SB4241E00 Apr.
Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Index Inspect Ignition System................................. 25 Inspection of Ignition Timing ......................... 25 Inspection of Spark Plug ............................... 26 Fuel System Maintenance ................................. 28 Chapter 1. GENERAL INFORMATION Replace LP Fuel Filter Element..................... 28 Precautions before Service ................................. 7 Testing Fuel Lock-off Operation .................... 29 Tightening Torque ......................................
Cooling System Recommendation ................ 58 Troubleshooting...........................................143 Coolant Pipe and Hose ................................. 60 Starter .........................................................144 Water Pump.................................................. 61 Chapter 5. ENGINE MANAGEMENT Thermostat ................................................... 63 Cylinder Head Assembly ................................... 65 SYSTEM (EMS) Lubrication System............
Sensor ........................................................ 194 N-2001 Regulator Service Testing .225 Oxygen Sensor (Pre-Catalyst)..................... 195 AVV (Air Valve Vacuum) Testing....227 Oxygen Sensor (Post-Catalyst) ................... 196 Connection of the MI-07 Service Tool ECT (Engine Coolant Temperature) Sensor 197 ......................................................227 LP Fuel Temperature Sensor ...................... 199 Idle Mixture Adjustment .................
Detonation / Spark Knock............................ 267 Backfire ...................................................... 268 Dieseling, Run-on ....................................... 268 Rough, Unstable, Incorrect Idle, or Stalling.. 269 Cuts Out, Misses......................................... 271 Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell ............... 272 High Idle Speed .......................................... 273 Excessive Exhaust Emissions or Odors.......
Chapter 1. GENERAL INFORMATION Precautions before Service Tightening Torque Removal and Disassembly Tighten the part properly to specified torque. Sealant For prevention of wrong installation or reassembly and for ease of operation, put mating marks to the parts where no function is adversely affected. Special Tool Use specified brand of sealant. Use of sealant other than specified sealant may cause water or oil leaks. Be sure to use Special Tools when their use is specified for the operation.
Replacement Part Genuine Part When oil seal, O-ring, packing and gasket have been removed, be sure to replace them with new parts. However, rocker cover gasket may be reused if it is not damaged. When the part is to be replaced, be sure to use genuine part. For selection of appropriate parts, refer to the Parts Catalog. Electrical System Rubber Parts 1. Be sure to disconnect the battery cable from the negative(-) terminal of the battery. Do not stain timing belt and V-belt with oil or water.
Precautions for catalytic Converter CAUTION If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. 1. Use only unleaded gasoline. 2. Do net run the engine while the truck is at rest for a long time. Avoid running the engine at fast idle for more than 5 minutes and at idle speed for more than 10 minutes. 3. Avoid spark-jump tests.
Tightening Torque Tightening Torque Table of Standard Parts Torque (kg·m) Bolt nominal diameter(mm) Pitch(mm) M5 Head mark 4 Head mark 7 0.8 0.3 ~ 0.4 0.5 ~ 0.6 M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1 M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5 M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0 M12 1.25 3.5 ~ 4.5 6~8 M14 1.2 7.5 ~ 8.5 12 ~ 14 M16 1.5 11 ~ 13 18 ~ 21 M18 1.5 16 ~ 18 26 ~ 30 M20 1.5 22 ~ 25 36 ~ 42 M22 1.5 29 ~ 33 48 ~ 55 M24 1.5 37 ~ 42 61 ~ 70 M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6 M6 1.0 0.5 ~ 0.
Recommended Lubricants and Capacities Recommended Lubricants Lubricant Specification Remarks Engine Oil API Classification SJ or above SAE 10W30 or SAE 5W30 Coolant (Antifreeze) Automotive antifreeze suitable for gasoline engines having aluminum alloy parts Concentration level 50%(normal) Concentration level 40%(tropical) Lubricant Capacities Description Engine Oil (liters) Coolant (liters) G(C)18S-5, G(C)20SC-5 G(C)20/25/30E-5 Oil Pan 3.7 3.7 Oil Filter 0.3 0.3 Total 4.0 4.
Engine Model and Engine Serial Number Engine Model G420FE G420F Emission Regulation Fuel Type LP/Dual Fuel Indication of Engine Model and Serial Number EPA/CARB* 2007 Compliant LP/Gasoline/Dual Fuel * EPA: Environmental Protection Agency * CARB: California Air Resources Board G420FE Engine Engine Model • Comply with EPA 2007 Emission Regulation G420FE/G420F • Electronic Control by ECM • Certified LP/Dual Fuel System available Engine Serial Number 30700001 to 39999999 Features and Benefits of G42
General Specification G420FE Engine GENERAL DESCRIPTION ENGINE TYPE: COMBUSTION SYSTEM: INTAKE MANIFOLD EXHAUST MANIFOLD VALVE CONFIGURATION: VALVE LIFTER/LASH ADJUSTER VALVE ROTATOR CAMSHAFT DRIVE DISPLACEMENT: BORE x STROKE BLOCK STRUCTURE HEAD STRUCTURE COMPRESSION RATIO: COMPRESSION PRESSURE: VALVE TIMING: FIRING ORDER: WEIGHT: ENGINE ROTATION: FUEL TYPE: CRANK VENTILATION IGNTION SYSTEM IGNITION TYPE: IGNITION TIMING: POWER TRANSISTOR IGNITION COIL: SPARK PLUGS: LUBRICATION SYSTEM OIL PRESSURE: OIL TEM
General Specification G420FE Engine G420F Engine LP FUEL SYSTEM LP FUEL SYSTEM MIXER: REGULATOR: FUEL TRIM VALVE (FTV): FUEL FILTRATION: GASOLINE FUEL SYSTEM GASOLINE FUEL SYSTEM FUEL PUMP MODULE FUEL INJECTOR ASS’Y ENGINE ELECTRIC ENGINE CONTROL MODULE(ECM): CRANK SENSOR CAM SENSOR TMAP: PEDAL ANGLE SENSOR: OXYGEN SENSOR: ECT-ECM: ECT-GAUGE TPS: THROTTLE BODY: LP FUEL LOCK-OFF: ENGINE OIL PR.
Engine Power and Torque G420FE Engine Power & Torque FORKLIFT MODEL G(C)15/18S-5 ENGINE MODEL RATED POWER MAX TORQUE GOVERNED SPEED LOW IDLE G420FE-LP Kw hp PS rpm N-m lbf-ft kgf-m rpm rpm rpm 33.6 45 46 2,400 147 108 15,0 1600 2450 750 G(C)20/25/30E-5 G420FE-DF(LP) G420FE-DF(Gas) & G420FE-LP 39.5 39.5 53 53 54 54 2,550 2,550 157 157 116 116 16.0 16.
