Download Print this page

Doosan D20G Service Manual

Hide thumbs Also See for D20G:

Disassembly/assembly (87 pages)

,

Specifications systems operation testing & adjusting (74 pages)

Table Of Contents

Table of Contents

Advertisement

Quick Links

For use in service manual

form SB4317E

This form lists the contents of the complete Service Manual for this product.

The items listed with form numbers are available and included in this manual.

If form numbers are listed with mark(*), they are not available for the initial

release of the manual. When items are updated, or supplements are added,

they will be provided separately.

TITLE

Service Manual Contents

Safety

Torque Specifications

ENGINE

3.3 Liter (B3.3) Diesel Engine

4TNV98 & 4TNE98 Diesel Engine

G424F(FE) LP/Gasoline Engine

POWER TRAIN

Power Train

VEHICLE SYSTEM

Vehicle System

Vehicle System D & A

Hydraulic Schematic

Electric Schematic

OPERATION & MAINTENANC E

Operation & Maintenance Manual

Models ; D20G, D25G, D30G

G20G, G25G, G30G

SERVICE MANUAL CONTENTS

NOTICE

SB4318E00

Jan. 2008

FORM NUMBER

SB4318E00

SB2003E00

SB2004E00

SB4310E00

SB4319E00

SB4320E00

SB4218E01

SB4219E01

SB4220E01

SB4321E00

SB4322E00

SB2360E00

Table of Contents

Advertisement

Table of Contents

Need help?

Need help?

Do you have a question about the D20G and is the answer not in the manual?

