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Table of Contents
Related Manuals for Ford DSG-423
Summary of Contents for Ford DSG-423
- Page 1 OPERATOR HANDBOOK LIQUEFIED PETROLEUM GAS (LPG) GASOLINE (EFI) & NATURAL GAS (NG) ENGINES EDI 106 , 200 Powe rtrain A lies & Components Provided By Ford Component Sales IMT # 99905334 Used through REFUSE3G3121003. Replaced with MSG425 engine.
- Page 2 WARNING: WARNING: ENGINE EXHAUST, SOME OF ITS CONSTITUENTS, AND CERTAIN VEHICLE COMPONENTS CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. IN ADDITION, CERTAIN FLUIDS CONTAINED IN VEHICLES AND CERTAIN PRODUCTS OF COMPONENT WEAR CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
- Page 3 FORD DSG-423 ENGINES GASOLINE (EFI) LIQUEFIED PETROLEUM GAS (LPG) NATURAL GAS (NG) Reproduction in any manner, in whole or in part, is prohibited without the express permission in writing from Engine Distributors, Inc. (EDI) EDI policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects, the right to change prices, specifications and equipment at any time without notice is reserved.
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Page 4: Table Of Contents
CONTENTS HEALTH & SAFETY ..................... 5 General Guidelines: ..................5 Important Safety Notice................. 5 Notes, Cautions, and Warnings ..............6 FORWARD ......................7 ENGINE IDENTIFICATION................... 7 U.S.A. Engine Identification Decal ..............7 Federal Emissions Warranty Statement............8 California Emission Control Warranty Statement .......... 8 What Is Covered? .................. - Page 5 CONTENTS STARTING THE ENGINE ................... 15 Initial Start-up ....................15 To Start From cold ..................16 STOPPING THE ENGINE .................. 17 Normal Conditions..................17 Abnormal Conditions ................... 17 RUNNING-IN PROCEDURE ................17 FUEL RECOMMENDATION ................18 Fuel Quality ....................18 Alcohol Gasoline Blends (Gasohol) ............
- Page 6 CONTENTS GENERAL MAINTENANCE INFORMATION ............. 28 Cooling System ................... 28 Draining, Flushing and Filling the Cooling System........30 Engine Lubrication System ................. 30 Electrical System..................31 Generator ....................31 Storage......................32 ENGINE SYSTEM CHECK................. 33 SPECIFICATIONS ....................36 General Specifications ................36 Fuel System ....................
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Page 7: Health & Safety
HEALTH & SAFETY WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED. Carrying out certain operations and handling some substances can be dangerous or harmful to the operator if the correct safety precautions are not observed. Some such precautions are recommended at the appropriate points in this book. While it is important that these recommended safety precautions are observed, care near machinery is always necessary, and no list can be exhaustive. -
Page 8: Notes, Cautions, And Warnings
manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that neither personal safety nor equipment integrity are compromised by the choice of methods, tools or parts. Notes, Cautions, and Warnings As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. -
Page 9: Forward
Distributors are listed at the back of this handbook. Regular maintenance will result in minimal operating costs. Engines manufactured by Ford Motor Company are available through EDI Distributors. When in need of parts or service, contact your local EDI Authorized Distributor. -
Page 10: Federal Emissions Warranty Statement
Federal Emissions Warranty Statement Engine Distributors, Inc. (EDI) warrants that your new (2006 or later model year) off-road large spark-ignition (LSI) is designed, built, and equipped to meet the applicable EPA emissions requirements and is free from defects in factory supplied materials and workmanship that could prevent it from conforming with these requirements. - Page 11 Manufacturer's Warranty Coverage: The 2006 or later off-road large spark-ignition compliant certified engines are warranted for three (3) years or 2500 hours, whichever occurs first. High cost emission related parts are warranted for five (5) years or 3500 hours, whichever occurs first.