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. • Solvent or oil damage may cause vacuum lines to become soft, resulting in a collapsed line while the engine is running.
Engine Oil Classification Recommended API classification: Above SJ Recommended SAE viscosity classification *1. 10W-30 engine oil is recommended If 10W-30 is not applicable, proper engine oil will be possible according to temperature ranges. The following lubricants should be selected for all engines to enhance excellent performance and maximum effect. 1. Observe the API classification guide. 2. Proper SAE classification number should be selected within ambient temperature ranges.
Checking Engine Oil Level Replacing Engine Oil and Filter CAUTION Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Exercise caution in order to minimize the length and frequency of contact of your skin to used oil.
Standard(250~400rpm) 3) Install the oil filler cap. 4. Start engine and check for oil leaks. Standard Limit 15kg/㎠ 14kg/㎠ 8. Follow the procedures (no.6-7) to each cylinder and check that compressed pressure values of all cylinders are within the limit. 5. Recheck engine oil level. Checking Compressed Pressure Limit 1.0kg/㎠ 9. If any of all cylinders is out of limit, add a small amount of engine oil to the spark plug hole, and re-proceed the procedures (no.6-7) to the cylinder.
Adjusting Timing Belt Tension 7. Install the timing belt upper cover (A) and tighten the bolt(B). Tightening torque 0.8~1.0kg·m Adjust the tension as the following order. 1. Remove the fan drive bracket. 2. Loosen the timing belt upper cover bolt (B) and disconnect the upper cover (A). 3. As the illustration, insert the hex wrench to the adjuster groove and turn it counterclockwise to move the arm indi-cator in the middle of the base groove.
Antifreeze DOOSAN recommends selecting automotive antifreeze suitable for gasoline engines using aluminum alloy parts. The antifreeze should meet ASTM-D3306 standard. Cooling System Maintenance Coolant Recommendation The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water (For the vehicles of tropical area, the engine cooling system is provided with a mixture of 40% ethylene glycol anti-freeze and 60% water at the time of manufacture.
Checking coolant leaks 1. After the coolant temperature drops below 38°C loosen the radiator cap. 2. Check that the coolant level reaches filler neck. 3. Install the radiator cap tester to the radiator filler neck and apply a pressure of 1.4kg/cm2 . While maintaining it for 2 minutes, check the radiator, hose, and connecting part for leak. CAUTION Because the coolant in the radiator is too hot, never open the cap when it hot, or injury may occur due to an outburst of hot water. Dry out the inspection part.
Checking and Adjusting Drive Belt 1. Checking tension 1) Press the middle of the water pump pulley and alternator pulley with 10kgf. 2) Inspect the belt deflection by pressing it. 3) If the belt deflection is out of the standard, adjust it as follows. Item Drive belt deflection (L) Standard New belt Used belt 4.0~4.4mm 5.1~5.7mm 1) Type • BORROUGHS BT - 33 - 73F 2.
Adjusting Checking Belt for Damage Crank pulley 1. Loosen the alternator support bolt “A” nut and adjusting lock bolt “B”. Check the following items and replace the belt if defective. 2. Adjust the belt tension by moving the alternator brace adjusting bolt to “T” direction. 1. Check the belt surface for damage, wear and crack. Alternator adjusting lock bolt “B” 1.2~1.5kg·m 2. Check the belt surface for oil or grease contamination. Alternator support bolt “A” 2~2.5kg·m 3.
Ignition System Maintenance CAUTION Inspect Battery System Because ignition timing is fixed by set data value in ECU, it is impossible to control on purpose. Fist, check that sensors send output properly to help determine ignition timing control. • Clean battery outer surfaces with a mixture of baking soda and water. • Inspect battery outer surfaces for damage and replace as necessary.
Inspection of Spark Plug Inspection and clean 3. Check the spark plug as below. 1) Insulator broken 2) Terminal worn 3) Carbon deposit 4) Gasket damaged or broken 5) Porcelain insulator of spark plug clearance 1) Ignition wire Ass’y 2) Ignition coil Ass’y 3) Spark plug 1. Disconnect the ignition wire ass’y from ignition coil ass’y. Remove the ignition coil ass’y by pulling the ignition coil hand. 2. Remove all spark plugs from the cylinder head using a sparkplug wrench. 4.
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 2~3kg·m SPARK PLUG ANALYSIS State Description Contact point is black Contact point is white • Density of the fuel mixture is thick • Density of the fuel mixture is thin • Lack of air intake • Ignition timing is fast • Spark plug is tight • Lack of torque G420F(FE) Service Manual 27 Chapter 2.
Fuel System Maintenance 8. Re-assemble the filter assembly aligning the scribe lines on the top and bottom covers. Replace LP Fuel Filter Element 9. Install the cover retaining screws, tightening the screws in an opposite sequence across the cover. Park the lift truck in an authorized refueling area with the forks lowered, parking brake applied and the transmission in Neutral. 10. Open the fuel valve by slowly turning the valve counterclockwise. 11.
Testing Fuel Lock-off Operation Pressure Regulator/Converter Inspection • Start engine. • Locate the electrical connector for the fuel lock (A). • Visually inspect the pressure regulator/converter (B) housing for coolant leaks. • Disconnect the electrical connector. • The engine should run out of fuel and stop within a short period of time. • Refer to Chapter 5 if the pressure regulator/converter requires replacement.
If air leaks past the FTVs when de-energized, replace the FTVs. Exhaust System Maintenance Inspect Engine for Exhaust Leaks Inspect Air/Fuel Valve Mixer Assembly • Start the engine and allow it to reach operating temperatures. • Refer to Chapter 5 for procedures regarding the LP mixer (D). Inspect Throttle Assembly • Perform visual inspection of exhaust system from the engine all the way to the tailpipe.
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. G420F(FE) Service Manual 31 Chapter 2.
G420F(FE) Service Manual 32 Chapter 2.
Chapter 3. ENGINE MECHANICAL SYSTEM General Information Engine Outline G420F(FE) Service Manual 33 Chapter 3.
G420F(FE) Service Manual 34 Chapter 3.