Questions and answers

Summary of Contents for Doosan D20G

Page 1 SB4320E00 POWER TRAIN Power Train SB4218E01 VEHICLE SYSTEM Vehicle System SB4219E01 Vehicle System D & A SB4220E01 Hydraulic Schematic SB4321E00 Electric Schematic SB4322E00 OPERATION & MAINTENANC E Operation & Maintenance Manual SB2360E00 Models ; D20G, D25G, D30G G20G, G25G, G30G...
Page 3 WARNING The proper and safe lubrication and maintenance Do not operate this machine unless you have for this machine, recommended by DOOSAN, are read and understand the instructions in the outlined in the OPERATION & MAINTENANCE OPERATOR'S GUIDE. Improper machine GUIDE for this machine.
Page 4 Reinstall the wiring so it is not damaged nor will it can be hazardous to your health. Components in be damaged in operation by contacting sharp DOOSAN products that may contain asbestos corners, or by rubbing against some object or hot fibers are brake pads, brake band and lining surface.
Page 5 SB2004E00 D e c . 1 9 9 8 Specifications TORQUE SPECIFICATIONS...
Page 6 STANDARD TORQUE FOR METRIC FASTENERS NOTE : Take care to avoid mixing metric and inch dimensioned fasteners. Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possible injury. Exceptions to these torques are given in the Service Manual where needed.
Page 7 STANDARD TORQUE FOR INCH FASTENERS Exceptions to these torques are given in the Service Manual where needed. INCH NUTS AND BOLTS THREAD STANDARD TORQUE SIZE inch ± ± ± ± 5/16 18.0 ± ± ± ± 7/16 ± ± ± ±...
Page 8 O-RING FACE SEAL FITTINGS O-RING FACE SEAL FITTING O-RING GROOVE STRAIGHT THREAD O-RING PORT FITTING END O-RING FACE SEAL NUT O-RING IDAS001B STRAIGHT THREAD O-RING FITTING (FOR O-RING FACE SEAL FITTING ONLY) THREAD STANDARD TORQUE SIZE inch ± ± 15 lb 5/16-24 ±...
Page 9 FITTING INSTALLATION 1. Put locknut (3), backup washer (4) and O-ring seal HYDRAULIC LINE INSTALLATION (5) as far back on fitting body (2) as possible. Hold these components in this position. Turn the fitting 1. For a metal tube to hose installation, install the tube into the part it is used on until backup washer (4) just and tighten all bolts finger tight.
Page 10 FLARED AND STRAIGHT THREAD O-RING FITTINGS û O-RING SWIVEL NUTS FLARED û FITTING-PLUG IDAS004B û FLARED AND STRAIGHT THREAD O-RING FITTINGS (EXCEPT O-RING FACE SEAL FITTINGS) THREAD NOMINAL TUBE O.D. STANDARD TORQUE SIZE inch METRIC INCH ± ± 3.18 .125 5/16 ±...
Page 11 FLARED AND 45 INVERTED FLARE FITTINGS û û INVERTED FLARED FLARED û û IDAS007B û FLARED AND 45 û INVERTED FLARE FITTINGS THREAD NOMINAL TUBE O.D. STANDARD TORQUE SIZE inch METRIC INCH ± ± 3.18 .125 5/16 ± ± 4.76 .188 ±...
Page 12 AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS O-RING FLARE û IDAS010B AIR CONDITIONING FITTINGS û FLARE FITTING END O-RING FITTING END STEEL TUBES ALUMINUM TUBES THREAD SIZE STANDARD TORQUE STANDARD TORQUE STANDARD TORQUE inch ± ± ± ± ± ± 5/8-18 ±...
Page 13 SB4310E00 Jan. 2008 Service Manual B3.3 Diesel Engine D20S-5, D25S-5, D30S-5, D33S-5, D35C-5 D20S-3, D25S-3, D30S-3, D32S-3, D33S-3 D20G, D25G, D30G...
Page 15 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 17: Table Of Contents
Index Excessive Noise (Continued) ....... 45 Engine Vibration Excessive ........46 Introduction Complete Engine About the Manual............5 How to Use the Manual..........5 Complete Engine ............. 47 Symbols ..............6 Engine Disassembly ..........47 Illustrations..............7 Engine Assembly..........66 Engine Identification Engine System Engine Identification...........
Page 18 Lubricating Oil Suction Tube (Block-Mounted) ... 191 Cooling System............192 Coolant Thermostat ..........194 Coolant Thermostat Housing ......... 195 Cooling System............196 Cooling System Diagnostics ........199 Engine Compression..........205 Specifications Specifications............208 Valves, Valve Guides, and Springs ....208 Rocker Arm Shaft, Push Rod and Tappets..
Page 19: About The Manual
About the Manual This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related problems and to provide recommended repair procedures. The material in this manual covers all Signature engines. The manual is divided into sections. Each section is equivalent to a group used in Cummins filmcard system.
Page 20: Symbols
Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: WARNING – Serious personal injury or extensive property damage can result if the warning instructions are not followed.
Page 21: Illustrations
Illustrations Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. th8sesa The illustrations are intended to show repair or replacement procedures.
Page 22: Engine Identification
Engine Identification Engine Dataplate The engine dataplate shows specific information about the engine. The engine serial number (ESN) and control parts list (CPL) provide information for ordering parts and for service needs. NOTE: The engine dataplate must not be changed unless approved Cummins...
Page 23: Specifications
Specifications Performance All Models Rated Power kW(PS) 43.4 (59) @ 2,200 rpm Max Torque Nm(kgf-m) 202 (20.6) @ 1,600 rpm Torque Rising 7.4 % for 2,200rpm rating @Rated Power g/kWh 227 @2,200 rpm BSFC @Max Torque g/kWh 219 @1,600 rpm @Dynamo 2,500 ±25 Low Idle rpm...
Page 24: Engine Diagrams
Engine Diagrams Engine Views The following illustrations show the locations of the major external engine components, filters, and other service and maintenance points. Some external components will be at different locations for different engine models. Intake Side (Naturally Aspirated) 00900138 1.
Page 25 Exhaust Side (Naturally Aspirated) 00900139 1. Oil Fill Cap 4. Dipstick 2. Thermostat Housing 5. Oil Filter 3. Alternator 6. Exhaust Manifold. Diesel Engine Engine Identification...
Page 26 Front View (Naturally Aspirated) 00900140 Rear View (Naturally Aspirated) 00900141 Diesel Engine Engine Identification...
Page 27 Exhaust Side (Naturally Aspirated) 00900146 1. Oil Strainer 8. Camshaft 2. Oil Pump 9. Piston 3. Oil Cooler (Optional) 10. Intake and Exhaust Valve 4. Regulator Valve 11. Rocker Arm 5. Oil Filter 12. Timing Gear 6. Safety Valve 13. Cooling Water. 7.
Page 28 Oil Pump 00900148 1. Bushing 8. Regulator Valve 2. Gear Drive (number of teeth: 7) 9. Valve Spring. 3. Pump cover 4. Oil Pump Drive Gear (number of teeth: 22) Oil pump 5. Driveshaft • Type: Gear Type 6. Drivenshaft •...
Page 29 Fuel System 05900870 1. Fuel supply from tank 6. Fuel shutoff solenoid 2. Hand priming pump 7. High-pressure fuel line 3. Fuel filter 8. Injector 4. Water in fuel sensor 9. Fuel drain manifold 5. Fuel pump 10. Fuel return to tank. Diesel Engine Engine Identification...
Page 30 Fuel Injection Pump 00900150 1. Pump Holder A. Fuel Inlet (from Fuel Tank) 2. Fuel Injection Pump Drive Gear B. To. Fuel Tank (number of teeth: 52) C. To Fuel Injection Pump 3. Drive Shaft D. To Fuel Injection Nozzle. 4.
Page 31 Fuel Injection Nozzle 00900151 1. Fuel Drain Line Connector A. Fuel Inlet (from injection pump) 2. Nozzle Holder B. Fuel Injection (to cylinder) 3. Adjusting Shim C. Fuel Return (to fuel tank). 4. Nozzle spring 5. Spring seat Fuel Injection Nozzle 6.
Page 32 Cooling System 00900147 1. Radiator 6. Cylinder Head 2. Thermostat 7. Piston 3. Water Temperature Gauge 8. Cylinder Block 4. Water Pump 9. Oil Cooler (optional). 5. Water Manifold A. From Oil Pump (oil). Diesel Engine Engine Identification...
Page 33 Air Intake System 00900227 1. Filtered Air 2. Air Heater 3. Intake Manifold 4. Intake Valve Port. Diesel Engine Engine Identification...
Page 34 Exhaust System 00900232 1. Exhaust Valve Port 2. Exhaust Manifold Diesel Engine Engine Identification...
Page 35: Troubleshooting Symptoms
Troubleshooting Symptoms Procedures and Techniques A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known about a complaint, the faster and easier the problem can be solved. The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and most logical things first.
Page 36: Engine Acceleration Or Response Poor
Engine Acceleration or Response Poor This is symptom tree T-033 Cause Correction Fill the supply tank. Refer to the OEM service Fuel level is low in the tank manual. Check vehicle brakes dragging, Vehicle parasitics are excessive transmission malfunction, cooling fan operation cycle time, and engine-driven units.
Page 37 Engine Acceleration or Response Poor (Continued) Correction Cause Exhaust system restriction is above Check the exhaust system for restriction. specification Perform a pop test on the injector(s). Injector is malfunctioning Correction Fuel grade is not correct for the application or Operate the engine from a tank of high-quality the fuel quality is poor.
Page 38: Engine Will Not Crank Or Cranks Slowly
Engine Will Not Crank or Cranks Slowly This is symptom tree T-078. Cause Correction Battery cables or connections are loose, Check the battery cables and connections. broken, or corroded (excessive resistance) Battery cables are not the correct gauge or Replace the battery cables with larger gauge or length shorter length cables.
Page 39 Engine Will Not Crank or Cranks Slowly (Continued) Cause Correction Check level. Verify dipstick Lubricating oil level is above specification calibration and oil pan capacity. Fill the system to the specified level. Analyze the oil and inspect the filters to locate Internal engine damage an area of probable damage.
Page 40 Engine Cranks But Will Not Start (No Exhaust Smoke) This is symptom tree T-003. Cause Correction Fuel level low in the tank Fill the supply tank. Improper fuel is being used Drain fuel and replace with correct fuel. Clogged fuel tank air breather hole Clean the fuel tank breather.
Page 41 Engine Difficult to Start or Will Not Start (Exhaust Smoke) This is symptom tree T-004. Cause Correction Starting aid malfunctioning or heater mount Replace the starting aid. Does not become warm Crank speed is too slow (minimum crank Verify drive units are not engaged. Check the Speed: 150 rpm) Battery and recharge or replace.
Page 42: Engine Difficult To Start Or Will Not Start Exhaust Smoke) (Continued)
Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued) Cause Correction Overhead adjustments are not correct Measure and adjust the overhead settings. Inspect the rocker levers, rocker shafs, and Overhead components are damaged valve for excessive damage. Replace as necessary.
Page 43: Engine Has Poor Respones
Engine Has Poor Respones This is symptom tree T-005. Cause Correction Clogged air cleaner element Clean or replace the air cleaner element Clogged fuel tank air breather hole Clean the fuel tank breather. Clogged prefilter Clean or replace the fuel filter or strainer. Clogged fuel filter or strainer Clean and repair the fuel piping Clogged or leaking fuel piping...
Page 44: Engine Stops During Operation
Engine Stops During Operation This is symptom tree T-006. Cause Correction Chassis powertrain is damaged or overloaded Refer to the OEM’s service manuals. Fuel level low in the tank Fill the supply tank. Clogged fuel tank air breather hole Clean the fuel tank breather. Clogged prefilter Clean the prefilter.
Page 45: Engine Runs Rough Or Misfires
Engine Runs Rough or Misfires This is symptom tree T-007. Cause Correction Fuel level low in the tank Fill the supply tank. Clogged fuel tank air breather hole Clean the fuel tank breather. Low idle speed is adjusted too low Adjust the low idle speed.
Page 46: Engine Power Output Low
Engine Power Output Low This is symptom tree T-008. Cause Correction Improper fuel is being used Drain and replace the fuel with the correct fuel. Clogged air cleaner element Clean or replace the air cleaner element. Clogged fuel tank air breather hole Clean the fuel tank breather.
Page 47: Engine Power Output Low (Continued)
Engine Power Output Low (Continued) Cause Correction Defective contact of valve or seat Replace the cylinder head. Resulting in low compression Replace the defective or clogged injection Defective or clogged injection nozzle nozzle. Injection pump is malfunctioning Replace the injection pump. Worn piston ring or cylinder resulting in low Replace the worn piston ring or cylinder.
Page 48: Excessive Exhaust (Black Smoke)
Excessive Exhaust (Black Smoke) This is symptom tree T-009. Cause Correction Check for added loading from malfunctioning accessories or driven units, brakes dragging, Engine is overloaded and other changes in vehicle, vessel, or equipment loading. Inspect the air cleaner element. Replace as Plugged air filter needed.
Page 49: Excessive Exhaust (White Smoke)
Excessive Exhaust (White Smoke) This is symptom tree T-009. Cause Correction Verify the correct starting procedure. Refer to Starting procedure is not correct Procedure (Normal Starting Procedure) in the Operation and Maintenance Manual. Coolant temperature is below specification or Check the air heater or warm the coolant water the intake manifold air temperature is below by heater core.
Page 50: Lubricating Oil Consumption Excessive
Lubricating Oil Consumption Excessive This is symptom tree T-010. Cause Correction Inspect the engine the external oil leaks. Lubricating oil leak (external) Tighten the capscrews, pipe plugs, and fittings. Replace the gaskets if necessary. Intake system is contaminated with dust Remove and clean intake manifold.
Page 51: Lubricating Oil Contaminated
Lubricating Oil Contaminated This is symptom tree T-011. Cause Correction Breather or breather hose is clogged Clean the breather and breather hose. Lubricating oil filter is clogged Replace the filter. Refer to Exhaust Gas Is Black (Incomplete Exhaust gas is black Combustion).
Page 52: Fuel Consumption Is Excessive
Fuel consumption Is Excessive This is symptom tree T-012. Cause Correction Check and repair the accessories. Refer to the Overloading from malfunctioning accessories OEM’s service manuals. Refer to the operation and maintenance manual Operator technique is not correct for proper operating speeds and loads. Check the fuel lines, fuel connections, and fuel filters for leaks.
Page 53: Coolant Contamination
Coolant Contamination This is symptom tree T-013. Cause Correction Review the coolant change interval. Drain and Coolant is rusty flush the system. Fill the system with the Correct mixture of coolant and water. Lubricating oil cooler for powertrain is damaged Refer to the OEM’s service manual.
Page 54: Coolant Loss
Coolant Loss This is symptom tree T-013.1 Cause Correction Inspect the radiator heater, hoses, and connection to locate the leak. If oil is present in Radiator or cab heater is leaking the coolant, check for a transmission or lubricating oil cooler leak. Inspect the engine and components for seal, External engine leak gasket, or drain cock leaks.
Page 55: Lubricating Oil Pressure Is Low
Lubricating Oil Pressure Is Low This is symptom tree T-014. Cause Correction Check the oil level. Verify the dipstick Lubricating oil lever is below specification calibration and the oil pan capacity. Fill the system to the specified level. Oil level or pressure sensor is damaged Replace the oil lever or oil pressure sensor.
Page 56: Oil Level Rises
Oil Level Rises This is symptom tree T-015. Cause Correction Rear crankshaft seal or seal surface is Repair or replace seal and surface damaged Replace the auxiliary pump. Refer to the OEM’s Auxiliary equipment has damaged pump seal service manual. Injector sleeve is damaged Replace the injector sleeve.
Page 57: Coolant Temperature Above Normal
Coolant Temperature above Normal This is symptom tree T-016. Cause Correction Inspect the engine and radiator for external Coolant level is below specification coolant leaks. Fan belt is slipping or the fan pulley is worn Replace the fan belt or pulley. Water temperature gauge is malfunctioning Replace the water temperature gauge.
Page 58: Excessive Noise
Excessive Noise This is symptom tree T-017. Cause Correction Belt is squeaking due to insufficient tension or Check and adjust belt tension. Make sure all the abnormally high loading pulleys rotate freely. Refer to Exhaust Gas is Black troubleshooting Exhaust leaks tree.
Page 59: Excessive Noise (Continued)
Excessive Noise (Continued) Cause Correction Injection pump is adjusted incorrectly Adjust or replace the injection pump. Worn piston ring or cylinder resulting in low Replace the worn piston ring or cylinder. compression Diesel Engine Troubleshooting Symptoms...
Page 60: Engine Vibration Excessive
Engine Vibration Excessive This is symptom tree T-018. Cause Correction Engine mounting bolts are loose or the engine Replace the engine mounting bolts or cushion. mounting cushion is broken Repair the alignment. Refer to the OEM’s Engine and powertrain is out of alignment service manual.
Page 61: Complete Engine
Complete Engine Engine Disassembly Service Tool Part No. Part Name Quantity 3375193 Unit Repair Stand or Engine Overhaul Stand 3375194 3163625 Bracket 3163292 Valve Spring Compressor 3397890 Flange Puller 3823137 Piston Ring Expansion Tool Engine Removal NOTE: Put tag on all hoses, lines, linkage, and electrical connections as they are removed to identify location and aid the installation process.
Page 62 WARNING Some state and federal agencies in the United States of America have determined that used oil is carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. Always use the proper procedures to dispose of the oil.
Page 63 Remove all chassis components necessary to remove the engine from the equipment. ra400ha Prepare a stable stand, Part No. 3375193 or 3375194, which will prevent the engine from falling over. Engine Weight (approx.): 255 kg [562 lb] 00900154 Remove the starting motor. 00900156 Install the bracket, Part No.
Page 64 WARNING This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift this component. The engine lifting equipment must be designed to lift the engine without causing personal injury. Put the engine on the stand. 00900208 Cover all the engine openings to prevent dirt and debris from entering the engine.
Page 65 Alternator Remove the adjusting capscrew and washer. Remove the capscrew, adjustment plate, and spacer. Remove the remaining capscrew and alternator. 00900159 Lubricating Oil Filter Remove the lubricating oil filter. 00900155 Dipstick Guide Remove the dipstick and dipstick guide. 00900160 Water Pump Remove the mounting capscrews, water pump, gasket, and o-ring.
Page 66 Thermostat Remove the two mounting capscrews, thermostat housing, thermostat and seal. 18900025 Exhaust Manifold Remove the eight capscrews, exhaust manifold, and gasket. Discard the gasket. 00900162 Fuel Injection Tubing Remove the clamp. Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head.
Page 67 Spill Tube Remove the spring hose clamps and hose. Remove the spill tube. 00900166 Injector CAUTION Be careful not to damage the tip of the injector when removing. Remove the mounting capscrew, washer, and injector. NOTE: When removing the injector, clean around 00900167 the injector, and insert a blind plug to prevent dust or dirt from entering the engine.
Page 68 00900251 Rocker Arm Assembly 1. Rocker Shaft 7. Cup Plug 2. Adjusting Screw Lock Nut 8. Snap Ring 3. Pedestal Mounting Capscrews 9. Thrust Washer (if equipped) 4. Separating Spring 10. Rocker Lever Pedestal 5. Rocker Shaft Indexing Screw 11. Rocker Lever 6.
Page 69 Pushrods Remove the pushrods from the cylinder head. NOTE: Mark the pushrods with tags showing the cylinder number, and keep it in a safe place. If there is no abnormality in the push rod, install it in the same position during assembly.
Page 70 Raise the cylinder head, and remove the valve. NOTE: Mark the valves with tags to show the place of installation and keep in a safe place. 00900174 Fuel Injection Pump, Rotary CAUTION Do not drop the nut, washer, or key. Failure to do so will result in the need to remove the front gear cover.
Page 71 Lubricating Oil Pan Remove the 24 capscrews, lubricating oil pan, and gasket. Discard the gasket. 00900178 Lubricating Oil Suction Tube Remove the two mounting capscrews, lubricating oil suction tube, and o-ring. Discard the o-ring. 00900179 Crankshaft Pulley Remove the capscrew and mounting plate. 00900180 Remove the crankshaft pulley using flange puller, Part No.
Page 72 Gear Housing Cover Remove the 17 capscrews and the gear housing cover. 00900181 NOTE: A noise damper is installed on some engines. The noise damper must be removed prior to removing the front oil seal. Remove the front oil seal from the gear housing cover. 00900182 Lubricating Oil Pump Remove the five capscrews and the lubricating oil...
Page 73 Camshaft Assembly Remove the two mounting capscrews through the casting holes in the camshaft gear. 00900185 Remove the thrust plate and camshaft assembly. NOTE: When removing the camshaft, lightly rotate the shaft while being careful not to damage the bushing. 00900186 Flywheel WARNING...
Page 74 Flywheel Housing WARNING This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift this component. Remove the nine capscrews, rear oil seal, and flywheel housing. 00900188 Remove the rear oil seal. 00900189 Block Water Heater NOTE:...
Page 75 Piston, Connecting Rod Assembly Remove Rotate the crankshaft with an engine barring tool until the pistons are below the carbon deposits, which are found above the ring travel area. pi900we CAUTION Do not use emery cloth or sandpaper to remove carbon from the cylinder bores.
Page 76 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury CAUTION Do not use the steel wire wheel in the piston travel area. Operate the wheel in a circular motion ck9breg to remove the deposits.
Page 77 NOTE: Do not remove the capscrews from the connecting rods at this time. Loosen the connecting rod capscrews. Use a rubber hammer to hit the connecting rod capscrews to loosen the caps. 01d00094 Remove the connecting rod capscrews. Remove the connecting rod cap. 01d00095 Remove the lower connecting rod bearing.
Page 78 The piston and connecting rod assemblies must be installed in the same cylinder number from which they were removed, to provide proper fit of worn mating surfaces, if parts are reused. Use a tag to mark the cylinder number from which each piston and rod assembly were removed.
Page 79 Crankshaft CAUTION Be careful not to hit the crankshaft against the cylinder block and damage the sliding surface. Remove the crankshaft. 00900204 Remove the upper main bearing. NOTE: Mark the main bearings and thrust bearing so that they can be installed into the correct position.
Page 80: Engine Assembly
Engine Assembly Service Tools Part No. Part Name Quantity 3375193 Unit Repair Stand or Engine Overhaul Stand 3375194 3163625 Bracket 3163292 Valve Spring Compressor 3823137 Piston Ring Expansion Tool 3397773 Piston Ring Compressor Setting the Unit in the Repair Stand Install bracket, Part No.
Page 81 Tappet NOTE: Rotate the engine block so that the cylinder head side is down. Coat the tappet with engine oil and install into the block. 00900215 Crankshaft CAUTION Confirm that there is no dirt or dust stuck to the rear face of the bearing before installation. Debris behind the bearing can cause severe engine damage.
Page 82 Main Bearing Cap CAUTION Confirm that there is no dirt or dust stuck to the rear face of the bearing before installation. Debris behind the bearing can cause severe engine damage. NOTE: Coat the inside face of the bearing with engine oil (SAE 30) before installation.
Page 83 Tighten the mounting capscrews in the order shown. Torque Value: Main Bearing Capscrews Step 1 113 N•m [83 ft-lb] 2 Loosen capscrews completely 3 132 N•m [98 ft-lb] 00900220 After tightening the mounting capscrews, make sure the crankshaft rotates smoothly 00900222 Measure the crankshaft end play using a dial indicator.
Page 84 Piston, and Connecting Rod Assembly When rebuilding an engine with the original cylinder block, crankshaft, and pistons, make sure the pistons are installed in their original cylinders. If replacing the piston(s), make sure the replacement piston(s) are the same grade as the original piston(s). If a new cylinder block or crankshaft is used, the piston grading procedure must be performed to determine the proper piston grade for each cylinder.
Page 85 Immerse the pistons in clean 15W-40 engine lubricating oil until the rings are covered. Allow the excess oil to drip off the assembly. pi800hd Position the rings so that the ring gaps are 120 degrees apart. pi9rihb CAUTION If using a strap type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring.
Page 86 Position the connecting rod journal for the piston to be installed to bottom dead center (BDC). 00900231 Take care to not damage the cylinder wall when inserting the connecting rod. Carefully push the piston into the bore while guiding the connecting rod to the crankshaft journal. cx900ld Lubricate threads...
Page 87 measure clearance between connecting rod cap and crankshaft. Measure the side clearance between the connecting rod and crankshaft. Connecting Rod Cap Side Clearance 0.20 0.0079 0.40 0.0160 cx900tb CAUTION To reduce the possibility of engine damage, the crankshaft must rotate freely. CAUTION If the connecting rod is not properly oriented (tang opposite the camshaft), it will contact the...
Page 88 CAUTION Make sure there is no Loctite in the oil hole, or severe engine damage can occur. Use extreme care not to apply Loctite to the oil hole in the camshaft bushing. 01900263 Use a small camshaft bushing driver set, Part Number 3823942, or equivalent, to install the camshaft bushing even with the front face of the cylinder block.
Page 89 Camshaft Install NOTE: When installing the camshaft, rotate the camshaft slightly while being careful not to damage the bushing. Install the thrust plate, camshaft assembly, and two capscrews. Tighten the capscrews through the casting holes in 00900238 the camshaft gear. Torque Value: 19 N•m [14 ft-lb] Measure the end play of the camshaft.
Page 90 Measure the end play of the idler gear. 00900243 Position the fuel injection pump assembly temporarily. Measure the backlash of each gear with a dial indicator, 3376050, or equivalent. 00900244 Match mark alignment: Naturally Aspirated Crankshaft gear 0.08 mm to 0.19 mm and idler gear [0.0031 in to 0.007 in] Camshaft gear...
Page 91 Fly Wheel Housing NOTE: Make sure the crankshaft oil seal is not damaged during installation. Lubricate the crankshaft oil seal with Lubriplate™ 105, or equivalent. Install the crankshaft oil seal into the flywheel housing. Inspect the rear face of the cylinder block and flywheel housing mounting surface for cleanliness 00900188 and raised nicks or burrs.
Page 92 Tighten the mounting capscrews in the sequence shown in the illustration. Torque Value: Step 1 108 N•m [80ft-lb] Step 2 191 N•m [141ft-lb] 16900117 Oil Pump Install the lubricating oil pump and five capscrews. Tighten the capscrews. 00900183 Torque Value: 19 N•m [14 ft-lb] Measure the end play of the lubricating oil pump drive gear.
Page 93 CAUTION Do not apply excessive force to the seal lip surface when aligning and installing the gear housing cover. Damage to the engine will occur if the seal is damaged. NOTE: Apply gasket sealant, Part No. 3823494, to the gear housing cover mounting surface. Install the gear housing cover and 17 capscrews.
Page 94 Lubricating Oil Pan NOTE: Apply a 1-mm [0.039-in] bead of gasket sealant, Part No. 3823494, to the mounting surface of the lubricating oil pan. Install a new gasket, lubricating oil pan, and 24 capscrews. Tighten the capscrews. Torque Value: 32 N•m [24 ft-lb] If the oil drain plug was removed, install the drain plug.
Page 95 Install the fuel injection pump washer and nut. Tighten the nut. Torque Value: 70 N•m [52 ft-lb] Refer to the rotary fuel injection timing in this procedure to make sure the fuel pump is timed correctly. ip9nuhb Tighten the fuel injection pump mounting capscrews. Torque Value: 31 N•m [23 ft-lb] Install the mounting bracket capscrews.
Page 96 Install the valve spring and spring seat on the valve stem. 00900173 Install the valve cotter into the valve stem groove while compressing the valve spring with spring pusher, Part No. 3398179. 00900172 After releasing the valve spring, tap the top of the valve stem with a plastic hammer to make certain the cotter is completely fitted.
Page 97 WARNING This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift this component. NOTE: Coat the capscrew threads with antifriction compound, Part No. 3824879. Install the cylinder head using four head capscrews as guides.
Page 98 00900251 Rocker Arm Assembly 1. Rocker Shaft 7. Cup Plug 2. Adjusting Screw Lock Nut 8. Snap Ring 3. Pedestal Mounting Capscrews 9. Thrust Washer (only used on some engines) 4. Separating Spring 10. Rocker Lever Pedestal 5. Rocker Shaft Indexing Screw 11.
Page 99 Adjusting Valve Clearance Adjust the valve clearance. Refer to Section 14. 03900077 Rocker Lever Cover Install the o-ring into the rocker lever cover. Install the rocker lever cover, three capscrews, and isolator assemblies. Tighten the capscrews. Torque Value: 9 N•m [7 ft-lb] 03900075 Injector Coat the injectors with anti-sieze compound, Part No.
Page 100 Spill Tube Install the spill tube. 00900166 Intake Manifold NOTE: Apply a 1-mm [0.039-in] bead of gasket sealant, Part No. 3823494, to the mounting surface of the intake manifold. Install the air inlet connection, intake manifold, and seven capscrews. Tighten the capscrews. Torque Value: 40 N•m [30 ft-lb] 00900164 Fuel Injection Tubing...
Page 101 Thermostat Install seal, thermostat, thermostat housing, and two mounting capscrews. Tighten the capscrews. Torque Value: 19 N•m [14 ft-lb] 18900025 Water Pump Install the o-ring, gasket, water pump, and mounting capscrews. Tighten the capscrews. Torque Value: 19 N•m [14 ft-lb] 00900161 Dipstick NOTE:...
Page 102 Block Water Heater Clean the core plug hole thoroughly. Make sure there are not burrs or sharp edges that might cut the o-ring. cs9pxea Lubricate the new heater o-ring with clean engine oil. cs9orwa The locking channel (T-Bar) should be threaded out to the end of the bolt.
Page 103 Hook the other leg of the channel in the hole and push the heater into the hole as far as possible by hand. cs900wi CAUTION Do not pull the heater into location with the locking bolt as the channel (T-Bar) can bend or cause the threads to strip.
Page 104 Alternator Install the alternator and capscrew. Install spacer, mounting capscrew, adjustment plate. Loosely install the washer and adjustment capscrew. 00900159 Fan Pulley Install the fan pulley. 00900255 Position the fan belt (2) into the fan pulley groove, and loosely tighten the adjustment capscrew (1). 00900158 Diesel Engine Complete Engine...
Page 105 WARNING Be careful not to injure your fingers or damage the alternator when adjusting the belt tension. Insert a bar or pipe between the alternator and the cylinder block. Raise the alternator to adjust the fan tension. NOTE: The belt must deflect 7 mm to 10 mm [0.28 in to 0.39 in] when pushed with finger- pressure of 6 kg [13 lb] at a point midway 00900257...
Page 106 WARNING This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift this component. The engine lifting equipment must be designed to lift the engine without causing personal injury. Engine Weight (approx.) 330 kg [660 lb] Remove the engine from the stand.
Page 107 Connect the drive units to the flywheel housing and flywheel. tr400wa Connect the intake and exhaust system pipes. oi400ha Connect the starter cable, engine ground straps, cab or chassis to engine hoses, tubing, electrical wires, and hydraulic lines. WARNING Always connect the negative (-) cable last. Connect the battery cables.
Page 108 WARNING Coolant is toxic. Keep away from children and animals. Save for reuse or dispose of in accordance with local regulations. Fill the engine with engine coolant. ra800wn NOTE: Remove all tags that were put on all hoses, lines, linkage, and electrical connections as they were removed to identify location during the removal process.
Page 109: Engine System
Engine System Bearing, Connecting Rod Normally, worn bearings can be detected by reduced oil pressure, but if this wear goes undetected, the excessive clearance will increase the impact between the bearing and crankshaft, causing a distinct knocking sound. cx9beva A connecting rod noise occurs when the engine is not loaded.
Page 110 Remove connecting capscrews connecting rod caps. cx9csma Remove the lower bearing shell from the connecting rod cap, and mark it with the letter L (lower) and the cylinder number from which it was removed. cx9begc Push the connecting rod away from the crankshaft to allow the upper bearing shell to be removed.
Page 111 WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recom- mendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING cx9beecf Some solvents are flammable and toxic. Read the manufacturer's instructions before using. WARNING Wear appropriate eye and face protection when using compressed air.
Page 112 Inspect the bearing shell seating surface for nicks or burrs. If nicks or burrs can not be removed with an abrasive pad, Part Number 3823258, or equivalent, the bearings must be replaced. If the bearings are damaged, they must be replaced as a set.
Page 113 NOTE: Bearing shells are identified by steel- stamped characters on the back of the bearings to indicate either standard (STD) or oversize (OS). A crankshaft that is machined undersize on the connecting rod or main bearing journals is marked on the front counterweight.
Page 114: Bearing, Main
Bearing, Main NOTE: The end play measurement is necessary for determining the wear of the thrust bearing and abnormal wear of the crankshaft. Measure the crankshaft end play using a dial indicator, Part Number 3824564, or equivalent, and magnetic base, Part Number 3377399, or equivalent. Crankshaft End Play 0.131 0.0052...
Page 115 WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recom- mendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING mb200gb Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause bodily injury.
Page 116 NOTE: If the crankshaft journals or main caps are damaged, the engine will need to be removed to complete the overhaul. Inspect the crankshaft journals for deep scratches, indications of overheating, and other damage. ks9bdsb CAUTION Confirm that there is no dirt or dust stuck to the rear face of the bearing before installation.
Page 117 CAUTION Install each thrust bearing with the oil groove on the outside. Failure to do so will cause engine damage. WARNING Do not let the thrust bearings slip out of place. 00900219 Engine damage will result if the thrust bearings are not properly installed.
Page 118 NOTE: Mark the lower main bearings and the two lower thrust bearings so that they can be installed in the correct position. Remove the upper thrust bearing. 00900205 Diesel Engine Engine System...
Page 119: Bearing, Thrust
Bearing, Thrust WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recom- mendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING mb200gb Wear appropriate eye and face protection when using compressed air.
Page 120 Inspect the crankshaft journals for deep scratches, indications of overheating, and other damage. Replace the crankshaft if excessive damage is found. ks9bdsb Determine the size of the thrust bearings removed, and obtain the same size for installation. Refer to Part Reuse Guidelines for the dimensions of the standard and undersize main bearing journals.
Page 121: Camshaft
Camshaft Remove the two mounting capscrews through the casting holes in the camshaft gear. 00900185 WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recom-...
Page 122 NOTE: When a new camshaft is installed; new tappets and push tubes must be installed also. Inspect the bearing journals for cracking, pitting, or scoring. Contact a Cummins Authorized Repair Location for pitting reuse criteria. cg9shsb Inspect the camshaft gear teeth for pitting. Inspect for cracks at the roots of the teeth.
Page 123 Measure the bend (1) of the camshaft. Bend of Camshaft 0.03 0.0012 Measure the camshaft lobe height (2) and thrust clearance (3). Camshaft Lobe Height Valves Standard MIN Repair Limits MAX 01900247 Intake 42.69 mm 42.20 mm [1.681 in] [1.661 in] Exhaust 43.04 mm 42.50 mm...
Page 124: Camshaft Bushings
Camshaft Bushings Initial Check Inspect the camshaft bore for damage and excessive wear. 01900259 Measure the camshaft bore. Camshaft Bore Diameter 53.53 2.107 01900260 Use a small bushing driver set, Part Number 3823942, or equivalent, to remove the camshaft bushing from the number 1 camshaft bore.
Page 125 Apply Loctite primer to the outside diameter of the camshaft bushing and the inside of the camshaft bore of the cylinder block. Allow the primer to dry. Apply a bead of Loctite 609, or equivalent, to 270 degrees along the edge of the bushing that will be installed toward the rear of the cylinder block.
Page 126: Camshaft Gear
Measure the installed camshaft bushing (1). Camshaft Bushing Bore Inside Diameter 50.50 1.988 53.60 1.992 01900265 Camshaft Gear WARNING When using solvents, acid, or alkaline materials cleaning, follow manufacturer's recommendations for use. Wear goggles and protective clothing to avoid personal injury. WARNING Wear appropriate eye and face protection when cg9geea...
Page 127: Connecting Rod
Connecting Rod CAUTION Prevent damage to the capscrews. Nicks in the body of the capscrew can cause an area of stress that can fail during engine operation. Damage to the threads will cause torque values to be incorrect and will damage the mating parts. bp8csba WARNING When using a steam cleaner, wear safety glasses...
Page 128 CAUTION Repair of rolled threads by use of a thread die is not recommended. The die can create a sharp corner on the minor diameter (root) of the threads. This sharp corner can cause an area of increased stress. Inspect the capscrews for the following: •...
Page 129 Inspect the connecting rod piston pin bushing for damage. Replace any connecting rod piston pin bushing that has evidence of scoring, galling, or scuffing. Replace any bushing that has turned in the bore. Special tools and precision machining are required to replace bushings.
Page 130 Measure the connecting rod crankshaft bore inside diameter with a bore dial indicator. Connecting Rod Crankshaft Bore Inside Diameter 61.00 2.402 61.025 2.403 If the connecting rod crankshaft bore inside diameter is not within specifications, the connecting rod must cx1brtc be replaced.
Page 131 Use the residual method. Apply coil shot amperage. Amperage (Ampere Turns) Minimum Maximum 2600 amperage direct 2800 amperage direct current current Ampere turn is an electrical current of one ampere flowing through the coil, multiplied by the number of turns in the coil. 01400343 Check for cracks.
