Tab The second available screen in the service tool display is the Fault screen. All ten stored fault codes are displayed in order of their occurrence. If a fault occurs and is stored it will not be stored again in the fault record until the fault has been cleared. This prevents the same re-occurring fault from being saved to all the stored records. Stored faults do not contain any type of date or time stamp to indicate when they occurred. Figure 8.
Ground Speed Screen Tab The Ground Speed screen displays parameters for the ground speed option. The Engine category of this screen gives the technician a quick reference of the engine state when making setpoint changes without having to switch screens. See the Service Screen display definitions for parameter explanations. If not used the Ground Speed Switch indicator will be open and the High Max RPM setpoint will still be active. See below for description. Figure 9.
DFC 12-353 Screen Tab Figure 10. Diagnostic Fault Codes 12-43 Screen DFC (Diagnostic Fault Codes) 12 through 353 are defined on this display for quick reference. Faults that are displayed in yellow have been enabled on the MI-07 system. Faults that appear in grey are included for future use but are not enabled. Refer to the service manual or the Advanced Diagnostics section of this manual for repair steps and further troubleshooting.
DFC 371-641 Screen Tab Figure 11. Diagnostic Fault Codes 371-641 Screen DFC (Diagnostic Fault Codes) 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.
DFC 642-995 Screen Tab Figure 12. Diagnostic Fault Codes 642-995 Screen DFC (Diagnostic Fault Codes) 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.
Signal I/O Screens 1-4 There are four Signal I/O (Inputs & Outputs) screens available to assist in troubleshooting. Each screen will display SECM inputs and outputs 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.
Manual Override Screens 1 & 2 CAUTION There are two manual override screens available for the technician to test for failed components or to isolate problems during troubleshooting. Manual overrides can override normal system function regardless of engine state. Active, suspected and occurred faults are displayed on each override screen for quick reference along with the ability to clear all faults.
Switched Components To override a switched state component such as the LP lock-off, enter the desired ON/OFF (1=On, 0=Off) in the Manual Value box. Place your mouse pointer over the Override Select parameter box, then simply click the pull down arrow and select the Override option. The SECM will now be overridden and the manual value will be used to either turn on or turn off the component. The override select box will turn red when in manual override.
Manual Spark Advance To override the ignition spark advance place your mouse pointer over the Lock Spark Adv., parameter box, then simply click the pull down arrow and select the “Locked” option. Figure 17. Overriding Ignition Spark Advance Spark advance will be overridden and locked from the SECM. This locked spark advance value will be displayed in the (Degrees +/- TDC) box. Enter the desired spark advance in the Spark Offset box. This offset value will be added to the Spark (Degrees +/- TDC) value.
Manual Override Screen 2 CAUTION Components that can be overridden on override screen 2 include the Low Oil Pressure Switch, Transmission Temperature Switch, Ground Speed Switch, Spark Advance, and the Malfunction Indicator Light (MIL). Be aware of fuel flow and ignition when performing any manual override of a system component as engine damage may result. Figure 18.
SECM field update with Service Tool SECM controllers can be upgraded in the field using MotoUpdate software. Typically, MotoUpdate and MotoViewer applications are packaged together in the MotoService software application. Software upgrade files may be released to the field to enhance performance, provide additional features, and/or correct software problems. This document provides step-by-step instructions for upgrading a SECM using MotoUpdate software.
STEP 2 - CONNECT THE COMPUTER Prior to launching the MotoUpdate software, a valid Criptoken must be installed in one of the available USB ports 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.
The next screen will provide a list of all of the available software upgrades available for the current engine, based upon what update files have been placed in the “Update” directory (as shown in Step-1 above). Please note that during this process, the software must query the SECM for the current software version, and therefore, the computer must be connected to the SECM and the ignition key must be in the ON position. In general, it is usually best to see the latest revision (e.g.
STEP 4 - PROGRAM THE MODULE Once the desired upgrade is located and highlighted, select Next to upgrade ithe module. Highlight the upgrade option desired, then select Next Follow the on-screen instructions to complete the update process. Once the programming process begins, it must run to completion. If power is interrupted or the process fails, the SECM may be rendered unusable. Several update screens will provide a running status of the upgrade process, as shown below.
Ground Speed Limits (Option) The maximum allowable speed of Doosan forklifts is an optional feature that can be easily activated using the MotoView service tool. This feature is very useful to customers with indoor warehouse operations. Here’s how you can activate the speed-limiting feature. 1) Install Speed control option onto the trucks 2) Set the new speed limit using the MotoView Service tool, if required.
How to Set New Speed Limit Maximum RPM for both the NEUTRAL state (Normal) and IN-GEAR state (Speed Limiting) are configurable using the MotoView Service Tool. [Figure 2] Ground Speed Select Screen of the MotoView Service Tool [Figure 2] shows the Speed Limit screen of the MotoView service tool. The green boxes are configurable for both the NEUTRAL MAX RPM Setpoint and the IN-GEAR MAX RPM Setpoint. The pressure switch state is displayed at the bottom of the screen and labeled NEUTRAL SWITCH STATE.
The same principle is applied to LPG in a container, commonly referred to as an LPG tank or cylinder. Typically an LPG tank is not filled over 80% capacity allowing for a 20% vapor expansion space. Outside air temperature effect’s an LPG tank and must be considered when using an LPG system. (Figure 2) shows the relationship between pressure and temperature in a LPG tank at a steady state condition.
LPG Fuel Tanks Installing LPG Fuel Tanks The two styles of LPG storage containers available for industrial use and lift truck applications are portable universal cylinders and permanently mounted tanks. Portable universal cylinders are used primarily for off-highway vehicles and are constructed in accordance with the DOT-TC (United States Department of Transport – Transport Canada).
Fuel Gauge Service Valve In figure 5 a visual fuel gauge is used to show the fuel level in the tank. A mechanical float mechanism detects the liquid propane level. A magnet on the end of the float shaft moves a magnetic pointer in the fuel gauge. Some units have an electronic sending unit using a variable resistor, installed in place of a gauge for remote monitoring of the fuel level. The gauge may be changed with fuel in the tank.
Most liquid service valves have an internal hydrostatic relief valve and are usually labeled “LIQUID WITH INTERNAL RELIEF”. The hydrostatic relief valve protects the fuel service line between the tank and the lock off from over pressurization. The internal hydrostatic relief valve has a minimum opening pressure of 375 PSIG and a maximum pressure of 500 PSIG.
Regulatory Compliance WARNING—EXPLOSION HAZARD EPA / CARB Emissions Certification Do not connect or disconnect while circuit is live unless area is known to be non-hazardous. When properly applied and calibrated, ’s MI-07 control system is capable of meeting EPA 2007 LSI emission standards (40 CFR Part 1048.101) when operating properly with an approved three-way catalyst.
Abbreviations ACFM Actual cubic feet per minute at the specified suction conditions AFR Air fuel ratio BHP Brake horsepower Bi-Fuel Able to operate on either of two fuels CTS Coolant temperature sensor CNG Compressed natural gas Dual Fuel Able to run simultaneously on two fuels, e.g. diesel and natural gas. Often this term is incorrectly used to describe bi-fuel operation. Spark-ignited engines are typically bi-fuel while compression ignition engines are dual-fuel.