Specifications Description Specification Limit GENERAL Type Cylinder number Bore Stroke Displacement Compression ratio Firing order Low idle Ignition timing @ low idle Valve timing Intake Open Close Exhaust Open Close Valve over rap CYLINDER HEAD Flatness of gasket surface Flatness of manifold mounting surface Oversize of valve seat hole Intake 0.3 mm OS 0.6 mm OS Exhaust 0.3 mm OS 0.6 mm OS Oversize of valve guide hole 0.05 mm OS 0.25 mm OS 0.50 mm OS In-line, DOHC 4 82 mm 93.
Description VALVE Stem O.D Intake Exhaust Thickness of valve head (Margin) Intake Exhaust Valve stem to guide clearance Intake Exhaust VALVE GUIDE Specification Limit 5.965 ~ 5.980 mm 5.950 ~ 5.965 mm 1.15 mm 1.35 mm 0.8 mm 1.0 mm 0.02 ~ 0.05 mm 0.035 ~ 0.065 mm 0.1 mm 0.13 mm Installed size Over size(O.D) Intake : 46, Exhaust : 54.5 0.05, 0.25, 0.50 mm VALVE SEAT Seat angle Over size 45° 0.3 mm, 0.6 mm VALVE SPRING Free length Load 48.86 mm 18.3kg/39 mm 40.0kg/30.5 mm 39 mm 1.
Description Specification Limit CONNECTING ROD BEARING Oil clearance Under size CRANKSHAFT Pin O.D Journal O.D Bend Out-of cylindricity of journal and pin End play Under size of pin 0.25 mm 0.50 mm 0.75 mm Under size of journal 0.25 mm 0.50 mm 0.75 mm OIL PUMP O.
Torque Specification Description Cylinder block Engine support bracket bolt and nut Cylinder head Cylinder head bolt M10 M12 Intake manifold bolt and nut Exhaust manifold nut Cylinder head cover bolt Camshaft bearing cap bolt Rear plate bolt Main moving Connecting rod cap nut Crankshaft bearing cap bolt Flywheel bolt Chain guide Starter bolt Timing belt Crankshaft pulley bolt Camshaft sprocket bolt Timing belt tensioner bolt Timing belt idler bolt Timing belt cover bolt Front case bolt Lubrication System Oi
Special Tools Tool (number and name) Illustration Use Crankshaft front oil seal installer (09214-32000) Installation of front oil seal Crankshaft front oil seal guide (09214-32100) Installation of front oil seal Camshaft oil seal installer (09221-21000) Installation of camshaft oil seal Valve guide installer (09221-22000(A/B)) Removal and installation of valve guide Cylinder head bolt wrench (09221-32001) Removal and tightening of cylinder head bolt Valve stem oil seal installer (09222-22001)
Tool (number and name) Illustration Use Valve stem seal remover (09222-29000) Removal of valve stem seal Crankshaft rear oil seal installer (09231-21000) 1. Installation of engine rear oil seal 2.
Troubleshooting Symptom Possible cause Remedy Low compression Cylinder head gasket damaged Worn or damaged piston ring Worn piston or cylinder Worn or damaged valve seat Replace gasket Replace ring Repair or replace piston and cylinder block Repair or replace valve and seat ring Low oil pressure Insufficient engine oil Oil pressure switch defective Oil filter clogged Worn oil pump gear or cover Thin or diluted engine oil Oil relief valve clogged(Open) Excessive bearing clearance Check engine oil lev
Timing Belt System Components 1. Timing belt upper cover. 2. Camshaft sprocket 3. Timing belt G420F(FE) Service Manual 4. Cylinder head cover 5. Idler 6. Tensioner 42 7. Crankshaft sprocket 8. Timing belt lower cover 9. Flange 10. Crankshaft pulley Chapter 3.
Removal 9. Remove the timing belt tensioner pulley. 1. Temporarily loosen the water pump pulley bolts. 2. Loosen the alternator bolt and remove the belt. 3. Remove the water pump pulley. 4. Remove the timing belt upper cover. 10. Remove the timing belt form the camshaft sprocket. NOTE: When reusing the timing belt, put an arrow mark on the rotation direction (or front side of engine)before removal to help re-install it to original installation direction. 11. Remove the idler. 5.
Inspection SPROCKET, TENSIONER, IDLER 1. Check the camshaft sprocket, crankshaft sprocket, tensioner and idler for wear, crack and damage and replace it if necessary. 2. Check the tensioner and idler pulley for smooth rotation, check for play and noise, and replace it if necessary. 3. If grease leak is inspected, replace it. TIMING BELT 1. Check the belt for oil or dust deposit and replace it if necessary. In case of small amount of oil or dust, clean it with a rag or paper instead of a solvent. 2.
Description 1. Back side rubber is hardened Specification Glossy back side. Due to non-elasticity and hardening, when pressing it with the tip of a finger, there is no sign of it. 2. Back side rubber is cracked 3. Canvas is cracked or detached 4. Tooth is excessively worn out (initial step) 5.
4. With no.1 cylinder piston to the dead point of compression stroke, align the timing mark on the camshaft sprocket and timing mark on the crankshaft sprocket. Assembly 1) After installing the tensioner, spring and spacer and tightening the bolt temporarily, tighten the long hole shaft washer of tensioner and bolt. 2) Install the spring bottom end to the front case as shown in the illustration.
13) Install the timing belt lower cover. Tightening torque 0.8 ~ 1.0kgf·m 7) Be sure that timing mark on each sprocket is placed on the proper position. 8) Remove the tensioner arm fixing pin. 14) Install the crankshaft pulley (A) together with the flange, tighten the bolt (B). When installing, align the crankshaft key with the pulley groove. 9) Insert a hexagonal wrench to the adjuster groove as below, rotate it counterclockwise to place the arm indicator in the middle of base groove.
PCV Valve Outline and Operation Principle Engine condition PCV valve Vacuum path No operating No operating Clogged Engine condition PCV valve Vacuum path At idle or deceleration Full operating Small Engine condition PCV valve Vacuum path Proper operating Proper operating Big Engine condition PCV valve Vacuum path High speed and overload Light operating Very big G420F(FE) Service Manual 48 Chapter 3.
TROUBLESHOOTING Service Procedure REMOVAL 1. Disconnect the vacuum hose from the PCV valve. Disconnect the PCV valve from the locker cover and reconnect the vacuum hose. 1. After disconnecting the vacuum hose (A), remove the PCV valve (B). 2. With the engine at idle, Check the intake manifold for vacuum when clogging the opened end of PCV valve. INSTALLATION Install the PCV valve and connect the vacuum hose. Tightening torque NOTE: The plunger in PCV valve will move back and forth. 0.8 ~ 1.2kgf·m 3.