Page 132 This procedure describes the magnetic particle inspection for connecting rod capscrews. bp8csse Use a Magnaflux or similar magnetic particle testing machine. Use the continuous method. Apply a head shot of 300 to 400 amperes direct current or rectified alternating current. bp8cssb Use an ultraviolet light.
Page 133 Use an ultraviolet light. Check for indications of cracks. Any indications of cracks are not acceptable. bp8cssc WARNING When using solvents, acids or alkaline materials cleaning, follow manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Page 134: Crankshaft
Crankshaft WARNING This assembly weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this assembly. CAUTION Be careful not to hit the crankshaft against the cylinder block and damage the sliding surface. 00900204 Remove the main bearings.
Page 135 Measure the front and rear oil seal contact areas for a wear groove. Crankshaft Front and Rear Oil Seal Wear Groove 0.25 0.010 If the wear groove exceeds the specification, replace the crankshaft. ks8seta Inspect the crankshaft connecting rod and main journals for deep scoring, overheating, or other damage.
Page 136 Measure the main journal (2). Connecting Rod Bearing Journal Diameter Standard 69.86 2.750 70.00 2.756 0.25mm 69.61 2.741 01900249 69.75 2.746 0.50mm 69.36 2.731 69.50 2.736 0.75mm 69.11 2.721 69.25 2.726 1.00mm 68.86 2.711 69.00 2.717 Bearing Clearance (2) = Main bearing inside diameter with bearing installed minus crankshaft journal diameter.
Page 137 Measure the clearance of the crankshaft pin journal Measurements Bearing 0.0011 0.029 to 0.089 Clearance to 0.0035 Check the roundness (3) of the connecting rod crankshaft pin journal. Connecting Rod Crankshaft Pin Journal 01900249 Out-of- 0.020 MAX 0.0008 Roundness Measure the bend of the crankshaft (4). Measurements Crankshaft 0.09...
Page 138 NOTE: The crankshaft must rotate freely by hand. 02900058 Diesel Engine Engine System...
Page 139: Crankshaft Gear, Front
Crankshaft Gear, Front NOTE: If there is damage to the front crankshaft gear teeth or there are signs of excessive heat, make sure to inspect the associated idler gear for damage. Inspect the crankshaft gear teeth for discolorations or signs of excessive heat (bluing). Inspect for cracks and broken or chipped teeth.
Page 140: Crankshaft Pulley
Crankshaft Pulley Remove the capscrew and mounting plate. Use a standard puller, Part Number ST 647, or equivalent, to remove the crankshaft pulley. 00900180 WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.
Page 141 Inspect the pulley for cracks, excessive wear in the belt grooves, or other damage. Inspect the mating surface and pulley bore areas for damage. da2pusa Align the crankshaft pulley with the crankshaft key. Install the crankshaft pulley, mounting plate, and capscrew.
Page 142: Crankshaft Seal, Front
Crankshaft Seal, Front NOTE: A noise dampener is installed on some engines. The noise dampener must be removed prior removing front crankshaft seal. Use a pry bar or suitable tool to remove the front crankshaft seal from the front gear cover. 00900182 Clean the gear cover seal bore and crankshaft surface of all oil, dirt, and seal residue.
Page 143: Crankshaft Seal, Rear
Crankshaft Seal, Rear Use a pry bar or suitable tool to remove the rear crankshaft seal. 00900189 CAUTION The seal lip and the sealing surface on the crankshaft must be free from all residue to reduce the possibility of seal leaks. Clean and dry the rear crankshaft sealing surface.
Page 144: Cylinder Block
Cylinder Block Diagnosis of cylinder block cooling and lubrication malfunctions has been discussed in those respective sections. The potential problems with the cylinder, the camshaft bore, and the crankshaft main journals are discussed in this section. ck900kb Malfunctions of the cylinder block, such as leaks or tappet bore wear, require a visual or dimensional inspection to isolate the problem.
Page 145 The head surface of the block is also critical to sealing the cylinder bores. Inspect the surface carefully during repair before assembly. ck900wf Use a strong solution of hot water and laundry detergent to clean the cylinder bores. ck9breh WARNING Wear appropriate eye and face protection when using compressed air.
Page 146 NOTE: Make sure to remove the tape covering the tappet and lubricating oil holes after the cleaning process is complete. Check the cylinder bore cleanliness by wiping with a white, lint-free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all residue is removed.
Page 147 Measure the surface flatness (1)(warpage limit). Surface Flatness Standard Repair Limit 0.00 to 0.08 mm 0.15 mm [0.006 in] [0.00 to 0.003 in] Measure the inner diameter of the main bearing (2). Inner Diameter of Main Bearing (Bearing Installed) 01900252 Standard 70.00 2.756...
Page 148: Gear Cover, Front
Gear Cover, Front Remove the 17 capscrews, front gear cover, cover plate, and gasket. Discard the gasket. 00900181 WARNING When using solvents, acids, or alkaline materials cleaning, follow manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Page 149 CAUTION Apply gasket sealant, Part Number 3164067, or equivalent, to the gear cover mounting surface. Install the new gasket, gear cover, and 17 capscrews. Tighten the capscrews. Torque Value: 19n.m [14 ft-lb ] 00900181 Diesel Engine Engine System...
Page 150: Idle Gear, Camshaft
Idle Gear, Camshaft NOTE: If a PTO accessory drive is used on the engine, the idler gear uses two bearings. Remove the capscrew, plate, shim, and front bearing. Remove the idler gear, rear spacer plate, rear bearing, and idler shaft. 01900258 WARNING When using solvents, acid, or alkaline materials...
Page 151 NOTE: If the burrs or raised material can not be removed with an abrasive pad, or equivalent, the camshaft idler gear shaft must be replaced. Inspect the idler shaft nose for burrs. Always connect the negative (-) cable last. Connect the battery cables. cg900sj Align the match marks on the idler gear, crankshaft gear, and camshaft gear.
Page 152 Position the fuel injection pump assembly temporarily. Measure the backlash of each gear with a dial indicator, 3376050, or equivalent. 00900244 Diesel Engine Engine System...
Page 153: Piston
Piston WARNING When using solvents, acids, or alkaline materials cleaning, follow manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING pi900ec Some solvents are flammable and toxic. Read the manufacturer's instructions before using. CAUTION Do not use the bead-blast method to clean the piston.
Page 154 CAUTION Do not use a ring groove cleaner and make sure not to scratch the ring sealing surface in the piston groove. Clean the remaining deposits from the ring grooves with the square end of a broken ring. pi900ee WARNING Wear appropriate eye and face protection when using compressed air.
Page 155 Measure the pin bore. NOTE: Measure the pin bore in the center area of the bore. The bore profile is tapered on the edges and will result in a measurement error. Piston Pin Bore Diameter 30.00 1.181 pi9brtc Diesel Engine Engine System...
Page 156: Piston Rings
Piston Rings Inspect the piston rings for the following: • Abrasive wear • Scuffing and scoring • Oil ring plugged with deposits. Abrasive wear is indicated by concentrated vertical scratches (B). The chromium plating is worn through and the face of the ring has a brighter finish, when compared to the dull satin finish of a new ring (A).
Page 157 Width of Piston Groove 0.079 Second 0.079 Oil Control 0.158 Use a new piston ring to measure the clearance in the ring groove. pi900te Piston Ring Clearance 0.06 0.0024 0.10 0.0039 Second 0.03 0.0012 0.07 0.0028 Oil Control 0.03 0.0012 0.07 0.0028 Position each ring in the cylinder below the ring...
Page 158 Identify the ring sets for installation in the cylinder where the end gap was measured. pi9rige CAUTION If a ring expander tool is being used, be careful not to over expand the ring. The top surface of the top and intermediate rings are identified as illustrated.
Page 159 NOTE: Make certain that the dot and the word “TOP” are facing up when installing the piston rings. Use piston ring expander, Part Number 3823137, or equivalent, to install the intermediate ring. pi900ac NOTE: ring shiny chrome appearance. Use piston ring expander, Part Number 3823137, or equivalent, to install the top ring.
Page 160: Piston And Connecting Rod Assembly
Piston and Connecting Rod Assembly There are a number of power-related problems, including excessive lubricating oil consumption, smoke, blowby, and poor performance, that can be caused by inadequate sealing between the piston rings and the cylinder walls. A blowby measurement can help detect the problem.
Page 161 CAUTION Do not use emery cloth or sandpaper to remove carbon from the cylinder bores. Aluminum oxide or silicon particles from these materials can cause serious engine damage. Use a scraper or a blunt-edged instrument to loosen the carbon deposits. Do not damage the cylinder with the scraper.
Page 162 On pistons with anodized coatings, do not stamp the anodized coating on the outer rim. Mark each piston according to the cylinder location. pi900gc Rotate the crankshaft to position the connecting rod caps at bottom dead center for removal. Mark each connecting rod and connecting rod cap according to the cylinder number location.
Page 163 Remove the lower connecting rod bearing. Mark the cylinder number and the letter “L” (lower) on the flat surface of the bearing tang. Push the connecting rod and piston assembly out of the cylinder bore. Care must be taken not to damage the connecting rod or bearing.
Page 164 Remove the piston pin retaining rings. cx9rrma NOTE: Heating the piston is not required. Remove the piston pin. Remove the connecting rod from the piston. pi9pima Make sure the FRONT marking on the piston and the numbers on the connecting rod and cap are oriented as illustrated.
Page 165 Lubricate the pin and pin bores with clean 15W-40 engine lubricating oil. pi9piwa NOTE: Pistons do not require heating to install the pin; however, the pistons do need to be at room temperature or above. Install the connecting rod. Install the piston pin. pi9pima Install the second retaining ring.
Page 166 When rebuilding an engine with the original cylinder block, crankshaft, and pistons, make sure the pistons are installed in their original cylinders. If replacing the piston(s), make sure the replacement piston(s) are the same grade as the original piston(s). If a new cylinder block or crankshaft is used, the piston grading procedure must be performed to determine the proper piston grade for each cylinder.
Page 167 Immerse the pistons in clean 15W-40 engine lubricating oil until the rings are covered. Allow the excess oil to drip off the assembly. pi800hd Position the rings so that the ring gaps are 120 degrees apart. pi9rihb CAUTION If using a strap type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring.
Page 168 Position the connecting rod journal for the piston to be installed to bottom dead center (BDC). cx900wf Take care to not damage the cylinder wall when inserting the connecting rod. Carefully push the piston into the bore while guiding the connecting rod to the crankshaft journal. cx900ld Lubricate threads...
Page 169 NOTE: Do not measure the clearance between the connecting rod cap and crankshaft. Measure the side clearance between the connecting rod and crankshaft. Connecting Rod Cap Side Clearance 0.20 0.0079 0.40 0.0160 cx900tb CAUTION To reduce the possibility of engine damage, the crankshaft must rotate freely.
Page 170: Gear Train Backlash, Front
Gear Train Backlash, Front This check must be performed after the gear cover is removed or before installation. The adjacent (engaging) gear must not turn as the gear being measured is turned. Position a dial indicator so the tip is contacting the surface of the gear tooth as shown.
Page 171: Camshaft Thrust Bearing
Camshaft Thrust Bearing Remove the thrust bearing. 00900186 CAUTION bearings separate during engine operation. room temperature vulcanized (RTV) sealant to hold the bearings together for assembly or the thickness can be too great when the room temperature vulcanized (RTV) sealant cures. NOTE: The camshaft thrust bearing has two bearings.
Page 172: Cylinder Head
Cylinder Head WARNING This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. Remove the mounting capscrews, cylinder head assembly, and gasket. Discard the gasket. 00900171 Use a valve spring compressor, Part Number 3163292, or equivalent, to compress the valve...
Page 173 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Wash the cylinder head in hot, soapy water solution. After rinsing, use compressed air to dry the cylinder head. 02900072 WARNING When using solvents,...
Page 174 Measure the cylinder head for surface flatness (1). Cylinder Head Flatness(warping limit) 0.00 0.00 0.05 0.002 The maximum repair limit on the cylinder head is 0.30 mm [0.012 in]. 02900128 Inspect the cylinder head capscrews for damaged threads, corroded surfaces, or a reduced diameter (due to capscrew stretching).
Page 175 If the capcrews are not damaged, they can be used again throughout the life of the engine unless the specified “free length” is exceed. To check the capscrew “free length”, place the head of the capscrew in the appropriate slot with the flange against the base of the slot.
Page 176 Install the valve spring and spring seat on the valve stem. 00900173 Install the valve collet onto the valve stem groove while compressing the valve spring with the valve spring compressor, Part Number 3163292, or equivalent. 00900172 After releasing the valve spring, tap the top of the valve stem with a plastic hammer to make sure the valve cotter is completely seated.
Page 177 Measure the injector nozzle protrusion (3) on the cylinder head Injector Nozzle Protrusion 2.84 0.112 3.40 0.138 The tolerance allowance on the nozzle protrusion is 00900129 2.700 to 3.500 mm [0.106 to 0.138 in]. CAUTION Remove all carbon and dirt from the contact surfaces of the cylinder block and cylinder head.
Page 178: Rocker Levers
Rocker Levers Adjusting Valve Clearance Remove the cylinder head cover. 03900075 Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of No. 4 cylinder, bring the No.1 cylinder into compression top dead center position Align the TOP engraved mark on the crankshaft pulley (1) with pointer (2).
Page 179 NOTE: Adjust intake and exhaust clearances in the following firing order rotating crankshaft 180 degrees in the normal direction: 1-2-4-3. 0390078 Adjust the valve clearances for intake valves No. 1 and No. 3. Adjust the valve clearances for exhaust valves No. 1 and No.
Page 180: Rocker Levers Assembly
Rocker Levers Assembly The rocker lever assembly contains the following components: 1. Rocker shaft 2. Adjusting screw locking nut 3. Rocker lever 4. Adjusting screw. 03900102 5. Rocker lever indexing screw 6. Pedestal mounting stud 7. Cup plug 8. Snap ring 9.
Page 181 Clean all parts in a strong solution of detergent in hot water. 03900105 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. The pedestals are made from powdered metal and will continue to show wetness after they have been cleaned and dried.
Page 182 Inspect the pedestal and shaft bore. Measure the pedestal shaft bore. Rocker Lever Pedestal Bore 0.75 03900107 Install the locknut and adjusting screw in the rocker lever. Install the rocker lever pedestals and rocker levers. Install the rocker lever shaft and thrust washers (if equipped).
Page 183: Rocker Lever Cover
Rocker Lever Cover Remove the three capscrews, isolator assemblies, o- rings, and rocker lever cover. Remove the gasket. Discard the gasket. 03900075 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Clean the rocker lever cover with a strong solution of detergent in hot water.
Page 184: Push Rods Or Tubes
Push Rods or Tubes NOTE: Mark the push rods with tags showing the location. Keep the push rods from getting damaged. Install the push rod in the same location during assembly. Remove the push rods from the cylinder head. 00900170 WARNING Wear appropriate eye and face protection when using compressed air.
Page 185: Tappet
Lubricate the push rod ends with clean lubricating engine oil. Install the push rods into the cylinder head in the location as marked. 00900170 Tappet NOTE: Mark the location of the tappets if tappets are to be used again. Remove the tappets. 00900206 WARNING Wear appropriate eye and face protection when...
Page 186 Inspect the face of the tappet for excessive wear, cracks, and other damage. Visual Limits (A) - Normal contact (exaggerated) (B) and (C) - Irregular contact (do not reuse). bp9tasa Pit marks on the tappet face are acceptable. The following criteria defines the size of the pits allowed: 1.
Page 187: Complete Engine
Complete Engine Measuring Compression Pressure WARNING WARNING To avoid personal injury, keep hands, long hair, Exhaust manifold and muffler are hot. Do not jewelry, and loose fitting or torn clothing away touch the exhaust manifold or muffler or personal from fans and other moving parts. injury will occur.
Page 188 CAUTION Do not allow dirt or foreign matter to get into the cylinder. Foreign objects in the cylinder can cause severe engine damage. Remove the nozzle holder assembly for each cylinder. Remove the injector. 0390167 Lubricate the sealing lips of the sleeve with anti-seize compound.
Page 189: Testing And Adjusting The Fan Belt Tansion
Crank the engine with the starting motor. Read the gauge when the pointer is stabilized. Engine Compression 1965 2944 14000062 Testing and Adjusting the Fan Belt Tansion Testing the Fan Belt Tension Check the amount the fan belt deflects when pushed with a force of 6 kg [13.2 lb] at a point midway between the fan pulley and the alternator pulley.
Page 190: Fuel System
Fuel System Fuel Injection Pump, Rotary CAUTION Do not drop the nut, washer, or key. Failure to do so will result in the need to remove the front gear cover. Remove the gear cover access cap. Rotate the engine until the keyway is vertical. Remove the nut and washer from the fuel injection 05900254 pump shaft.
Page 191 CAUTION Make sure the key does not fall into the gear housing. Failure to do so can result in engine damage. Install the Woodruff key into the fuel injection pump. Align the key in the fuel injection pump with the keyway in the injection pump gear.
Page 192 Install the fuel pump drive access cover. Tighten the two capcrews. 10 mm 13 n.m [10 ft-lb ] 12 mm 19 n.m [14 ft-lb ] 14900071 Set the number 1 cylinder at compression top dead center (TDC) by aligning the pointer on the gear cover to the TDC line on the crankshaft pulley.
Page 193 NOTE: Check that the stylus end of the dial gauge contacts the plunger head and is not bottomed out. Install the dial gauge, Part Number 3377259, or equivalent, into the distributor head. 5p9towa Rotate the crankshaft in the opposite direction of normal engine rotation (counterclockwise) slightly, until the dial gauge stops moving.
Page 194 Remove the dial gauge. Install the distributor head bolt and new copper washer into the fuel injection pump. Torque Value: 17 n.m [13 ft-lb ] 14900074 Install the fuel pump drive access cover. 10 mm 13 n.m [10 ft-lb ] 12 mm 19 n.m [14 ft-lb ] 14900071 If the fuel lines are opened, the low-pressure lines can...
Page 195: Injector
WARNING Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a hot exhaust manifold, which can cause a fire. WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the fs900wg work area and areas sharing ventilation to reduce the possibility of severe personal injury or death...
Page 196 Check the opening pressure. a. Open valve. b. Operate lever at one stroke per second. c. Read pressure indicated when spray begins. Nominal Injector Opening Pressure: 19.6 Mpa [2843 psi] fi900de If the opening pressure is out of specification, disassemble the injector and change the shims in order to change the opening pressure.
Page 197 Disassembly Remove the copper sealing washer and discard. filsema Clamp the nozzle holder in a soft jawed vise and remove the nozzle nut. fi900fb Remove the nozzle needle valve and intermediate plate. NOTE: To avoid damage, place the injector nozzle and needle valve in a suitable bath of clean test oil.
Page 198 Assembly NOTE: Make sure all mating surfaces and pressure faces are clean and lubricated with fuel oil before assembly. fi900ab WARNING Install the same thickness of shims that were removed in disassembly. Use the pressure spring to make sure the shims are installed flat. Install the shims.
Page 199 Install the needle valve and nozzle assembly. fi900ce Install the nozzle nut. fi900ob Diesel Engine Engine System...
Page 200: Lubricating System
Lubricating System Measuring Oil Pressure WARNING When measuring the oil pressure, be careful not to get caught in rotating parts. always remove or install plug or oil pressure gauges with the engine stopped. Remove the oil pressure sensor, and install the pressure gauge.
Page 201 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Clean the lubricating oil cooler housing and hoses with a strong solution of detergent in hot water. Dry the components with compressed air. 07900330 Inspect the lubricating oil cooler and hoses for cracks or other damage.
Page 202: Lubricating Oil Pressure Regulator (Main Rifle)
Lubricating Oil Pressure Regulator (Main Rifle) Remove the pin that holds the regulator spring and valve in the lubricating oil pump. Remove the lubricating oil pressure regulator from the lubricating oil pump. 07900322 Inspect the valve spring and body for damage or excessive wear.
Page 203 Measure the clearance between the regulator body and valve (1). Valve and Body Clearance Standard Standard Tolerance Size Clearance Valve Body 0.050 mm 0.020 mm 0.030 07900324 11 mm -0.077 mm -0.020 mm 0.097 mm [0.43 in] [0.002in] [0.008 in] [0.001 in] [0.003 in] [0.008 in]...
Page 204 Remove the five mounting capscrews (2) and spacer (3). Remove the lubricating oil pump (1). 07900326 Inspect the lubricating oil pump housing for damage. Measure the axial (1) and radial (2) clearance. Axial and Radial Pump Gear Clearance Inspection Clearance Standard Item Limit...
Page 205: Lubricating Oil Suction Tube (Block-Mounted)
Lubricating Oil Suction Tube (Block-Mounted) Remove the two mounting capscrews from the lubricating oil suction tube. Remove the lubricating suction tube and o-ring from the cylinder block. Discard the o-ring. 00900179 WARNING When using solvents, acids, or alkaline materials cleaning, follow manufacturer's recommendations for use.
Page 206: Cooling System
Install the o-ring and lubricating suction tube onto the cylinder block. Install the two mounting capscrews into the lubricating oil suction tube. Tighten the capscrews. Torque Value: 19 n.m [14 ft-lb] 00900179 Cooling System Loosen the alternator mounting capscrew (3) and the belt tension adjustment capscrew (2).
Page 207 Measure the belt tension in the center span of the pulleys. Check the belt tension using a click-type belt tension gauge, Part Number 3822524, or equivalent, or a Burroughs gauge, Part Number ST-1138, equivalent. Fan Belt Deflection fa9blsb New Belts Used Belts Loosen the mounting capscrew of the alternator (1) and belt tension adjustment capscrew (2).
Page 208: Coolant Thermostat
Coolant Thermostat Remove the thermostat and seal from the water pump cavity. 08900320 CAUTION Do not let dirt or debris fall into the thermostat cavity when cleaning the gasket surfaces. Failure to do so can cause engine damage. Clean the mating surfaces. 08900321 Inspect the thermostat (1) for damage such as obstructions caused by debris, broken springs, or...
Page 209: Coolant Thermostat Housing
NOTE: Do not allow the thermostat or thermometer to touch the side of the container. Suspend the thermostat and a 100°C [212°F] thermometer in a container of well-mixed water. Heat the water slowly at a temperature of 77°C [171°F] so the wax element in the thermostat has sufficient time to react to the rising water temperature.
Page 210: Cooling System
Install the thermostat housing onto the water pump. 08900325 Cooling System WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. WARNING Coolant is toxic.
Page 211 During filling, air must be vented from the engine coolant passages. The air vents through the “jiggle pin” openings to the top radiator hose and out the fill opening. Additional venting is provided for engine equipped with a aftercooler. Open the petcock during filling.
Page 212 WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. Operate the engine for 5 minutes with a coolant temperature above 82°C [180°F]. Shut the engine off, and drain the cooling system. oi800w10 If the water being drained is still dirty, the system must be flushed again until the water is clean.
Page 213: Cooling System Diagnostics
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Install the pressure cap. Operate the engine until it reaches a temperature of 82°C [180°F], and check for coolant leaks.
Page 214 CAUTION The engine coolant passages must be completely filled with coolant. During operation, entrapped air mixes with the coolant, which results in cavitation corrosion and poor heat transfer. Highly aerated coolant can cause localized overheating of the cylinder head and block, which can result in a cracked head, scored cylinder, or blown head gasket.
Page 215 CAUTION Never use water alone for coolant. Damage from corrosion can be the result of using water alone for coolant. The small holes in the head gasket are especially susceptible to plugging. These holes are orifices and their size is critical. Do not enlarge the size of the orifices.
Page 216 Air in the coolant can result in loss of coolant from the overflow when the aerated coolant is hot. The heated air expands, increasing the pressure in the system, causing the cap to open. Similarly, coolant can be displaced through the overflow if the head gasket leaks compression gases to the coolant system.
Page 217 The coolant flow can also be reduced if the inlet hose to the water pump collapses. A hose will usually not collapse while the engine is running at low speed. Check the hose while the engine is running at rated speed.
Page 218 Shutters are designed to control airflow across the radiator. If the shutters fail to open when needed, the engine can run hot. Failure of the shutters to close can result in too much airflow and the engine running cold. Make sure that the air temperature sensor is functioning correctly.
Page 219: Engine Compression
Engine Compression WARNING To reduce the possibility of personal injury, keep hands, long hair, jewelry, and loose fitting or torn clothing away from fans and other moving parts. Measure the engine compression pressure while the engine is a minimum temperature of 50°C [122°F]. Adjust the overhead.
Page 220 WARNING While testing the injectors, keep hands and body parts away from the injector nozzle. Fuel coming from the injector is under extreme pressure and can cause serious injury by penetrating the skin. CAUTION Do not allow dirt or debris to enter into the 0090016 cylinder port.
Page 221 Most compression leakage can be prevented by applying a small amount of lubricating engine oil to the mounting section of the compression adapter. Connect the compression gauge to the compression adapter. 14900060 Start the engine. With the pointer on the gauge stabilized, check and read the gauge.
Page 222: Specifications
Specifications Valves, Valve Guides, and Springs 18900014 Inspection Item Standard Remarks VALVES Tolerance: -0.035 mm Intake [-0.0014 in] -0.050 mm Nominal: [-0.0020 in] Stem Diameter 8 mm Tolerance: [0.3130 in] -0.050 mm Exhaust [-0.0020 in] -0.065 mm [-0.0026 in] 0.035 to 0.065 mm Intake Clearance Limit: [0.0014 to 0.0026 in]...
Page 223: Rocker Arm Shaft, Push Rod And Tappets
Rocker Arm Shaft, Push Rod and Tappets 18900016 Inspection Item Standard Remarks VALVE ROCKER ARM SHAFT Tolerance: 19 mm Diameter of Shaft -0.020 mm [0.75 in] [-0.0008 in] Tolerance: Nominal: 0.030 mm Diameter of Rocker Arm Shaft Hole 19 mm [0.0012 in] [0.75 in] 0.010 mm...
Page 224: Cylinder Head
Cylinder Head 18900011 Inspection Item Standard Remarks CYLINDER HEAD Repair Limit: 0.00 to 0.05 mm Surface Flatness (Warpage Limit) 0.30 mm [0.00 to 0.002 in] [0.012 in] Repair Limit: 1.00 ±0.100 mm Intake 2.00 mm [0.039 ±0.004 in] [0.079 in] Valve Seat Repair Limit: 0.90 ±0.100 mm...
Page 225: Cylinder Block
Cylinder Block 18900012 Inspection Item Standard Remarks CYLINDER BLOCK Repair Limit: 0.00 to 0.08 mm Surface Flatness (Warpage Limit) 0.15 mm [0.00 to 0.003 in] [0.006 in] Repair Limit: 70.000 mm 70.200 mm [2.756 in] [2.764 in] Repair Limit: 69.750 mm U/S 0.25 69.950 mm [2.746 in]...
Page 226: Camshaft And Camshaft Bushing
Camshaft and Camshaft Bushing 18900015 Inspection Item Standard Remarks CAMSHAFT Naturally Aspirated Naturally Aspirated 0.03 mm Bend of Shaft — [0.0012 in] Repair Limit: 42.69 mm Intake 42.20 mm [1.681 in] [1.661 in] Height Repair Limit: 43.04 mm Exhaust 42.50 mm [1.694 in] [1.673 in] Repair Limit:...
Page 227: Crankshaft
Crankshaft 18900019 Inspection Item Standard Remarks CRANKSHAFT 0.131 to 0.351 mm Repair Limit: 0.40 mm Thrust Clearance [0.0052 to 0.0138 in] [0.016 in] 70.000 mm Repair Limit: 69.86 mm [2.756 in] [2.750 in] 69.75 mm Repair Limit: 69.61 mm U/S 0.25 [2.746 in] [2.741 in] 69.50 mm...
Page 228: Timing Gear
Timing Gear 18900018 Inspection Item Standard Remarks TIMING GEAR Naturally Aspirated Crankshaft gear 0.08 mm to 0.19 mm and idler gear [0.0031 in to 0.007 in] Camshaft gear 0.08 mm to 0.19 mm and idler gear [0.0031 in to 0.007 in] Replacement Limit: Injection pump...
Page 229: Flywheel
Flywheel 18900013 Inspection Item Standard Remarks FLYWHEEL Repair Limit: Face Runout of Flywheel Housing — 0.30 mm [0.012 in] Repair Limit: Radial Runout of Flywheel Housing — 0.35 mm [0.014 in] Repair Limit: Face Runout of Flywheel — 0.15 mm [0.0059 in] Repair Limit: Radial Runout of Flywheel...
Page 230: Cylinder
Cylinder 18900020 Inspection Item Standard Remarks CYLINDER Repair Limit: Tolerance: Bore 95.00 mm 0.022 mm 95.15 mm [3.740 in] [0.0008 in] [3.746 in] Roundness of Cylinder — Repair Limit: 0.02 mm [0.0008 in] Cylindricity of Cylinder — Diesel Engine Specifications...
Page 231: Piston
Piston 18900020 Inspection Item Standard Remarks PISTON Repair Limit: Diameter 95.00 mm 94.85 mm [3.740 in] [3.734 in] Repair Limit: 0.06 to 0.10 mm 2.0 mm 0.15 mm [0.0024 to 0.0039 in] [0.079 in]* [0.0059 in] Clearance Between Repair Limit: 2.0 mm Piston Ring Second...
Page 232: Connecting Rod, Piston Ring And Piston Pin
Connecting Rod, Piston Ring and Piston Pin 18900022 Inspection Item Standard Remarks PISTON PIN Nominal OD: Outer Diameter 30.00 mm — [1.181 in] Clearance Limit: 0.004 to 0.018 mm Clearance 0.05 mm [0.0002 to 0.0007 in] [0.002 in] PISTON RING Clearance Limit: 0.30 to 0.45 mm 2.00 mm...
Page 233: Oil Pump
Oil Pump 18900017 Inspection Item Standard Remarks Clearance Limit: 0.030 to 0.085 mm Axial 0.10 mm [0.0012 to 0.0033 in] [0.0039 in] Clearance of Pump Gear Clearance Limit: 0.045 to 0.090 mm Radial 0.13 mm [0.0018 to 0.0035 in] [0.0051 in] Diesel Engine Specifications...
Page 234: Regulator Valve
Regulator Valve 18900023 Inspection Item Standard Remarks Standard Standard Clearance Tolerance Size Clearance Limit Shaft Hole Clearance -0.050mm 0.020 mm 0.030 to Between -0.077mm -0.020mm 0.097 mm Valve and Body 11 mm [0.43 in] [0.002 in] [0.0008 in] [0.001 to [0.003 in] [0.0008 in] 0.004 in]...
Page 235: Thermostat
Thermostat 18900024 Inspection Item Standard Remarks THERMOSTAT Cracking Temperature: 82° C ±2° C [180° F ±2° F] (Fully Open: Shall open fully Fully Open Temperature: when immersed in hot water 95° C [203° F] Thermostat bath at a temperature between Replace 77°...
Page 236: Capscrew Markings And Torque Values
Capscrew Markings and Torque Values CAUTION When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts.
Page 237: Capscrew Markings And Torque Values - U.s Customary
Capscrew Markings and Torque Values - U.S. Customary Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb 1/4 - 20 - 28 5/16 - 18 - 24 3/8 - 16 - 24 7/16 - 14 - 20 1/2 - 13...
Page 238: Fraction, Decimal, Millimeter Conversions
Fraction, Decimal, Millimeter Conversions Fraction inch Fraction inch 1/64 0.0156 0.397 33/64 0.5156 13.097 1/32 0.0313 0.794 17/32 0.5313 13.494 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.0781 1.984 37/64 0.5781 14.684 3/32 0.0938 2.381 19/32 0.5938...
Page 239: Newton-Meter To Foot-Pound Conversion Chart
Newton-Meter to Foot-Pound Conversion Chart N•m ft-lb N•m ft-lb N•m ft-lb 8.850756 in-lb 44 in-lb 53 in-lb 62 in-lb 71 in-lb 80 in-lb 89 in-lb 0.737562 ft-lb NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803. Pipe Plug Torque Values Size Torque Torque...
Page 240: Tap-Drill Chart - U.s. Customary And Metric
Tap-Drill Chart - U.S. Customary and Metric NOTE ON SELECTING TAP-DRILL SIZE: The tap drill size shown on this card give the theoretical tap drill size for approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60% range as these sizes will provide about 90% of the potential holding power.
Page 241: Weight And Measures - Conversion Factors
Weight and Measures - Conversion Factors From U.S. From Metric Customary To U.S. Quantity U.S. Customary Metric Customary To Metric Multiply By Multiply By Unit Name Abbreviation Unit Name Abbr. sq. inch sq. millimeters 645.16 0.001550 Area sq. centimeters 6.452 0.155 sq.
Page 242: Special Tools
Special Tools Style Tool No. Tool name ST 647 Standard Puller 3163086 Lubriplate™ Multi-Purpose Lubricant 3163720 Dowel Pin Extractor 3164067 Silicone Sealant 3164438 Depth Gauge Assembly Diesel Engine Special Tools...
Page 243 Style Tool No. Tool name 3164900 Crankshaft Seal Installer 3375066 Sealant 3375068 Sealant 3822709 Thread Repair Inserts 3823258 Abrasive Pad Diesel Engine Special Tools...
Page 244 Style Tool No. Tool name 3823942 Small Bushing Driver Set 4918219 Precision Straightedge 3822509 Injector Bore Brush 3824379 Antiseize Lubricant 4918219\ Precision Straightedge Diesel Engine Special Tools...
Page 245 Style Tool No. Tool name ST 647 Standard Puller 3164488 Digital Multimeter 3164489 Digital Multimeter 3164491 Pressure/Vacuum Module 3375326 Bearing Separator Tool Diesel Engine Special Tools...
Page 246 Style Tool No. Tool name 3377462 Digital Optical Tachometer 3823705 Graduated Beaker 3824510 QD Contact Cleaner 4918193 Injection Timing Gauge Kit 4818677 Fuel Pump Drive Gear Retention Tool Diesel Engine Special Tools...
Page 247 Style Tool No. Tool name 4918679 Fuel Return Flow Hose (Fuel Pump) ST 1273 Pressure Gauge 3164325 Fuel System Leak Tester Fuel Return Flow Hose (fuel rail pressure 3164617 relief valve) 3164706 Injector Remover Diesel Engine Special Tools...
Page 248 Style Tool No. Tool name 3376579 Filter Cutter 3376946 Injection Nozzle Tester 3376947 Injector Nozzle Cleaning Kit 3400157 Fuel Filter Wrench 3823705 Graduated Beaker Diesel Engine Special Tools...
Page 249 Style Tool No. Tool name 3824879 Antiseize Lubricant 3163338 Black Light Lamp 3164067 Silicone Sealant 3164491 Pressure/Vacuum Module 3375273 Pressure Gauge Kit Diesel Engine Special Tools...
Page 250 Style Tool No. Tool name 3376579 Tube (Filter) Cutter 3400157 Oil Filter Wrench 3400158 Oil Filter Wrench 3823876 Lubricating Oil Cooler Test Kit CC-2800 Refractometer Diesel Engine Special Tools...
Page 251 Style Tool No. Tool name ST-1138 Belt Tension Gauge 3164488 Digital Multimeter 3164489 Digital Multimeter 3375066 Sealant 3376050 Dial Indicator Assembly Diesel Engine Special Tools...
Page 252 Style Tool No. Tool name 3377399 Magnetic Base Indicator Holder 3822524 Belt Tension Gauge 3822985 Combustion Leak Test Kit 3822994 Engine Coolant Analyzer 3824319 Coolant Dam/Pressure Tester Diesel Engine Special Tools...
Page 253 SB4319E00 Jan. 2008 Service Manual 4TNV98 & 4TNE98 Diesel Engine D20S-5, D25S-5, D30S-5, D33S-5, D35C-5 (4TNV98 : EM0Q3, EM0Q4, EM0Q5) D20S-5, D25S-5, D30S-5, D33S-5, D35C-5 (4TNE98 : EM0QC, EM0QD, EM0QE) D20G, D25G, D30G (4TNE98)
Page 255 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 257 Section 1. GENERAL SERVICE Section 2. PERIODIC MAINTENANCE INFORMATION Before You Begin Servicing ........ 29 Component Identification ........7 Introduction ............40 Location of Labels..........8 The Importance of Periodic Maintenance 40 Engine Nameplate (Typical)...... 8 Performing Periodic Maintenance... 40 Emission Control Regulations .......
Page 258 Measuring Instruments........77 Specification......... 157 Cylinder Head............. 80 Checking Fuel Injection Timing..... 158 Cylinder Head Components....80 Adjusting Fuel Injection Timing..... 161 Disassembly of 4-Valve Cylinder Head ... 82 Fuel Injectors............ 163 4TNE98 Engine........87 Removal of Fuel Injectors..... 163 Disassembly of Cylinder Head....
Page 259 Section 5. COOLING SYSTEM Method ..........236 Quick Reference Table For Troubleshooting ..239 Before You Begin Servicing....... 201 Troubleshooting Charts........240 Introduction............203 Wiring Diagram..........243 Cooling System Diagram ........203 Engine Coolant Pump Components....204 Engine Coolant System Check......205 Engine Coolant Pump ........
Page 261 Section 1. GENERAL SERVICE INFORMATION Component Identification (1) Lifting Eye (Flywheel End). Figure 4-1a, Figure 4-1b shows where the major (3) Lifting Eye (Engine Cooling Fan End). engine components are located. (4) Engine Coolant Pump. (5) Engine Cooling Fan. (6) Crankshaft V-Pulley. (7) V-Belt. 4TNV98 ENGINE (8) Side Filler Port (Engine Oil).
Page 262 Location of Labels Engine Nameplate (Typical) Figure 4-2 shows the location of regulatory and safety labels on Yanmar TNV & TNE series engines. 4TNE98 ENGINE Emission Control Regulations EPA / ARB Regulations - USA Only 4TNV98 ENGINE Yanmar engines meet Environmental Protection Agency (EPA) (U.
Page 263 Emission Control Labels The 97/68/EC Directive Certified Engines Since emission control regulations are being issued on a global basis, it is necessary to identify which The engines described in this manual have been regulations a particular engine complies with. We certified by the 97/68/EC Directive.
Page 264 Function of Major Engine Components Components Functions The air cleaner prevents airborne contaminants from entering the engine. Since the air cleaner is application specific, it must be carefully selected by an application engineer. It is not part of the basic engine Air Cleaner package as shipped from the Yanmar factory.
