Page 1 SB4251E00 May. 2007 Service Manual G424FE LP/Dual Fuel Engine G424F LP Engine G20P-5, G25P-5, G30P-5, G33P-5, G35C-5 GC20P-5, GC25P-5, GC30P-5, GC33P-5...
Page 3: Important Safety Information
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 5: Table Of Contents
Engine Model and Engine Serial Number ..12 Inspect Air/Fuel Valve Mixer Assembly ..27 General Specification ........13 Inspect for Intake Leaks........ 27 G424F/G424FE Engine Power and Torque..15 Inspect Throttle Assembly......27 Checking the TMAP Sensor......27 Chapter 2. RECOMMENDED MAINTENANCE Exhaust System Maintenance......
Page 6: Index
Pistons and/or Connecting Rods ...... 97 Ignition System..........143 Rings .............. 9999 Exhaust System...........144 SECM............146 Chapter 4. ENGINE ELECTRICAL SECM Wiring Diagrams for G424FE ....149 SYSTEM G424F EMS (Engine Management System) Overview ............152 Specifications ..........101 General Description ........152 Ignition System ..........102 LPG Fuel System Operation ......155...
Page 7 Electronic Throttle Body ......176 Chapter 7. MPI GASOLINE FUEL Chapter 6. LPG FUEL DELIVERY DELIVERY SYSTEM SYSTEM Specification .............212 G424FE LP System Inspection and Repair ..177 Components Location........213 Removal and Installation ......177 Fuel Pressure Test ...........214 Hose Connections........ 178 Injector ..............216 Removal and Installation of N-2007 LP Fuel Pump............219...
Page 8 Appendix Acceleration..........237 Detonation / Spark Knock......239 Backfire ............240 Service Tool Software (MotoView)....279 Dieseling, Run-on ........240 Introduction ..........279 Rough, Unstable, Incorrect Idle, or Stalling.. 241 Connection of the Service Tool ....280 Cuts Out, Misses......... 243 MotoView Display Screens ......281 Poor Fuel Economy / Excessive Fuel SECM field update with Service Tool ...293 Consumption LPG Exhaust Smell ....
Page 9: Chapter 1. General Information
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 10: Electrical System
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 11 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 12: Tightening Torque
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 13: Recommended Lubricants And Capacities
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 G(C)20/25/30/33P-5 Oil Pan...
Page 14: Engine Model And Engine Serial Number
G424FE/G424F 30700001 to 39999999 • Electronic Control by ECM • Certified LP/Dual Fuel System available Features and Benefits of G424FE/G424F Engine – Closed loop LP Carburetion system • Al head with valve seat inserts – Closed loop MPI Gasoline system –...
Page 15: General Specification
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...
Page 16 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...
Page 17: G424F/G424Fe Engine Power And Torque
G424F/G424FE Engine Power and Torque G424FE G424F ENGINE MODEL unit G424FE-LP G424FE-DF(GAS) G424F-LP G424FE-DF(LP) 46.2 44.7 46.2 RATED POWER 62.9 60.8 62.9 2,550 2,550 2,550 ibf-ft MAX TORQUE Kgf-m 18.5 17.5 18.5 2,200 2,200 2,200 GOVERNED SPEED 2,600 2,600 2,600...
Page 18: Chapter 2. Recommended Maintenance
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 19: Engine Oil Classification
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 20: Checking Engine Oil Level
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 21: Checking Compressed Pressure
3. Refill with engine oil filter. CAUTION 1) Clean and install the oil drain plug with a new gasket. At this time, necessarily screen the spark plug 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 22: Cooling System Maintenance
DOOSAN prefers the use of distilled water or deionized water to reduce the potential and severity of chemical insolubility.
Page 23: Checking Coolant Leaks
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 24: Checking And Adjusting Drive Belt
3. Tighten the bolt “A” and then tighten “B” to the Checking and Adjusting Drive Belt 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 25: Ignition System Maintenance
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 •...
Page 26: Inspection Of Spark Plug
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 27 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 28: Fuel System Maintenance
8. Re-assemble the filter assembly aligning the Fuel System Maintenance 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 29: Pressure Regulator/Converter Inspection
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 30: Maintenance Schedule
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 31 G424F(FE) Service Manual Chapter 2. Recommended Maintenance...
Page 32: Chapter 3. Engine Mechanical System
Chapter 3. ENGINE MECHANICAL SYSTEM General Information Engine Outline G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 33: Technical Specifications
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 34 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 35: Shells Selection Table
Shells Selection Table MAIN BEARINGS – STANDARD SIZE (*) (*) ALL MEASURES ARE IN MILLIMETERS G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 36 MAIN BEARINGS – 0.50 UNDERSIZE (*) G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 37 CONNECTING ROD BEARINGS CONNECTING ROD BEARINGS 0.25 UNDERSIZE 0.50 UNDERSIZE G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 38: Recommended Torque Values
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 39 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 40: Troubleshooting
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 41: Engine Exploded View
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 42 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 43: Intake Manifold And Gasket
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 44 4. Drain the coolant, releasing the radiator lower hose. 5. Disconnect the fitting of gasoline fuel hose from the fuel tank. (G424FE DF) 6. Disconnect the fuel hose and balance line, air hose. 7. Disconnect carburetor assembly by using 5mm hex-bit socket wrench handle.