Intake and Exhaust System Intake Manifold Components COMPONENTS MAP sensor G420F(FE) Service Manual 50 Chapter 3.
REMOVAL INSTALLATION 1. Disconnect the map sensor and the connector. 2. Remove the P.C.V valve hose. 1. After replacing the intake manifold gasket, install it to the cylinder head and then to the intake manifold. 3. Disconnect the fuel injector connector and the wiring harness. 2. Install the delivery pipe and injector assembly to the intake manifold. 4. Remove the delivery pipe with the fuel injector attached.
Exhaust Manifold COMPONENTS CAUTION Do not tighten parts excessively, observe the specified torque. G420F(FE) Service Manual 52 Chapter 3.
REMOVAL 1. Remove the heat protector. 2. Detach the exhaust manifold from the cylinder head. INSPECTION 1. Check the exhaust manifold for damage and crack. 2. Exhaust manifold gasket Check the gasket for tear or damage. INSTALLATION 1. Installation is the reverse order of removal. CAUTION Do not reuse the exhaust manifold nut. G420F(FE) Service Manual 53 Chapter 3.
Cooling System General Description Cooling System Schematic (1) Cylinder head. (2) Thermostat. (3) Recovery tank. (5) Radiator top hose. (7) Cylinder walls. (8) Radiator. (9) Radiator lower hose. (10) Water pump. thermostat (2) is open the coolant will go through radiator top hose (5) and into the top tank of radiator (8). Coolant then goes through the cores of the radiator.
Testing and Adjusting 5. Inspect the drive belts for the fan. Adhere to the following warnings when performing any tests or adjustments while the engine is running: 6. Check for damage to the fan blades. 7. Look for air or combustion gas in the cooling system. WARNING 8. Inspect the filler cap and the surface that seals the cap. This surface must be clean. Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. 9.
Cooling System Leak Check Pressure Cap Test To test the cooling system for leaks, use the following procedure: WARNING If the engine has been in operation and the coolant is hot, slowly loosen the pressure cap to the first stop and let the pressure out of the cooling system, then remove the pressure cap. 1. Remove pressure cap from the radiator. Pressure Cap Diagram (A) Sealing surface of cap and radiator. 2. Make sure the radiator is full (hot) or nearly full (cold) of coolant.
Thermostat Test Thermostat To test the thermostat opening temperature, use the following procedure: WARNING The pan, water and thermostat will be very hot and can cause burns. Do not touch the pan, water or thermostat. Handle the components with an insulated device for protection. 1. Remove the thermostat from the engine. 2. Hang the thermostat in a pan of water. Put a thermometer in the water. Put the thermostat completely under water. Do not let the thermostat make contact with the pan. 3.
NOTE: Another condition that can cause heat problems is the ignition timing. Retarded (late) timing causes the engine to send more heat to the cooling system. Advanced (early) timing causes the engine to send less heat to the cooling system. Cooling System Heat Problems To check if there is a good reason for heat problems do the checks that follow: 1. The indications of a heat problem are as follows: Cooling System Recommendation a.
Filling at over 20 liters per minute can cause air pockets in the cooling system. Antifreeze DOOSAN recommends selecting automotive antifreeze suitable for gasoline engines using aluminum alloy parts. The antifreeze should meet ASTM-D3306 standard. After draining and refilling the cooling system, operate the engine with the radiator cap removed until the coolant reaches normal operating Make proper antifreeze additions. temperature and the coolant level stabilizes.
Coolant Pipe and Hose COMPONENTS INSPECTION Check the coolant pipe and hose for crack, damage, and clogging and replace it if necessary. INSTALLATION After getting water around O-ring, insert it the groove in the coolant intake pipe end and press-fit the pipe. CAUTION Do not apply oil or grease to the O-ring. Take care not to dirt the coolant pipe connecting part with sand or dust. Press-fit the coolant intake pipe completely. G420F(FE) Service Manual 60 Chapter 3.
Water Pump COMPONENTS G420F(FE) Service Manual 61 Chapter 3.
2. Check the bearing for damage, abnormal noise and bad rotation and replace the water pump if necessary. REMOVAL 3. Check the seal unit from C hole for leak and replace the water pump assembly if necessary. INSTALLATION B A B 1. Drain the engine coolant. CAUTION A System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool. A 1. Clean the gasket surface of the water pump body and cylinder block. 2.
Thermostat COMPONENTS INSPECTION INSTALLATION 1. Check that the thermostat flange is correctly inserted to the thermostat housing socket. At this time, upward the jiggle valve and make contact to the hole. 2. Install a new gasket and water inlet fitting. 3. Add coolant. 1. Check the valve closed at room temperature. 2. Check for defect or damage. 3. Heat the thermostat as shown in the illustration and measure the valve open temperature and full open temperature.
FAN DRIVE COMPONENTS REMOVAL 1. Remove the fan pulley. 2. Remove the fan bracket. INSPECTION Check the bearing for damage, abnormal noise and sluggish rotation, and replace the bracket assembly if necessary. INSTALLATION Installation is the reverse order of removal. G420F(FE) Service Manual 64 Chapter 3.
Cylinder Head Assembly Components 1. Cylinder block 2. Cylinder head gasket 3. Cylinder head G420F(FE) Service Manual 4. Cylinder head bolt 5. Gasket 6. Cylinder head cover 65 Chapter 3.
1. HLA(Hydraulic Lash Adjuster) 2. Retainer 3. Valve spring 4. Stem seal 5. Spring seat G420F(FE) Service Manual 6. Valve 7. Key 8. Chain sprocket 9. Intake camshaft 10. Camshaft sprocket 66 11. Exhaust camshaft 12. Camshaft bearing cap 13. Timing chain 14. Retainer lock Chapter 3.
Disassembly 3. Remove the stem seal with pliers. NOTE: Do not reuse the stem seal. 1. Using the 8mm and 10mm hexagon wrench, tighten the cylinder head bolts in order by tightening 2-3 times as shown in the illustration. • Take care not to come the cylinder head gasket debris into the cylinder. 2. Using the special tool “valve spring compressor (09222-28000, 09222-28100)”, remove the retainer lock. And then, remove the spring retainer, valve spring, spring seat and valve.