Page 265 Function of Cooling System Components Components Functions The TNV engine is liquid-cooled by means of a cooling system. The cooling system consists of a radiator, radiator cap, engine cooling fan, engine coolant pump,thermostat, and reserve tank. Note that all cooling system components are required for proper engine Cooling System operation.
Page 266 Diesel Fuel • The total aromatics content should not exceed 35% by volume. Less than 30% is preferred. Diesel Fuel Specifications • The PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume. Diesel fuel should comply with the following •...
Page 267 Precautions and concerns regarding the use of Filling The Fuel Tank bio-fuels: DANGER 1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components. 2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth. FIRE AND EXPLOSION HAZARD! 3.
Page 268 DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions. Before you operate the engine, check for fuel leaks. Replace rubberized fuel hoses every two years or every 2000 hours of engine operation, whichever comes first, even if the engine has been out of service.
Page 269 Priming the Fuel System To prime the fuel system on engines not equipped with an electric fuel system: The fuel system needs to be primed under certain 1. Place an approved container under the air bleed conditions. port. • Before starting the engine for the first time. 2.
Page 270 Engine Oil NOTE: • Be sure the engine oil, engine oil storage CAUTION containers, and engine oil filling equipment arefree of sediment and water. Only use the engine oil specified. Other engine oils may affect warranty coverage, • Change the engine oil after the first 50 hours of cause internal engine components to seize and / peration and then every 500 hours thereafter.
Page 271 Checking Engine Oil Adding Engine Oil 1. Make sure the engine is level. 1. Make sure the engine is level. 2. Remove the dipstick (Figure 4-5, (1)) and wipe it 2. Remove the oil cap (Figure 4-5, (4)). with clean cloth. 3.
Page 272 Engine Coolant CAUTION DANGER COOLANT HAZARD! SCALD HAZARD! Wear eye protection and rubber gloves when NEVER remove the radiator cap if the engine is you handle long life or extended life engine hot. Steam and hot engine coolant will spurt out coolant.
Page 273 Engine Coolant Specifications Filling Radiator with Engine Coolant Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time guidelines and specifications: or refilling it after it is flushed.
Page 274 Engine Coolant Capacity (Typical) NOTE: The capacities listed are for the engineonly without a radiator. Refer to theoperation manual provided by the drivenmachine manufacturer for the actualengine coolant capacity on yourmachine. The following are the engine coolant capacities for various Yanmar engines. Engine Coolant Engine Model Capacity...
Page 275 Engine General Specifications Vertical In-line, Water Cooled, Type 4-Cycle Diesel Engine 4TNV98 Direct Injection Combustion System 4TNE98 Indirect Injection Starting System Electric Starting Cooling System Radiator Lubricating Forced Lubrication with System Trochoid Pump PTO Position Flywheel End Direction of Counterclockwise Viewed from Rotation the Flywheel End NOTE: The information described in Principal...
Page 276 Principal Engine Specifications 4TNV98 EPA Tier 2 Engine Model 4TNV98 Version VM (SDF) Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.858 x 4.331 in. (98 x 110 mm) Displacement 202.502 cu in. (3.319 L) 2200 hp SAE 61.2...
Page 277 4TNE98 EPA Tier 3 Engine Model 4TNE98 EPA Tier 3 Version VM (BQDF(C)) Type Vertical Inline Diesel Engine Combustion System Indirect Injection, No Turbocharger Aspiration Natural No. of Cylinders Bore × Stroke 3.86 x 4.33 in. (98 x 110 mm) Displacement 202.5 cu in.
Page 278 Engine Service Standards Reference Inspection Item Standard Limit page See Measuring 0.006 - 0.010 in. and Adjusting Intake / Exhaust Valve Clearance (0.15 - 0.25 mm) Valve Clearance on page 104 4TNV98 See Checking and Adjusting Fuel Injection Timing on page 157. Fuel Injection With Plunger Lifted Timing...
Page 279 Tightening Torques for Standard Bolts and Nuts Use the correct amount of torque when you tighten the fasteners on the machine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure.
Page 280 Nominal Thread Item Tightening Torque Remarks Diameter x Pitch 7 - 9 ft·lb (87 -104 in·lb, M6 x 1.0 mm 9.8 -11.8 N·m, 1.0 -1.2 kgf·m) 17 - 21 ft·lb (200 - 251 in.·lb, M8 x 1.25 mm 22.6 - 28.4 N·m, Use 80% of the 2.3 - 2.9 kgf·m) value at left when...
Page 281 Abbreviations and Symbols Japanese Automobile Standards JASO Organization Abbreviations. kelvin kilogram ampere kgf/cm² kilogram force per square centimeter alternating current kgf/m kilogram force per meter ACEA Association des Constructeurs kilometers Européens d’Automobilies kilopascal ampere-hour kilowatt American Petroleum Institute liter Air Resources Board L/hr liter per hour ATDC...
Page 282 Unit Conversions Units of Torque ft-lb 1.3558 = N·m Unit Prefixes ft-lb 0.1383 = kgf/m in.-lb 0.1130 = N·m Prefix Symbol Power in.-lb 0.0115 = kgf/m mega x 1,000,000 kgf/m 7.2330 = ft-lb kilo x 1,000 kgf/m 86.8000 = in.-lb centi x 0.01 kgf/m...
Page 283 Section 2. PERIODIC MAINTENANCE Before You Begin Servicing DANGER DANGER EXPLOSION HAZARD! NEVER check the remaining battery charge by SCALD HAZARD! shorting out the terminals. This will result in a NEVER remove the radiator cap if the engine is spark and may cause an explosion or fire. Use a hot.
Page 284 DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! Diesel fuel is flammable and explosive under Diesel fuel is flammable and explosive under certain conditions. certain conditions. Before you operate the engine, check for fuel Be sure to place the diesel fuel container on the leaks.
Page 285 DANGER DANGER CRUSH HAZARD! FIRE AND EXPLOSION HAZARD! When you need to transport an engine for repair, Diesel fuel is flammable and explosive under have a helper assist you to attach it to a hoist certain conditions. and load it on a truck. Place an approved container under the air bleed NEVER stand under a hoisted engine.
Page 286 WARNING WARNING EXHAUST HAZARD! SEVER HAZARD! NEVER operate the engine in an enclosed area Keep hands and other body parts away from such as a garage, tunnel, underground room, moving/rotating parts such as the cooling fan, manhole ship’s hold without proper flywheel or PTO shaft.
Page 287 WARNING WARNING SUDDEN MOVEMENT HAZARD! Engaging the transmission or PTO at an elevated engine speed could result unexpected movement of the equipment. Failure to comply could result in death or ALCOHOL AND DRUG HAZARD! serious injury. NEVER operate the engine while you are under the influence of alcohol or drugs.
Page 288 WARNING WARNING BURN HAZARD! Batteries contain sulfuric acid. NEVER allow battery fluid to come in contact with clothing, EXPOSURE HAZARD! skin or eyes. Severe burns could result. Wear personal protective equipment such as ALWAYS wear safety goggles and protective gloves, work shoes, eye and hearing protection clothing when servicing the battery.
Page 289 WARNING WARNING BURN HAZARD! SHOCK HAZARD! If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid Turn off the battery switch (if equipped) or being burned. disconnect the negative battery cable before servicing the electrical system.
Page 290 CAUTION CAUTION Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. Prevent dirt and debris from contaminating the COOLANT HAZARD! engine oil. Carefully clean the oil cap/dipstick and the surrounding area before you remove Wear eye protection and rubber gloves when the cap.
Page 291 CAUTION CAUTION Observe the following environmental operating For maximum engine life, Yanmar recommends conditions to maintain engine performance and that when shutting the engine down, you allow avoid premature engine wear: the engine to idle, without load, for five minutes. This will allow the engine components that •...
Page 292 CAUTION CAUTION New Engine Break-in: • On the initial engine start-up, allow the engine to idle for approximately 15 minutes while you check for proper engine oil pressure, diesel fuel leaks, engine oil leaks, coolant leaks, and ALWAYS be environmentally responsible. for proper operation of the indicators and/or gauges.
Page 293 CAUTION CAUTION NEVER use high-pressure water or compressed If the fuel filter/water separator is positioned air at greater than 28 psi (193 kPa; 19 686 higher than the fuel level in the fuel tank, water mmAq) or a wire brush to clean the radiator fins. may not drip out when the fuel filter/water Radiator fins damage easily.
Page 294 Introduction Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar This section of the Service Manual describes the parts when replacement parts are needed. Genuine procedures for proper care and maintenance of the replacement parts help ensure long engine life. engine.
Page 295 Periodic Maintenance Schedule Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively.
Page 296 ○:Check ◇:Replace Periodic Maintenance Interval Every Every Every Every Every Every System Check Item Daily 1000 1500 2000 hours hours hours hours hours hours Check and Refill Engine Cool ○ Check and Clean Radiator Fins ○ Check Engine Coolant Temp. ○...
Page 297 Periodic Maintenance Procedures 4TNE98 For D25S-5 Only WARNING Daily Perform the following procedures daily. • Drain Fuel Filter / Water Separator HIGH PRESSURE HAZARD! • Check Fuel Hoses and Engine Coolant Hoses • Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as Drain Fuel Filter / Water Separator a broken fuel injection line.
Page 298 1. Position an approved container under the fuel filter / water separator (Figure5-1, (1)) to collect CAUTION the contaminants. 2. Loosen the drain cock (Figure5-1, (2)) at the bottom of the fuel filter / water separator. Drain any water collected inside. 3.
Page 299 Daily CAUTION After Initial 50 Hours of Operation Only use the engine oil specified. Other engine oils may affect warranty coverage, cause Perform the following maintenance after the initial internal engine components to seize and / or 50 hours of operation. shorten engine life.
Page 300 7. After all oil has been drained from the engine, The engine oil in a new engine becomes reinstall the oil drain plug (Figure 5-2, (1)) and contaminated from the initial break-in of internal parts. It is very important that the initial oil and filter tighten to 139.8 - 47.0 ft·lb (53.9 - 63.7 N·m;...
Page 301 4. Add new engine oil to the engine as specified in Check and Adjust Cooling Fan V-Belt Adding Engine Oil on page 17. The V-belt will slip if it does not have the proper tension. This will prevent the alternator from CAUTION generating sufficient power.
Page 302 2. If necessary, adjust the V-belt tension. Loosen 6. After adjusting, run the engine for 5 minutes or the adjusting bolt (Figure 5-5, (1)) and move the more. Check the tension again using the alternator (Figure 5-5, (2)) with a pry bar (Figure specifications for a used V-belt.
Page 303 Drain the fuel filter / water separator as follows: CAUTION 1. Position an approved container under the fuel filter / water separator (Figure 5-7, (1)) to collect If the fuel filter / water separator is positioned the contaminants. higher than the fuel level in the fuel tank, water may not drip out when the fuel filter / water separator drain cock is opened.
Page 304 Check Battery CAUTION DANGER ALWAYS be environmentally responsible. EXPLOSION HAZARD! Follow the guidelines of the EPA or other NEVER check the remaining battery charge by governmental agencies for the proper disposal shorting out the terminals. This will result in a of hazardous materials such as engine oil, spark and may cause an explosion or fire.
Page 305 If operating the machine where the ambient CAUTION temperature could drop to 5°F (-15°C) or less, remove the battery from the machine at the end of the day. Store the battery in a warm place until the next use. This will help start the engine easily at low ambient temperatures.
Page 306 Check and Clean Radiator Fins CAUTION FLYING OBJECT HAZARD! ALWAYS wear eye protection when servicing the engine and when using compressed air or Figure 5-10 high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Check and Adjust Cooling Fan V-Belt Failure to comply may result in minor or moderate injury.
Page 307 Checking and adjusting the governor lever: CAUTION 1. Check that the governor lever (Figure 5-11, (1)) NEVER attempt to adjust the low or high idle makes uniform contact with the high idle (Figure speed limit screw. This may impair the safety 5-11, (2)) and low idle (Figure 5-11, (3)) speed and performance of the machine and shorten its limit screws when the engine speed control is in...
Page 308 3. Blow air (Figure 5-12, (3)) through the element Every 500 Hours of Operation from the inside out using 42-71 psi (0.29- 0.49MPa; 3.0-5.0 kgf/cm²) compressed air to Perform the following maintenance every 500 hours remove the particulates. Use the lowest possible of operation.
Page 309 Change the engine oil every 250 hours of operation CAUTION after the initial change at 50 hours. Replace the engine oil filter at the same time. See Replace For maximum engine life, Yanmar recommends Engine Oil and Engine Oil Filter on page 45. that when shutting the engine down, you allow the engine to idle, without load, for five minutes.
Page 310 Figure 5-14a 4. Place an approved container under fuel filter. Figure 5-14 5. Carefully open the drain plug (Figure 5-15a, (1)) 4. Clean the filter mounting surface and apply a to drain fuel from the fuel filter. small amount of diesel fuel to the gasket of the new fuel filter.
Page 311 10. Remove the fuel filter sensor assembly (Figure Clean Fuel Filter / Water Separator 5-15, (5)) by turning it to the left (Figure 5-15, (3)). DANGER 11. Carefully remove the in-line fuel filter (Figure 5- 15, (7)) from the output nipple (Figure 5-15, (8)) that goes to the fuel injection pump.
Page 312 2. Close (Figure 5-15, (2)) the fuel cock (Figure 5- CAUTION 15, (3)). 3. Loosen the drain cock (Figure 5-15, (4)) and drain the contaminants. See Drain Fuel Filter/Water Separator on page 41. 4. Turn the retaining ring (Figure 5-15, (5)) to the ALWAYS be environmentally responsible.
Page 313 Every 1000 Hours of Operation CAUTION Perform the following maintenance every 1000 hours of operation. • Drain, Flush and Refill Cooling System With New Coolant • Adjust Intake/Exhaust Valve Clearance COOLANT HAZARD! Drain, Flush and Refill Cooling System With Wear eye protection and rubber gloves when New Coolant you handle long life or extended life engine coolant.
Page 314 5. After draining the engine coolant, flush the radiator and engine block to remove any rust, scale and contaminants. Then reinstall and tighten the drain plug or close the drain cock in the radiator. Reinstall and tighten the cylinder block drain plug or reconnect the coolant hose at the oil cooler.
Page 315 Every 1500 Hours of Operation Inspect Crankcase Breather System Proper operation of the crankcase breather system Perform the following maintenance every 1500 is required to maintain the emission requirements of hours of operation. the engine. The EPA / ARB requires that the crankcase breather system is inspected every 1500 •...
Page 316 Failure of the diaphragm and / or spring will cause Regularly check the fuel system and engine coolant the loss of pressure control and allow an excessive system hoses. If they are cracked or degraded, amount of crankcase fumes to be routed to the replace them.
Page 317 Section 3. ENGINE Before You Begin Servicing WARNING WARNING FUME / BURN HAZARD! To prevent possible eye injury, always wear Always read follow safety related SAFETY GLASSES while servicing the engine. precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers.
Page 318 CAUTION CAUTION Only use the engine oil specified. Other engine Any part which is found defective as a result of oils may affect warranty coverage, cause inspection or any part whose measured value internal engine components to seize and / or does not satisfy the standard or limit must be shorten engine life.
Page 319 CAUTION Keep the piston pin parts, piston assemblies, and connecting rod assemblies together to be returned to the same position during the reassembly process. Label the parts using an appropriate method. CAUTION Do not allow the honing tool to operate in one position for any length of time.
Page 320 Introduction This section of the Service Manual describes servicing of the engine. Cylinder Head Specifications Adjustment Specifications Valve Bridge Clearance Model Valve Clearance (4-Valve Head Only) 0.006 - 0.010 in. 4TNV98 (0.15 - 0.25 mm) 0.006 - 0.010 in. 4TNE98 (0.15 - 0.25 mm) Cylinder Head 4TNV98 Engine...
Page 321 Intake / Exhaust Valve and Guide Cont 4TNV98 Engine Reference Inspection Item Standard Limit Page 0.2756 - 0.2762 in. 0.2787 in. Guide Inside Diameter (7.000 - 7.015 mm) (7.08 mm) Valve Stem Outside 0.2734 - 0.2740 in. 0.2717 in. Intake Diameter (6.945 - 6.960 mm) (6.90 mm)
Page 322 Push Rod Reference Inspection Item Standard Limit Page See Push Less than 0.0012 in. Page Push Rod Bend Rod Bend 0.0012 in. (0.03 mm) (0.03 mm) on page 93. Rocker Arm and Shaft Reference Inspection Item Standard Limit Page 0.7283 - 0.7291 in. 0.7311 in.
Page 323 (Camshaft Cont.) Reference Inspection Item Standard Limit Page 1.9681 - 1.9707 in. 1.9736 in. Bushing Inside Diameter (49.990 - 50.055 mm) (50.130 mm) 1.9655 - 1.9665 in. 1.9642 in. Gear End Camshaft Outside Diameter (49.925 - 49.950 mm) (49.890 mm) 0.0016 - 0.0051 in.
Page 324 Crankshaft and Piston Specifications Crankshaft NOTE : Check appropriate parts catalog for various sizes of replacement main bearing inserts. Reference Inspection Item Standard Limit Page 0.0008 in. Bend (1/2 the dial gauge reading) (0.02 mm) Journal Outside 2.2816 - 2.2820 in. 2.2796 in.
Page 325 Piston Reference Inspection Item Standard Limit Page Piston Outside Diameter 3.8555 - 3.8567 in. 3.8541 in. Inspection of (Measure at 90° to the Piston Pin.) (97.930 - 97.960 mm) (97.895 mm) Pistons, Piston Rings and Wrist Piston Diameter Measure Location(Upward 0.8661 in.
Page 326 Connecting Rod Connecting Rod Small End Inspection Item Standard Limit Reference Page 1.1821 - 1.1826 in. 1.1838 in. Wrist Pin Bushing Inside Diameter (30.025 - 30.038 mm) (30.068 mm) See Inspection of 1.1806 - 1.1811 in. 1.1795 in. Connecting Rod on Wrist Pin Outside Diameter (29.987 - 30.000 mm) (29.959 mm)
Page 327 Cylinder Block Specifications Cylinder Block Reference Inspection Item Standard Limit Page 3.8583 - 3.8594 in. 3.8634 in. Cylinder Inside Diameter (98.000 - 98.030 mm) (98.130 mm) Inspection of Cylinder Roundness 0.0004 in. (0.01 mm) 0.0012 in. Block on Cylinder Bore or less (0.03 mm) page 121.
Page 328 (Torque for Bolts and Nuts Cont.) Lubricating Oil Thread Diameter and Application Component Torque Pitch (Thread Portion and Seat Surface) 80 - 87 ft·lb Main Bearing Cap Bolt M11 x 1.25 mm (108.1 - 117.9 N·m; Applied 11.0 - 12.0 kgf·m) 80 - 94 ft·lb Crankshaft Pulley Bolt M14 x 1.5 mm...
Page 329 Special Service Tools Tool Name Applicable Model and Tool Size Illustration Model Valve Guide 0.787 in. 2.953 in. 0.256 in. 0.394 in. 4TNV98 Tool (For (20 mm) (75 mm) (6.5 mm) (10 mm) Removing 0.787 in. 2.953 in. 0.295 in. 0.433 in.
Page 330 (Special Service Tools Cont.) Tool Name Applicable Model and Tool Size Illustration Filter Wrench (For Removal / Installation Available Locally of Engine Oil Filter) Camshaft Bushing Tool 0.709 in. 2.756 in. 1.968 in. 2.087 in. (For (18 mm) (70 mm) (50 mm) (553 mm) Extracting...
Page 331 Measuring Instruments Instrument Name Application Illustration Dial Indicator Locally Available Measure shaft bend and end play Measurements of narrow or deep Test Indicator Locally Available portions that cannot be measured by dial gauge For holding the dial gauge when Magnetic Stand Locally Available measuring For measuring the outside diameters of...
Page 332 Instrument Name Application Illustration V-Block Locally Available For measuring shaft bend For tightening nuts and bolts to the Torque Wrench Locally Available specified torque For measuring piston ring gaps, Feeler Gauge Locally Available piston ring clearance, and valve adjustment clearance For checking concentration of Battery Coolant Tester antifreeze and the battery electrolyte...
Page 333 Instrument Name Application Illustration For measuring resistance, voltage and Circuit Tester continuity of electrical circuits For measuring compression Compression Gauge Kit pressureGauge Set Part No. TOL- 97190080 Adapter for direct injection 2-valve New Comperssion Test cylinder headAdapter Part No. 119802- Adaptor 92950 4TNV98 &...
Page 334 Cylinder Head Cylinder Head Components 4TNV98 Engine Figure 6-36 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine...
Page 335 1) Crankcase Breather Cover. 2) Diaphragm Spring. 3) Diaphragm Cup. 4) Crankcase Breather Diaphragm. 5) Oil Fill Cap. 6) Valve Cover Nut. 7) Valve Cover Nut O-Ring . 8) Valve Cover Gasket. 9) Support Bolt. 10) Rocker Arm Shaft Support. 11) Wave Washer.
Page 336 Disassembly of 4-Valve Cylinder Head CAUTION Prepare a clean, flat working surface on a workbench large enough to accommodate the Remove install high-pressure fuel cylinder head assembly. Discard all gaskets, O-rings injection lines assembly whenever and seals. Use new gaskets, O-rings and seals on possible.
Page 337 Figure 6-38 10. Remove the engine coolant pump. See Disassembly of Engine Coolant Pump on page 207. Removal of Valve Cover NOTE: The high pressure fuel injection lines and valve cover grommets must be removed prior to removing the valve cover. See Removal of Fuel Injectors on page 163.
Page 338 Removal of Rocker Arm Assembly Disassembly of Rocker Arm Assembly 1. Remove the fuel injectors from the cylinder head. NOTE : Identify the rocker arms so they can be See Removal of Fuel Injectors on page 163. reinstalled with the original matching valve and pushrod.
Page 339 Removal of Cylinder Head 1. Loosen the cylinder head bolts following the sequence shown in (Figure 6-43). Figure 6-43 1) Cooling Fan End 2) Camshaft Side Figure 6-44 2. Remove the cylinder head bolts (Figure 6-44, (1)). Removal of Intake and Exhaust Valves 3.
Page 340 3. Remove the valve keepers (Figure 6-46, (1)). Removal of Valve Guides 4. Slowly release the tension on the valve spring. NOTE : Removal of the valve guides should be postponed until inspection and measurement 5. Remove the spring retainer (Figure 6-46, (2)), procedures have been performed.
Page 341 4TNE98 Engine Figure 6-1 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine...
Page 342 1) Valve Cover Nut 2) Valve Cover Nut O-ring 3) Valve Cover 4) Valve Cover Gasket 5) Rocker Arm Shaft 6) Rocker Arm Shaft Retaining Screw 7) Cylinder Head Bolt 8) Glow Plug Harness 9) Valve Cap 10) Valve Keepers 11) Spring Retainer 12) Valve Spring 13) Valve Stem Seal...
Page 343 Disassembly of Cylinder Head Removal of Glow Plugs 1. Remove the glow plug cover (Figure 6-3, (2)) Prepare a clean, flat working surface on a from each of the glow plugs (Figure 6-3, (1)). workbench large enough to accommodate the cylinder head assembly.
Page 344 Figure 6-4 3. Remove the valve cover (Figure 6-4, (3)). Discard the valve cover gasket (Figure 6-4, (4)). Figure 6-6 Removal of Rocker Arm Assembly Disassembly of Rocker Arm Assembly 1. Remove the rocker arm shaft alignment screw 1. Remove the bolt (Figure 6-6, (1)) and locking (Figure 6-7, (1)) from the support bracket that nuts (Figure 6-6, (2)) that retain the rocker arm support brackets to the cylinder head.
Page 345 Figure 6-7 4. .If necessary, remove the valve adjusting screw (Figure 6-7, (7)) and lock nut (Figure 6-7, (8)) from the rocker arms. Removal of Cylinder Head 1. Loosen the cylinder head bolts following the sequence shown in (Figure 6-8). Figure 6-9 Removal of Intake / Exhaust Valves 1.
Page 346 4. Slowly release the tension on the valve spring. 5. Remove the spring retainer (Figure 6-11, (3)), valve spring (Figure 6-11, (4)) and valve stem seal (Figure 6-11, (5)). Figure 6-12 Cleaning of Cylinder Head Components WARNING Figure 6-11 6. Repeat this procedure until all the intake and exhaust valve springs and valve stem seals are FUME / BURN HAZARD! removed.
Page 347 Thoroughly clean all components using a non- Inspection of Push Rods metallic brush and an appropriate solvent. Each part must be free of carbon, metal filings and other Push Rod Bend debris. 1. Place the push rods on a flat inspection block or layout bed.
Page 348 Inspection of Valve Guides Valve Guide Inside Diameter Visually inspect the valve guides for distortions, scoring or other damage. NOTE : Measure the valve guides while they are installed in cylinder head. Use a telescoping gauge and micrometer to measure the inside diameter at each end of the valve guide.
Page 349 If distortion exceeds the service limit, resurface or Valve Stem Bend replace the cylinder head. Remove only enough material to make the cylinder head flat, but do not Place the valve stem on a flat inspection block or remove more than 0.008 in (0.20 mm). layout bed.
Page 350 Coat the valve seat with a thin coat of bluing compound. Install the valve and rotate to distribute bluing onto the valve face. The contact pattern should be approximately centered on the valve face (Figure 6-57, (1)) and even in width. Figure 6-56 Valve Face and Valve Seat Always check the clearance between the valve and...
Page 351 Free Length Grind the valve face and/or valve seat as necessary to return them to serviceable condition. Grinding is needed if the valve and valve seat do not contact Use a caliper to measure the length of the spring correctly. Check the valve margin and valve (Figure 6-60).
Page 352 Reassembly of Cylinder Head 3. Finish installing the valve guides (Figure 6-63, (1)) into the cylinder head to the proper height (Figure 6-63, (3)) using the valve guide installation Use new gaskets, O-rings, and seals on reassembly tool (Figure 6-63, (2)). See Intake/Exhaust Valve of the cylinder head.
Page 353 2. Measure the distance (Figure 6-65, (1)) from the cylinder head to the valve stem seal to ensure proper clearance (Figure 6-65, (2)) between the 4TNE98 Engine guide and seal. See Intake/Exhaust Valve and Guide on page 67. Figure 6-65 3.
Page 354 Reassembly of Cylinder Head 4TNE98 Engine 1. Carefully clean both the combustion surface of the cylinder head and the top surface of the cylinder block. Then place a new cylinder head gasket (Figure 6-67, (2)) on the cylinder block. 2. Position the cylinder head on the on the cylinder head gasket.
Page 355 IMPORTANT The wave washers (Figure 6-70, (2)) must be installed with the bow facing the rocker arms (Figure 6-70, (1)). Figure 6-68 1) Fan End 2) Camshaft Side Reassembly of Rocker Arm Assembly 4TNV98 Engine Figure 6-70 1. Reinstall the valve bridges (Figure 6-69, (3)) in their original locations and ensure each seat (Figure 6-69, (4)) is in place.
Page 356 4TNE98 Engine NOTE : To properly align the rocker arm shaft with the rocker arm shaft supports, first reinstall one of the end rocker arm supports (Figure 6-72, (6)) with 1. Lubricate the rocker arm shaft. Slide the rocker a hole for the shaft alignment stud (Figure 6-72, (5)). arm support brackets (Figure 6-30, (4)), springs Align the hole in the rocker arm shaft and the hole in (Figure 6-30, (5)) and rocker arms (Figure 6-30,...
Page 357 9. Reinstall the high pressure and fuel return lines. Reassembly of the Valve Cover See Installation of the Fuel Injectors on page 167. 1. Lightly grease a new valve cover gasket (Figure 6-73, (6)). Place the gasket in the groove of the 10.
Page 358 Measuring and Adjusting Valve • If there is no valve clearance, and the cylinder is at TDC of the compression stroke, extreme wear, Clearance or damage to the cylinder head or valves may be possible. Measure and adjust while the engine is cold. •...
Page 359 4TNE98 Engine 1. Remove the valve cover. See Removal of Valve Cover on page 103. NOTE : If adjusting each cylinder individually, the cylinder to be adjusted first does not have to be the No. 1 cylinder. Select and adjust the cylinder where the piston is nearest to the top dead center after turning, and make adjustment for other cylinders in the order of firing by turning the crankshaft.
Page 360 4TNV98 Engine The 4-valve cylinder head operates two valves with IMPORTANT a single rocker arm by employing a valve bridge (Figure 6-77, (1)) between the two valves (Figure 6- Do not loosen or tighten the valve adjusting screw 77, (2)). Clearance (Figure 6-77, (4)) between the lock nut without holding the valve bridge.
Page 361 7. Tighten the lock nut (Figure 6-80, (1)), while holding the valve bridge (Figure 6-80, (3)) with a wrench (Figure 6-80, (2)). Verify that the valve clearance (Figure 6-81, (2) is zero “0”. Figure 6-80 Figure 6-82 9. If adjustment is required, proceed to the next step. 10.
Page 362 Figure 6-83 12. Hold the adjusting screw (Figure 6-83, (4)) while tightening the valve adjusting screw lock nut (Figure 6-83, (5)). Recheck the clearance. 13. Apply oil to the contact surface between the adjusting screw and push rod. 14. Rotate the crankshaft to measure and adjust the set of valves.
Page 363 Crankshaft and Camshaft Components Figure 6-84 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine...
Page 364 (1) Cylinder Block. (2) Camshaft Bushing. (3) Gear Case (8) Front Crankshaft Seal. (9) Gear Case Cover (10) Tappets. (11) Camshaft. (12) Camshaft Gear Key. (13) Camshaft End Plate. (14) Camshaft Gear. (15) Idler Gear Shaft. (16) Idler Gear Bushing. (17) Idler Gear.
Page 365 Disassembly of Engine Head on page 80. 9. Remove the fuel injection pump from the gear Prepare a clean, flat working surface on a case / front plate only if it must be sent out for workbench large enough to accommodate the repair, or will interfere with other procedures such engine components.
Page 366 Figure 6-86 (1) Fuel Injection Pump Drive Gear. (2) Camshaft Drive Gear. (3) Auxiliary Drive Gear (Optional). Figure 6-85 (4) Crankshaft Drive Gear. (5) Direction of Rotation. (6) Oil Pump Drive Gear (4TNV94L - 4TNV106). Checking Timing Gear Backlash (7) Idler Gear. Prior to removing the timing gears, measure the gear backlash and determine the gear wear.
Page 367 Measuring Idler Gear-to-Camshaft Gear Backlash CAUTION 1. Drive a small wooden wedge between the crankshaft gear and idler gear to prevent the idler Do not loosen or remove the four bolts retaining gear from rotating. the fuel injection pump drive gear to the fuel injection pump hub.
Page 368 Removal of Camshaft 1. Before removing the camshaft, check the camshaft end play. • Method A : Install a dial indicator (Figure 6-92, (1)) on the cylinder block. Move the camshaft (Figure 6-92, (2)) back and forth to measure the end play.
Page 369 Removal of Gear Case or Front Plate 2. Remove the two bolts (Figure 6-94, (3)) retaining the camshaft thrust plate (Figure 6-94, (1)). NOTE : The camshaft must be removed before the gear case / front plate can be removed. See Inspection of Camshaft on page 125.
Page 370 Disassembly of Crankshaft and Piston 1. Using a feeler gauge, measure the connecting rod side clearance as shown (Figure 6-97). See Components Connecting Rod on page 72 for the standard limit. If the measurement is out of specification, replace Removal of Pistons the crankshaft, connecting rod, or both.
Page 371 IMPORTANT Mark the connecting rod caps and connecting rods so the caps and connecting rods stay together. (a) Remove the bearing cap. Do not remove the bearing inserts at this time. (b) Wipe oil from the bearing insert and crankshaft journal surfaces.
Page 372 Removal of Crankshaft 1. Remove the flywheel (Figure 6-101, (1)) from the crankshaft. 2. Remove the bolts from the rear oil seal assembly (Figure 6-101, (2-3)). Remove the assembly from the engine. Figure 6-100 8. Remove the circlips (Figure 6-100, (5)) from the wrist pin.
Page 373 • Method B : Use a feeler gauge to measure the 4. Remove the main bearing caps (Figure 6-104, (3)). Be sure to note the markings clearance (Figure 6-103, (3)) between the thrust bearing (Figure 6-103, (1)) and crankshaft on the main bearing caps, or mark them yourself, (Figure 6-103, (2)).
Page 374 NOTE : Do not remove the crankshaft gear unless the gear or crankshaft are damaged and require replacement. 8. If necessary, remove the crankshaft gear (Figure 6-107, (1)), parallel pin (Figure 6-107, (2)) and key (Figure 6-107, (3)). If using a gear puller, be careful not to damage the threads in the end of the crankshaft.
Page 375 Measure Crankshaft Bearing Oil Clearance 2. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212 to the outside diameter of a new oil seal (Figure 6-108, (2)), and install in the gear Oil clearance should be checked during disassembly case cover.
Page 376 Inspection of Pistons, Piston Rings and Wrist 5. Subtract the piston measurement from the greatest measurement acquired during cylinder inspection (see Inspection of Cylinder Block on page 109) to obtain piston-to-cylinder clearance. Record the measurements. See Piston on page NOTES 71 for specifications.
Page 377 NOTES • On an engine with low hours, the pistons, piston rings and cylinders may be reused if they are found to be within specifications. • On an engine with high hours, the pistons rings should be replaced and the cylinder honed (see Honing and Boring on page 126) or replaced.
Page 378 2. Measure the outside diameter of the tappet stem Inspection of Connecting Rod (Figure 6-118, (1)). See Tappet on page 72 for the 1. Measure the wrist pin bushing bore using a bore service limit. gauge (Figure 6-116, (1)). Replace the bushing if not within specifications.
Page 379 4. Use the color check method or Magnaflux® to Inspection of Camshaft inspect the crankshaft for cracks. Replace the crankshaft if evidence of fractures are found. 1. Use V-blocks and a dial indicator to check camshaft bend (Figure 6-121). Place the indicator 5.
Page 380 Honing and Boring Pistons must move freely in the cylinders while maintaining adequate compression and oil sealing. If the cylinder walls are scuffed, scored, out-of-round, or tapered beyond specifications, rebore and hone to restore cylinders to usable condition. Slight imperfections can be corrected by honing alone. 1.
Page 381 • When honing is completed, wash the cylinder block with hot water and soap. The cylinder wall CAUTION is adequately cleaned when a white rag wiped in cylinder comes out clean. Use brushes to clean Do not allow the honing tool to operate in one all passages and crevices.
Page 382 NOTE : The actual appearance of the match marks on the piston and connecting rod may vary, but they will always be in the same locations. Figure 6-127 3. Reinstall one circlip (Figure 6-127, (5)) into the piston. Ensure the circlip is securely seated in the groove.
Page 383 Piston Assembly When correctly assembled, the piston identification mark (Figure 6-129, (2)) stamped into the top of the piston will be on the same side of the connecting rod as the match marks (Figure 6-129, (4)) stamped into the connecting rod and connecting rod cap. When installed in the cylinder, the piston identification mark (Figure 6-129, (2)) stamped on the top of the piston must face the fuel injection...
Page 384 IMPORTANT Always use a piston ring installation tool (expander) when installing piston rings. Never attempt to install piston rings by hand. 3. Reinstall the oil ring expander (Figure 6-133, (4)). Reinstall the oil ring (Figure 6-133, (3)) with the end gap at 180° from the expander end gap. 4.
Page 385 7. Lubricate and install the piston wrist pin (Figure6- 70,(3)) through the piston and wrist pin bushing. 6. Install the second circlip (Figure6-70,(4)). 7. Install the piston rings: • Use piston ring pliers to install the piston rings. • Install each piston ring on the piston with the punched manufacturer’s mark (Figure6-72,(1)) facing upward.
Page 386 Installation of Crankshaft 1. If removed, reinstall the keys and timing gear on the crankshaft. 2. Reinstall new bearing inserts (Figure 6-135, (1)) and thrust bearing (Figure 6-135, (2)) in the cylinder block and main bearing caps. Apply a liberal coat of clean engine oil to the bearings and crankshaft journals.
Page 387 Installation of Pistons 5. Apply a light coat of clean engine oil to the bearing cap bolts and tighten the bolts to the specified torque in two stages (1/2 then full torque). See Special Torque Chart on page 6-25 IMPORTANT for specifications.
Page 388 4. Reinstall the bearing inserts (Figure 6-140, (1)) in the connecting rod and cap. Piston Orientation to Cylinder - By Model Orient the piston identification mark stamped on top 5. Apply a liberal coat of clean engine oil to the of the piston on the fuel injection pump side of the bearing inserts and crankshaft journal.
Page 389 4TNE98 Engine 1. Lubricate No. 1 piston and piston rings. 2. Using the piston insertion tool (piston ring compressor), compress the piston rings on the No.1 piston. 3. Carefully install the piston into No.1 cylinder. Be sure the punched mark on the connecting rod is facing the fuel injector side and the embossed mark on the connecting rod is facing the flywheel.
Page 390 Reassembly of Camshaft and Timing 2. Rotate the cylinder block so that gravity will keep the tappets (Figure 6-143, (5)) in place and out of Components the way of the camshaft lobes when the camshaft is being reinstalled. Installation of Gear Case or Front Plate NOTE : If the engine is not installed on an engine 1.
Page 391 Installation of Gear Case Cover 1. Apply a continuous bead of Three Bond Liquid Gasket No. 1212, Yanmar Part No. 977770- 01212 to the mounting area of the gear case cover (Figure 6-146, (1)). Be sure to circle the bolt holes. 2.
Page 392 Installation of Oil Pan 1. Reinstall the oil pickup tube (Figure 6-148, (1)) using a new O-ring (Figure 6-148, (2)). Figure 6-149 Figure 6-148 Final Reassembly of Engine 2. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212 to the mounting surface of the oil 1.
Page 393 Section 4. FUEL SYSTEM Before You Begin Servicing WARNING WARNING ENTANGLEMENT HAZARD! FUME / BURN HAZARD! Stop the engine before you begin to service it. Always read follow safety related precautions found on containers of hazardous NEVER leave the key in the key switch when substances like parts...
Page 394 CAUTION CAUTION NEVER remove or attempt to remove the After marking the position of the pump drive tamper-proof devices from the full-load fuel gear, do not rotate the engine crankshaft. adjusting screw or the high-speed throttle limit Rotating the crankshaft will cause the fuel screw on the fuel injection pump and governor injection pump to become misaligned.