Page 45 12. Insert the fuel rail with injectors in the hole of manifold and paste oil and grease to o-ring of 6. With a 13-mm socket wrench, extension and injector. (G424FE) proper torque wrench; tighten. 13. With a 12-mm socket wrench, extension and Tighten proper torque wrench;...
Page 46 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 47: Exhaust Manifold And Gasket
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 48 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 49: Timing Belt
Timing Belt Components 1) Cover 2) Bolt 3) Adapter 4) Bolt 5) Cover 6) Bolt 7) Sprocket 8) Washer 9) Bolt 10) Belt-timing 11) Tensioner-Timing Belt 12) Bolt 13) Spacer 14) Key 15) Seal 16) Sprocket 17) Washer 18) Bolt 19) Bolt 20) Stud 21) Nut...
Page 50 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 51 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 52 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 53: Timing Belt Tensioner
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 54: Pcv Valve
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 55: Crankcase Ventilation
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 56: Service Procedure
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 57: Camshaft Timing Pulley And/Or Seal
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 58: Crankshaft Front Seal
• 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 59: Camshaft Case Cover And Gasket
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 60 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 61: Rocker Arms, Linkage, Valve Lifters With
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 62: Cooling System
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 63 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 64: Testing And Adjusting
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 65 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 66 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 67: Cooling System Recommendation
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 68: Thermostat Housing
9. Thermostat housing. Make proper antifreeze additions. 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 69: Water Pump
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 70: Lubrication System
Lubrication System General Description Lubricating system is the full-flow filtered pressure- OIl Filter 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 71 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 72 the engine’s internal parts. Too Much Oil Consumption • 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 73: Oil Pan
Installation Oil Pan Install or connect Removal 1. Adhesive sealant in the oil pan. Remove or disconnect 2. Oil pan-to-engine attaching bolts, without 1. Drain the oil on a proper container, removing the tightening. oil pan drain plug, with Torx T45 wrench. 3.
Page 74: Oil Pump
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 75: Oil Pump Assembly
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 76: Camshaft Case Assembly
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 77 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 78 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 79 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 80: Cylinder Head
Tighten 40. Battery negative cable. • Bolt: 18 – 28 N·m (13 – 20.5 lb·ft.) 41. Change the engine oil, in view of possible water contamination. 26. With a 15-mm socket wrench and torque wrench, tighten the nuts attaching the upper support to the cylinder head.
Page 81: Valve, Spring Or Seal
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 82 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 83: Engine Disassembly
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 84 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 85 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 86 G424F(FE) Service Manual Chapter 3. Engine Mechanical System...
Page 87: Engine Assembly
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 88 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 89 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 90 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 91 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 92: Cylinder Block
54. Engine assembly; see “Engine Assembly – Cylinder Honing Installation”, in this section. Note: Some of the services that are next presented are not necessarily performed when reconditioning Cylinder Block an engine. The performance should depend on the inspections Removal to which the engines will be submitted before reconditioning.
Page 93: Crankshaft
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 94 • 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 95 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 96 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. Obs.: Whenever is necessary to remove the Important cylinder head, a new gasket should be used.
Page 97 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 98 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 99: Pistons And/Or Connecting Rods
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 100 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 101: Rings
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 102 • Install the connecting rod upper shell lubricated Tighten 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 103: Chapter 4. Engine Electrical System
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 104: Ignition System
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 105: Inspection Of Ignition Coil
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 106: Spark Plug Wire Inspection
Spark Plug Wire Inspection a. Twist each spark plug boot 1/2 turn. 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 107: Spark Plug Replacement
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 108 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 109: Charging System
Charging System • Reduced ignition system voltage output - 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 110 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 111 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 112: Troubleshooting Procedure