Valve Inspection Cylinder Head 1. Check the cylinder head for crack, damage and leak. 2. Clean out fur, adhesive and accumulated carbon and after cleaning the oil passage, bleed the passage with compressed air to check it for clogging. 1. Clean the valve with a wire brush. 2. Check each valve for wear and damage and inspect the head and stem for torsion. If the stem end is cave or worn, trim it. At this time, trim it least. Also, trim the valve surface.
Valve spring Standard Limit 3. Measure the clearance between the valve stem and guide and if the measured value exceeds the limit, replace the valve guide and valve. Free height 48.86mm Installed load 18.3kg / 39mm Compressed load 40.0kg / 30.5mm Out-of-squareness 1.5°or less Free height -1.0mm Out-of-squareness 3° VALVE SEAT CORRECTION Valve stem and guide clearance Intake 0.02 ~ 0.05mm Exhaust 0.035 ~ 0.065mm Intake 0.1mm Exhaust 0.
VALVE SEAT RING REPLACEMENT 1. If the valve seat insert is excessively worn, cut the insert ring wall as shown in the illustration “A” using a valve seat cutter at a normal temperature. 2. After removing the seat ring, Cut the seat insert bore as same size as the following table as shown in the illustration “A” using a reamer or cutter. 3. Heat the cylinder head to 250°C and press-fit the oversize seat. At this time the oversize seat ring maintains a normal room temperature.
Valve guide oversize VALVE GUIDE REPLACEMENT Size Size mark Cylinder head bore size 0.05 OS 5 11.05 ~ 11.068mm 0.25 OS 25 11.25 ~ 11.268mm 0.50 OS 50 11.50 ~ 11.518mm Because the valve guide is press-fitted, replace the valve guide as the following procedures using a valve guide installer or proper tool. 1. Remove the valve guide pressed toward cylinder block using a push rod of valve guide installer. 2. Cut the valve guide insert bore of the cylinder head to the valve guide oversize. 3.
ASSEMBLY CAUTION Prior to assembly, clean each component. Apply a new engine oil to the perturbation part and rotation part. Replace a new oil seal. VALVE 4. Taking care not to press the valve stem seal down to the retainer bottom, press-fit the spring with the special tool valve spring compressor (09222-28000, 09222-28100)and put the retainer lock in. Remove spring compressor after pisition retainer lock exactly. 5.
HEAD 1. Clean out all gasket surfaces of the cylinder block and cylinder head. 2. Put new cylinder head gaskets on the cylinder block with the identification marks faced upward. Do not apply seal-ant to the gasket and do not reuse the used cylinder head gasket. Take care not to make a mistake of gasket. 3. Put the cylinder head on the cylinder block. 4. Apply a slight coat of engine oil to the spiral portion of bolt. 5. Insert the washer to the bolt and insert it to the cylinder head. 6.
Lubrication System General Description Lubricating system is the full-flow filtered pressurefeed oil system and the oil reserved in the oil pan is fed with pressure to each part of engine. After the oil pressure is adjusted through the relief valve, the oil is fed to the cylinder blocks and cylinder head. In the cylinder head the oil is forcibly fed to the camshaft journals, rocker arm pivots and further cam surfaces. G420F(FE) Service Manual OIl Filter 74 Chapter 3.
Testing and Adjusting Adhere to the following warnings when performing any tests or adjustments while the engine is running. WARNING Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. WARNING Engine Oil Viscosity Recommendation Exhaust fumes contain carbon monoxide (CO) which can cause personal injury or death. Start and operate the engine in a well ventilated area only. In an enclosed area, vent the exhaust to the outside.
turn on during operation only when there is insufficient engine oil pressure to properly lubricate 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. Look for leakage at the oil pan gasket and all lubrication system connections. Check to see if oil comes out of the crankcase breather.
Inspection Oil Pressure Switch Oil pressure switch is located on the front right side of the engine and if oil pressure in the lubrication system drops less than 0.29kg/cm2, the oil pressure warning lamp illuminates. Hexagonal width of this switch is 24mm. 1. Using an ohmmeter, measure an electric current and re-place the oil pressure switch if an electric current is not detected. Removal and Installation 2.
Front Case and Oil Pump COMPONENTS 1. Filter 2. Front case 3. Gasket 4. Oil screen 5. Plug 6.Relief spring G420F(FE) Service Manual 7.Relief plunger 8.Oil seal 9.Inner rotor 10.Outer rotor 11.Pump cover 78 Chapter 3.
REMOVAL 5. Remove the oil pan and oil screen. 1. Drain engine oil. 2. Remove the drive belts. 3. Turn the crankshaft and align the white groove on the crank-shaft pulley with the pointer on the lower cover. 4. Remove the timing belt. 5. Remove the oil pan and oil screen 6. Remove the front case. 1) Remove the screws (B) from the pump housing, then separate the housing and cover (A). 2) Remove the inner (A) and outer (B) rotos. G420F(FE) Service Manual 79 Chapter 3.
INSPECTION Body length A 25mm(0.98in) B 20mm(0.787in) C 38mm(1.496in) D 45mm(7.771in) Tightening torque 19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft) 1. Install oil pump. 1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side. 2) Install the oil pump cover (A) to front case with the 7screws (B). Tightening torque 5.9~8.8N.m 4. Apply a light coat of oil to seal lip. (0.6~0.9kgf.m, 4.3~6.5lb-ft) 5. Using the SST(09214-32000), install the oil seal. 6.
DISASSEMBLY Outer gear Side clearance Inner gear 0.04~0.09mm (0.0016~0.0035in.) 0.04~0.085mm (0.0016~0.0033in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case. 1. Remove the relief plunger. Remove the plug (A), spring (B) and relief plunger (A). INSPECTION 4. Inspect rotor rip clearance. Using a feeler gauge, measure the tip clearance between the inner and outer rotor tips. Tip clearance 0.025~0.069mm (0.0010~0.0027in.
5. Inspect rotor body clearance. Using a feeler gauge, measure the clearance between the outer rotor and body. Body clearance 0.12~0.185mm (0.0047~0.0073in.) If the body clearance is greater than maximum, replace the rotor as a set. If necessary, replace the front case. REASSEMBLY 1. Install relief plunger. Install relief plunger (A) and spring (B) into the front case hole, and install the plug(A). Tightening torque G420F(FE) Service Manual 39.2~49.0kgf.m (28.9~36.2lb-ft) 82 Chapter 3.