Page 395 4TNV98 ENGINE Introduction This section of the Service Manual describes the procedures necessary to remove, install, and time the MP fuel injection pump and its associated system components. This fuel injection pump is representative of the fuel injection pumps used on other TNV DI model engines.
Page 396 Stop Solenoid Cold Start Device The MP fuel injection pumps are equipped with a The Yanmar TNV model engines are equipped with stop solenoid that controls the fuel flow inside the a cold start device (CSD). fuel injection pump. The cold start device is located in the upper section With the starter switch in the OFF position, no of the fuel injection pump and is connected to the current flows to the stop solenoid and the solenoid...
Page 397 Fuel System Specifications Special Torque Chart Lubricating Oil Application Component Tightening Torque (Thread Portion and Seat Surface) 29 ft·lb Fuel Injector Retainer Bolt Not Applied (39.2 N·m; 4 kgf·m) 83-91 ft·lb Fuel Pump Drive 4TNV98 (113-123 N·m; Not Applied Gear Nut 11.5-12.5 kgf·m) 22-25 ft·lb High-Pressure Fuel Injection Line Nuts...
Page 398 Test and Adjustment Specifications Engine Injector Model Fuel Injector Pressure Fuel Injection Timing Class ID mark* 3133-3278 psi See Checking and Adjusting 4TNV98 (21.6-22.6 MPa; Fuel Injection Timing on page 220-230 kgf/cm² NOTE: Fuel injection pressure of a new fuel injector is reduced approximately 72.5 psi (0.5 MPa; 5.0 kgf/cm²) after about 5 hours of operation due to the initial break in of the engine.
Page 399 Special Service Tools Tool Name Application Illustration For tightening nuts and bolts to Torque Wrench Locally Available the specified torque Used in conjunction with a slide Fuel Injector Yanmar Part No. hammer to remove the fuel Removal Tool 129470-92305 injectors (2-valve cylinder heads) Measuring Instruments Instrument Name Application...
Page 400 Fuel System Diagram Figure7-3 (1) Diesel Fuel Tank. (2) Fuel Filter / Water Separator. (3) Electric Fuel Pump. (4) Fuel Filter. (5) Air Bleed Orifice. (6) Fuel Supply Line. (7) Low Pressure Gallery. (8) Pressure Control Valve. (9) Trochoid Pump. (10) Oil Seal. (11) Fuel Injection Pump Cam. (12) Engine Crankcase.
Page 401 Fuel System Components 4-Valve Cylinder Head Figure 7-5 (1) High-Pressure Fuel Injection Lines. (2) Fuel Return Line. (3) Return Line-to-Cylinder Head Bolt (4) Fuel Injector. (5) Injection Line Grommet. (6) Front Plate or Timing Gear Case. (7) Gear Case Cover. (8) Fuel Injection Pump Drive Gear Nut. (9) Lock Washer.
Page 402 Fuel Injection Pump CAUTION Removal of Fuel Injection Pump Remove or install the high-pressure fuel injection lines as an assembly whenever 1. Loosen the cooling fan V-belt. possible. Disassembling the high-pressure fuel injection lines from the retainers or bending any 2.
Page 403 12. Separate the stop solenoid wiring connector (Figure 7-8, (2)). 13. Remove the rear fuel injection pump bracket(s) (Figure 7-8, (1)) from the fuel injection pump. NOTE: Configuration of the fuel injection pump rear brackets may vary depending upon engine model. Figure 7-9 15.
Page 404 16. To position the fuel injection pump for easier removal and installation, install a dial indicator CAUTION (see Checking and Adjusting Fuel Injection Timing on page 157) into the injection pump Do not loosen or remove the four bolts retaining plunger opening.
Page 405 22. Locate the mark stamped into the upper outside 20. Remove the pump drive gear and hub as an mounting boss of the fuel injection pump. assembly using an appropriate two-bolt gear puller (Figure7-14). Highlight this mark and make a corresponding mark on the gear case or front plate (Figure 7- 16, (1)).
Page 406 NOTE: The MP4 fuel injection pumps (4TNV98 model engines) are fastened to the gear case with CAUTION four (4) studs and nuts. NEVER remove or attempt to remove the 24. Remove the fuel injection pump (Figure 7-17, tamper-proof devices from the full-load fuel (1)).
Page 407 To locate the timing index number for the engine 2. If installing the fuel injection pump on an engine with the front gear case cover removed, the fuel being serviced use the Timing Index Chart under “FIE Specs” on the Yanmar Distributor Website injection pump drive gear can be aligned with the (http://distributor.yanmar.co.jp).
Page 408 • Tighten the fuel injection pump retaining nuts to 4. Align the key on the fuel injection pump shaft with specification. See Special Torque Chart on page the keyway in the fuel injection pump drive gear hub. Reinstall the fuel injection pump into the fuel 143.
Page 409 • Calculate the difference between the timing index The above calculated difference indicates that the numbers (Figure 7-26, (1)) of the fuel injection replacement fuel injection pump is to be installed pump that you removed and the replacement fuel at +0.5° (advanced) from the “Standard Mark” injection pump.
Page 410 6. Reinstall the rear bracket(s) (Figure 7-29, (1)) to the fuel injection pump. Tighten the rear support bolts. NOTE: Configuration of the fuel injection pump rear brackets may vary depending on the model. Figure 7-30 9. Apply Three Bond Liquid Gasket No. 1212 or equivalent sealant to the sealing surface of the pump cover.
Page 411 Checking and Adjusting Fuel Injection Timing Determining the Fuel Injection Timing Specification 1. Locate and record the fuel injection pump timing index number (Figure 7-34, (1)) stamped into the boss on the engine side of the fuel injection pump housing (Figure 7-33, (1)). Treat this number as though there is a decimal point between the two digits.
Page 412 2. Using the FIR number for the engine being Checking Fuel Injection Timing serviced use the Fuel Injection Reference (FIR) Chart under “FIE Specs” on the Yanmar NOTE: Some fuel may drain from the fuel injection Distributor Website pump during this process. Make provisions to (http://distributor.yanmar.co.jp).
Page 413 6. Using a wrench on the crankshaft pulley bolt, rotate the crankshaft in a clockwise direction while looking through the flywheel inspection port (Figure7-39, (1)). Rotate the crankshaft until the injection timing marks on the flywheel are visible. Figure 7-37 5.
Page 414 NOTE: The TDC (Top Dead Center) mark can be identified by the cylinder numbers stamped near the TDC mark on the flywheel. If you are uncertain as to the timing degree designation of the timing marks on the flywheel timing grid, you can determine the timing degree designation by measuring the timing grid.
Page 415 10. Rotate the crankshaft counter-clockwise until Adjusting Fuel Injection Timing the dial indicator shows that the injection pump plunger is at the bottom of its stroke. Rock the If the timing marks did not align when performing crankshaft back and forth slightly to confirm a the Checking Fuel Injection Timing on page 158, point where the dial indicator shows no the following steps must be performed to properly...
Page 416 9. Tighten the fuel injection pump mounting nuts 3. Note the reading on the dial indicator (Figure 7- and rear bracket(s). 44, (1)). If the reading is less than 2.5mm (0.098 in.), the fuel injection timing is “retarded.” If the dial indicator reading is greater than 2.5mm 10.
Page 417 Fuel Injectors 6. Remove the injector nozzle protector (Figure 7- 48, (5)) and seat (Figure 7-48, (6)) from the cylinder head. Discard both items. Removal of Fuel Injectors 7. Repeat steps to remove the remaining fuel 4-Valve Cylinder Head injectors. 1.
Page 418 Testing of Fuel Injectors CAUTION CAUTION Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. 1. Thoroughly clean the fuel injector nozzle using FLYING OBJECT HAZARD! clean diesel fuel and a brass wire brush. ALWAYS wear eye protection when servicing the engine and when using compressed air or 2.
Page 419 6. Pump the operating lever more rapidly to Disassembly and Inspection of Fuel repeatedly “pop” the injector and observe the Injectors spray pattern. The pattern should be a very fine uniform spray (Figure 7-50). If a dripping or an CAUTION uneven pattern is seen (Figure 7-51), service or replace the injector.
Page 420 5. Turn the injector over and remove the nozzle Adjusting Fuel Injector Pressure body, nozzle valve, valve stop spacer, nozzle spring seat, nozzle spring, and shims. The fuel injectors open when pressure reaches a predetermined pressure threshold. They close 6. Inspect the sealing surfaces (Figure 7-53, (2)) when the pressure is reduced below that threshold.
Page 421 See the parts catalog for available shims. Installation of the Fuel Injectors 4-Valve Cylinder Head CAUTION 1. Reinsert a new nozzle seat (Figure 7-57, (6)) Each pressure adjusting shim removed or and nozzle protector (Figure 7-57, (5)) in the added changes the pressure threshold by cylinder head for each injector.
Page 422 4TNE98 ENGINE Fuel System Special Torque Chart Lubricating Oil Application Component Tightening Torque (Thread Portion and Reference Page Seat Surface) 29.4 ft·lbs See Installation of Fuel Fuel Injector Not Applied (39.2 N·m, 4 kgf·m) Injectorson page 200 43.5 - 51.0 ft·lbs Fuel Pump Drive See Installation of the Fuel (59 - 69 N·m,...
Page 423 Fuel System Components Figure 7-1 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System...
Page 424 Fuel System Components Figure 7-2 Fuel is fed from the fuel tank into the fuel inlet of the Although the fuel pressure in the pump chamber is injection pump by the feed pump built into the proportional to the pump revolution, excessive fuel injection pump via the oil separator and fuel filter.
Page 425 Structure And Operation Of Fuel Injection Pump Figure 7-3 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System...
Page 426 Overview Governor Pump Figure 7-4 The drive shaft directly receives the engine revolution via the timing belt (or gear) and transfers it to the cam disc via the cross coupling. Since the Figure 7-5 dowel pin of the cam disc is integrated with the plunger and fixed in the groove in the plunger collar, The governor is located above the inspection pump the plunger operates at the same speed as the cam...
Page 427 Timer Feed Pump (Vane Type) Figure 7-6 Figure 7-7 At the bottom of the injection pump is the built-in The feed pump functions to feed fuel from the fuel tank to the pump chamber. timer. A timer spring having a set force is installed on the low pressure side of the timer piston.
Page 428 Figure 7-9 shows typical relationships between Regulating Valve pump revolutions and pump chamber pressure. The hydraulic timer directly uses the pump chamber pressure for controlling the injection timing. Figure 7-8 The regulating valve regulates the fuel feeding pressure of the feed pump so that the fuel pressure in the pump chamber is maintained within the specified pressure range.
Page 429 Plunger Operation Figure 7-3 The drive shaft simultaneously drives the feed pump, cam disc and plunger. The plunger spring presses the plunger and cam disc onto the roller. When the cam disc turns by means of the drive shaft, the face cam moves on the roller to activate the plunger’s reciprocating operation.
Page 430 Process Injection Process Suction Process Figure 7-12 Figure 7-10 Figure 7-13 The plunger begins rotating at the same time the Figure 7-11 lifting process of the cam disc begins. When the inlet port of the plunger barrel is covered by the When the inlet port of the plunger barrel overlaps plunger, pressure feeding of fuel is initiated.
Page 431 End of Injection Uniform Pressure Process Figure 7-14 Figure 7-16 Figure 7-15 Figure 7-17 When the plunger is further lifted up by the cam When the plunger turns a further 180° after the end disc until the cutoff port of the plunger just overruns of fuel injection, the uniform pressure slit of the the control sleeve, the high-pressure fuel in the plunger meets the outlet port of the plunger barrel.
Page 432 Reverse Rotation Prevention Fuel Injection Volume Adjustment Mechanism Mechanism Figure 7-18 Figure 7-19 While the plunger is rotating in the correct direction, The fuel injection volume is increased or decreased the fuel is sufficiently drawn into the plunger since by changing the control sleeve position, resulting in the inlet port of the plunger barrel opens during the change of the effective stroke.
Page 433 Delivery Valve Assembly Delivery Valve Holder with Damping Valve Figure 7-21 The delivery valve holder with damping valve functions to prevent cavitation erosion in the pipe at Figure 7-20 high speed, unstable fuel injection and secondary injection. The delivery valve assembly consists of the delivery valve and valve seat.
Page 434 All - Speed Governor Figure 7-22 Figure7-22 shows the composition of the all-speed governor. Revolution of the shaft is transferred to the flyweight holder acceleration gear via the drive gear to turn the flyweight holder. The flyweight holder is supported by the governor shaft.
Page 435 The start and tension levers contact each other and move together during engine operation. Above the tension lever is the governor spring which is connected to the control lever. Movement of the control lever is capable of changing the set force of the governor spring.
Page 436 At Start of Engine Figure 7-25 It is necessary to increase the injection volume in order to improve the starting characteristics at engine start. When the accelerator pedal is pressed while the engine is stopped, the tension lever is pulled until it comes into contact with press-in pin M by governor spring force.
Page 437 During Idling Figure 7-26 When the engine starts and the accelerator pedal is released, the control lever returns to the idle position and the tension of the governor spring becomes zero. Therefore, the flyweight opens outwardly even at low revolutions to move the governor sleeve to the right.
Page 438 At Full-Load Maximum Speed Control Figure 7-27 When the accelerator pedal is pressed down all the way and the control lever comes into contact with the maximum speed stopper bolt, the tension of the governor spring becomes maximum. At this time, the tension lever is fixed at the position where is contacts pin M being pressed into the pump housing.
Page 439 At No-Load Maximum Speed Control Figure 7-28 When the engine revolutions increase and the flyweight centrifugal force exceeds the governor spring set force, the governor sleeve moves to make the governor lever assembly turn clockwise with fulcrum M . As a result, the control sleeve moves in the direction of no-injection (to the left) for controlling speed so as not to exceed the full-load maximum speed.
Page 440 Full-Load Position Adjustment Mechanism Figure 7-29 The full-load position is determined by the amount the full-load adjusting screw is driven. When the screw driven, corrector lever turns counterclockwise with M being the fulcrum to move the control sleeve to the fuel increase direction. When the screw is loosened, the control sleeve moves to the fuel decrease direction.
Page 441 Structure And Operation Of Timer Consequently, the timer is installed under the The ignition period which occurs in the combustion injection pump in order to correct the ignition delay process of a diesel engine tends to increase as the period by shortening the injection timing of the speed becomes higher.
Page 442 Magnetic Valve (Stop Solenoid) Figure 7-31 The magnetic valve (stop solenoid) turns on or off as the ignition switch of the vehicle is operated to open or close the fuel path connected to the inlet port of the plunger barrel. When the ignition switch is turned on, power is supplied to the magnetic valve to lift the armature, thus opening the fuel path.
Page 443 Removal Of Fuel Injection Pump • Finish loosening all the high pressure fuel line nuts and remove the fuel lines as an assembly. Be careful not to bend any of the fuel lines. 1. Remove fuel supply line from the fuel injection pump.
Page 444 Figure 7-35 10. Remove the seven bolts from the fuel injection pump cover (Figure7-36, (1)) on the front gear Figure 7-34 case. Remove the cover. • Loosen the bolt (Figure7-34, (2)) that fastens NOTE: The cover is secured with an adhesive the remaining bracket to the cylinder block and sealant.
Page 445 CAUTION Do not rotate the engine with the injection pump removed. Figure 7-39 Figure 7-37 13. Using a two-bolt gear puller, remove the Also make matching marks (Figure7-38, (1)) on the injection pump drive gear (Figure7-39, (3)) from rear of the gear case housing and on the fuel the injection pump shaft.
Page 446 Installation Of The Fuel Injection 3. Install the drive gear retaining nut (Figure7-42, (1)) and washer (Figure7-42, (2)). While holding Pump the engine with a wrench on the crankshaft pulley bolt, torque the retaining nut to 43.5 - 51 ft 1.
Page 447 Figure 7-45 Figure 7-43 9. Reinstall the two bolts (Figure7-45, (1)) to the L- 5. Reinstall the cooling fan (Figure7-44, (1)), shaped bracket that holds the injection pump at spacer (if equipped) (Figure7-44, (2)) and V-belt the bottom / rear. Tighten the two bolts and the bolt that secures the bracket to the cylinder block (Figure7-44, (3)).
Page 448 Checking / Adjustment Of Fuel Injection Timing 1. Using a wrench on the front crankshaft pulley bolt, rotate the engine clockwise until the timing mark on the crankshaft pulley is aligned with the “O” or TDC (Top Dead Center) mark on the timing grid of the gear case cover.
Page 449 10. Then retighten the pump mounting nuts and the 4. Install Yanmar timing tool (Figure7-49, (1)), into mounting bracket bolts. the port where the bolt was removed. This will provide a reading of the injection pump plunger lift. NOTE: Rotating the injection pump away from the engine advances the injection timing.
Page 450 Servicing The Fuel Injectors CAUTION Removal of the Fuel Injectors Remove the high-pressure fuel injection lines as an assembly whenever possible. 1. Remove the high pressure fuel lines. Disassembling the high-pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines.
Page 451 Inspection and Testing of the Fuel 5. Adding or removing a 0.1 mm shim (shims are available in 0.4 mm increments) changes the Injectors pressure by 174 - 319 PSI (1.2 - 2.2 MPa). Visually inspect the fuel injectors and nozzle protectors for deposits or damage.
Page 452 Figure 7-54 8. If the fuel injector fails any of these tests, it should be repaired or replaced as necessary. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System...
Page 453 Judgement Criteria on Atomization Condition Injection Pattern Pressure Gauge Pointer fluctuate Same as A. Pointer stays at Although the Pressure does Reading around the valve a position near pointer reaches not increase opening the valve the valve even when the tester lever is pressure.
Page 454 Cleaning of Nozzle (Figure7-55, (2)) on the fuel injection pump. 1. Clean the exterior of the nozzle, taking care not • Tighten the high pressure fuel line nuts to damage the needle. (Figure7-55, (1)) on the fuel injectors. 2. Pull out the needle and clean carefully so as not to damage it.
Page 455 Section 5. COOLING SYSTEM Before You Begin Servicing DANGER WARNING ENTANGLEMENT HAZARD! SCALD HAZARD! Stop the engine before you begin to service it. NEVER remove the radiator cap if the engine is NEVER leave the key in the key switch when hot.
Page 456 WARNING CAUTION Only use the engine coolant specified. Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale and/or shorten engine life. BURN HAZARD! Prevent dirt and debris from contaminating the If you must drain the engine oil while it is still engine coolant.
Page 457 Introduction This section of the Service Manual describes the procedures necessary to service the 4TNV84 engine coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model engines. For specific part detail, see the parts catalog for the engine you are working on. Cooling System Diagram Figure 8-1 (1) Cylinder Head.
Page 458 Engine Coolant Pump Components Figure 8-2 (1) Thermostat Cover. (2) Thermostat Cover Gasket. (3) Thermostat. (4)Thermostat O-Ring. (5) Special O-Ring. (6) Engine Coolant Pump. (7) Temperature Switch. (8) Gasket. (9) Engine Coolant Pump Gasket. (10) V-Belt. (11) Engine Coolant Pump V-Pulley. (12) Spacer. (13) Engine Coolant Fan 4TNV98 &...
Page 459 Engine Coolant System Check 1. Before removing the engine coolant pump or thermostat, it will be necessary to drain the engine coolant. Drain the coolant into a clean Check the engine coolant system for leakage. container if the coolant is to be reused. Otherwise, properly dispose of the coolant.
Page 460 • On models not equipped with an oil cooler, remove the coolant drain plug (Figure 8-6, (1)) from the engine block. Figure 8-7 Figure 8-6 7. Disconnect the coolant hoses and the temperature switch lead wire from the engine 5. Loosen the alternator mounting bolts. Loosen coolant pump.
Page 461 Disassembly of Engine Coolant Pump Cleaning and Inspection 1. Remove the thermostat cover (Figure 8-8, (1)). Thermostat Discard the gasket. 1. Check for proper operation of the thermostat. Place the thermostat (Figure 8-10, (1)) and an accurate thermometer (Figure 8 -10, (2)) in warm water.
Page 462 Reassembly of Engine Coolant Pump Installation of Engine Coolant Pump 1. Reinstall the thermostat (Figure 8-12, (1)) and a 1. Position the engine coolant pump on the engine new O-ring. and install a new gasket. Install a new special O- ring (Figure 8-12, (5)) on assembly between the engine coolant pump and the joint.
Page 463 5. Inspect the condition of the V-belt. There must be clearance (Figure 8-14, (1)) between the V-belt and the bottom of the pulley groove. If there is no clearance (Figure 8-14, (2)) between the V-belt and the bottom of the pulley groove, replace the V-belt.
Page 464 Section 6. LUBRICATION SYSTEM Before You Begin Servicing WARNING WARNING ENTANGLEMENT HAZARD! Stop the engine before you begin to service it. BURN HAZARD! NEVER leave the key in the key switch when you Keep your hands and other body parts away servicing engine.
Page 465 CAUTION CAUTION Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. Prevent dirt and debris from contaminating the engine oil. Carefully clean the oil cap/dipstick and the surrounding area before you remove the FLYING OBJECT HAZARD! cap.
Page 466 Introduction This section of the Service Manual describes the procedures necessary to service the 4TNV98 Trochoid oil pump. See Replace Engine Oil and Engine Oil Filter on page 51 for engine oil and engine oil filter replacement procedures. Oil Pump Service Information Engine Oil Pressure - All Models At Rated Engine RPM At Low Idle Speed...
Page 467 Rotor Shaft Clearance Reference Model Inspection Item Standard Limit Page 0.5110 - 0.5126 in. 0.5138 in. Gear Case Bearing I.D. Check Rotor (12.980 - 13.020 mm) (13.05 mm) Shaft 0.5100 - 0.5108 in. 0.5096 in. 4TNV98 Clearance Rotor Shaft O.D. (12.955 - 12.975 mm) (12.945 mm) 0.0014 - 0.0026 in.
Page 468 Lubrication System Diagram Figure 9-1 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System...
Page 469 Checking Engine Oil Pressure Trochoid Oil Pump Perform an engine oil pressure check if there is any Oil Pump Components indication of low oil pressure such as the oil pressure indicator is on or the oil pressure gauge The oil pump on these model engines is located in indicates low oil pressure.
Page 470 Disassembly of Oil Pump CAUTION If the oil pump must be replaced, replace it as an assembly only. not replace individual components. Remove the engine cooling fan guard (if equipped), engine cooling fan (Figure 9-15, (3)), spacer (Figure 9-15, (2)), engine coolant pump V-pulley Figure 9-16 (Figure 9-15, (1)) and V-belt.
Page 471 Check Rotor Shaft Clearance Outer Rotor to Inner Rotor Tip Clearance Determine the outer rotor to inner rotor tip clearance. Determine the rotor shaft clearance. Measure the Insert a feeler gauge between the top of an inner outside diameter of the rotor shaft (Figure 9-20, (1)) and the bore diameter in the gear case housing rotor tooth (Figure 9-18, (1)) and the top of an outer (Figure 9-20, (2)).
Page 472 3. Reinstall the oil pump assembly (Figure 9-22, (1)) into the gear case housing (Figure 9-22, 2). Tighten the bolts to specified torque. Figure 9-22 4. Reinstall the gear case cover and crankshaft pulley. See Installation of Gear Case Cover on page 137.
Page 473 Section 7. STARTER MOTOR Before You Begin Servicing WARNING WARNING ENTANGLEMENT HAZARD! Stop the engine before you begin to service it. SHOCK HAZARD! NEVER leave the key in the key switch when Always read follow safety related you are servicing the engine. Someone may precautions found on containers of hazardous accidentally start the engine and not realize you substances...
Page 474 CAUTION CAUTION The starter motor is water-proofed according to JIS D 0203, R2 which protects the motor from rain or general cleaning. Do not use high- pressure wash or submerse the starter motor in water. FLYING OBJECT HAZARD! ALWAYS wear eye protection when servicing the engine and when using compressed air or CAUTION high-pressure...
Page 475 This section of the Service Manual covers the servicing of the starter motor. This starter motor is used in this section to show the service procedures for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the engine you are working on. Starter Motor Information No Load Loaded DOOSAN Mfg. Part Mfg. Part Specification...
Page 476 Starter Motor Specifications A408417 DOOSAN Part Number 3.0 hp (2.3 kW) Nominal Output Weight 12.1 lb(5.5 kg) Clockwise Revolution Direction (As Viewed From Pinion) Magnetic Shift Engagement System 11 V / 140 A max Terminal Voltage / Current No-load 4100 rpm (min-1) Revolution 2.5 V / 1050 A max...
Page 477 Starter Motor Troubleshooting 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor...
Page 478 Starter Motor Components Figure 11-1 (1) Pinion Shaft. (2) M4 Bolts (3 used). (3) Bearing Retainer. (4) Pinion Clutch Assembly. (5) Return Spring. (6) Pinion Stop. (7) Retaining Ring. (8) Gear Housing. (9) Shift Lever. (10) Torsion Spring. (11) Plunger. (12) Dust Covers (Shims). (13) Magnetic Switch Assembly (Solenoid).
Page 479 Starter Motor WARNING SHOCK HAZARD! Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system. Check the electrical harnesses for cracks, abrasions, damaged corroded connectors. ALWAYS keep the connectors and terminals clean. Failure to comply could result in death or Figure 11-2 serious injury.
Page 480 Figure 11-6 6. Pull the armature assembly (Figure 11-6, (3)) out from the field coil assembly (Figure 11-6, (2)). Figure 11-4 7. Remove the two M6 bolts (Figure 11-7, (1)) 3. Remove the two M5 through bolts (Figure 11-4, retaining the magnetic switch assembly (Figure (4)).
Page 481 9. Remove the three M4 bolts (Figure 11-9, (1)) securing the bearing retainer assembly (Figure 11-9, (2)) to the gear housing. Remove the bearing retainer assembly from the gear housing. Figure 11-11 Cleaning and Inspection Armature Commutator Surface Inspection Figure 11-9 If the commutator surface is rough, polish the surface with a #500 to #600 emery cloth (Figure 10.
Page 482 Armature Coil Continuity Test Check for continuity between the commutator segments using a multimeter (Figure 11-15). The multimeter should indicate continuity. Figure 11-13 See Starter Motor Specifications on page 222 for the service limit. Measure Commutator Insulation Depth Measure the depth of the insulating material Figure 11-15 (Figure11-14, (1)) between commutator segments If the multimeter does not indicate continuity,...
Page 483 Field Coil Insulation Test Measure Armature and Commutator Run-Outs Measure the armature core run-out and the Check for continuity between the field coil terminal commutator run-out using a dial indicator (Figure and the yoke using a multimeter (Figure11-19). The multimeter should not indicate continuity. 11-17).
Page 484 Magnetic Switch Series Coil Continuity Test If the starter motor becomes wet, replace the Check for continuity between the “S” and “M” magnetic switch even if the magnetic switch terminals using a multimeter (Figure11-22). The assembly function is normal. multimeter should indicate continuity. Shunt Coil Continuity Test If the multimeter does not indicate continuity, replace the magnetic switch.
Page 485 Slide the pinion clutch assembly on the shaft. It Contact Continuity Test should slide smoothly on the shaft (Figure11-25). Depress the plunger at the bottom of the magnetic Rust, too much grease or damage could prevent switch. Check for continuity between the “B” and the pinion clutch from sliding smoothly.
Page 486 Reassembly of Starter Motor 5. Reassemble the magnetic switch assembly to the gear housing. Pry the pinion away from the gear housing to allow installation of the magnetic 1. Apply the appropriate starter bendix grease switch assembly (Figure 11-29). (obtain locally) to the pinion shaft. Reassemble the pinion shaft (Figure 11-27, (5)), pinion clutch assembly (Figure 11-27, (1)), return spring (Figure 11-27, (4)) and pinion stop (Figure 11-...
Page 487 8. Position the brush springs in brush holders Check Pinion Projection Length (Figure 11-31). Reinstall the brushes in the brush holders. Reversing the brushes will cause 1. Connect the positive (+) lead from a battery to the starter motor to turn backwards. the “S”...
Page 488 No-Load Test 6. Use a suitable tachometer to monitor the rpm of the starter. Test the characteristics of the starter motor by 7. Turn the switch to the ON position. Monitor the performing a no-load test. rpm, amperage draw and voltage. For test specifications, see page 221 for the appropriate CAUTION starter motor.
Page 489 Section 8. TROUBLESHOOTING Special Service Tools For measuring compression pressure Yanmar Gauge Set Part No. TOL-97190080 Adapter for direct injection 2-valve cylinder head Yanmar Adapter Part No. 119802-92950 Compression Gauge Kit Adapter for direct injection 4-valve cylinder head for 4TNV94L/98/98T Yanmar Adapter Part No.
Page 490 Troubleshooting By Measuring 4. Before installing the compression gauge (Figure 14-1, (1)) adapter, crank the engine with the stop Compression Pressure solenoid disconnected for a few seconds to clear the cylinder of any residual fuel. Compression pressure drop is one of the major causes of increasing blow-by gas (engine oil 5.
Page 491 Standard Compression Pressure (Reference Value) Compression Pressure Engine Model Deviation Between at 250 rpm (250 min-1) Cylinders Standard Limit 483 - 513 psi 384 - 414 psi 29 - 43 psi 4TNV98 (3.33 - 3.53 MPa; (2.65 - 2.85 MPa; (0.2 - 0.3 MPa;...
Page 492 Compression Pressure Engine Model Deviation Between at 250 rpm (250 min-1) Cylinders Standard Limit 426 ± 15 psi 341 ± 15 psi 29 to 43 psi 4TNE98 (2.94 ± 0.1 MPa, (2.35 ± 0.1 MPa, (0.2 to 0.3 MPa; 30 ± 1 kgf/cm²) 24 ±...
Page 493 Measured Value and Troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective Action Clogged element Clean the element. Air Cleaner Element Broken element Replace the element. Defect at element seal portion Valve Clearance Excessive or no clearance...
Page 494 Troubleshooting Charts 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting...
Page 495 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting...
Page 496 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting...
Page 497 Wiring Diagram Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine manufacturer for specific information. 4TNV98 Engine 4TNV98 &...
Page 498 4TNE98 Engine 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting...
Page 499 SB4320E00 Jan. 2008 Service Manual G424FE LP/Engine G424F LP/Gasoline Engine G20G, G25G, G30G...
Page 501 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 503 Testing Fuel Lock-off Operation ....26 Index Pressure Regulator/Converter Inspection..27 Inspect Air/Fuel Valve Mixer Assembly ..27 Inspect for Intake Leaks........ 27 Inspect Throttle Assembly......27 Checking the TMAP Sensor......27 Chapter 1. GENERAL INFORMATION Exhaust System Maintenance......27 Inspect Engine for Exhaust Leaks....
Page 504 Oil Pump Assembly ........... 73 G424FE EMS (Engine Management System) Camshaft Case Assembly ......... 74 Overview ............131 General Description ........131 Cylinder Head............. 78 LPG Fuel System Operation ......134 Valve, Spring or Seal ......... 79 Electronic Throttle System ......141 Ignition System..........142 Engine Disassembly ..........
Page 505 AVV (Air Valve Vacuum) Testing..184 ..............216 Removal ............216 Connection of the MI-07 Service Tool... 184 Idle Mixture Adjustment......185 Inspection............217 Parts Description......... 188 Installation ...........217 CA100 Mixer for G424FE Engine ..188 N-2007 Regulator for G424FE Engine.. 190 Fuel Pump............218 Removal (Including Fuel Filter And Fuel G424F LPG System Inspection and Repair..
Page 506 Chapter 9. ADVANCED DIAGNOSTICS Reading Diagnostic Fault Codes..... 248 Displaying Fault Codes (DFC) from SECM Memory............. 248 Clearing Fault (DFC) Codes......248 Fault Action Descriptions........ 249 Fault List Definitions........249 Table 1. Fault List Definitions ...... 250 Table 2. Diagnostic Fault Codes (Flash Codes) ..............
Page 507 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.
Page 508 Replacement Part Genuine Part When oil seal, O-ring, packing and gasket have When the part is to be replaced, be sure to use been removed, be sure to replace them with new genuine part. parts. For selection of appropriate parts, refer to the Parts However, rocker cover gasket may be reused if it is Catalog.
Page 509 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.
Page 510 Tightening Torque Tightening Torque Table of Standard Parts Torque (kg·m) Bolt nominal diameter Pitch (mm) (mm) Head mark 4 Head mark 7 0.3 ~ 0.4 0.5 ~ 0.6 0.5 ~ 0.6 0.9 ~ 1.1 1.25 1.2 ~ 1.5 2.0 ~ 2.5 1.25 2.5 ~ 3.0 4.0 ~ 5.0...
Page 511 Recommended Lubricants and Capacities Recommended Lubricants Lubricant Specification Remarks Engine Oil API Classification SJ or above SAE 10W30 or SAE 5W30 Automotive antifreeze Concentration level 50%(normal) Coolant (Antifreeze) suitable for gasoline engines Concentration level 40%(tropical) having aluminum alloy parts Lubricant Capacities Description G20/25/30G-5 Oil Pan...
Page 512 Engine Model and Engine Serial Indication of Engine Model and Serial Number Number Engine Emission Fuel Type Model Regulation EPA/CARB* G424FE 2007 Compliant G424F LP/Gasoline * EPA: Environmental Protection Agency * CARB: California Air Resources Board G424FE Engine Engine Model Engine Serial Number •...
Page 513 General Specification G424FE Engine G424F Engine GENERAL DESCRIPTION ENGINE TYPE: Water-cooled, Inline 4-Cycle, 4-Cylinders COMBUSTION SYSTEM: Squish Combution Chamber INTAKE MANIFOLD Cast Aluminum (with injector ports) EXHAUST MANIFOLD Cast Iron (dual channel) VALVE CONFIGURATION: SOHC, 2 Valves per Cylinder VALVE LIFTER/LASH ADJUSTER Stationary Hydraulic Lash Adjusters VALVE ROTATOR Exhaust Rotator...
Page 514 G424FE Engine G424F Engine COOLING SYSTEM WATER PUMP ROTATION: Toothed Timing Belt Drive- Clockwise from front of engine Opening Temperature: 82°C (180°F) THERMOSTAT: Fully Open Temperature: 95°C (203°F) COOLING WATER CAPACITY: 3.0 L LP FUEL SYSTEM Closed loop LP Carburetion Open loop LP Carburetion LP FUEL SYSTEM System...
Page 515 G424F/G424FE Engine Power and Torque G424FE G424F ENGINE MODEL unit G424FE-LP G424F-LP G424F- GAS 46.2 46.2 44.7 RATED POWER 62.9 62.9 60.8 2,550 2,550 2,550 ibf-ft MAX TORQUE Kgf-m 18.5 18.5 17.5 2,200 2,200 2,200 GOVERNED SPEED 2,600 2,600 2,600 LOW IDLE G424F(FE) Service Manual Chapter 1.
Page 516 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 •...
Page 517 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.
Page 518 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.
Page 519 3. Refill with engine oil filter. CAUTION 1) Clean and install the oil drain plug with a new At this time, necessarily screen the spark plug gasket. hole with a rag. Because hot coolant, oil, fuel, and other foreign material, being penetrated in Torque 40~70 N·m the cylinder through cracks can come into the...
Page 520 DOOSAN prefers the use of distilled water or deionized water to reduce the potential and severity of chemical insolubility.
Page 521 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.
Page 522 Checking and Adjusting Drive Belt 3. Tighten the bolt “A” and then tighten “B” to the specified torque. CAUTION If the belt tension is too excessive, noise as well as early wear of belt occurs and the water pump bearing and alternator bearing are damaged. If the belt is too loose, due to early wear of belt and insufficient power of alternator, battery and water pump become inefficient and finally...
Page 523 Ignition System Maintenance CAUTION Inspect Battery System Because ignition timing is fixed by set data value in ECU, it is impossible to control on • Clean battery outer surfaces with a mixture of purpose. baking soda and water. Fist, check that sensors send output properly to help determine ignition timing control.
Page 524 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.
Page 525 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 Contact point is black white...
Page 526 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 10.
Page 527 Pressure Regulator/Converter Checking the TMAP Sensor Inspection • Verify that the TMAP sensor (F) is mounted tightly into the manifold or manifold adapter (E), with no • Visually inspect the pressure regulator/converter leakage. (B) housing for coolant leaks. • If the TMAP is found to be loose, remove the •...
Page 528 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 Chapter 2.
Page 529 G424F(FE) Service Manual Chapter 2. Recommended Maintenance...
Page 530 Chapter 3. ENGINE MECHANICAL SYSTEM General Information Engine Outline G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 531 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......................57.9820 – 57.9950 mm Journal diameter ........................ 48971 – 49987 mm Maximum clearance between trunnion and shell ..............0.015 – 0.041 mm Clearance between journal and connecting rod shell ............
Page 532 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 0.060 mm (exhaust) Available oversize ....................0.075 a 0.150 e 0.250 mm Valve seat eccentricity tolerance (between maximum and minimum readings)........