Troubleshooting Procedure Inspection before Starting 1. Alternator and drive belt tension inspection. G424F(FE) Service Manual Chapter 4. Engine Electrical System...
Page 113 2. Alternator and outer terminal connection inspection. G424F(FE) Service Manual Chapter 4. Engine Electrical System...
Page 114 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 115 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 116 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 117: Starting System
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 118: Diagnosis Procedure
Diagnosis Procedure The starting motor solenoid has two functions: 1. Engages the pinion with flywheel. The following simplified procedure is intended to help the serviceman determine if a starting motor 2. Is a high current switch rated about 1000 amps needs to be removed and replaced or repaired.
Page 119 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 120: Start Relay Tests
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 121: Troubleshooting
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 122 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 123: Chapter 5. Engine Management System (Ems)
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...
Page 124 Q’ty Components Items Specifications G424FE G424F Transmission Oil Actuation Temperature 125°C Temperature Switch Ground speed limit Type Normal Open option option 145 ± 28 kPa switch Actuation Pressure Electronic Throttle System Q’ty Components Items Specifications G424FE G424F Electronic Throttle Minimum Electrical 1.5 ohms...
Page 125 20~25 Ω LP Fuel Lock-off Electrical Resistance N-2007 LP Regulator Fuel Supply Pressure 10 psi to 250 psi (68.95 kPa to For G424FE 1723.69 kPa) Fuel Inlet Fitting 1/4” NPT Fuel Outlet Fitting Two 3/4” NPT fittings with one plugged and one 1/8”...
Page 126 (-1.25 ± 0.87 mbar)@1.7 lbm/hr LPG) -1.35 ± 0.5 inH2O@32.1 lbm/hr LPG (-3.36 ± 1.25 mbar)@32.1 lbm/hr LPG) CA100 Mixer Fuel For G424FE Fuel Inlet Fitting 1/2” NPT Fuel inlet fitted with Delphi temperature sensor 2.25” (57.15mm) ID inlet, four #10- Air Intake Flange 24 screws in 1.94”...
Page 127 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 128: Service Standard
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 129: Component Location
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 130 Pre-Catalyst Oxygen Sensor Post-Catalyst Oxygen Sensor Pedal Angle Sensor Engine Oil Pressure Switch Transmission Oil Temperature Switch Ground speed limit switch (option) G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 131 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 132 Gasoline Injectors and fuel rail Gasoline Fuel Pump Ass'y G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 133: G424Fe Ems (Engine Management System) Overview
Manifold Pressure/Temperature Sensor Manifold Pressure/Temperature Sensor Manifold Pressure/Temperature Sensor Manifold Pressure/Temperature Sensor [Figure 1] MI-07 Dual Fuel System for G424FE Engine The SECM makes any necessary corrections to the connecting the accelerator pedal to the electronic throttle through the electrical harness; mechanical...
Page 134 Dual Fuel System of G424FE (certified engine system) INPUT OUTPUT Crank Sensor Throttle body CAM sensor (Dual Fuel Only) lgnition coil TMAP sensor 2 Fuel trim valves Coolant Temp LP fuelock valve EG oil pressure switch 4 Injectors SECM T/M Temp switch...
Page 135 The MI-07 system uses an advanced speed-density control strategy for fuel, spark, and air throttle Q’ty DESCRIPTION control. Key features include the following. G424FE G424F-LP • Closed-loop fuel control with fuel specific controls Engine Control Module for LPG, and gasoline (MPI) fuels (SECM 48-pin) •...
Page 136: Lpg Fuel System Operation
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 137 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 138 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 139 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 140 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 141 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 142 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 143: Mpi Gasoline System Operation
MPI (multi-point injection) system is used for G424FE dual fuel engine. An electric fuel pump in For fuel consumption reduction, engine performance gasoline fuel tank supplies the fuel and generates...
Page 144: Electronic Throttle System
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 145: Ignition System
Figure 15. Throttle Body Assembly Exploded View Wasted Spark DIS Ignition System The G424F and G424FE engine has a wasted spark ignition system (2 cylinders per coil). Wasted spark ignition is a type of distributor-less ignition system where a pair of multi tower coils is mounted near the spark plugs.
Page 146: Exhaust System
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) The MI-07 system utilizes two HEGO (O2) sensors. DIS COMPONENTS 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 147 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 148: Secm
The SECM provides a transducer ground for all the SECM sensors, and a low side driver signal controlling the fuel lock-off, MIL, gasoline injectors, gasoline fuel General Description The Small Engine Control Module (SECM) controller pump, and FTVs. has full authority over spark, fuel and air. Utilizing a Freescale micro controller, the SECM has 48 pins of Fuel Management During engine cranking at startup, the SECM...
Page 149 NOTE : The DV-E5 throttle is not a serviceable Speed Management 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 150 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 151: Secm Wiring Diagrams For G424Fe
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.
Page 152 Figure 21. SECM Wiring Diagram for G424FE Dual Fuel System. G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 153 Figure 22. SECM Wiring Diagram for G424FE LP System. G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 154: G424F Ems (Engine Management System) Overview
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 155 LP 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 Throttle position sensor T/M Inching pressure switch (option) G424F(FE) Service Manual Chapter 5.