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Page 12: What Is Covered
What Is Covered? The Federal and California emission warranties cover the following parts. 1. Air / Fuel Feedback Control System and Sensors 2. Air Induction System (Supplied and Warranted by Equipment Manufacturer) 3. Carburetor system (internal parts and/or pressure regulator or fuel mixer or injection system) 4. -
Page 13: Parts And Service
PARTS AND SERVICE Replacement parts can be obtained through your local EDI Distributors listed in the back portion of this handbook. They also may be found in the yellow pages under “Engines” or contact EDI at: 1-800 220 2700. EDI Distributors are equipped to perform major and minor repairs. They are anxious to see that all of your maintenance and service needs are quickly and courteously completed. -
Page 14: Before Operating The Engine
BEFORE OPERATING THE ENGINE 1. Before operating a new engine it should be thoroughly inspected to ensure that during transit and installation it has not suffered damage likely to affect its subsequent operation. Controls and instruments should be studied carefully in order that their functions are thoroughly understood. -
Page 15: Safety Switch (Where Fitted)
4. Start - In this position, the starter solenoid is energized and the starter motor cranks the engine. The switch, when released, automatically returns to the RUN position. Safety Switch (where fitted) A low oil pressure/high water temperature safety switch may be fitted. This automatically shuts off the ignition when the oil pressure drops below a pre-set value, or when the water temperature rises above a pre-set value. -
Page 16: Instruments
INSTRUMENTS Your Engine Distributors, Inc. (EDI) Powered Equipment will have been fitted with instruments selected by the manufacturer. The types of instruments most likely to be encountered are detailed here. A typical instrument panel is shown below. Ammeter Oil Pressure Gauge Combined Temp. -
Page 17: Temperature Gauge (Where Fitted)
Temperature Gauge (Where Fitted) The temperature gauge enables a close check to be kept on the coolant temperatures. Malfunction Indicator Light (Where Fitted) Used on all industrial engines. This light will illuminate whenever there is an engine malfunction such as low oil pressure, high engine temperature, fuel injection system fault. -
Page 18: To Start From Cold
To Start From cold 1. Where possible, disconnect the driven equipment, eg, fully depress the clutch where a manual transmission is fitted. If your unit is equipped with the engine warning light system, always turn the ignition switch to the ON position to make sure that each warning light is operating before starting engine. -
Page 19: Stopping The Engine
STOPPING THE ENGINE Normal Conditions Following normal operating conditions, lower the engine speed to idle, disengage the clutch, and then turn the ignition switch to the OFF position. If the engine has been running under high power, let it run at fast idle speed a few minutes to cool the engine down. -
Page 20: Fuel Recommendation
The other way is the catalytic hydrolysis of ethylene, a petroleum product, is the primary synthetic method. Compared to gasoline the energy content of ethanol is 66%. Ford engines should operate satisfactory on gasohol blends using unleaded gasoline and containing no more than 10% ethanol by volume. - Page 21 CAUTION: Discontinue use of any gasohol or alcohol/gasoline blend if per- formance problems occur. Do not use such fuels unless they are UNLEAD- NOTE: It is highly recommended that a Fuel Stabilizer, Ford Part Number E8AZ- 19C544-A or an equivalent additive be used for any length of storage. It is imperative in any application where the fuel will not be consumed within thirty days.
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Page 22: Lubrication And Maintenance
LUBRICATION AND MAINTENANCE The importance of correct lubrication, periodic inspection and adjustment cannot be over-emphasized. It will determine, to a very large extent, the service the engine will give. Detailed instructions regarding this maintenance are given in the following pages. Your Authorized EDI Distributor listed in the back section of this manual, will be pleased to carry out this regular maintenance for you. -
Page 23: Recommended Maintenance Schedules
RECOMMENDED MAINTENANCE SCHEDULES Hours Running Or Miles Driven Maintenance Operation Check engine oil level and top up if necessary Check engine coolant level and top up if necessary with correct mixture Check visually for oil, fuel or coolant leaks Lubricate PTO release bearing Check all instruments, controls and warning lights. -
Page 24: Recommended Maintenance Operations
SAE 10W40 CAUTION: Use Ford/Motorcraft “Formu- la E” SAE 5W-20 engine oil or equiva- lent that meets Ford Specification WSS- M2C930-A (API Classification – SJ). If SJ oils are not available, SH oils are accept- able. Use only engine oil displaying the... -
Page 25: Used Engine Oils
Used Engine Oils WARNING: PROLONGED AND REPEATED CONTACT MAY CAUSE SERIOUS SKIN DISORDERS INCLUDING DERMATITIS AND SKIN CANCER. WARNING: AVOID EXCESSIVE CONTACT—WASH THOROUGHLY AFTER CONTACT. KEEP OUT OF THE REACH OF CHILDREN. WARNING: PROTECT THE ENVIRONMENT: IT IS ILLEGAL TO POLLUTE DRAINS, WATER COURSES OR SOIL. -
Page 26: Check Engine Oil Level
This filter is especially designed for use in engines built by Ford to give successful operation with the recommended oil filter change intervals. Contact your nearest EDI distributor listed in the back section to obtain the correct filter. -
Page 27: Fuel Filter - Efi
Fuel Filter - EFI The fuel filter is located between the fuel tank and the fuel pump. Ignition System - DIS The Distributorless Ignition System (DIS) used on this engine does not have a distributor or vacuum advance mechanism. Ignition timing is set by design and cannot be readily changed. -
Page 28: Check Condition Of Ancillary Drive Belts
Check Condition of Ancillary Drive Belts WARNING: ENGINE SHOULD BE STOPPED AND ANY REMOTE STARTER DISABLED BEFORE CHECKING BELTS. The serpentine ancillary belt used to drive the generator and water pump, is tensioned automatically and does not require adjustment. The belts should be visually inspected for signs of wear or damage. It should be renewed if necessary. -
Page 29: Renew Air Cleaner Element
Renew Air Cleaner Element Your air cleaner filters air entering the engine induction system and acts as a silencer and a flame arrester. Air that contains dirt and grit produces an abrasive fuel mixture, and can cause severe damage to the cylinder walls and piston rings. Damage to the cylinder walls and piston rings will cause high oil consumption and short engine life. -
Page 30: General Maintenance Information
GENERAL MAINTENANCE INFORMATION The following section outlines some aspects of general maintenance which will be of value to the operator. Cooling System To obtain maximum engine service life, its operating temperature must be maintained by an efficient cooling system. CAUTION: Under no circumstances should the engine be started without liq- uid in the cooling system. - Page 31 Motorcraft Premium Gold engine coolant, or equivalent, has long life characteristics and if the concentration is kept to a maximum of 50% it will provide adequate frost protection and inhibiting for the life of the engine. NOTE: If a major component of the cooling system is renewed such as the radiator, water pump etc., the system should be flushed and re-filled with a 50% solution of Motorcraft Premium Gold engine coolant, or equivalent, and clean water.