CAM Shaft, HLA, Timing Chain Components L4GC043A G420F(FE) Service Manual 83 Chapter 3.
8. Loosen the bearing cap bolt and after removing the bear-ing cap, remove the camshaft. Removal 9. Remove the timing chain. 10. Remove the HLA. 1. Remove the breather hose and P.C.V hose. 2. Remove the center cover. 3. Remove the ignition coil. 4. Remove the timing belt upper cover. 5. Remove the cylinder head cover. 6. Remove the tensioner. 7. Loosen the camshaft sprocket bolt and remove the cam-shaft sprocket. G420F(FE) Service Manual 84 Chapter 3.
Oil Seal Inspection 1. Check the oil seal surface for wear and if the seal lip portion is worn, replace it. 2. Check the camshaft oil seal lip contact surface for partial wear and replace it if necessary. HLA(Hydraulic Lash Adjuster) 1. HLA O.D : Ø33(-0.025/-0.041)mm 2. How to remove noise when it heard from valve 1) Prior to engine warm-up, check that the engine oil level is normal. Camshaft 2) Warm-up the engine. 1.
Timing Chain 5) If the valve noise is still heard after following the above step 4), replace the hydraulic lash adjuster(HLA) which makes noise. 1. Check the timing chain bushing and plate portion for wear and if those are severely worn, replace those. 6) If the valve noise is heard after replacing parts, necessarily repeat the above step 4).
3. Install the camshaft cap. Check the intake and exhaust identification marks.(Check cap number and arrow and take care not to change the bearing cap position and direction.) 5. Using the special tool camshaft oil seal installer and guide, press the camshaft oil seal. Necessarily apply engine oil to the oil seal lip. Insert the oil seal through the camshaft front end and install it by tapping on the installer with a hammer until the oil seal reaches 8.5mm from the camshaft front end.
Cylinder head cover 0.8 ~ 1.0kg·m Apply engine oil to the oil seal lip to help install the cylinder head cover oil seal to the spark plug pipe smoothly. CAUTION Necessarily tighten the cylinder head cover bolt to the specified torque. If it is tightened too much, the head cover can be deformed resulting in oil leaks and the head cover bolt can be broken resulting in cylinder head replacement. When installing after head cover removing, necessarily apply sealant to the head cover rear and front portion.
G420F(FE) Service Manual 89 Chapter 3.
Crankshaft Components G420F(FE) Service Manual 90 Chapter 3.
3) Measure the thickness of the crankshaft and connecting rod bearing. Disassembly 1. Remove the timing belt train, front case, flywheel, cylinder head assembly, and oil pan. 2. Remove the rear oil seal. 4) Calculate clearance by subtracting O.D of the journal pin and thickness of the bearing from diameter of the bore. 3. Disconnect the connecting rod cap. Journal oil clearance 0.028 ~ 0.048mm Pin oil clearance 0.024 ~ 0.044mm Main bearing cap bolt 2.7 ~ 3.
Assembly 5. Install the bearing cap and tighten the cap bolt to the specified torque from the center in order. (Tighten the bearing cap bolts to the specified torque by tightening bolts step by step 2-3 times equally) 1. After checking the sensor wheel for damage and crack, replace it if necessary. 2. Inspect the clearance between the sensor wheel and crank position sensor. Clearance between sensor wheel and crank position sensor 0.5 ~ 1.1mm Main bearing cap bolt 2.7 ~ 3.
7. Using the special tool Crankshaft oil seal installer (09231-21000), fully insert the oil seal into the crankshaft rear oil seal case. 8. Install the rear oil seal case and gasket and tighten 5 bolts. When installing, apply engine oil to the oil seal round and crankshaft. 9. Install the flywheel, front case, oil pan, and timing belt train. G420F(FE) Service Manual 93 Chapter 3.
Flywheel and Housing Components Removal Inspection 1. Remove the flywheel. 1. Check the ring gear for damage and crack and replace it if necessary. 2. Remove the flywheel housing. Assembly 1. Install the flywheel housing and tighten the bolt to the specified torque. 2. Install the flywheel assembly and tighten the bolt to the specified torque. Flywheel bolt G420F(FE) Service Manual 94 12 ~ 13kg·m Chapter 3.
Piston and Connection Rod Components G420F(FE) Service Manual 95 Chapter 3.
Disassembly Inspection Piston and Pistonpin 1. Check the piston for scratch, wear, etc. and replace it if necessary. 2. Check the piston ring for break, damage and abnormal wear and replace it if necessary. When replacing the piston, the ring should be replaced also. 3. Check that the piston pin is inserted in the piston hole and replace the piston and pin if necessary. Piston should be smoothly pressed at normal room temperature. Piston Ring 1.
Item Specified value Limit No.1 piston ring end gap 0.23 ~ 0.38 1mm No.2 piston ring end gap 0.33 ~ 0.48 1mm Oil ring end gap 0.20 ~ 0.60 1mm When just replacing the ring without correction of cylinder bore, place the ring to the cylinder lower part where less worn-out and measure the gap. When replacing the ring, use the same size of ring. Item Piston ring over size 3.
3) Using a press, press-fit the piston pin into the pin hole with the specified pressure on the pin end through the push rod. If the pressure is required more than the specified value, follow the next step. Assembly Press-fit pressure of piston pin 350 ~ 1350kg 4) Rotate the push rod to a half turn, remove the piston connecting rod assembly from the support. 5) After press fitting the piston pin, check that the connecting rod for smooth slip and free movement. 1.
CAUTION After installing 3 pieces of oil ring, check the upper and lower side rails for smooth rotation The spacer expander gap should be away from the rail gap to 45° or more. 3. Using a piston ring clamp, insert the piston and connecting rod assembly as the cylinder number into the cylinder and face the arrow mark on the piston head toward the engine crankshaft pulley. Install a vinyl cover to the cap bolt not to damage the cylinder bore and crank pin. 2) After installing no.2 piston ring, install no.
4. Install the connecting rod cap and tighten the cap nut to the specified torque. When installing the connecting rod cap, align the cylinder number on the connecting rod big end with cylinder number on the cap. 5. Inspect clearance of the connecting rod big end. Clearance of connecting rod big end 0.1 ~ 0.25mm 6. Install the oil screen. 7. Install the oil pan. 8. Install the cylinder head. G420F(FE) Service Manual 100 Chapter 3.
Engine Block Component Tightening torque : N•m(kgf.cm , lbf•ft) G420F(FE) Service Manual 101 Chapter 3.