Page 156 • Small engine control module (SECM), firmware and calibration † • Fuel system sensors and actuators • Ignition system including spark plugs, cables, coils and drivers Q’ty DESCRIPTION G424FE G424F Engine Control Module (SECM 48-pin) None None Camshaft Position Sensor...
Page 157: Lpg Fuel System Operation
The LP fuel filter of G42F engine is the same as that 1000 rpm at no load. A variety of fault conditions can of G424FE engine. See, “G424FE EMS overview” initiate limp-home mode. These fault conditions and resulting actions are determined during calibration MI-07 Fuel Lock-Off (Electric) and are OEM customer specific.
Page 158 stage) valve closes. Unlike most other N-2001 Operation regulator/converters, the N-2001 primary valve closes with fuel pressure rather than against Refer to Figure 6. pressure, extending primary seat life and adding Liquid propane, at tank pressure, enters the N-2001 additional safety. through the fuel inlet port (1).
Page 159 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 160 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 161: Electronic Throttle System
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 162: Secm Wiring Diagrams For G424F Lp Engine
SECM Wiring Diagrams for G424F LP Engine G424F(FE) Service Manual Chapter 5. Engine Management System (EMS)
Page 163: Ems Inspection And Repair
• 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 164 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 165: Camshaft Position Sensor
Camshaft Position Sensor Sensor Inspection (G424FE- Dual Fuel 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.
Page 166 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 167 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 168 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 169: Iat (Intake Air Temperature) Sensor
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 170: Oxygen Sensor (Pre-Catalyst)
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 171: Oxygen Sensor (Post-Catalyst)
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 172: Ect (Engine Coolant Temperature) Sensor
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 173 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 174: Lp Fuel Temperature Sensor
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 175: Angle Sensor-Accelerator
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 176: Transmission Oil Temperature Switch
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 177: Ground Speed Limit Switch (Optional)
Ground Speed Limit Switch (optional) [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 178: Electronic Throttle Body
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 179: Chapter 6. Lpg Fuel Delivery System
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 180: Hose Connections
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 181 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 182: Removal And Installation Of N-2007 Lp Regulator
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 183: Removal And Installation Of Ca100 Mixer For G424Fe
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 184 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 185: Tests And Adjustments
N-2007 Regulator Service Testing Tests and Adjustments 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 regulator). To check the secondary regulation • LP gas is highly flammable. To prevent (output) a simple vacuum hand pump can be used personal injury, keep fire and flammable to simulate the vacuum signal transmitted from the...
Page 186 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 187: Avv (Air Valve Vacuum) Testing
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 188: Idle Mixture Adjustment
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 189 measurement at Closed Loop Idle of 25-60% is Factory Adjustment Procedure: 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 190 8. If the FTV duty cycle reading is above 55% adjust Field Adjustment Procedure: 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 191: Parts Description
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 192 Exploded View of CA100 Mixer (Certified) Figure 44. CA100 Certified Mixer Exploded View G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM...
Page 193: N-2007 Regulator For G424Fe Engine
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...
Page 194 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 195: G424F Lpg System Inspection And Repair
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 196: G424F Fuel System Connections
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 197: Removal And Installation Of N-2001 Lp Regulator/Converter
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 198: Removal And Installation Of Ca100 Mixer For G424F
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 199 NOTE : A plastic O-ring spacer and an O-ring are CA100 Mixer Installation Steps 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 200: Tests And Adjustments
Secondary Stage (Break-Off) Test Tests and Adjustments 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 201 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 202: Avv (Air Valve Vacuum) Testing
AVV (Air Valve Vacuum) Testing Connection of the MI-07 Service Tool To use the Service Tool, a USB (Universal Serial Purpose of Test 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 203: Idle Mixture Adjustment
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 204 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 205: Parts Description
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 206 Exploded View CA100 Mixer Figure 44. CA100 Non-Certified Mixer Exploded View G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM...
Page 207: Ca100 Disassembly And Service
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 208: Ca100 Disassembled Service
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 209: N-2001 Regulator For G424F Engine
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 210 Exploded View N-2001-RSA Regulator Figure 47. N-2001 Regulator Exploded View G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM...