Page 533 Shells Selection Table MAIN BEARINGS – STANDARD SIZE (*) (*) ALL MEASURES ARE IN MILLIMETERS G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 534 MAIN BEARINGS – 0.50 UNDERSIZE (*) G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 535 CONNECTING ROD BEARINGS CONNECTING ROD BEARINGS 0.25 UNDERSIZE 0.50 UNDERSIZE G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 536 Recommended Torque Values nuts N•m Starter to cylinder block Exhaust manifold to cylinder head 18-22 Dipstick oil tube to cylinder block 20-30 DIS Ignition Module to camshaft housing carrier Throttle body to intake manifold 11-13 Pressure plate to camshaft housing Intake manifold to cylinder head 18-22 Crankshaft position sensor...
Page 537 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° Coolant temperature sensor to thermostat housing Thermostat housing to cylinder head Carrier plate (DIS ignition module) to camshaft housing Relief valve plug to oil pump 45 - 60 Toothed belt cover, lower part to rear toothed belt cover...
Page 538 Troubleshooting Symptom Possible cause Remedy Cylinder head gasket damaged Replace gasket Worn or damaged piston ring Replace ring Low compression Worn piston or cylinder Repair or replace piston and cylinder block Worn or damaged valve seat Repair or replace valve and seat ring Insufficient engine oil Check engine oil level Oil pressure switch defective...
Page 539 Engine Exploded View (1 of 2) 1) RING KIT 2) PISTON 3) BEARING KIT 5) ROD 6) BOLT 13) INDICATORK,OIL LVL 14) HOSE 16) GASKET 17) BOLT 20) PLUG 21) ENGINE 22) SEAL 23) BOLT 24) GEAR 25) GEAR 26) SEAL 27) COVER 28) BOLT 41) PAN,OIL...
Page 540 Engine Exploded View (2 of 2) 1) ENGINE 3) SPARK PLUG 4) ARM 5) SEAT 6) ADJUSTER 7) KEY 8) CAP 9) SPRING 10) SEAL 11) SEAT 12) GUIDE 28) STUD 29) NUT 31) MANIFOLD 32) GASKET 33) VALVE 34) SEAT 35) VALVE 36) SEAT 37) GASKET...
Page 541 Intake manifold and gasket Components 1) Gasket 2) Intake Manifold Assy 3) Stud Bolt 4) Nut 5) Fitting 6) Tmap 7) Bolt 8) Bracket-Stay 9) Washer 10) Bolt 11) Washer 12) Bolt 13) Pipe 14) Plug 15) Hose 16) Hose 17) Clamp 18) Washer 19) Bolt...
Page 542 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.
Page 543 Installation 7. Put the pipe on the manifold. 8. With a 10-mm socket wrench, extension and Install or connect proper torque wrench; tighten. 1. Coolant pipe attaching bolt with cylinder block in Tighten its place. • Bolts: 5 – 6 N·m (3.7 – 4.4 lb·ft.). 9.
Page 544 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.
Page 545 Exhaust Manifold and Gasket Components 1) Gasket 2) Adapter-Exhaust Manifold 3) Bolt 4) Washer 5) O2 Sensor 6) Stud Bolt 7) Washer 8) Bolt 9) Exhaust Manifold 10) Shield 11) Gasket G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 546 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.
Page 547 Timing Belt Components 1) Cover 2) Bolt 3) Adapter 4) Bolt 5) Cover 6) Bolt 7) Sprocket 8) Washer 9) Bolt 10) Belt-timing 11) Tensioner-Timing Belt 12) Bolt 13) Spacer 14) Key 15) Seal 16) Sprocket 17) Washer 18) Bolt 19) Bolt 20) Stud 21) Nut...
Page 548 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.
Page 549 Description Specification Glossy back side. Due to non-elasticity and hardening, 1. Back side rubber is hardened 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 Tooth loaded from canvas is worn (elastic canvas fiber rubber 4.
Page 550 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.
Page 551 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.
Page 552 PCV Valve Outline and Operation Principle Engine condition No operating Engine condition At idle or deceleration PCV valve No operating PCV valve Full operating Vacuum path Clogged Vacuum path Small Engine condition Proper operating Engine condition High speed and overload PCV valve Proper operating PCV valve...
Page 553 Crankcase Ventilation Secondary Vent Secondary Vent (Fresh Air Port) (Fresh Air Port) Primary Vent Primary Vent “Herringbone separator” lies on horizontal. “Herringbone separator” lies on horizontal. Oil Fill Cap Oil Fill Cap to PCV to PCV Shown here in vertical for viewing ease. Shown here in vertical for viewing ease.
Page 554 TROUBLESHOOTING Service Procedure REMOVAL 1. Disconnect the vacuum hose from the PCV valve. 2. With the engine at idle, Check the intake manifold 1. After disconnecting the vacuum hose (A), remove for vacuum when clogging the opened end of PCV the PCV valve (B).
Page 555 Camshaft Timing Pulley and/or Installation Seal Install or connect Removal 1. New seal in the camshaft case, with the aid of tool KM-422, camshaft pulley washer and bolt. Remove or disconnect 2. Camshaft timing pulley and its bolt, with a 22-mm 1.
Page 556 • 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.
Page 557 Camshaft Case Cover and Crankshaft Accessory Pulley Gasket 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. Crankshaft accessory pulley attaching bolt, with a 2.
Page 558 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.
Page 559 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.
Page 560 Cooling System General Description Water Outlet Assy Water Outlet Assy (attaches to cyl head) (attaches to cyl head) Upper outlet to Upper outlet to ancillary device ancillary device Lower outlet Lower outlet Carrier Carrier to water to water pump inlet pump inlet Cylinder Cylinder...
Page 561 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.
Page 562 Testing and Adjusting 5. Inspect the drive belts for the fan. Adhere to the following warnings when performing 6. Check for damage to the fan blades. any tests or adjustments while the engine is running: 7. Look for air or combustion gas in the cooling WARNING system.
Page 563 Pressure Cap Test Cooling System Leak Check To test the cooling system for leaks, use the following procedure: WARNING If the engine has been in operation and the coolant is hot, slowly loosen the pressure cap to the first stop and let the pressure out of the cooling system, then remove the pressure cap.
Page 564 Thermostat Cooling System Heat Problems The thermostat is the wax pellet type. A jiggle To check if there is a good reason for heat problems valve (which improves air bleeding during water do the checks that follow: supply) is provided on the flange part. When the thermostat is closed, the circulation of coolant is 1.
Page 565 For these reasons, be sure to maintain the concentration level within the DOOSAN prefers the use of distilled water or specified range. deionized water to reduce the potential and severity of chemical insolubility.
Page 566 Make proper antifreeze additions. 9. Thermostat housing. Adding pure antifreeze as a makeup solution for Installation cooling system top-up is an unacceptable practice. It increases the concentration of antifreeze in the Install or connect cooling system which increases the concentration of 1.
Page 567 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.
Page 568 Lubrication System General Description OIl Filter Lubricating system is the full-flow filtered pressure- feed oil system and the oil reserved in the oil pan is fed with pressure to each part of engine. After the oil pressure is adjusted through the relief valve, the oil is fed to the cylinder blocks and cylinder head.
Page 569 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)
Page 570 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.
Page 571 Oil Pan Installation Install or connect Removal 1. Adhesive sealant in the oil pan. Remove or disconnect 2. Oil pan-to-engine attaching bolts, without 1. Drain the oil on a proper container, removing the tightening. oil pan drain plug, with Torx T45 wrench. 3.
Page 572 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.
Page 573 8. Sealing washer. Important • The Tensioner roller lug (1) should be positioned 9. Spring. 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. •...
Page 574 Camshaft Case Assembly Tighten • Switch: 30 – 50 N·m (22 – 36,7 lb·ft) Removal 10. Install the oil pump; see “Oil Pump – Installation”, Remove or disconnect in this section. 1. Depressurize the fuel system: • Fuel-off solenoid valve disconnect. •...
Page 575 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;...
Page 576 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.
Page 577 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) 11.
Page 578 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 Cylinder Head the cylinder head.
Page 579 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...
Page 580 Important Important • If the lash is out of the specification, which is • If necessary use a 45° ± 3° Valves for corrosion. 0.015 – 0.042 mm (intake) and 0.038 – 0.072 Corroded valves, once not excessively worn, can be refaced by special equipment, as mm (exhaust), ream the guide to install an follows: oversize valve.
Page 581 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°...
Page 582 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.
Page 583 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.
Page 584 G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 585 Tighten Important: • Whenever the crankshaft is removed, it should • Bolts: 50 N·m + 45° + 15°. be positioned standing up in the flywheel, to 6. Crankshaft seal, with tool KM-658. prevent it from warping. Engine Assembly Installation Install or connect 1.
Page 586 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.
Page 587 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.
Page 588 34. Remove tool S-9406182 from the flywheel with a Tighten 17-mm combination wrench. • 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.
Page 589 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 13- mm socket wrench and torque wrench.
Page 590 Cylinder Honing 54. Engine assembly; see “Engine Assembly – Installation”, in this section. Note: Some of the services that are next presented Cylinder Block are not necessarily performed when reconditioning an engine. The performance should depend on the inspections Removal to which the engines will be submitted before reconditioning.
Page 591 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 •...
Page 592 • 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.
Page 593 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.
Page 594 18. A new cylinder head gasket, with the TOP mark 9. Connecting rod cap bolts, without fully tightening, turned upward and toward the engine front side. with a 14-mm socket wrench and handle. Important Obs.: Whenever is necessary to remove the cylinder head, a new gasket should be used.
Page 595 34. Remove tool S-9406182 from the flywheel with a 22. New cylinder head attaching bolts, in the 17-mm combination wrench. 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.
Page 596 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.
Page 597 5. Cylinder head; see “Cylinder Head – Removal”, in 47. A new seal ring in the crankcase phase and reference sensor. this section. 48. Crankshaft phase and reference sensor in the 6. Turn the engine 180° to have access to the cylinder block and attaching bolt;...
Page 598 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.
Page 599 D. Oil control ring. Obs.: This procedure should be performed with protecting gloves. These procedures should be followed so that the E. Lower compression ring. connecting rod projection is located opposite the F. Upper compression ring. arrow in the piston head. Rings Measure Gap between the tips of the selected ring, according...
Page 600 Tighten • Install the connecting rod upper shell lubricated only in the face turned toward the journal and pull the connecting rod until it touches the • Bolt: 4 – 10 N·m (3 – 7 lb·ft.) journal. 8. Adhesive sealant in the cylinder block and install the crankcase and attaching bolts, with a Torx E12 wrench and torque wrench;...
Page 601 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 Alternator Item Specification Rated output 13.5V - 80A...
Page 602 Ignition System Wasted Spark DIS Ignition System The G424F and G424FE engine has a wasted spark Spark-ignited engines require accurate control of ignition system (2 cylinders per coil). spark timing and spark energy for efficient combustion. The MI-07 ignition system provides this Wasted spark ignition is a type of distributor-less control.
Page 603 Magnetic crankshaft position sensors can be tested MISFIRES with an ohmmeter, and the sensor output voltage DIS problems can include many of the same and waveform can be read with an oscilloscope. The ailments as other ignition systems such as misfiring, output voltage of a Hall Effect crankshaft position sensor can be checked with a voltmeter.
Page 604 a. Twist each spark plug boot 1/2 turn. Spark Plug Wire Inspection b. Pull only on the boot or use a tool designed for Sparking plug wire integrity is vital for proper engine this purpose in order to remove the wires from operation.
Page 605 Spark Plug Replacement CAUTION Removal Only use a spark plug socket or wrench to tighten the spark plugs. Do not force the spark Remove or disconnect plug into the cylinder head. Any misalignment can damage the aluminum threads in the 1.
Page 606 c. Inspect for sign of tracking that occurred near b. Best for a loose terminal post by twisting and the insulator tip instead of the center electrode pulling the post. The terminal post should NOT move. (4). 2. Inspect the insulator for flashover or carbon d.
Page 607 • Reduced ignition system voltage output Charging System - Weak coil pack - Worn ignition wires General Description - Incorrect combustion - Excessive idling or slow speeds under light The alternator is an electrical and mechanical loads can keep spark plug temperatures so components driven by a belt from engine rotation.
Page 608 Alternators Troubleshooting The alternators used on these engines have three Charging system defect is almost caused by lack of phase, full-wave, rectified output. They are the brush pan belt tension and faulty function of wiring, type. Refer to the Alternator Coverage chart for connector, and voltage regulator.
Page 609 Refer to the following troubleshooting table Symptom Possible cause Remedy Fuse cut off Replace With ignition switch ON, Bulb burnt out Replace charging warning lamp Loose wiring connection Retighten does not illuminate Bad connection of L terminal Inspect and replace wiring Loose or worn drive belt Correct or replace With the...
Page 610 Troubleshooting Procedure Inspection before Starting 1. Alternator and drive belt tension inspection. G424F(FE) Service Manual Chapter 4. Engine Electrical System...
Page 611 2. Alternator and outer terminal connection inspection. G424F(FE) Service Manual Chapter 4. Engine Electrical System...
Page 612 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 Chapter 4. Engine Electrical System...
Page 613 Drop of Electric Pressure Test of Alternator Test Output Wire 1. Start the engine. This test is to check that wiring is correctly connected between the alternator “B“ terminal and 2. Repeating ON and OFF of headlight and small battery (+) terminal. light, adjust the engine speed until an ammeter reads 20A and at that time measure voltage.
Page 614 3. With the engine running at 2,500 rpm, turn ON the 2. Turn the ignition switch OFF. high beam headlights, place the heater blower 3. Disconnect the battery ground cable. switch at ”HIGH” measure the maximum output current using a ammeter. 4.
Page 615 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.
Page 616 The starting motor solenoid has two functions: Diagnosis Procedure 1. Engages the pinion with flywheel. The following simplified procedure is intended to help the serviceman determine if a starting motor 2. Is a high current switch rated about 1000 amps needs to be removed and replaced or repaired.
Page 617 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 NOTICE voltage (power) available during cranking varies according to the temperature of the batteries. The Do not operate the starting motor for more than following chart is a guide as to what to expect from a 30seconds at a time.
Page 618 5. Is voltage equal to or greater than shown in Start Relay Tests Figure1? Relay • If the starting motor voltage is correct, the battery and starting motor cables down to the 1. Put the multimeter on the 200 ohm scale. motor are within specifications.
Page 619 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.
Page 620 Starter Repair Removal Remove or disconnect WARNING Always disconnect the cable at the battery before make repairs 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.
Page 621 Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS) General Information Specifications SECM and Sensor/Switch Inputs Q’ty Components Items Specifications G424FE G424F Environmental / Ambient Operating -20 °F to 221°F [-29 °C to 105 °C] Electrical Temperature None None Specifications 8-16 Vdc Operating Voltage Engine Control Module Operating Temperature -20 °F to 221°F [-29 °C to 105 °C]...
Page 622 Q’ty Components Items Specifications G424FE G424F Ground speed limit Type Normal Open 145 ± 28 kPa switch Actuation Pressure Electronic Throttle System Q’ty Components Items Specifications G424FE G424F Electronic Throttle Minimum Electrical 1.5 ohms System Resistance of Throttle Actuator Ignition System Components Specification Q’ty Components Items...
Page 623 LP Fuel Components Specification Q’ty Components Items Specifications G424FE G424F LP Fuel System Operating Temperature -20 °F to 221°F [-29 °C to 105 °C] Requirements LPG Composition HD5 / HD10 LPG. Failure to use fuel Requirements compliant with HD5 or HD10 standards will void the user warranty.
Page 624 Q’ty Components Items Specifications G424FE G424F N-2001 LP Regulator Fuel Supply Pressure 10 psi to 250 psi (69 kPa to 1724 kPa) For G424F Fuel Inlet Fitting 1/4” NPT Fuel Outlet Fitting One 3/4” NPT and one 1/8” NPT fitting with plug Fuel Supply -20 °F to 120 °F [-29 °C to 49 °C]...
Page 625 Q’ty Components Items Specifications G424FE G424F CA100 Mixer Fuel For G424F Fuel Inlet Fitting 1/2” NPT Fuel inlet fitted with Delphi temperature sensor Air Intake Flange 2.25” (57.15mm) ID inlet, four #10- 24 screws in 1.94” (49.28mm) square pattern Mixer Mounting Flange 1.87”...
Page 626 Service Standard Basic Idle rpm (After warm up) No Load 750±15 rpm Ignition Timing (After warm up, at idle) 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...
Page 627 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 Chapter 5. Engine Management System (EMS)
Page 628 Pre-Catalyst Oxygen Sensor Post-Catalyst Oxygen Sensor Pedal Angle Sensor Engine Oil Pressure Switch Transmission Oil Temperature Switch Ground speed limit switch G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 629 Electronic Throttle Body Fuel Trim Valve(FTV) Ignition Coil LP Fuel Lock-off N-2007 LP Regulator CA100 Mixer G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 630 Gasoline Injectors and fuel rail Gasoline Fuel Pump Ass'y G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 631 G424FE EMS (Engine Management System) Overview General Description MI-07 control system provides a complete, fully MI-07 is a closed loop system utilizing a catalytic integrated engine management system that meets muffler to reduce the emission level in the exhaust or exceeds 2007 emission standards for Large gas.
Page 632 LP System of G424FE (certified engine system) INPUT OUTPUT Crank Sensor Throttle body TMAP sensor lgnition coil Coolant Temp 2 Fuel trim valves EG oil pressure switch LP fuelock valve T/M Temp switch CAN communication SECM Accel pedal angle sensor Throttle position sensor Pre Oxygen sensor Post Oxygen sensor...
Page 633 • LPG mixer MI-07 System Components • LPG pressure regulator • Fuel trim valves The MI-07 control system provides electronic control • Fuel trim orifices to the following subsystems on mobile industrial • Small engine control module (SECM), firmware engines: and calibration †...
Page 634 LPG Fuel System Operation Other system features include: The principles outlined below describe the operation Tamper-Resistance of MI-07 on an LPG fuel system. Special tools, equipment, knowledge, authorization are required to effect any changes to An LPG fuel system consists of the following the MI-07 system, thereby preventing unauthorized components: personnel from making adjustments that will affect...
Page 635 pressure regulator outlet pressure changes by the MI-07 Fuel Lock-Off (Electric) same amount and in the same direction. The end The fuel lock-off is a safety shutoff valve, normally result is that a change in FTV modulation changes held closed by spring pressure, which is operated by the outlet pressure of the regulator/fuel inlet an electric solenoid and prevents fuel flow to the pressure of the mixer, and thus the AFR.
Page 636 When an operator turns on the key switch the lock- the propane is reduced, the liquid propane vaporizes and refrigeration occurs inside the regulator due to off is opened, but if the operator fails to crank the engine the SECM will close the lock-off after 5 the vaporization of liquid propane.
Page 637 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, Figure 7.
Page 638 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.
Page 639 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.
Page 640 Branch-Tee Fitting secondary diaphragm, which lowers the reference A branch-tee fitting is installed in the atmospheric pressure, closing the N-2007 secondary valve and vent port of the N-2007 with one side of the branch- leaning the air/fuel mixture. The MI-07 system is tee connected to the intake side of the mixer forming calibrated to run rich without the FTV.
Page 641 Electronic Throttle System MI-07 Electronic Throttle Conventional throttle systems rely on a mechanical linkage to control the throttle valve. To meet The electronic throttle system controls engine output fluctuating engine demands a conventional system (speed and torque) through electronic control of will typically include a throttle valve actuator mass airflow to the engine.
Page 642 There are multiple limp-home modes available with Ignition System electronic throttle control: 1. If the throttle itself is suspected of being inoperable, the SECM will remove the power to Spark-ignited engines require accurate control of the throttle motor. When the power is removed, spark timing spark...
Page 643 and length. There are fewer parts to malfunction on Exhaust System the DIS system when compared to a distributor type system. Heated Exhaust Gas Oxygen Sensors (HEGO) DIS COMPONENTS The MI-07 system utilizes two HEGO (O2) sensors. One sensor is a pre-catalyst sensor that detects the In a typical DIS ignition system, a crankshaft amount of oxygen in the exhaust stream and is position sensor generates a basic timing signal by...
Page 644 converter. It reduces the unburned hydrocarbons The HEGO stoichiometric air-fuel ratio voltage target and carbon monoxide by burning (oxidizing) them is approximately 500 mV and changes slightly as a function of speed and load. When the pre-catalyst over a platinum and palladium catalyst. Cerium is HEGO sensor sends a voltage signal less than 450 also used to promote oxygen storage and improve mV the SECM interprets the air-fuel mixture as lean.
Page 645 SECM The SECM provides a transducer ground for all the sensors, and a low side driver signal controlling the General Description fuel lock-off, MIL, gasoline injectors, gasoline fuel The Small Engine Control Module (SECM) controller pump, and FTVs. has full authority over spark, fuel and air. Utilizing a Fuel Management Freescale micro controller, the SECM has 48 pins of During engine cranking at startup, the SECM...
Page 646 Speed Management NOTE : The DV-E5 throttle is not a serviceable Drive-by-wire refers to the fact that the MI-07 control assembly. If a TPS sensor fails, the assembly system has no throttle cable from the foot pedal to should be replaced. the throttle body.
Page 647 Drive-By-Wire Signal Flow Process 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...
Page 648 SECM Wiring Diagrams for G424FE CAUTION—PROPER WIRING To prevent system faults be sure to follow good wiring practices. Poor wiring cause unexpected or intermittent failures not related to MI-07 components. The schematics on the next pages are wiring diagrams for G424FE engines. Figure 22: LP certified system G424F(FE) Service Manual Chapter 5.
Page 649 Figure 22. SECM Wiring Diagram for G424FE LP System. G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 650 G424F EMS (Engine Management System) Overview General Description MI-07 control system provides a complete, fully Engine speed is monitored by the SECM through a integrated engine management system for naturally variable reluctance (VR) sensor. Intake manifold air aspirated engines. temperature and absolute pressure are monitored with a TMAP sensor.
Page 651 Dual Fuel System of G424F INPUT OUTPUT Crank Sensor Throttle body TMAP sensor lgnition coil Coolant Temp EG oil pressure switch LP fuelock valve SECM T/M Temp switch CAN communication Accel pedal angle sensor 4 Injectors Throttle position sensor Fuel Pump T/M Inching pressure switch CAM sensor...
Page 652 CA-100 CA-100 LP Mixer MI-07 System Components (Certified) The MI-07 control system provides electronic control Electronic Throttle Body to the following subsystems on mobile industrial engines: MI-07 System Features • Fuel delivery system The MI-07 system uses an advanced speed-density •...
Page 653 LPG Fuel System Operation Other system features include: Tamper-Resistance The principles outlined below describe the operation Special tools, equipment, knowledge, of MI-07 on an LPG fuel system. authorization are required to effect any changes to the MI-07 system, thereby preventing unauthorized An LPG fuel system consists of the following personnel from making adjustments that will affect components:...
Page 654 secondary (2nd stage) valve and the primary (1st N-2001 Operation stage) valve closes. Unlike most other regulator/converters, the N-2001 primary valve Refer to Figure 6. closes with fuel pressure rather than against Liquid propane, at tank pressure, enters the N-2001 pressure, extending primary seat life and adding through the fuel inlet port (1).
Page 655 imbalance on the secondary diaphragm, which CA100 Mixer Operation overcomes the secondary spring force, opening the Vapor propane fuel is supplied to the CA100 mixer secondary valve and allowing vapor propane to flow by the N-2001 pressure regulator/converter. The out of the expansion chamber, through the mixer uses a diaphragm type air valve assembly to secondary chamber to the mixer.
Page 656 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 A main mixture adjustment valve on the fuel inlet of vacuum (AVV) chamber (above the diaphragm) and the CA100 is not used in the MI-07 system, however atmospheric...
Page 657 exactly calculated fuel as a spray to engine to MPI Gasoline System Operation best combustion under the condition of various engine load and speed. MPI (multi-point injection) system is used for G424F gasoline engine. An electric fuel pump in gasoline For fuel consumption reduction, engine performance fuel tank supplies the fuel and generates the enhancement and emission reduction, ECM controls...
Page 658 Electronic Throttle System The electronic throttle system of G424F engine is the same as that of G424FE engine. See, “Electro- nic throttle system of G424FE EMS overview” Ignition System The Ignition system of G424F engine is the same as that of G424FE engine. See, “Ignition system of G424FE EMS overview”...
Page 659 SECM Wiring Diagrams for G424F Engine RED 12 AWG RED 14 AWG RED 14 AWG RED 18 AWG INJ 1 INJ 3 BATT_B22 B5_CRNK+ KEY_ON_B8 PINK COLOR B6_CRNK- COLOR MPRD_A22 COLOR LS01_A5 COLOR LS03_A4 COLOR B10_CAM+ COLOR LS04_A7 COLOR LS02_A8 COLOR A24_LSO9_MIL COLOR...
Page 660 • Fuel Temperature Sensor (FTS) EMS Inspection and Repair -40°F to 266°F (-40ºC to 130ºC) range, 48K ohm to 57 ohm sensor range Engine Control Module (SECM) • HEGO (3) 0 to 1 V The 48-pin Small Engine Control Module (SECM) •...
Page 661 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/turn- off delay Minimum pulse width resolution of 1 usec • FTV drivers (2) 10A peak, 45V max. To drive an on/off fuel trim valve with a minimum impedance of 5 ohms Capable of continuous on-time Drive circuit designed for minimum turn-on /turn-...
Page 662 Camshaft Position Sensor Sensor Inspection (G424F Gasoline Only) Component Location CAM shaft Position Sensor 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 4.
Page 663 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.
Page 664 Removal Crankshaft Position Sensor 1. Remove the timing belt front cover. See Timing Belt Front Cover, Remove. Component Location 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.
Page 665 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 Test specification Ignition SW. ON 4~5V At idle 0.5~2.0V...
Page 666 IAT (Intake Air Temperature) Sensor Inspection Sensor 1. Using a multimeter, measure the IAT sensor resistance between terminals 3 and 4. IG.SW.ON Temperature Resistance(kΩ) ℃ (°F) 0 (32) 4.5 ~ 7.5 20 (68) 2.0 ~ 3.0 40 (104) 0.7 ~ 1.6 80 (176) 0.2 ~ 0.4 MAP sensor...
Page 667 Oxygen Sensor (Pre-Catalyst) Component Location Schematic Diagram [CIRCUIT DIAGRAM] HO2S (B1/S1) A23 - HO2S HEATER (B1/S1) B13 - HO2S SIGNAL B1 - HO2S GND Pre - Catalyst Oxygen Sensor After Main Relay Description [HARNESS CONNECTORS] The heated oxygen sensor is mounted on the front side of Catalytic Muffler, which detects the oxygen concentration in the exhaust gas.
Page 668 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 Description rear HO2S detects emission gas purified by the The rear heated oxygen sensor is mounted on the catalytic converter.
Page 669 ECT (Engine Coolant Temperature) Sensor Component Location Sensor Inspection ECT Senser 1. Remove the engine coolant temperature sensor from the intake intake manifold. Description 2. With the temperature sensing portion of the The Engine Coolant Temperature Sensor (ECTS) is engine coolant temperature sensor immersed in located in the engine coolant passage of the cylinder hot water, check resistance.
Page 670 Schematic Diagram [CIRCUIT DIAGRAM] B15_ECT_SIGNAL B1_GND [HARNESS CONNECTORS] Installation 1. Install engine coolant temperature sensor and tighten it to specified torque. Tightning torque Engine coolant temperature sensor " 15~20Nm (150~200 kg.cm, 11~15 lb.ft) 2. Connect the harness connector securely. G424F(FE) Service Manual Chapter 5.
Page 671 LP Fuel Temperature Sensor Location [Harness Connectors] Description Inspection The LP Fuel Temperature Sensor (FTS) is located in 1. Remove the LP fuel temperature sensor from the the LP fuel passage of the LP mixer for detecting the adapter connected to LP mixer. LP fuel temperature.
Page 672 Angle Sensor-Accelerator [Harness Connectors] Location Inspection 1. Disconnect the Accelerator Pedal’s connector Description from the main engine harness. Angle Sensor-Accelerator located accelerator pedal assembly. The engine speed 2. Inspect the electrical conditions with a follow management deals with a Drive-by-wire system. basic specification.
Page 673 Transmission Oil Temperature Switch Location [Harness Connectors] Description Inspection Transmission Oil Temperature Switch is located in 1. Remove the Transmission Oil Temperature the adapter on transmission (T/M) for operating by Switch from the transmission. the transmission (T/M) oil temperature change. This switch is normally open, and then it is closed as the 2.
Page 674 Ground Speed Limit Switch [Harness Connectors] Location Description Inspection Ground Speed Limit Switch is located in the 1. Remove the Ground Speed Limit Switch from the pressure port on transmission (T/M) for operating by transmission. the transmission (T/M) oil pressure change. This switch is normally opened, and then it is closed as 2.
Page 675 Electronic Throttle Body Location [Harness Connectors] Description Inspection The MI-07 system uses electronic throttle control 1. Check for loose, dirty or damaged connectors and (ETC). The SECM controls the throttle valve based wires on the harness on engine RPM, engine load, and information received from the foot pedal.
Page 676 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.
Page 677 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°...
Page 678 DIAGRAM NOTES Trim valves must be positioned N-2007 Regulator Solenoid (AFS Lock Off Valve) vertically with flow arrows in position Plastic WYE Fitting (black color) Brass Tee Fitting. 1/4 Tube x 1/8 shown for 7/32” (5.56mm) ID Tube NPTF x 1/4 Tube Fuel outlet must be min 15°...
Page 679 N-2007 Installation Steps Removal and Installation of N-2007 LP Regulator Refer to Figure 28. Follow the procedures below for removal and 1. Install the nipple extension (6) with the lock-off to reinstallation of the N-2007 regulator in certified the regulator. systems.
Page 680 2. Purge the system of fuel by starting the engine Removal and Installation of CA100 Mixer for and running until all trapped fuel in the system is G424FE exhausted and the engine shuts down. Follow the procedures below for removal and reinstallation of the CA100 mixer in certified systems.
Page 681 NOTE : A plastic O-ring spacer and an O-ring are CA100 Certified Mixer Installation Steps inside the mixer/adapter assembly. Be careful not to lose these items when removing the assembly from Refer to Figure 30. the throttle (Figure 31). 1. Install the vacuum port barb onto the mixer (9). 2.
Page 682 Tests and Adjustments N-2007 Regulator Service Testing checking N-2007 regulator/converter WARNING—PROPER USE operation, the following tests can be performed (See Chapter 5 for removal/installation of the N-2007 • LP gas is highly flammable. To prevent regulator). To check the secondary regulation personal injury, keep fire and flammable (output) a simple vacuum hand pump can be used materials away from the lift truck when work is...
Page 683 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.
Page 684 5. If the measured pressure drop is low, check for vacuum leaks in the manifold, throttle, mixer, CAUTION TMAP sensor and attached hoses. • 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.
Page 685 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.
Page 686 Factory Adjustment Procedure: 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 NOTE : Be sure engine is fully warm (ECT>167°F duty cycle cannot be adjusted below 60%, the [75°C]) before performing the idle mixture mixer is faulty and should be replaced.
Page 687 Field Adjustment Procedure: 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 idle mixture adjustment should only be the FTV duty cycle reading is within the optimum necessary on a new mixer that does not have the range (35-55%).
Page 688 Parts Description CA100 Mixer for G424FE Engine Parts List of CA100 Mixer (Certified) REF NO DESCRIPTION Torx Screws (T-25) #10-24 x 5/8” Lockwashers (T-210) #10 SST Mixer Cover Mixer Spring Diaphragm Air Valve Assembly Gas Valve Cone (part of air valve assembly) Mixer Body Expansion Plug Cap Ø...
Page 689 Exploded View of CA100 Mixer (Certified) Figure 44. CA100 Certified Mixer Exploded View G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM...
Page 690 N-2007 Regulator for G424FE Engine Parts List of N-2007 Regulator (Certified) REF NO DESCRIPTION N-2007 Body Diaphragm, Primary Assembly Springs, Primary Assembly Cover, Primary Assembly Spring, Secondary Seat, Red Dowel Pin Ø 0.094” x 1” L (Ø 2.39mm x 25.4mm L) Hardened Steel Diaphragm, Secondary Assembly Lever, Secondary Seat, Secondary...
Page 691 Exploded View of N-2007 Regulator (Certified) Figure 46. N-2007 Certified Regulator Exploded View G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM...
Page 692 G424F LPG System Inspection and Repair Removal and Installation WARNING – PROPER USE • LP gas is highly flammable. To prevent perso- nal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. •...
Page 693 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.
Page 694 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.
Page 695 1. Close the liquid outlet valve in the forklift cylinder Removal and Installation of CA100 Mixer for or fuel storage container. G424F Follow the procedures below for removal and 2. Purge the system of fuel by starting the engine reinstallation of the CA100 mixer in non-certified and running until all trapped fuel in the system is systems.
Page 696 CA100 Mixer Installation Steps 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 1. Install the vapor fuel inlet fitting onto the mixer. the throttle (Figure 31).
Page 697 Tests and Adjustments Secondary Stage (Break-Off) Test 1. Connect the vacuum pump, the Magnehelic gauge and the regulator vapor outlet to the Union WARNING – PROPER USE Tee fitting (Figure 30). Make sure there is no leakage at any of the fittings. •...
Page 698 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) 2.
Page 699 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) communica- Check for excessive or inadequate pressure drop tion adapter by KVaser will be required along with a across CA100 mixer.
Page 700 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.
Page 701 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.
Page 702 Parts Description CA100 Mixer for G424F Engine Refer to Figure 45 exploded view on facing page. REF NO. DESCRIPTION Screws 10-24 x 5/8” T-25 Button Head SEMS Mixer Cover Mixer Spring Diaphragm Gas Valve Cone (part of air valve assembly) Mixer Throttle Body Gasket Screws 12-24 x 5/8”...
Page 703 Exploded View CA100 Mixer Figure 44. CA100 Non-Certified Mixer Exploded View G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM...
Page 704 CA100 Disassembly and Service Figure M4 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). Figure M5 2. Gently remove the diaphragm cover from the top of the mixer.
Page 705 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.
Page 706 N-2001 Regulator for G424F Engine Refer to Figure 47 exploded view on facing page. Parts List N-2001-RSA Regulator REF NO. DESCRIPTION Cover Screws 8-32 x 5/8” SEMS Torx Screws (T-15) 8-32 x 5/8” Tamper Resistant Lockwasher #8 Internal Tooth Secondary Cover Secondary Diaphragm Assembly Pan Head Screw 10-24 x 1/4”...
Page 707 Exploded View N-2001-RSA Regulator Figure 47. N-2001 Regulator Exploded View G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM...
Page 708 N2001 Regulator Disassembly Steps: Figure R5 Figure R3 Figure R5 Remove the six primary diaphragm cover screws (4) Figure R4 and the primary cover assembly (5). 1. Remove the six secondary cover screws (1), the secondary cover (2) and the secondary diaphragm (3).
Page 709 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.