Tightening torque : N•m(kgf.cm , lbf•ft) G420F(FE) Service Manual 102 Chapter 3.
Disassembly 1. Remove flywheel. 10. Remove oil screen. Remove the 2bolts (C), oil screen (A) and gasket (B). 2. Remove flywheel housing. 11. Check the connecting rod end play. 3. Install engine to engine stand for disassembly. 12. Remove the connecting rod caps and check oil clearance. 4. Remove timing belt. 13. Remove piston and connecting rod assemblies. 5. Remove cylinder head. 1) Using a ridge reamer, remove all the carbon from the top of the cylinder. 6. Remove oil level gauge assembly (A).
18. Lift the crankshaft (A) out of the engine, being careful not to damage journals. NOTE: Arrange the main bearings and trust washers in the correct order. 19. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the pistonand pin as a set. 20. Remove piston rings. 1) Using a piston ring expender, remove the 2compressionrings. 2) Remove the 2side rails and oil ring by hand.
Inspection 4) Clean the crank pin and bearing. Connecting Rod and Crankshaft 5) Place plastigage across the crank pin. 6) Reinstall the bearing half and cap, and torque the nuts. Tightening torque 50~53 Nm(500~530kgf.cm,36.9~39lbf.ft) NOTE: Do not turn the crankshaft. 1. Check the connecting rod end play. Using feeler gauge, measure the end play while moving the connecting rod back and forth. 7) Remove the 2 nuts, connecting rod cap and bearinghalf. 8) Measure the plastigage at its widest point.
Connecting rod mark location Discrimination of crankshaft MARK INSIDEDIAMETER a WHITE 48.00~48.006mm (1.8896~1.8899in.) b NONE 48.006~48.012mm (1.8899~1.8902in.) c YELLOW 48.012~48.018mm (1.8902~1.8904in.) MARK Ⅰ WHITE Ⅱ NONE 44.955~44.960mm (1.7698~1.7700in.) Ⅲ YELLOW 44.948~44.955mm (1.7696~1.7698in.) Place of identification mark (Connecting rod bearing) Discrimination of connecting rod CLASS OUTSIDE DIAMETER OF PIN 44.960~44.966mm (1.7700~1.7703in.
11) Selection CRANKSHAFT INDENTIFICATI ON MARK I(YELLOW) II(NONE) III(WHITE) NOTE: Do not turn the crankshaft. CONNECTING ROD IDENTIFICATI ON MARK ASSEMBLING CLASSIFICATI ON OF BEARING a (WHITE) D(YELLOW) b (NONE) C (GREEN) c (YELLOW) B(NONE) a (WHITE) C (GREEN) b (NONE) B (NONE) c (YELLOW) A (BLACK) a (WHITE) B (NONE) b (NONE) A (BLACK) c (YELLOW) AA (BLUE) 5) Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil clearance : 0.028 ~ 0.
Discrimination of cylinder block Connecting rods 1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod i s installed, make sure that the notches for holding the bearing in place are on the same side. 2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced aswell.
Discrimination of crankshaft bearing CLASS MARK THICKNESS OF BEARING AA BLUE 2.014~2.017mm (0.0793~0.0794in.) A BLACK 2.011~2.014mm (0.0791~0.0793in.) B NONE 2.008~2.011mm (0.0790~0.0791in.) C GREEN 2.005~2.008mm (0.0789~0.0790in.) D YELLOW 2.002~5.005mm (0.0788~0.0789in.) If the end play is greater than maximum, replace the thrust bearings as a set. Thrust bearing thickness : 2.44 ~ 2.47 mm(0.096 ~ 0.097in.
Cylinder Block Standard diameter: 82.00 ~ 82.03 mm (3.2283 ~ 3.2295in.) 6. Check the cylinder bore size code on the cylinder block bottom face. 1. Remove gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 3. Inspect top surface of cylinder block for flatness.
Class Piston outer diameter Size code A 81.97~81.98mm (3.2271~3.2275in.) A B 81.98~81.99mm (3.2275~3.2279in.) None C 81.99~82.00mm (3.2279~3.2283in. C 5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder). 6. Check the clearance between the piston and cylinder. Standard: 0.02-0.04 mm (0.0008-0.0016 in.) 8. Select the piston related to cylinder bore class. NOTE: When Boring The cylinders, finish all of the cylinders to the same oversize.
3. Calculate the difference between the cylinder bore diameter and the piston diameter. Piston-to-cylinder clearance 0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.) 4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. 5. Inspect piston ring end gap. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston.
Piston Pins Reassembly 1. Measure the diameter of the piston pin. NOTE: Thoroughly clean all parts to assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts. Piston pin diameter 20.001~20.006 mm (0.7874 ~ 0.7876in.) 1. Assemble piston and connecting rod. 1) Use a hydraulic press for installation. 2. Measure the piston pin-to-piston clearance.
5. Install thrust bearings. Install the 2 thrust bearings (A) under the No.3journal position of the cylinder block with the oil grooves facing outward. 3. Install connecting rod bearings. 1) Align the bearing claw with the groove of the connecting rod cap.- 6. Place crankshaft on the cylinder block. 2) Install the bearings (A) in the connecting rod and connecting rod cap (B). 7. Place main bearing caps on cylinder block. 4. Install main bearings. 8. Install main bearing cap bolts.
3) Retighten the bearing cap bolts by 6065 in the numerical order shown. Tightening torque Main bearing cap bolt: 30Nm (300kgf.cm,22lbf.ft)+60˚~65˚ 4) Check that the crankshaft turns smoothly. 9. Check crankshaft end play. 11. Install a new gasket and rear oil seal case (A) with 5 bolts (B). Tightening torque 10~12Nm (100~120kgf.cm, 7.3~8.8lbf.ft) NOTE: Check that the mating surfaces are clean and dry. 10. Install piston and connecting rod assemblies.
3) Install the oil pan (A) with the 19 bolts. Uniformly tighten the bolts in several passes. Tightening torque 10~12Nm (100~120kgf.cm, 7.3~8.8lbf.ft) 16. Install water pump. (see page EM-104) 14. Install oil screen. Install a new gasket (B) and oil screen (A) with 2 bolts (C). Tightening torque 12~15Nm (120~150kgf.cm,9~11lbf.ft) 17. Install oil pressure sensor. 1) Apply adhesive to 2 or 3 threads. Adhesive: MS721-39 (B) or equivalent. 2) Install the oil pressure sensor (A).