Page 211: N2001 Regulator Disassembly Steps
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 212 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 213: N2001 Disassembled Service
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 214: Chapter 7. Mpi Gasoline Fuel Delivery System
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 215: Components Location
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 216: Fuel Pressure Test
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 217 Inspect Fuel Leakage On Connection • Observing the declination of the fuel pressure when the gage reading drops and perform the necessary repairs using the table below. 1. Connect the battery negative (-) terminal. 2. Apply battery voltage to the fuel pump terminal Probable Supected Condition...
Page 218: Injector
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 219: Injector Inspection
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 220 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 221: Fuel Pump
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 222: Chapter 8. Basic Troubleshooting
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 223: Basic Troubleshooting Guide
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 224: Basic Inspection Procedure
4. Repair or replace the component that has a Basic Inspection Procedure 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 225: Connector Inspection Procedure
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 226 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 227 normal). To find exact break point, check sub line of Electrical Circuit Inspection Procedure 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 228 ● 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 229: Symptom Troubleshooting Guide Chart
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 230 Irregular Idling Or Engine Is Suddenly Stopped G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 231 Engine Hesitation Or Insuffient Accelelation G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 232 G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 233 Troubleshooting Guide for MPI Gasoline System • The following number represents inspection order. G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 234 G424F(FE) Service Manual Chapter 8. Basic Troubleshooting...
Page 235: Basic Troubleshooting
An intermittent “Service Engine Soon” light with no Basic Troubleshooting 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 236: Surges And/Or Stumbles
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 237: Engine Cranking But Will Not Start / Difficult To Start
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 238 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 239: Lack Of Power, Slow To Respond / Poor High
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 240 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 241: Detonation / Spark Knock
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 242: Backfire
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 243: Rough, Unstable, Incorrect Idle, Or Stalling
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 244 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 245: Cuts Out, Misses
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 246: Poor Fuel Economy / Excessive Fuel Consumption Lpg Exhaust Smell
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 247: High Idle Speed
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 248: Excessive Exhaust Emissions Or Odors
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 249: Diagnostic Aids For Rich / Lean Operation
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 250: Chart T-1 Restricted Exhaust System Check
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 251: Chapter 9. Advanced Diagnostics
Chapter 9. ADVANCED DIAGNOSTICS MI-07 systems are equipped with built-in fault Clearing Fault (DFC) Codes 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 252: Fault Action Descriptions
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 253: Table 1. Fault List Definitions
Table 1. Fault List Definitions CODE FAULT DESCRIPTION (MI04 CODE) Learned full pedal end of APP1 sensor range higher than APP1AdaptHiMax expected (64) APP1AdaptHiMin Learned full pedal end of APP1 sensor range lowe APP1AdaptLoMax than expected Learned idle end of APP1 sensor range higher than APP1AdaptLoMin (63) expected...
Page 254 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 255 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 256 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 257 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 258 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 259 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 260 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 261 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 262 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 263: Dfc Probable Fault Action
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 Check INJ1 wiring for an open circuit Inj1Open SECM (Signal) A5 to Injector 1 Pin A Gasoline Injector 1 open...
Page 264 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 leaks ECTOverTempFault Engine coolant temperature in the system. (1) TurnOnMil is high. The sensor has Possible ECT short to GND, check ECT (2) Delayed Engine measured an excessive...
Page 265 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 low, normally set if the TPS1 signal TurnOnMil (22) SECM Pin B23 (signal) to ETC Pin 6 SECM...
Page 266 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 267 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 TMAP Pin 4 to SECM Pin B18 (signal) MAPTimeRangeHigh Manifold Absolute Pressure TMAP Pin 1 to SECM Pin B1 (sensor Sensor Input is High, GND)
Page 268: Turnonmil
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 Air Temperature TMAP Pin 1 to SECM Pin B1 (sensor Sensor Input is High normally GND)
Page 269: Refer To Application Manual For Specific
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 module Pin A (of both...
Page 270: N/A