Page 710 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 poor...
Page 711 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 Fuel Pressure Regulator Regulated Fuel Pressure 350 kPa (3.5kg/cm², 49.8psi) Fuel Pump Type Electrical, in-tank type...
Page 712 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 Chapter 7. MPI Gasoune Fuel Delivery System...
Page 713 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.
Page 714 • Observing the declination of the fuel pressure Inspect Fuel Leakage On Connection 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 Probable Supected Condition...
Page 715 Remove Service Tool And Connect the Description Fuel Line Based on information from various sensors, the ECM measures the fuel injection amount. The fuel 1. Disconnect the Fuel Pressure Gage and Hose injector is a solenoid-operated valve and the fuel from the Fuel Pressure Gage Connector.
Page 716 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 Standard value : 12-14Ω...
Page 717 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.
Page 718 Fuel Pump Removal (Including Fuel Filter And Fuel Pressure Regulator) 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.
Page 719 Chapter 8. BASIC TROUBLESHOOTING Preliminary Checks Visual/Physical check Several of the procedures call for a “Careful MI-07 systems are equipped with built-in fault Visual/Physical Check” which should include: diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) •...
Page 720 Basic Troubleshooting Guide Customer Problem Analysis Sheet 1. Forklift Information (I) VIN: (II) ProductionDate: (III) Hour meter Reading: (hrs) 2. Symptoms □ Engine does not turn over □Incomplete combustion □ Unable to start □ Initial combustion does not occur □ Difficult to start □...
Page 721 Basic Inspection Procedure 4. Repair or replace the component that has a problem. Measuring Condition Of Electronic Parts 5. Verify that the problem has disappeared with the Resistance road test. The measured resistance at high temperature after ● SIMULATING VIBRATION vehicle running may be high or low.
Page 722 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.
Page 723 Checking Point for Connector Wire Harness Inspection Procedure 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.
Page 724 Electrical Circuit Inspection Procedure normal). To find exact break point, check sub line of line 1as described in next step. ● Check Open Circuit b. Disconnect connector (B), and measure for 1. Procedures for Open Circuit resis tance between connector (C) and (B1) and between (B2) and (A) as shown in [FIG.3].
Page 725 ● Check Short Circuit b. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground 1. Test Method for Short to Ground Circuit as shown in [FIG.7]. • Continuity Check with Chassis Ground The measured resistance between connector (B1) If short to ground circuit occurs as shown in [FIG.5], and chassis groundis1Ω...
Page 726 Symptom Troubleshooting Guide Chart for MPI Gasoline System Engine Is Not Starting Engine Is Difficult To Start (Cranking OK) G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 727 Irregular Idling Or Engine Is Suddenly Stopped G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 728 Engine Hesitation Or Insuffient Accelelation G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 729 G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 730 Troubleshooting Guide for MPI Gasoline System • The following number represents inspection order. G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 731 G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 732 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, •...
Page 733 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.
Page 734 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.
Page 735 Engine Cranking but Will Not Start / Difficult to Start (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION 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.
Page 736 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.
Page 737 Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During Acceleration (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION 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.
Page 738 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 Check for proper fuel level:...
Page 739 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. PROBABLE CAUSE CORRECTIVE ACTION Perform fuel system diagnosis check: •...
Page 740 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.
Page 741 Rough, Unstable, Incorrect Idle, or Stalling (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION Reset excess flow valve. Excess flow valve closed • Close liquid valve. • Wait for a “click” sound. Slowly open liquid valve. Repair/replace as required Clogged fuel filter See Chapter 4 Fuel Filter Replacement Remove obstruction from the fuel line.
Page 742 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 Check fuel system specifically for plugged fuel filter, low pressure.
Page 743 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.
Page 744 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 CORRECTIVE ACTION Check all hoses and gaskets for cracking, kinks, or leaks. Verify that there are no vacuum leaks.
Page 745 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.
Page 746 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 Always high ADC Always low ADC between high and low Trim valve duty cycle >...
Page 747 Diagnosis: Chart T-1 Restricted Exhaust System Check 1. With the engine idling at normal operating temperature, observe the exhaust system Proper diagnosis for a restricted exhaust system is backpressure reading on the gage. Reading essential before replacement of any components. should not exceed 1.25 psig (8.61 kPa).
Page 748 Chapter 9. ADVANCED DIAGNOSTICS Clearing Fault (DFC) Codes MI-07 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) To clear the stored fault codes from SECM memory as Diagnostic Fault Codes (DFC) or flash codes, you must complete the reset fault pedal maneuver.
Page 749 Fault Action Descriptions Fault List Definitions Each fault detected by the SECM is stored in All the analog sensors in the MI-07 system have memory (FIFO) and has a specific action or result input sensor range faults. These are the coolant that takes place.
Page 750 Table 1. Fault List Definitions CODE FAULT DESCRIPTION (MI04 CODE) Learned full pedal end of APP1 sensor range higher than APP1AdaptHiMax expected (64) Learned full pedal end of APP1 sensor range lower than APP1AdaptHiMin expected Learned idle end of APP1 sensor range higher than APP1AdaptLoMax expected Learned idle end of APP1 sensor range lower than...
Page 751 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) No CAM signal when engine is known to be rotating, broken CamEdgesFault CAM sensor leads or defective CAM sensor Loss of synchronization on the CAM sensor, normally due CamSyncFault to noise on the signal or an intermittent connection on the CAM sensor No crankshaft signal when engine is known to be rotating,...
Page 752 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) EST1 output open, possibly open EST1 signal or defective EST1_Open spark module (42) EST1 output shorted high or low, EST1 signal shorted to EST1_Short ground or power or defective spark module EST2 output open, possibly open EST2 signal or defective EST2_Open spark module...
Page 753 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) 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.
Page 754 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) GasFuelAdaptRangeHi In LPG mode, system had to adapt lean more than expected (73) GasFuelAdaptRangeLo In LPG mode, system had to adapt rich more than expected (72) Pre-catalyst O2 sensor indicates extended lean operation on GasO2FailedLean Pre-catalyst O2 sensor indicates extended rich operation on GasO2FailedRich...
Page 755 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) (Electronic Throttle Control Driver has Failed) Indeterminate fault on Hbridge driver for Electronic Throttle Control. HbridgeFault_ETC Possibly either ETC+ or ETC- driver signals have been (29) shorted to ground Engine speed has exceeded the third level (3 of 3) of HardOverspeed overspeed protection...
Page 756 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) Check Engine Lamp Fault, signal has opened or shorted to LSDFault_CheckEngine ground or power or defective check engine lamp Crank Disable Fault, signal has opened or shorted to ground or LSDFault_CrankDisable power or defective crank disable relay Dither Valve 1 Fault, signal has opened or shorted to ground or...
Page 757 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (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 LiqPostO2Inactive these faults recheck if this fault sets.
Page 758 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) SensVoltRangeLow Sensor reference voltage XDRP too low (55) ServiceFault1 Service Interval 1 has been reached ServiceFault2 Service Interval 2 has been reached ServiceFault3 Service Interval 3 has been reached Service Interval 4 has been reached—time to replace HEGO ServiceFault4 sensors...
Page 759 Table 1. Fault List Definitions (cont’d.) CODE FAULT DESCRIPTION (MI04 CODE) TPS2 sensor voltage out of range low, normally set if TPS2 TPS2RangeLow signal has shorted to ground, circuit has opened or sensor has failed TPS sensors differ by more than expected amount. TPS_Sensors_Conflict NOTE: The TPS is not a serviceable item and can only be repaired by replacing the DV-EV throttle assembly...
Page 760 Table 2. Diagnostic Fault Codes (Flash Codes) CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION* FIRST CHECK NONE None, used as end of the fault list Signifies the end of one pass None identification through the fault list (1) TurnOnMil Check INJ1 wiring for an open circuit Inj1Open (2) DisableLiquid SECM (Signal) A5 to Injector 1 Pin A...
Page 761 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check coolant system for radiator blockage, proper coolant level and for ECTOverTempFault leaks in the system. Engine coolant temperature (1) TurnOnMil Possible ECT short to GND, check is high.
Page 762 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT CORRECTIVE ACTION PROBABLE FAULT ACTION * FIRST CHECK Check throttle connector connection and TPS1RangeLow TPS1 sensor for an open circuit or short to TPS1 sensor voltage out of range (1) TurnOnMil low, normally set if the TPS1 signal (22) (2) CutThrottle...
Page 763 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK TPS2AdaptHiMin Learned WOT end of TPS2 None sensor range lower than expected TPS1AdaptLoMax Learned closed throttle end None of TPS1 sensor range higher than expected TPS2AdaptLoMax Learned closed throttle end...
Page 764 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT CORRECTIVE ACTION PROBABLE FAULT ACTION * FIRST CHECK Check TMAP connector and MAP signal wiring for a shorted circuit MAPTimeRangeHigh TMAP Pin 4 to SECM Pin B18 (signal) TMAP Pin 1 to SECM Pin B1 (sensor Manifold Absolute Pressure GND) Sensor...
Page 765 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION, PROBABLE FAULT FAULT ACTION * FIRST CHECK Check TMAP connector and IAT signal wiring for a shorted circuit IATRangeHigh TMAP Pin 2 to SECM Pin B12 (signal) Intake Temperature TMAP Pin 1 to SECM Pin B1 (sensor Sensor Input is High normally GND) set if the IAT temperature...
Page 766 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT CORRECTIVE ACTION PROBABLE FAULT ACTION * FIRST CHECK Check coil driver wiring and connector for open circuit SECM Pin A6 (EST4) to OEM ignition system. EST4_Open EST4 See application manual. Verify GND on output open, possibly open TurnOnMil ignition...
Page 767 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT CORRECTIVE ACTION PROBABLE FAULT ACTION * FIRST CHECK EST2_Short EST2 output shorted high or low, EST2 signal shorted None ground or power or defective spark module EST3_Short EST3 output shorted high or low, None EST3 signal...
Page 768 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION FIRST PROBABLE FAULT FAULT ACTION * CHECK EST7_Short EST7 output shorted high or low, None EST7 signal shorted to ground or power or defective spark module EST8_Short EST8 output shorted high or low, None EST8 signal shorted to ground or power or defective spark module...
Page 769 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check ETC driver wiring for a shorted HbridgeFault_ETC circuit Electronic Throttle Control SECM Pin A17 to ETC + Pin 1 Driver failed. SECM Pin A18 to ETC - Pin 4 Indeterminate fault (1) TurnOnMil...
Page 770 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Measure transducer power at the TMAP connector with a multimeter TMAP Pin 3 XDRP +5 Vdc to TMAP Pin 1 XDRG GND Verify transducer power at the SECM SensVoltRangeLow (1) TurnOnMil with a multimeter...
Page 771 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK APP2RangeLow APP2 sensor voltage out of range Check foot pedal connector low, normally set if the APP2 signal TurnOnMil (65) • Check APP2 signal at SECM PIN B16 has shorted to ground, circuit has opened or sensor has failed APP1RangeHigh...
Page 772 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check FTV1 for an open wire or FTV connector being disconnected FTV1 LSDFault_Dither1 (1) TurnOnMil Pin 1 (signal) to SECM Pin A1 Dither Valve 1 Fault, signal has (2) DisableGasO2Ctrl FTV1 Pin 2 (power) to SECM (DRVP) opened or shorted to ground or...
Page 773 CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check fuel lock off valve for an open wire or connector being disconnected or signal shorted to GND Lock off Pin B (signal) from SECM Pin LSDFault_LockOff Fuel lock off Valve Fault, signal Lock off Pin A (power) from main relay opened shorted...
Page 774 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK GasFuelAdaptRangeHi (1) TurnOnMil Check fuel trim valves, e.g. plugged In LPG mode, system had (2) DisableGasO2Ctrl valve or hose. Check for plugged (73) to adapt lean more than (3) DisableGasPostO2Ctrl orifice(s).
Page 775 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK GasO2FailedRich (1) TurnOnMil Check fuel trim valves, e.g. plugged Pre-catalyst O2 sensor (2) DisableGasO2Ctrl valve or hose. (77) indicates extended rich (3) DisableGasPostO2Ctrl Check for plugged orifice(s).
Page 776 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check that Post-catalyst O2 sensor connections are OK. O2 (return) Pin 4 to SECM Pin B1 O2 Pin 2 (HEATER GND) to SECM (DRVG GNG) Pins A16, B17 O2 Pin 1 (HEATER PWR) to Post O2 Heater Relay.
Page 777 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK O2RangeLow Pre-catalyst O2 sensor None voltage out of range low, sensor signal shorted to ground O2_PostCatRangeLow Post-catalyst O2 sensor None voltage out of range low, sensor signal shorted to ground O2RangeHigh...
Page 778 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK TransOilTemp (1) TurnOnMil Refer drivetrain manufacturer’s Excessive transmission oil (2) DelayedEngine transmission service procedures temperature Shutdown ServiceFault1 Perform service procedure related to Service Interval 1 has been None Service Interval 1 (determined by OEM)
Page 779 Appendix Service Tool Software Kit Service Tool Software (MotoView) Service tool software kit consists of USB-CAN converter, Service tool software (MotoView) and Introduction Extension cable. 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.
Page 780 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).
Page 781 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.
Page 782 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”/ “Closed- Loop” control listing. This description informs the technician whether the emission system is using Figure 7 Clearing Faults closed loop feedback from the oxygen sensors to...
Page 783 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.
Page 784 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.
Page 785 DFC 12-353 Screen Tab Figure 10. Diagnostic Fault Codes 12-353 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.
Page 786 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.
Page 787 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.
Page 788 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.
Page 789 Manual Override Screens 1 & 2 CAUTION There are two manual override screens available for Be aware of fuel flow and ignition when the technician to test for failed components or to performing any manual override of a system isolate problems during troubleshooting. Manual overrides can override normal system function component as engine damage may result.
Page 790 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.
Page 791 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.
Page 792 Manual Override Screen 2 CAUTION Components that can be overridden on override Be aware of fuel flow and ignition when screen 2 include the Low Oil Pressure Switch, performing any manual override of a system Transmission Temperature Switch, Ground Speed Switch, Spark Advance, and the Malfunction component as engine damage may result.
Page 793 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.
Page 794 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.
Page 795 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...
Page 796 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.
Page 797 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 customers with indoor warehouse operations. Here’s how you can activate the speed-limiting feature.
Page 798 How to Set New Speed Limit Maximum RPM for both the HIGH MAX RPM state (Normal) and SWITCHED MAX RPM 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...
Page 799 LPG And LPG Fuel Tanks 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 LPG Fuel Supply allowing for a 20% vapor expansion space. Outside air temperature effect’s an LPG tank and must be Liquefied petroleum gas (LPG) consists mainly of considered when using an LPG system.
Page 800 LPG Fuel Tanks Installing LPG Fuel Tanks The two styles of LPG storage containers available When installing a tank on a lift truck, the tank must for industrial use and lift truck applications are be within the outline of the vehicle to prevent portable universal cylinders...
Page 801 Fuel Gauge Service Valve In figure 5 a visual fuel gauge is used to show the The service valve is a manually operated valve fuel level in the tank. A mechanical float mechanism using a small hand wheel to open and close the fuel detects the liquid propane level.
Page 802 Filler Valve Most liquid service valves have an internal hydrostatic relief valve and are usually labeled “LIQUID WITH INTERNAL RELIEF”. The liquid filler valve (Figure 9) has a male thread to hydrostatic relief valve protects the fuel service line receive a fuel nozzle and typically has a plastic or between the tank and the lock off from over brass screw on cap that is retained with a small pressurization.
Page 803 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 Substitution of components may impair suitabil- emission standards (40 CFR Part 1048.101) when ity for Class I, Division 2, or Zone 2 applications.
Page 804 Abbreviations ACFM Actual cubic feet per minute at the specified suction conditions Air fuel ratio Brake horsepower Bi-Fuel Able to operate on either of two fuels Coolant temperature sensor 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.
Page 805 SB4218E01 Jan. 2008 Power Train Specification System Operation Testing & Adjusting Disassembly & Assembly D20G, D25G, D30G with B3.3 Engine D20G, D25G, D30G with 4TNE98 Engine G20G, G25G, G30G with G424F Engine G20G, G25G, G30G with G424FE Engine...
Page 807 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 809 Index Specification Torque Converter ..........5 Transmission............6 Final Drive and Wheel ........... 7 System Operation General Information..........8 Torque Converter ..........9 Transmission............11 Transmission Power Flow........12 Transmission Hydraulic System......13 Differential and Drive Axle ........21 Testing and Adjusting Troubleshooting...........
Page 811 Specification Torque Converter (1) Torque for bolts (plate to torque converter Apply Loctite No. 242 or 243.) ........ 60 ± 5 N·m (44.4 ± 3.7 lb·ft) (2) Torque for bolts (plate to flywheel) ........25 ± 7 N·m (18.5 ± 5 lb·ft) Power Train Specification...
Page 812 Transmission (1) Torque for Lock nut (Apply Loctite No. 242 or (5) Ring gear runout measured on back ..... 0.1 ~ 0.2 mm (0.0039 ~ 0.0078 in) T.I.R 243)......10 ± 5 N·m (7.4 ± 3.7 lb·ft) (6) Backlash of spiral bevel gear (2) Torque for bolts that hold case cover (Apply ....
Page 813 Final Drive and Wheel (1) Torque for bolts that hold brake assembly to drive axle arm (Apply Loctite No.262)..........110 ± 10 N·m (81.4 ± 7.4 lb·ft) (2) Tighten nut slowly until torque required to 200 L 10 N·m (148 L 7.4 lb·ft) and release the insidenut by 1/8~1/10 circle.
Page 814 System Operation General Information (1) Engine. (2) Torque Converter. (3) Power Shift Transmission. (4) Drive Axle. The basic components of the power train are engine (1), torque converter (2), power shift transmission (3), drive axle (4) and the wheels. A transaxle contains a power shift transmission and a differential.
Page 815 Torque Converter Torque Converter AA. Components Turned by Engine Flywheel. BB. Components Turned by (AA). CC. Stationary components. (1) Transmission Input Shaft. (2) Pump Stator Support. (3) Stator. (4) Turbine. (5) Housing. (6) Impeller. The torque converter hydraulically connects the The torque converter has four main parts : housing engine to the transaxle.
Page 816 The transmission pump sends oil through a small passage in stator support (2). The oil flows around the shaft of the stator support (2) and into the converter. Impeller (6) turns with housing (5) at engine speed and makes the oil go toward the outside of the impeller (6), around the inside of the housing (5) and makes against the blades of the turbine (4).
Page 817 Transmission General Information (1) Toruqe Coverter. (2) Input Shaft. (3) Clutch Cylinder. (4) Piston (Forward). (5) Forward Clutch Pack. (6) Gear (forward). (7) Gear. (8) Gear. (9) Output Gear. (10) Pinion. (11) Piston (Reverse). (12) Reverse Clutch Pack. (13) Gear (Reverse). (14) Pump.
Page 818 Transmission Power Flow Neutral With the control for the transaxle in neutral position and the engine running, power will flow from the engine flywheel through torque converter (1) to the input shaft (2) that turns the clutch cylinder (3) in the same direction as the flywheel.
Page 819 Main Relief Valve (3) Transmission Hydraulic System Oil from the pump (2) flows to the main relief valve The hydraulic circuit mainly consists of the torque (3). The regulator valve relieves the oil pressure converter charging pump which generates the produced by the charging pump of the torque hydraulic pressure, and the control valve which convertor (9) at the specified pressure to protect the...
Page 820 Hydraulic System Power Train System Operation...
Page 821 Neutral Position When the transaxle is in NEUTRAL position, with the engine running, oil is pulled from reservoir (11), through the suction filter (1) to pump (2). From there, pump oil flows through passage to main relief valve (3). Oil from main relief valve (3) flows through passage to torque converter (9).
Page 822 Hydraulic System Power Train System Operation...
Page 823 Forward Direction When the transaxle is in FORWARD, the oil from the reservoir (11), through the pump (2), torque converter (9) and oil cooler (10) circuits will be the same as explained in NEUTRAL position. Oil will flow from the inching valve (4) through passage and modulating valve (5) to directional valve (6).
Page 824 Hydraulic System Power Train System Operation...
Page 825 Reverse Direction When the transaxle is in REVERSE, the oil from the reservoir (11), through the pump (2), torque converter (9) and oil cooler (10) circuits will be the same as explained in NEUTRAL position. Oil will flow from the inching valve (4) through passage and modulating valve (5) to directional valve (6).
Page 826 Hydraulic System Power Train System Operation...
Page 827 Differential and Drive Axle (1) Spider. (2) Pinion. (3) Gear. (4) Differential case. (5) Spur gear. (6) Axle Case. (7) Drum. (8) Hub. (9) Shaft. (10) Spur gear (Ring). The location of the differential is in the front of the lift During a turn, the force (traction) that is on the drive truck.
Page 828 washed clean. Do not use parts with damage. Use Testing and Adjusting new parts. Troubleshooting Checks During Operation Troubleshooting can be difficult. A list of possible problems and corrections is on the pages that follow. NOTICE This list of problems and corrections will only give an Before these checks are started, fill the transmission indication of where a problem can be and what with oil to the correct level.
Page 829 Problem: Transmission gets hot. Problem: Transmission operates in reverse only. Probable cause: Probable Cause : 1. Restriction in cooling lines. 1. Discs and plates have too much wear in forward direction clutch. 2. Oil level too high or too low. 2.
Page 830 Problem: Low pressure to FORWARD and Problem: Transmission does not operate in REVERSE clutches. forward or reverse. Probable Cause: Probable Cause: 1. Inching valve stuck. 1. Clutch discs and plates have too much wear. 2. Linkage adjustment is not correct. 2.
Page 831 Problem: Noise on turns only. Transmission Tests and Adjustments Probable Cause: Transmission Pressure Tests 1. Differential pinion gears too tight on the spider or the pinion shaft. 2. Side gears tight in differential case. WARNING 3. Differential pinion or side gears have a defect. To prevent personal injury, when the transaxle is tested, move the truck to a clear area, that is 4.
Page 832 Most problems in the hydraulic circuit can normally be found when the pump pressure is checked. If more information is necessary, gauges can be installed at each pressure tap location. Locations of the pressure taps and procedures for testing are given as follows.
Page 833 Converter Stall Test 2. Engage the wheel brakes and push the accelerator pedal down completely. Read the The converter stall test is a test to check engine RPM on the tachometer, then release the power. It can also be used to locate a problem in the accelerator pedal.
Page 834 Disassembly & Assembly Instruction Precautions : 1. Disassembly : Torque converter Hold converter (1) and take it off the gearbox as a. Tightening torque for bolt (2) shall be 55~65 N·m shown above. The converter (1) itself is not (40~48 lb·ft) for reassembling. Apply LOCTITE separable.
Page 835 3. Disassembly : Oil pump ass’y Take stator seat (1) out of pump ass’y together with driving gear (2) and driven gear (3). Take the oil seal (5) out from pump case (4). Precautions : Dering the disassembly, the oil seal (5) can be 2.
Page 836 4. Disassembly : Converter case Use a wrench to screw off bolt (1) and washer (2). 46 mm Tap converter case (3) lightly with a copper hammer to separate the case and gearbox case (9). Take off a converter case and paper gasket (8).
Page 837 5. Disassembly : Clutch assembly 46mm Take off clutch ass’y from the gearbox along the direction as indicated by arrow. Precautions : 100mm Apply suitable amount of lubricating oil on the hole surface A during the assembly. Take care not to damage seal ring B.
Page 838 46mm 100mm 90mm Jig A. Pressing tool Jig B. Pressing tool (use when reassembling bearings) (use when disassembling clutch ass’y) 8. Disassemble idle shaft 7. Disassemble clutch ass’y Remove the idle shaft (2) together with the Use pliers to draw out retainer ring (1), spacer (3), bearings.
Page 839 10. Disassemble : Strainer (1) Remove cover (2) and take out the strainer (1). Item (5) is gasket. 46mm 100mm Jig A. Pressing tool (use when reassembling bearings) 9. Disassemble bearing (1) from idler shaft (2) by means of drawing tool . Precautions : Use pressing tool to assemble bearings.
Page 840 11. Disassemble differential ass’y from gear box Straighten the bent area of locking plate (2) and unscrew bolt (1) to remove bearing seat (3). Take out the differential ass’y (4). Precautions : a. Tightening torque for bolt (1) shall be 140~165 N·m (103~120 lb·ft) for reassembling.
Page 841 12. Disassembly: differential ass’y Remove bearings (1) and (11) Line up the mark on R.H differential case (10) with on L.H case (3). Straighten the bent area of locking plate (16) and unscrew nut (17) to remove the plate (16) and bolt (15).
Page 842 13. Unscrew bolt (1) and remove washer (2) and 14. Tap with a copper hammer on reduction gear (2) bearing cover (3), O-ring (4) and shim (5). along the direction as indicated by arrow to dismantle bearing (1), gear shaft (2), spacer (3) Precautions : and bevel gear (4) Precautions :...
Page 843 15. Disassembly : Output Shaft Unscrew and remove bolt (1), washer (2), support plate (3), shim (4) and shaft ring (5). Tap the right side A of output shaft (7) gently to remove the shaft together with the bearings and nut on it.
Page 844 16. Disassembly: Output shaft components Screw a round nut into the shaft groove and pry it up. And then, screw the nut out with a wrench. Tap the pressing tool gently in the direction indicated by arrow to remove all the parts on the shaft.
Page 845 17. Disassembly: inching valve ass’y Unscrew bolts (1) and (4) and remove washers (2) and (5). Dismantle inching valve ass’y (6) and paper gasket (3) from the case. Remove elastic retainer (11) by pliers. Take out Oring (12), sleeve (13), spring (14), inching piston(15), shaft (16) and spring (17) successively.
Page 846 18. Disassembly : control valve ass’y Unscrew and remove bolt (1) and washer (2) to lift control valve ass’y out from the case. Unscrew and remove bolt (1) and (4), washer (2) and (3) to separate control valve (6) from cover (7).
Page 847 19. Disassembly: Control valve Take out the pins (1) and (2). Unscrew and remove threaded plug (3), spring (4) and steel ball (5). And then, take out control valve and all the rest parts. Precautions : Tightening torque for plug (3) when reassembling shall be 40~55 N·m (30~40 lb·ft).
Page 848 20. Disasembly: Control valve cover Take out the elastic pin (7). Unscrew and remove bolt (3), cover (10) of release valve, filter (14) and connector (9). And then, take off all the rest parts on valve cover. Precautions : a. Tightening torque for bolt (3) when reassembling shall be 25~32 N·m (18~24 lb·ft).
Page 849 Drive Axle Disassembly 1. Drain the drive axle oil. IBPD186P Typical Example 5. Loosen lock nut and remove the plate (4). (Tool Ref. No : Jig H) IBPD183P Typical Example 2. Loosen the bolts (1). IBPD187P Typical Example 6. Remove bearing cone (5) from the hub. IBPD184P Typical Example 3.
Page 850 IBPD189P IBPD194P Typical Example 11. Loosen the bolts (12) and remove the drive axle 8. Remove bearing cone and cup from the hub and housing by using lifting device. drum. Assembly The assembly procedure is the reverse order of removal, but requires additional care as noted below. IBPD190P 9.
Page 851 IBPD191P IBPD188P 5. Coat rib of oil seal with lithium grease. 3. Install brake assembly. Install the hub and drum. Tighten the bolts to a torque of 150 to 210 N·m (111 to 156 lb·ft). NOTE : Remove dirt or oil in the inside surface of the brake drum completely.
Page 852 IBPD185P Typical Example 7. Coat mating surface of hub with liquid gasket. IBPD203P Typical Example 8. Install the drive shaft and tighten the bolts to a torque of 110 to 120 N.m (81 to 88 lb.ft). 9. Fill the drive axle housing with oil. NOTE : All bolts should be coated with Loctite #271 thread lock when installing.
Page 853 Special Service Tools and Jigs < Unit : mm > Ref. No. Tool/Jig Name Illustration 46 mm Pressing tool for assembling Jig A 100 mm bearing * Locally Manufactured 90mm Pressing tool for Jig B disassembling clutch ass’y * Locally Manufactured Pressing tool for assembling Jig C bearing...
Page 854 Ref. No. Tool/Jig Name Illustration Drive Axle Jig E Pinion Bearing Adjustment Jig * Locally Manufactured Drive Axle Jig F Pinion Bearing Adjustment Jig * Locally Manufactured Drive Axle Jig G Pinion Depth Check Jig * Locally Manufactured Power Train Disassembly &...
Page 855 Ref. No. Tool/Jig Name Illustration Drive Axle Jig H Hub Nut Installer -0.8 +0.8 +0.4 * Locally Manufactured Power Train Disassembly & Assembly...
Page 857 SB4219E01 Jan. 2008 Vehicle System Specification System Operation Testing & Adjusting D20G, D25G, D30G with B3.3 Engine D20G, D25G, D30G with 4TNE98 Engine G20G, G25G, G30G with G424F Engine G20G, G25G, G30G with G424FE Engine...
Page 859 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 861 Index Specification........5 Testing and Adjusting ....32 Hydraulic Control Valve......... 5 Troubleshooting ..........32 Hydraulic Pump ............ 6 Visual Checks ..........32 Lift Cylinder............6 Performance Tests ........32 Standard............6 Hydraulic Oil Temperature (Too Hot) ....32 Full Free Triple and Full Free Lift....7 Hydraulic System and Mast ......33 Tilt Cylinder............
Page 862 Tilt Cylinder Alignment ........62 Drift Test............. 63 Steering System ..........64 Steer Wheel Bearing Adjustment....64 Steering Axle Stop Adjustment..... 65 Steering Knuckle Bearing Preload Adjustment ..............65 Steering System Pressure Check....66 ..............66 Brake System ............. 67 Brake System Air Removal ......
Page 863 Specification Hydraulic Control Valve (1) Torque for bolts that hold control valve sections together ..... 40 ± 3 N·m (360±24 lb·in) (2) Adjust main system relief valve pressure for lift and tilt as shown above. See “Relief valve pressure check” in Testing &Adjusting. (3) Adjust auxiliary relief value pressure for the attachment as shown above.
Page 864 Hydraulic Pump Lift Cylinder Flow rate of flow protector FFL and FFT Mast D700495........45 to 53 liter/min A215044 ........90 to 106 liter/min STD Mast A371156 ........85 to 90 liter/min Standard (1) Tighten mounting bolts to a torque of .........55 ±10 N·m (440±90 lb·in) (2) Apply Loctite #262.
Page 865 Full Free Triple Lift and Full Free Lift Full Free Triple Lift And Full Free Lift Primary Secondary (1) Put pipe sealant on the last three threads of cap. (1) Put pipe sealant on the last three threads of cap. NOTE : All seals to be lubricated with hydraulic oil.
Page 866 Cyl. Stroke (X) Cyl. Closed (Z) Part No. Angle* Tilt Angle* mm (in) mm (in) A375282 6° 12° 167 (6.57) 514 (20.24) D20G, G20G A375322 6° 6° 110 (4.33) 571 (22.48) D25G, G25G A375324 6° 4° 92 (3.62) 589 (23.19)
Page 867 Mast Carriage (1) With mast at 475 mm (18.7 in) channel lap, equally shim both sides until contact (A) is made (1) Select bearings from the chart to obtain (zero clearance) between bearings and mast minimum clearance (C) between bearings and uprights.
Page 868 Lift Relay Group-Standard Lift WARNING Do not put a lift truck into service if the chain wear indication is 2% or more. A reading of 2% or more could cause damage or injury to persons. (1) Put LOCTITE NO. 242 Thread Lock on the threads of the relay group locknuts after adjustment of the lift chains is completed.
Page 869 Lift Relay Group - Full Free Lift WARNING Do not put a lift truck into service if the chain wear indication is 2% or more. A reading of 2% or more could cause damage or injury to persons. (1) Tighten bolts until contact is made with guard. (2) Put LOCTITE NO.
Page 870 Lift Relay Group - Full Free Triple Lift WARNING Do not put a lift truck into service if the chain wear indication is 2% or more. A reading of 2% or more could cause damage or injury to persons. (1) Maximum chain wear ....Less than 2% (See Chain Wear in TESTING &...
Page 871 Lift & Tilt Mounting Group pack must not be more than three shims maxi- mum. (2) Install bearing outer race to a depth of (F) ........4.5±0.8 mm (.177±.031 in). (3) Tilt cylinder installation shown. (4) Install bearing outer race to a depth of (G) ......
Page 872 Steering Wheel (9) (Full Free Lift Mast Only) : Tighten nuts until U-bolt is firm against cylinder, do not apply standard torque. (10) (Full Free Lift Mast Only): With chains adjusted for equal tension run mast to full lift. If mast does not kick (move) to one side, no shims are needed.
Page 873 Steering Gear (1) Pin (1) in the body must be aligned with internal pump gear (gerotor) (2) and drive (3) as shown. (4) Tighten bolts in sequence shown. Tighten to a first torque of ........ 14.1±2.8 N·m (125±25 lb·in) Tighten to a final torque of .... 28.2±2.8 N·m (250±25 lb·in) (5) Torque for plug ....11.3 N·m (100 lb·in) Plug to be flush (even) with or below mounting...
Page 874 Steer Axle and Wheel NOTE : Steer axles with tapered roller bearings shown. (1) Do the steps that follow for steer wheel bearing adjustment. a. Tighten nut (1) slowly to 135 N·m (100 lb·ft) while turning the wheel. b. Loosen nut (1) completely. Tighten it again to ........
Page 875 Steer Wheel Mounting Shoe Brake (1) Torque for bolts and nuts that hold steer wheel ........120±20 N·m (90±15 lb·ft) (1) Axle shaft bolt....110±10N·m(81±7.4 lb·ft) (2) Nut ......200±10N·m(148±7.4 lb·ft) (3) Torque for bolts that hold plate to final drive cover ......180±30N·m(133±22 lb·ft) (4) Torque for nuts that hold brake drum to hub .........460±20N·m(339 ±15 lb·ft) Vehicle System...
Page 876 System Operation Hydraulic System Basic Schematic - Standard FFT mast STD mast Engine Basic Hydraulic Actuator System Schematic (1) Lift Cylinder (2) Flow Protector-primary (3) Lift Cylinder-Primary (4) Flow Protector-Secondary (5) Side Shfit Cylinder (6) Tilt Cylinder (7) Control Valve (8) Hydraulic Line (To Steering Unit) (9) Relief valve-Auxiliary (10) Relief Valve-Main (11) Gear Pump (12) Suction Filter (13) Return Filter (14) Hydraulic Tank (15)-(21) Hydraulic Line (22) Flow Regulator Valve Vehicle System System Operation...
Page 877 The hydraulic system has a hydraulic tank (14) and a gear pump (11) which is installed at the engine. The gear pump (11) sends the pressurized fluid through hydraulic line (15) to control valve (7). The first block of control valve contains a steering spool to supply the control flow (12 LPM) through hydraulic line (8) to steering unit with the higher priority.