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Page 32: Draining, Flushing And Filling The Cooling System
Draining, Flushing and Filling the Cooling System WARNING: NEVER REMOVE THE PRESSURE Radiator Drain Cock RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE. TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF... -
Page 33: Electrical System
Electrical System A NEGATIVE EARTH (NEGATIVE GROUND) SYSTEM IS USED. GCP - Power Distribution Box Part of -5250010- Wiring Harness Starter Empty Relay Fuse Amps Circuits protected Battery Voltage to EPR Ignition Voltage to GCP and Relays Battery Voltage to GCP Fuel pump Battery Voltage out of Power Relay Not used... -
Page 34: Storage
Ford Fuel stabilizer comes in an 8 fl.oz. bottle for consumer use and should be available through all EDI Distributors. The correct ratio is 2 oz. Stabilizer to 5 gallons of gasoline. -
Page 35: Engine System Check
ENGINE SYSTEM CHECK GCP System Check NOTE: Items listed in the possible cause column generally do not set a diagnostic trouble code (DTC) or illuminate the MIL light. NOTE: EDI engines are used in many different applications and equipment. When performing any system diagnosis be aware of any OEM inputs or equipment monitoring devices that may have an effect on the engine’s performance or any of the engine’s operating systems. - Page 36 SYMPTOM POSSIBLE CAUSE Engine Does Not Crank • Dead Battery • Ground Loss • Ancillary Components Binding or Seized • OEM Shutdown - Oil Level Safety • Starter Lockout Relay Failure • Ignition Switch Failure • Bad Starter • Crank Control Wire Failure •...
- Page 37 SYMPTOM POSSIBLE CAUSE Lack of Power • Ancillary Components Binding • Intake Air Restriction • Crossed Spark Plug Wires • Spark Plugs Fouled • Fuel System Failure • Low Fuel Pressure • Low Cylinder Compression Spark Knock • Poor Quality or Contaminated Fuel •...
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Page 38: Specifications
Hot@2000 rpm: 200-268 kPa (29-39 psi) Oil Type: Super Premium SAE5W20 WSS M2C930-A Service Oil fill capacity (including filter): 4.0 qt. (3.78 L) = 3.5 qt. Pan + 0.5 qt. filter Oil filter Ford Service Part Number:1S7G 6714 DA Motorcraft: FL 910... -
Page 39: Cooling System
Thermostat: Type: Wax element Commences opening: 88.9°C Fully open:100°C Coolant 50% Motorcraft Premium Gold engine coolant plus 50% clear water Ford Specification: WSS-M97B51-A1 Drive Belts Front end accessory drive belt & tension Serpentine belt with automatic tension control. Electrical System... -
Page 40: Conversion Table
CONVERSION TABLE TO CONVERT FROM MULTIPLY BY FROM DIVIDE BY Distance inches 25.4 inches 0.0254 feet 304.8 feet 0.3048 yards 0.9144 mile 1.609 Area 645.16 0.0929 0.8361 Volume 16.3871 1 liter 0.016387 pint (us) 1 liter 0.47318 pint (uk) 1 liter 0.56826 quart (us) 1 liter... -
Page 41: Edi Distributors
Blackwood, NJ 08012 NORTH Engine 303 Interstate Drive 800-220-7080 CAROLINA Distributors, Inc. Archdale, NC 27263 3148 OHIO Graham Ford Inc. 707 W. Broad St. 614-464-6000 Columbus, OH 43222 North Coast Ford 11885 Bellaire Road 216-251-5800 Industrial Cleveland, OH 44135 PENNSYLVANIA... - Page 42 EDI Worldwide Service Engine Distributors Inc 400 University Court Blackwood NJ 08012 Service/Warranty 1-800-220-2700 1-856-228-7298 1-856-228-5657(fax parts & service) 1-856-228-5531(fax sales)
- Page 44 EDI Worldwide Service Engine Distributors Inc 400 University Court Blackwood NJ 08012 Service/Warranty 1-800-220-2700 1-856-228-7298 1-856-228-5657(fax parts & service) 1-856-228-5531(fax sales)
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