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT CORRECTIVE ACTION PROBABLE FAULT ACTION * FIRST CHECK Check coil driver wiring and connector for shorts SECM Pin A10 (EST2) to ignition EST2_Short EST2 module Pin D (4-pin connector) output shorted high or low, Verify GND on ignition module Pin A EST2 signal shorted to TurnOnMil...
Page 271 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 272 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 has failed. SECM Pin A18 to ETC - Pin 4 Indeterminate fault on Check the ETC internal motor drive by...
Page 273 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 with a multimeter (1) TurnOnMil...
Page 274 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 TurnOnMil • Check APP2 signal at SECM PIN (65) signal has shorted to ground, circuit has opened or sensor has...
Page 275 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 Pin 1 (signal) to SECM Pin A1 Dither Valve 1 Fault, signal FTV1 Pin 2 (power) to SECM (DRVP) has opened or shorted to TurnOnMil...
Page 276 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK GasFuelAdaptRangeHi Check fuel trim valves, e.g. plugged In LPG mode, system had TurnOnMil valve or hose. Check for plugged (73) to adapt lean more than orifice(s).
Page 277 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK GasO2FailedRich Check fuel trim valves, e.g. plugged Pre-catalyst O2 sensor (1) TurnOnMil valve or hose. (77) indicates extended rich (2) DisableGas O2Ctrl Check for plugged orifice(s). operation on LPG Correct other faults that may contribute to 772 (e.g.
Page 278 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 279 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK Check if O2 sensor installed before the O2RangeLow catalyst is shorted to GND or sensor Pre-catalyst O2 sensor (1) TurnOnMil GND. voltage out of range low, (2) DisableLiquid O2Ctrl O2 (signal) Pin 3 to SECM Pin B13 (3) DisableGas O2Ctrl...
Page 280 Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. CORRECTIVE ACTION PROBABLE FAULT FAULT ACTION * FIRST CHECK (1) TurnOnMil TransOilTemp Refer to drivetrain manufacturer’s Excessive transmission oil (2) Delayed transmission service procedures temperature EngineShutdown Perform service procedure related to ServiceFault1 Service Interval 1 has been None Service Interval 1 (determined by...
Page 281: Appendix
Appendix Service Tool Software Kit Service Tool Software (MotoView) Service tool software kit consists of USB-CAN converter, Service tool software (MotoView) and Extension cable. Introduction The MI-07 Service Tool is a graphic interface to the SECM (Small Engine Control Module) and is made up of several screens to aid the technician in system diagnostics using a personal computer.
Page 282: Connection Of The Service Tool
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 283: Motoview Display Screens
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 284 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 closed loop feedback from the oxygen sensors to Figure 7 Clearing Faults...
Page 285 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 286 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 287 DFC 12-353 Screen Tab Figure 10. Diagnostic Fault Codes 12-43 Screen DFC (Diagnostic Fault Codes) 12 through 353 are defined on this display for quick reference. Faults that are displayed in yellow have been enabled on the MI-07 system. Faults that appear in grey are included for future use but are not enabled.
Page 288 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 289 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 290 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 291 Manual Override Screens 1 & 2 CAUTION There are two manual override screens available for the technician to test for failed components or to Be aware of fuel flow and ignition when isolate problems during troubleshooting. Manual performing any manual override of a system overrides can override normal system function component as engine damage may result.
Page 292 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 293 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 294 Manual Override Screen 2 CAUTION Components that can be overridden on override screen 2 include the Low Oil Pressure Switch, Be aware of fuel flow and ignition when Transmission Temperature Switch, Ground Speed performing any manual override of a system Switch, Spark Advance, and the Malfunction component as engine damage may result.
Page 295: Secm Field Update With Service Tool
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 296 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 297 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 298 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 299: Ground Speed Limits (Option)
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 300 How to Set New Speed Limit Maximum RPM for both the NEUTRAL state (Normal) and IN-GEAR state (Speed Limiting) are configurable using the MotoView Service Tool. [Figure 2] Ground Speed Select Screen of the MotoView Service Tool [Figure 2] shows the Speed Limit screen of the Allowable Range of RPM Limits MotoView service tool.
Page 301: Lpg And Lpg Fuel Tanks
The same principle is applied to LPG in a container, LPG And LPG Fuel Tanks 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 302: Lpg Fuel Tanks
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 303 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 304 Most liquid service valves have an internal Filler Valve hydrostatic relief valve and are usually labeled The liquid filler valve (Figure 9) has a male thread to “LIQUID WITH INTERNAL RELIEF”. 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 305: Regulatory Compliance
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 306: Abbreviations
Abbreviations Actual cubic feet per minute at the specified suction conditions ACFM Air fuel ratio Brake horsepower Able to operate on either of two fuels Bi-Fuel Coolant temperature sensor Compressed natural gas Able to run simultaneously on two fuels, e.g. diesel and natural gas. Dual Fuel Often this term is incorrectly used to describe bi-fuel operation.