Page 878 Optional Schematic with hyd. locking system FFT mast STD mast Engine Basic Hydraulic Actuator System Schematic (1) Lift Cylinder (2) Flow Protector-primary (3) Lift Cylinder-Primary (4) Flow Protector-Secondary (5) Side Shfit Cylinder (6) Tilt Cylinder (7) Control Valve (8) Hydraulic Line (To Steering Unit) (9) Relief valve-Auxiliary (10) Relief Valve-Main (11) Gear Pump (12) Suction Filter (13) Return Filter (14) Hydraulic Tank (15)-(24) Hydraulic Line (25) Flow Regulator Valve (26) Solenoid Block (27) Lift Lock Solenoid (28) Unload Solenoid (29) Emergency Manual Over Ride Valve Vehicle System...
Page 879 In addition to the basic hydraulic operation, there is safety unload function on the first block of control valve that lifting and tilting don’t work even though its lever is shifted, when operator leaves a seat for more than 3 seconds. The solenoid valve (28) for unload function is electrically connected to the electric on-off switch beneath a seat.
Page 880 Hydraulic Control Valve Control valve has specific section of lift and tilt. Overflow valve and flow-priority valve could be mounted on the side port of inlet. Oil circuit is of parallel with neutral back-flow function. When the spool is in the neutral position, pump is in the free load condition.
Page 881 Working Principle of Lifting Valve Section 1. Neutral Position Oil from the pump returns to the tank through unload path. Working principle of tilting valve 1. Neutral Position 2. Lifting up of spools Oil from the pump returns to the tank through unload Close the unloading path, oil from the pump opens a path.
Page 882 3. Tilting down of spool While unload path is closed, oil from pump opens a Working Principle of Accessory Valve Section load check through parallel path and flow out from Port B. With the pressure goes up, oil at Port Are 1.
Page 883 Main Relief Valve 1. Free Action Condition of relief valve When the circuit pressure is lower than the rated values, relief valve keeps balance. Pressure at Port P is filled in the spring chamber through poppet throttle hole. By the work of spring force and oil pressure, main poppet is squashed into the seat of slip while the pilot poppet is also in the condition of close by the force of spring.
Page 884 PF Relief Valve Working principle is same as main relief valve. Instruction is omitted here. Over-load Relief Valve (Port Over-flow Valve) Working principle is same as main relief valve. Below is only the description of cavitation-proof. When working port pressure is lower than that off low-back port, main poppet is open and flow-back oil goes into working port to play the function of cavitation.
Page 885 Steering System Steering Cylinder Steering cylinder (1) gives power assistance through the use of pressure oil at either end of the cylinder piston. The steering cylinder is double ended and the body of the cylinder is mounted stationary to the steer axle.
Page 886 Steering Gear Steering Gear (1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs. (8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section. Lift trucks use the non load sensing, open center (oil The metering section is a small hydraulic pump.
Page 887 Oil Flow The oil from the priority valve flows through inlet (4). When the steering wheel is stationary (NEUTRAL), the oil is stopped by spool (1). The oil can not flow through the steering gear to the steering cylinder until the steering wheel is turned. The steering wheel is connected to spool (1) by a shaft assembly and splines.
Page 888 Brake System Master Cylinder (2) Master cylinder Brake fluid from remote reservoir (1) to replenish master cylinder (2). The master cylinder has a piston which pushes brake liquid into the brake lines. The reservoir, located on the cowl, is connected to inlet of master cylinder.
Page 889 Shoe Type Brake Automatic Adjustment Brakes with automatic adjustment are adjusted on the reverse braking action. In this example the drum rotation is counterclockwise (in reverse) which causes a counterclockwise rotation of the brake shoes. Secondary shoe (4) moves away from cylinder (2) that causes link (1) to move toggle lever (6) in a clockwise rotation.
Page 890 Testing and Adjusting Visual Checks Troubleshooting A visual inspection of the hydraulic system and its components is the first step when a diagnosis of a Troubleshooting can be difficult. A list of possible problem is made. Lower the carriage to the floor and problems and corrections are on the pages that follow these inspections;...
Page 891 Problem: The hydraulic system will not lift the 3. The setting on the relief valve is too low. load. 4. Too many restrictions in the system. Probable Hydraulic Cause: 5. Hydraulic oil level in the tank is too low. 1. There is an air leak, which lets air into the 6.
Page 892 8. Seals in tilt cylinder worn or damaged. Probable Mechanical Cause: 9. Unload function doesn’t work correctly. 1. The mast is not in alignment with the other lifting components and does not slide freely. Probable Mechanical Cause: 2. Not enough lubricant on the parts of the mast that move.
Page 893 The probable Hydraulic cause: 1. Sleeve in a solenoid valve for unload function is stuck to a housing. button of an emergency manual override valve in solenoid block Unload solenoid in solenoid block Probable Electric Cause: 1. Not to supply the electric power to solenoid valve in solenoid block.
Page 894 7. The system operates at too high a pressure. Problem: The lift or tilt cylinders do not hold their position with the valve control levers in neutral position. a. Relief valve setting too high. b. Attachment components cause a restriction Probable Electric Cause during movement.
Page 895 Problem: Spools do not return to neutral. Hydraulic Control Valve Probable Cause: Problem: The control spools do not move freely. 1. The springs are broken. Probable Cause: 2. The spool is bent. 1. The temperature of the oil is too high. 3.
Page 896 Problem: Low oil pressure. Problem: Foreign material behind the wiper rings causing scratches on the cylinder rod. Probable Cause: Probable Cause: 1. Low oil level. 1. The wiper rings show wear and do not remove dirt and foreign material. 2. Priority valve relief valve spring weak. 3.
Page 897 Problem: Pedal resistance is not solid (spongy). Problem: The temperature of the oil is too hot. Probable Cause: Probable Cause: 1. The viscosity of the oil is wrong. 1. Leakage or low fluid level. 2. Air mixed with the oil. 2.
Page 898 Problem: Brake will not make application. Probable Cause: 1. Leakage or low fluid level. 2. Lining surface looks like glass (glazed), or worn. 3. Oil or brake fluid is on the lining. 4. Air in the brake hydraulic system. 5. Defective master cylinder. 6.
Page 899 Hydraulic System Relief Valve Pressure Check CONTROL VALVE Kgf/ ITEM ㎠ LIFT (2630 18100 (181± (185± TILT ±35) ±250 2.5) 2.5) NON EU 2.0t LIFT (3130 21550 (216± (220± TILT ±35) ±250 2.5) 2.5) LIFT (2840 19500 (195± (199± Pressure Tap Location TILT ±35) ±250...
Page 900 Tilt and Sideshift Relief Valve Check and Adjustment 1. Start the engine and activate the hydraulics until the hydraulic oil is at the normal operating temperature. Put the mast in the full tilt back position. 2. With the engine at high idle, hold the tilt control lever in the full tilt back position and watch the gauge.
Page 901 6. Repeat Steps 4 and 5 until there are no air Lift Cylinder Air Removal (Only FFT & bubbles at the setscrews. FFL Mast) 7. After all the air is removed, tighten the setscrews After the lift cylinder has been disassembled and to a torque of 5 to 7 N·m (45 to 60 lb·in).
Page 902 Delayed Engine Shutdown System Operation The delayed engine shutdown system will shut the engine down if no proper action is taken by the operator. This system makes use of the engine oil pressure switch, transmission oil temperature switch and water (coolant) temperature sensor to get the required truck condition.
Page 903 Diagram of Delayed Engine Shutdown System G20/25/30G G424F(E) ENGINE – LP TRUCK G20/25/30G G424F(E) ENGINE – GAS TRUCK Vehicle System Testing and Adjusting...
Page 904 Trouble shooting of Delayed Engine Shutdown System When the ignition key is turned on, the MIL Lamp 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. If a detected fault condition exists, the fault or faults will be stored in the memory of the small engine control module (SECM).
Page 905 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN : G20/25/30G G424F(E) - LP Vehicle System Testing and Adjusting...
Page 906 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN : G20/25/30G G424F(E) - GAS Vehicle System Testing and Adjusting...
Page 907 OSS (Operator Sensing System) 4. Water separator (sediment) warning – only diesel Operation Water separator lamp indicates when the engine is running and there is much water in the fuel filter Operator Sensing System is operated by seat switch exceeding 100cc. built into the seat.
Page 908 Operator Sensing System Schematic Vehicle System Testing and Adjusting...
Page 909 Trouble shooting of Operator Sensing System CONDITION PROBABLE FAULT CORRECTIVE ACTION 1. Buzzer warning 1. Seat switch open 1. Check seat switch 2. Parking brake 2. Parking brake switch open 2. Check parking brake switch light 3. Controller defect 3. Check continuity of wire from seat switch to controller (SW2) 4.
Page 910 CONDITION PROBABLE FAULT CORRECTIVE ACTION 1. Buzzer 1. Seat switch open 1. Check seat switch warning 2. Fift lock / Unload 2. Check Lift lock/Unload Solenoid 2. Mast interrupt solenoid defect light 3. Check continuity of wire from solenoid-lift lock(2) or 3.
Page 911 Mast and Carriage Mast And Carriage Bearings Mast Adjustment Part No. Bearing Size Bearing O.D.* NOTE: The Standard, Full Free Lift and Full Free D581814 Under Size 108.6 mm (4.276 in) Triple Lift mast load bearings are all adjusted the D581815 Standard 109.6 mm (4.135 in)
Page 912 Mast Adjustment Lower Bearings (A) Zero clearance. (B) Minimum clearance. (C) Zero clearance. (3) Bearing. (4) Bearing. (5) Shims. (6) Shims 3. Install 1 mm shim to each bearing of intermediate lower and stationary upper basically. Lifting by crane, insert intermediate mast into stationary mast from the upper side.
Page 913 B. Upper Bearing Adjustment of Stationary Mast 5. In case of standard and full free mast, inner lower bearings can be easily extruded by pulling down 1. Lift by crane, and pull out intermediate mast from the inner mast from the bottom of stationary mast. stationary mast.
Page 914 C. Upper Pad Adjustment 2. Make sure stationary mast upper bearings are properly shimmed by rolling up and down and moving intermediate mast to right and left. If clearance between both masts can be detected, pull out the intermediate mast from the stationary mast with crane and add shim 0.5 mm or 1 mm to both stationary upper bearings.
Page 915 D. Lower Bearing Adjustment of Inner Mast 2. Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 475 mm (18.7 in). Mast Adjustment Lower Bearings (A) Zero Clearance.
Page 916 Carriage Adjustment NOTE : The standard, Full Free Lift and Full Free Triple Lift carriage load bearings are all adjusted the same way. The Full Free Triple Lift carriage is shown in the following illustrations. To make the carriage clearance adjustments, carriage must be removed from the mast.
Page 917 Mast And Carriage Bearings Part No. Bearing Size Bearing O.D.* D581814 Under Size 108.6 mm (4.276 in) D581815 Standard 109.6 mm (4.135 in) D581816 Over Size 110.7 mm (4.358 in) *Permissible tolerance ±0.08mm (.003in) 5. Tighten screw (5) that holds the top bearings to the carriage to a torque of 34L7 N·m (25L5 lb·ft) Chain Adjustment Chain Adjustment Check...
Page 918 Chain Adjustment Chain Wear Test If the tension is not the same on both chains, do the Chain wear test is a measurement of wear of the procedure that follows: chain links and pins. Do the steps that follow to check chain wear.
Page 919 Carriage and Mast Height Adjustment Forks Parallel Check 1. Move the mast either forward or backward so it is 1. Lift the mast and operate the tilt control lever, until in the vertical position. the top surface of the forks is parallel with the floor. Place two straight bars, that are the same width 2.
Page 920 Tilt Cylinder Alignment Tilt Cylinder Length Check If the tilt cylinders are out of alignment, extra stresses in the mast assembly and the mast hinge area will result. To prevent damage, the tilt cylinders must stop evenly at the end of the tilt back and tilt forward strokes.
Page 921 Drift Test WARNING Drift is movement of the mast or carriage that is Tilt cylinder pivot eyes can loosen if the torque there sult of hydraulic leakage in the cylinders or on the pivot eye clamping bolt is not tight control valve.
Page 922 Steering System Drift Test For The Tilt System Steer Wheel Bearing Adjustment 1. Put a rated capacity load on the forks on the lift truck. Operate the lift truck through a complete lift and tilt cycle until the oil is at normal temperature for operation, 45 to 55°C (113 to 131°F).
Page 923 Steering Axle Stop Adjustment Steering Knuckle Bearing Preload Adjustment Steer Angle (1) Bolt. (2) Nut. (3) Bolt. (A) 76°angle. Use the procedure that follows to make an Steering Knuckle Bearing Preload Adjustment adjustment to the steer axle turning angle. (4) Steering link. (5) Shims. (6) Bearing. 1.
Page 924 5. The indication on the pressure gauge must be the Steering System Pressure Check priority valve relief setting of 9,000 +0 /+300 kPa (1,305 +0 /+43 psi). If the indication is correct and If the steering system does not work correctly, check a problem exists, then there is possibly a the hydraulic tank for the correct oil level and the mechanical failure in the steering system.
Page 925 Brake System Brake Adjustment The brakes make an adjustment automatically when Brake System Air Removal an application is made in reverse, but only after an application has been made in the forward direction. Systems With Remote Reservoir With each reverse brake application, there happens an adjustment until the lining-to-drum clearance is made small enough to stop the movement of the automatic adjustment linkage.
Page 926 Pedal Adjustment The brake pedal must have proper free play to let the master cylinder piston return to the release position and open the relief outlet. Approximately 5 mm of free play on the pedal is required. Hydraulic pressure in the brake lines goes back through the relief opening and releases the brakes.
Page 927 2. Adjust stopper bolt for the brake pedal to meet 130 ~135 mm (A) between end of pedal & floor 353 mm plate. For reference, the distance (B) between the top of transmission and pedal shown below is about 353 130 ~ 135 mm 3.
Page 928 4. Adjust the push rod clearance for the brake 7. Make sure the same level of 2 pedals. master cylinder. The required free play on the brake pedal is about 3 ~ 8 mm. 8. Finally check the distance between floor plate & end of brake pedal should be 130 mm.
Page 929 Parking Brake Test Parking Brake Adjustment WARNING To prevent personal injury, the operator must be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move. 1. Drive the fully loaded lift truck up a 15% incline. 2.
Page 931 SB4220E01 J a n . 2 0 0 8 Vehicle System Disassembly & Assembly D20G, D25G, D30G with B3.3 Engine D20G, D25G, D30G with 4TNE98 Engine G20G, G25G, G30G with G424F Engine G20G, G25G, G30G with G424FE Engine...
Page 933 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 935 Index Hood (with seat) Assembly ........5 Overhead Guard ..........6 Forks..............7 Backrest............... 7 Carriage ............... 7 Mast..............13 Standard Lift Cylinder..........28 Secondary Lift Cylinder ........31 Primary Lift Cylinder ..........34 Tilt Cylinder ............37 Hydraulic Pump...........42 Steering Wheel............51 Steering Unit ............52 Brake Master Cylinder .........62 Steer Wheel &...
Page 937 Hood (with seat) Assembly Remove & Install Hood (with seat) Assembly 5. Remove the washers and four bolts (3). WARNING The hood and seat assembly can fall when nut (1)is removed from the support cylinder rod. To avoid personal injury, support the seat and hood assembly before removing nut (1).
Page 938 Overhead Guard Remove & Install Overhead Guard 3. Remove the washers, nuts, and two bolts (3). 4. Remove front overhead guard (1). Front over 1. Support overhead guard (1) with lifting straps and head guard (1) weighs approximately 30 kg (66 lb). a hoist 5.
Page 939 Forks Backrest Remove & Install Forks Remove & Install Backrest 1. Fasten a hoist to the backrest. Remove bolts (2) that fasten the backrest to the carriage. 2. Remove backrest (1). Backrest (1) weighs about 40 kg (90 lb). 3. install backrest (1) in the reverse order of removal. Carriage Remove &...
Page 940 NOTE: For purposes of reassembly, identify and mark all hydraulic lines and connectors before removing or disconnecting. (Typical Example) (Typical Example) 3. Remove four bolts (8) from the chain guard/hose support assembly (6). Set the hoses aside, clear of the primary cylinder and cross head. (Typical Example) 1.
Page 941 (Typical Example) 5. Use tool (A) to remove retainer ring(11) from the cross head shaft. 6. Remove cross head (12) from the shaft. (Typical Example) 7. Raise the inner mast to pull out carriage as shown. 8. Remove carriage (14) from bottom of inner mast (15).
Page 942 (Typical Example) (Typical Example) 10. Install cross head (12) and retaining ring(11). 13. Connect two hydraulic line (4) in their original positions. End By: a. Install backrest. b. Install forks. Disassemble Carriage Start By: a. Remove carriage. (Typical Example) 11. Put the chains in position over cross head (12).Install nuts(9) onto the chain anchors to a torque of 270 ±...
Page 943 (Typical Example) 2. Remove four lower roller bearings (3) and the shims from the carriage. (Typical Example) Carriage adjustment (3) Upper bearings. (4) Shims. 2. Remove screw (5) and washer (4). Remove top (5) Bolt. (6) Screw. (7)Middle bearings. (8) Lower roller bearings (6) and the shims.
Page 944 (Typical Example) 2. Find narrowest point by ruler on the inner mast in 6. Position chains (6) on the carriage. Install pins (7) the area where the bearings make contact. and the roll pins. 3. Install enough shims (4) that have been divided End By: into two equal groups behind bearings (3).
Page 945 Mast Remove & Install Mast Start By: a. Remove forks. b. Place truck on the pit so to disassemble and assemble the mast mounting caps. WARNING Tilt cylinders (7) can drop when pin (6) is removed. To avoid component damage or personal injury, support tilt cylinder (7) while removing pin (6).
Page 946 Disassemble Mast WARNING Start By: Loosen the tension of straps to be connected with hoist when mast assembly (2) is tilted a. Remove primary lift cylinder. forward. If straps are too tight, mast assembly (2) could slide off when bolts(8) are removed. b.
Page 947 (FFT Mast) 2. Remove hose sheave (3). 5. Remove top cylinder retainer bolt (6) from each 3. Remove chain nut (4) from the top of the side of the mast. mast(each side). (Typical Example) 4. Disconnect and remove chains (5) from the bottom of the mast.
Page 948 (STD Mast) (STD Mast) 7. Remove cylinder bottom retainer bolt (9) from each side of mast. (STD mast only) (FFT Mast) 9. Fasten a nylon strap and hoist to lift cylinder, as shown. Hoist and remove lift cylinder (11). Each (STD Mast) cylinder weighs about 50 kg (110 lb).
Page 949 (Typical Example) 10. Check the condition of bearings (12) located in 13. Remove rollers (15) and the shims from the each of the tilt cylinder pin bores. Replace bearings (12) with new if worn or damaged. inner channel mast. (Typical Example) 11.
Page 950 (Typical Example) 15. Remove rollers (17) and the shims from the intermediate mast channel. (FFT mast only) 16. Remove nylon pads (18) and the shims. (Typical Example) 17. Remove rollers (19) and the shims from the stationary mast channel. 18. Remove nylon pads (20) and the shims. Vehicle System Disassembly &...
Page 951 Assemble Mast Mast And Carriage Bearings NOTE: The standard, Full Free Lift and Full Free Part No. Bearing Size Bearing O.D.* Triple Lift mast load bearings are all adjusted the same way. The mast shown in D581814 Under Size 108.6 mm (4.276 in) the following illustrations is the Full Free Triple Lift mast.
Page 952 NOTICE When the correct amount of shim has been installed behind rollers (1) there will be contact (zero clearance)between the rollers and the inner mast at most narrow point of mast (refer to step 4). (Typical Example) Mast Adjustment Lower Bearings (A)Zero clearance.
Page 953 (Typical Example) 8. In case of standard and full free mast, inner lower bearings can be easily extruded by pulling down the inner mast from the bottom of stationary mast. If intermediate mast is stuck and cannot move by rolling up and down, there might be excessive shim.
Page 954 C. Upper Pad Adjustment (Typical Example) 11. In case of standard and full free mast, stationary upper bearings can be easily extruded by pulling down the inner mast from the bottom of stationary mast. If intermediate mast is stuck and can-not move by rolling up and down, there might be excessive shim.
Page 955 D. Lower Bearing Adjustment of Inner Mast (Typical Example) 14. Find narrowest point by ruler on the intermediate mast in the area where the inner lower bearings make contact full length of intermediate mast excluding minimum channel lap 475 mm (18.7 in). Mast Adjustment Lower...
Page 956 E. Upper Bearing Adjustment of intermediate Mast Follow same procedure with above B. F. Upper Pad Adjustment of Intermediate Mast Follow same procedure with above C. 17. If the bearings (13) were removed from the mast Mast Adjustment Lower Bearings(A) Zero clearance.
Page 957 (STD Mast) (STD Mast) (FFT Mast) (FFT Mast) 20. Fasten a hoist and nylon strap to secondary 21. Install secondary cylinder mounting brackets cylinder (11). Install secondary cylinders (11) into (10) over the secondary cylinders. the stationary mast. (STD Mast) 22.
Page 958 (STD Mast) 23. Connect lift hose (7) and return hose (8). (FFT Mast) 24. Install top retainer bolt (6) to the secondary cylinders). 25. Install hydraulic steel tube to each secondary cylinder. When install the steel tube, assembling angle should be kept as shown in above figure. (FFT mast only) Vehicle System Disassembly &...
Page 959 (Typical Example) 30. Install primary lift cylinder (2). (FFT mast only) 26. Connect chains (5) at the bottom of the mast. 27. Connect chains (4) at the chain bracket of stationary mast upper. (Typical Example) 28. Install sheave of lift hose. (FFT mast only) 31.
Page 960 Standard Lift Cylinder Disassembly Start By: a. Remove standard lift cylinders. 33. Install carriage chains to primary lift cylinder. (FFT mast only) 1. Put standard lift cylinder (1) in position on vise (A). (Typical Example) 34. Install hydraulic hose (25) of side shifter to side shifter cylinder (26) 2.
Page 961 3. Remove bearing (3) with wrench (C). 6. Remove O-ring seal (6) and back-up ring (7) from the bearing.. 4. Remove rod (4) from the cylinder body. 7. Remove wiper seal (8) and seal (9) from the bearing. 5. Remove split rings (5) from the cylinder rod. Vehicle System Disassembly &...
Page 962 Assembly 4. Install split rings (5) on the cylinder rod. 1. Install seal (2) in the bearing. 2. Install wiper seal (1). Install the seal with the lip toward the outside. 5. Install cylinder rod (6) in the cylinder body. NOTE: Install back-up ring (4) with the curved side contacting the O-ring seal.
Page 963 Secondary Lift Cylinder Disassembly Tools Needed Hydraulic Cylinder Repair Stand Wrench Assembly Start By: 7. Tighten setscrew (8) with wrench (B) to a torque a. Remove standard lift cylinders. of 6 ± 1 N•m (53 ± 9 lb•in). End By: a.
Page 964 3. Remove rod (3) from the cylinder body. 7. Remove ring (11), wear ring (12) and O-ring (13) from the bearing. 4. Remove stop ring (4) from the cylinder rod. 8. Remove wiper seal (14) and retaining ring (15) 5. Remove wear ring(5), U-packing(6) and backup from the bearing.
Page 965 Assembly 5. Install stop rings (10) on the cylinder rod. 6. Install wear ring (11), U-packing (12) and backup 1. Install U-packing (1) in the bearing. ring (13). 2. Install wiper seal (2) and retaining ring (3). Install the seal with the lip toward the outside. 7.
Page 966 Primary Lift Cylinder Remove & Install Primary Lift Cylinder Start By: a. Remove carriage. WARNING To prevent personal injury, move the control 3. Pull the cylinder out far enough to disconnect levers backward and forward to release any pres-sure in hydraulic system. Slowly loosen the elbow (3).
Page 967 Disassemble Primary Lift Cylinder Tools Needed Hydraulic Cylinder Repair Stand Wrench Assembly Start By: a. Remove primary lift cylinder. 4. Remove wear ring (4), U-packing (5) and backup ring (6). 1. Remove flow protector valve (1) from the cylinder body. 5.
Page 968 7. Remove wiper seal (12) and retaining ring (13) 3. Install O-ring seal (4) and two rings(5). and U-packing (14) from the bearing. Assemble Primary Lift Cylinder Tools Needed Hydraulic Cylinder Repair Stand Wrench Assembly 4. Install check valve (6), retaining ring (7) and spacer (8).
Page 969 Tilt Cylinder Remove & Install Tilt Cylinder NOTE: The procedure for removing and installing the tilt cylinders is the same for both cylinders. WARNING If both tilt cylinders are removed at the same time the mast can fall. To avoid possible 6.
Page 970 2. Remove retainer bolt (6) from pin (5). Remove pin (5). 3. Remove tilt cylinder (4). 4. Install the tilt cylinder in the reverse order of removal. 5. Adjust the tilting angle. Be sure to engage the rod into the anchor more than 32min. Also, inspect if both tilt cylinders have the uneven tilting.
Page 971 4. Remove piston and seal assembly (4) from the Disassemble & Assemble Tilt cylinder rod. Cylinder 5. Remove head assembly (5). Tools Needed Spanner Wrench Start By: a. Remove tilt cylinder. (Typical Example) 6. Remove spacer (6) from the cylinder rod. 7.
Page 972 9. Remove seal (11) from the spacer. 12. Install seal (14) in the head. Position the lip of the seal toward the inside of the head. 13. Install seal (15). 14. Install seal (16) in the cylinder head. Position the lip of seal (16) toward the outside of the cylinder head.
Page 973 16. Install seal (11) in the spacer. 19. Install seals (10) and O-ring seal (9) on the piston. (Typical Example) 20. Install head assembly (5) on the cylinder rod. 17. Install spacer (6). 21. Install piston assembly (4) onto the cylinder rod. 18.
Page 974 Hydraulic Pump (A372287 for EM0K2 & EM0K3) Disassemble Hydraulic Pump a. Start by remove hydraulic pump. 4. Remove Seal (6) and (4) from pump part (5). 1. Remove four cap screws (1) and washers. 5. Remove wear plate (7) from pump assembly (4). 2.
Page 975 Assemble Hydraulic Pump 1. It is important that the relationship of the back- plate, body, wear plate and front plate is correct. There are two half moon cavities in the body. NOTE: The smaller half moon port cavity must be on the pressure side of the pump.
Page 976 4. Place new wear plate (4), seal. The side of the 7. Install wear plate (7) into housing. wear plate with the mid section cut-away must be on the suction side of pump. 8. Install seal (11) and (10) to pump part (9). 5.
Page 977 10. Place washer over drive shaft into housing. Liberally oil shaft seal (13) and install over driveshaft, carefully so that rubber sealing lips are not cut. 11. Install four cap screws (14) and washers. Vehicle System Disassembly & Assembly...
Page 978 Hydraulic Pump (D514289 for EM0QM & EM0QN) Disassemble Hydraulic Pump A. Start by removing the hydraulic pump. 2. Remove four cap screws (3). 3. Remove hydraulic pump cover part from pump assembly. 1. Remove snap ring (1) from pump assembly (2). Vehicle System Disassembly &...
Page 979 4. Remove a plate seal and Back-up (4) from pump cover part. 6. Remove gear assemblies (6) from the body. 5. Remove the side plate (5) from the body. Vehicle System Disassembly & Assembly...
Page 980 7. Remove the side plate (7) from the body. 8. Remove the body (8) from pump assembly. 9. Finished. Vehicle System Disassembly & Assembly...
Page 981 Assemble Hydraulic Pump NOTE: The small half noon port cavity must be on the pressure side of pump. The side of wear plate must be on suction side of pump as bellow photo of the description (4) and please prepare a set of repair kit. 4.
Page 982 7. Install new plate seal and Back-up (7) to pump 9. Install four cap screws (10). cover part (7). 10. Install a new snap ring (11) into pump assembly. 8. Install pump cover part (8) to pump assembly (9). 11. Finished. Vehicle System Disassembly &...
Page 983 Steering Wheel 3. Use a rubber hammer to remove the steering wheel from the shaft. Remove & Install Steering Wheel NOTE: Use the following steps to install the steering wheel. 4. Put the steering wheel on the steering wheel shaft on its original position.
Page 984 Steering Unit WARNING Remove & Install Steering Unit To prevent personal injury be sure pressure in the hydraulic system has been released before Start By: disconnecting any hydraulic lines. Slowly loosen the cap of the hydraulic tank to release any a.
Page 985 Disassemble Steering Unit Cleanliness is extremely important when repairing a steering unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly. Use a wire brush to remove foreign material and debris from around exterior joints of the unit.
Page 986 8. Remove drive. 9. Remove spacer plate. 11. Remove housing from vise. Place housing on a 10. Remove seal from housing. clean soft cloth to protect surface finish. Use a thin bladed screwdriver to pry retaining ring from housing. 12. Rotate spool and sleeve until pin is horizontal. Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing.
Page 987 13. Remove quad ring seal from seal gland bushing. 16. Remove spool and sleeve assembly from 14 14. Use a thin bladed screwdriver to pry dust seal from seal gland bushing. Do not damage bushing. hole end of housing. ATTENTION: Identify and mark all hydraulic hoses for purposes of reassembly.
Page 988 18. Push spool partially from control end of sleeve, 21. Remove check ball seat. then remove 4 centering springs from spool 22. Tip housing to remove check ball. carefully by hand. 19. Push spool back through and out of sleeve. Rotate spool slowly when removing from sleeve.
Page 989 Assemble Steering Unit Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage.
Page 990 11. Position the spool and sleeve assembly so that the splined end of the spool enters the 14 hole end of housing first. ATTENTION: Be extremely careful that the parts do 12. Place housing on clean lint free cloth. Install 47,5mm [1.86 in.] ID seal in housing.
Page 991 16. Install seal gland bushing over the spool end 18. Clamp housing in vise. Clamp lightly on edges of with a twisting motion. Tap the bushing in place with a rubber hammer. Make sure the bushing is mounting area. Do not over tighten jaws. flush against the bearing race.
Page 992 21. Rotate spool and sleeve assembly until pin is parallel with port face. Install drive, make sure you engage drive with pin. To assure proper alignment, mark drive as shown. Note relation- ship between slotted end of drive to splined end of drive when marking.
Page 993 24. Install drive spacer (s) when used, in meter. 25. Install 73,5 mm [2.89 in.] ID seal in gerotor (meter)or end cap, see notes. 26. Install end cap on gerotor, align holes. 27. Install 7 dry cap screws in end cap. Pretighten Spacer Actual Displacement screws to 11-17 N•m [100-150 lb•in] then torque...
Page 994 Disassemble & Assemble Brake Brake Master Cylinder Master Cylinder Remove & Install Brake Master Start By: Cylinder (Boosted) a. Remove brake master cylinder. 1. Remove the cotter pin from pin (1). Remove pin 1. Slip boot (4) off of body (5). (1).
Page 995 5. Remove elbow (6) plug (7), washers (8) and NOTE: Be sure to check the condition of seal (18) connector (9) from master cylinder. when disassembling the brake master cylinder. purposes reassembly, position seal (18) into the bore of body 8.
Page 996 Steer Wheel & Bearing Remove Steer Wheel & Bearing Tools Needed Floor Jack Driver Set Lock Nut Installer NOTE: The procedure to remove the steer wheels is 4. Straighten and remove split pin (4). the same for the right and left steer wheel. 5.
Page 997 7. Remove bearing cup (8) from the hub (7). 8. Remove seal, bearing cup and cone from the bank of hub. NOTE: Check the condition of all seals, bearings and components. If any parts are worn or damaged, use new parts for replacement. For purposes of assembly, lower the temperature of the bearing cups before installing into steer wheel (5).
Page 998 Steering Knuckle, Kingpin, And Bearing Remove Install Steering Knuckle, King Pins And Bearing Tools Needed Drive Set Start By: a. Remove steer wheels. 3. Remove the top grease nipple (6). NOTE: The procedure to remove and install the steering knuckle, kingpin, and bearing is the same for both sides of the lift truck.
Page 999 Steer Axle Remove & Install Steer Axle Tools Needed Jack Stand WARNING Be sure the pressure in the hydraulic system is 6. Remove the knuckle (5), spacer (10) and shim released before any lines or hoses have been disconnected. (11). During the reassembly, the clearance between the knuckle and axle beam should be lower than 0.5mm.
Page 1000 9. Seat steer axle (4) as follows: 5. Lower the steer axle onto the bolt heads with the a. Install bolts (2) through cap (3) and into the floor jack or lift truck. mounting bosses approximately two bolt 6. Remove bolts (2) and mounting caps (3) from the threads b.
Page 1001 Steering Cylinder Remove & Install Steering Cylinder Start By: a. Remove steer axle. 1. Remove the pin retaining bolt and pin (2) from the tie rod at each end of steering cylinder (1). 2. Remove four bolts (3). For installation purposes, the torque for bolts (3) is 250 ±...
Page 1002 Disassemble Steering Cylinder Tools Needed Pliers NOTE: Steering cylinder has two rods positioned between the cylinder end caps. These rods are attached to the cylinder end caps with nuts at each end. Remove the nuts and rods before removing the cylinder end caps from the cylinder tube.
Page 1003 Assemble Steering Cylinder Tools Needed Pliers 6. Remove and inspect O-ring seal (6). 1. Assemble each end cap as follows; a. Install O-ring seal (2). b. Install wear ring (1). c. Install u-cup seal (3). d. Install wiper seal (4). 7.
Page 1004 3. Install O-ring seal (6) on the cylinder rod. 7. Install cylinder tube (10) on the rod assembly. 4. Install piston (7) on the cylinder rod. 8. Install end caps (11) on cylinder tube (10). 5. Install rings (8). NOTE: Install the nuts and rods on steering cylinder 6.
Page 1005 Hydraulic Control Valve Remove And Install Hydraulic Control Valve WARNING Hydraulic oil under pressure can remain in the hydraulic system after the engine and pump have been stopped. Personal injury can result if the pressure is not released before any work is 3.
Page 1006 b. disassembly of front cover. Disassemble Hydraulic Control Valve 1. remove O-ring(11) from the lateral face. 2. remove hex plug(6) and priority connector(5). Start by : NOTE: purpose assembly, 3. remove FD sleeve(4), ball retainer(7), steel identification mark on valve sections. ball(8), spring(9).
Page 1007 c. disassembly of lift section. d. disassembly of tilt section. 1. remove O-ring(15), poppet(11) and spring remove O-ring(13), poppet(9) spring(10)from lateral face carefully not to from lateral face. damage the face. 2. Loose bolts (14), and remove cap(7). 2. remove two hex bolts(12) and cap(5). 3.
Page 1008 Assemble Hydraulic Control Valve Start by : NOTE: make sure all valve parts are clean and free of dirt. e. disassembly of auxiliary section. 1. remove O-ring(13), poppet(9) and spring (10) from lateral face. 2. Loose bolts(12), and remove cap(5). 3.
Page 1009 b. assembly of lift section. c. assembly of tilt section. section using vice lateral(machined)faces not to be damaged. section using vice lateral(machined)faces not to be damaged. 2. Install spool(2) into body(1) smoothly and 2. Install spool(2) into body(1) smoothly and slowly.
Page 1010 e. assembly of section. place each section in a row, insert tie rod, and tight- en nut by 27.4-31.4N•m. NOTE: in case of excessive torque, it could make as pool sticking. In case of insufficient torque, it could make an external leakage problem. Note Dust seal mounting procedure.
Page 1011 Cause and Measure on failure of control valve Problem: large drift of cylinder Problem: External leakage form dust seal Cause Cause 1. internal leakage of spool damage. 1. damaged seal lip or seal worn away. 2. leakage of port relief valve and shut-off plug. 2.
Page 1012 Counterweight Remove & Install Counterweight Tools Needed Link Bracket 3. Remove towing pin (7). 4. Remove the washer plate and bolts (8). 5. Use the hoist and tooling (A) to remove counterweight (6). weight counterweight is approximately 1753 kg (3865 lb). NOTE: The following steps are for installation of the counterweight.
Page 1013 Engine Remove & Install Engine Tools Needed Link Bracket NOTE: Procedures for Gasoline, L.P. and Diesel engines are all similar. The engine shown in the following illustrations is for Diesel B3.3 engine. 2. Disconnect the two battery cables (1). Remove Start by : the washers, two bolts (2) and battery assembly (3).
Page 1014 6. Remove the washers, two bolts not shown and 11. Loosen clamps and disconnect the two transmission cooler hoses (15). tube assembly (9). 7. Remove the washers, two bolts and muffler assembly. Remove, eight bolts (16) baffle assembly(17), if equipped. 8.
Page 1015 (Typical Example) 16. Disconnect wires (23) from alternator (24). 13. Remove radiator mounting bolts (18). NOTICE Place identification marks wires connectors to assure proper assembly. 14. For easy removal of radiator, loosen four bolts(19) and remove radiator (20). 17. Disconnect connector (25) from transmission switch.
Page 1016 (Typical Example) 19. Disconnect wire (27) from circuit breaker (28).To 22. Remove the six bolts (34) that hold the converter remove engine from the truck, other wires or connectors not shown should be disconnected. to the flywheel. During the reassembly, the tightening torque is 28 ±...
Page 1017 24. Remove the washers and bolts (35) from the End By : converter housing. During the reassembly, the a. Install overhead guard* tightening torque is 55 ± 10 N•m (40 ± 10 lb•ft). b. Install counterweight* c. Install hood assembly* Refer topics “Over...
Page 1019 SB4321E00 Jan. 2008 Hydraulic Schematic D20G, D25G, D30G with B3.3 Engine D20G, D25G, D30G with 4TNE98 Engine G20G, G25G, G30G with G424F Engine G20G, G25G, G30G with G424FE Engine...

This manual is also suitable for:

D30g G30g D25g G20g G25g

Save PDF