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Doosan G424FE Service Manual

Index

Chapter 1. GENERAL INFORMATION

Precautions before Service

Tightening Torque

Recommended Lubricants and Capacities

Engine Model and Engine Serial Number

General Specification

G424F/G424FE Engine Power and Torque

Chapter 2. RECOMMENDED MAINTENANCE

General Maintenance

Cooling System Maintenance

Ignition System Maintenance

Fuel System Maintenance

Exhaust System Maintenance

Maintenance Schedule

Chapter 3. ENGINE MECHANICAL SYSTEM

General Information

Engine Exploded View

Intake Manifold and Gasket

Exhaust Manifold and Gasket

Timing Belt

Timing Belt Tensioner

PCV Valve

Camshaft Timing Pulley And/Or Seal

Crankshaft Timing Pulley

Crankshaft Front Seal

Crankshaft Accessory Pulley

Timing Belt Rear Cover

Camshaft Case Cover and Gasket

Rocker Arms, Linkage, Valve Lifters with

Cylinder Head and Eegine

Cooling System

Thermostat Housing

Water Pump

Lubrication System

Oil Pan

Oil Pump

Oil Pump Assembly

Camshaft Case Assembly

Cylinder Head

Valve, Spring or Seal

Engine Disassembly

Engine Assembly

Cylinder Block

Crankshaft

Pistons And/Or Connecting Rods

Rings

Chapter 4. ENGINE ELECTRICAL SYSTEM

Specifications

Ignition System

Charging System

Starting System

Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)

General Information

G424FE EMS (Engine Management System) Overview

G424F EMS (Engine Management System) Overview

EMS Inspection and Repair

Chapter 6. LPG FUEL DELIVERY SYSTEM

G424FE LP System Inspection and Repair

G424F LPG System Inspection and Repair

Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM

Specification

Components Location

Fuel Pressure Test

Injector

Fuel Pump

Chapter 8. BASIC TROUBLESHOOTING

Preliminary Checks

Basic Troubleshooting Guide

Basic Troubleshooting

Chapter 9. ADVANCED DIAGNOSTICS

Reading Diagnostic Fault Codes

Displaying Fault Codes (DFC) from SECM Memory

Clearing Fault (DFC) Codes

Fault Action Descriptions

Fault List Definitions

Dfc Probable Fault Action

Appendix

Service Tool Software (Motoview)