18. Install oil level gauge assembly. 1) Install a new O-ring on the oil level gauge. 2) Apply engine oil on the O-ring. 3) Install the oil level gauge assembly (A) with the bolt. Tightening torque 12~15Nm (120~150kgf.cm, 9~11lbf.ft) 19. Install cylinder head. 19. Install timing belt. 20. Remove engine stand. 21. Install flywheel housing. 22. Install flywheel. Tightening torque 120~130Nm (1200~1300kgf.cm,89~96lbf.ft) G420F(FE) Service Manual 117 Chapter 3.
Chapter 4. ENGINE ELECTRICAL SYSTEM Specifications Ignition Coil Item Specification 1st coil resistance 0.71±10%(Ω) 2nd coil resistance 18~19.5±15%(kΩ) Spark Plug Item Type Specification NGK PFR6N CHAMPION RC8PYPB Spark plug gap 0.7 ~ 0.8mm Starter Motor Item Specification Output 12V- 1.7 kW Pinion tooth number 8 Item Specification Rated output 13.5V - 90A RPM 1,000 ~ 18,000rpm Voltage regulator type Electronic, Built-in type Alternator G420F(FE) Service Manual 118 Chapter 4.
Ignition System Coil-On-Plug Ignition System Spark-ignited engines require accurate control of spark timing and spark energy for efficient combustion. The MI-07 ignition system provides this control. The system consists of the following components: Coil-on-plug (COP) is a type of distributorless ignition system where individual ignition coils are mounted directly over each spark plug. No spark plug wires are used.
Misfires COP Checks COP problems can include many of the same ailments as other ignition systems such as misfiring, hard starting, or a no start. Spark plugs can still be fouled by oil or fuel deposits, as well as pre-ignition and detonation. Individual ignition coils can be tested with an ohmmeter the same as those on a conventional distributor or DIS ignition system. Measure primary and secondary resistance and compare to specifications.
Components Circuit Diagram SECM G420F(FE) Service Manual 121 Chapter 4.
Inspection of Ignition Timing NOTE: Affective ECU input to lgnition timing control Coolant temperature sensor Oxygen sensor MAP sensor(Engine load) Crankshaft position sensor Throttle position sensor Intake Air Temperature sensor 1. Inspection condition Coolant temperature : 80-90°C (At normal temperature) Lamp and all accessories : OFF Transmission : In neutral position Parking brake : ON 6) Check that actual ignition timing is changed with engine RPM increased.
Inspection Circuit Diagram 1. Connect terminal #2 (Ground) of Power TR to Battery (-). 2. Connect terminal #3(IB) of Power TR to Battery (+5V). If the resistance between terminal #2 and terminal #1(OC) is lower than 10 ohms, it is OK. 3. Disconnect terminal #3(IB) of Power TR to Battery (+5V). If the resistance between terminal #2 and terminal #1(OC) is infinite, it is OK. Inspection of Ignition Coil Description The operation of the ignition system is essentially the same as any other ignition system.
Inspection of Spark Plug Component and Circuit Diagram Inspection and clean ① Ignition wire Ass’y ② Ignition Coil Ass’y ③ Spark Plug 1. Disconnect the ignition wire ass’y from the ignition coil ass’y. Inspection 2. Remove the ignition coil ass’y by pulling the ignition coil with hand. 1. 1st Coil Resistance Measurement Measure resistance between no.1 (Ba+) and no.3 (ECU) terminals of ignition coil. 3. Remove all spark plugs from the cylinder head using a spark plug wrench.
3. Check the spark plug as below. 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.
Charging System Alternators General Description The alternators used on these engines have three phase, full-wave, rectified output. They are the brush type. Refer to the Alternator Coverage chart for detailed systems operation information The alternator is an electrical and mechanical components driven by a belt from engine rotation. It is used to charge the storage battery during the engine operation. The alternator is cooled by an external fan mounted behind the pulley.
Components G420F(FE) Service Manual 127 Chapter 4.
Troubleshooting 1. Faulty battery charging Charging system defect is almost caused by lack of pan belt tension and faulty function of wiring, connector, and voltage regulator. One of most important thing during troubleshooting of charging system is determining the reason between overcharging and lack of charging. So, prior to inspection of alternator, check the battery for charging. Faulty alternator causes the following symptoms.
Troubleshooting Procedure Inspection before Starting 1. Charging warning lamp inspection. 2. Alternator and drive belt tension inspection. G420F(FE) Service Manual 129 Chapter 4.
3. Alternator and outer terminal connection inspection. 4. Battery outer terminal inspection. G420F(FE) Service Manual 130 Chapter 4.
Inspection after Starting 1. Inspection of alternator charging warning lamp operation test. 2. When starting, belt slip and noise inspection 3. Inspection of battery voltage at idling (At this time charge battery only) G420F(FE) Service Manual 131 Chapter 4.
Test Drop of Electric Pressure Test of Alternator Output Wire 1. Start the engine. This test is to check that wiring is correctly connected between the alternator “B“ terminal and battery (+) terminal. 2. Repeating ON and OFF of headlight and small light, adjust the engine speed until an ammeter reads 20A and at that time measure voltage. Result 1. If voltmeter reading is within the standard, it is normal. Test voltage Maximum 0.2V 2.
2. Turn the headlight ON and start the engine. 2) Inspect the drive belt for tension. (See “Engine body” ) 3. With the engine running at 2,500 rpm, turn ON the high beam headlights, place the heater blower switch at ”HIGH” measure the maximum output current using a ammeter. 2. Turn the ignition switch OFF. 3. Disconnect the battery ground cable. NOTE: This test should be done as soon as possible to measure the exact maximum current because output current drops rapidly after starting the engine. 4.
Disassembly and Installation 1. Nut 2. Pulley 3. Bushing 4. Front cover assembly 5. Front bearing 6. Bearing cover 7. Bearing cover bolt G420F(FE) Service Manual 8. Rotor coil 9. Rear bearing 10. Bearing cover 11. Stator coil 12. Rear cover 13. Through bolt 14. Seal 134 15. Rectifier assembly 16. Stud bolt 17. Brush holder assembly 18. Brush holder bolt 19. Slip ring guide 20. Cover Chapter 4.
Removal and Installation Disassembly 1. Disconnect the battery (A) terminal. 1. After removing the mounting nuts (B), remove the generator cover (A) using a screwdriver. 2. Disconnect the alternator “B” terminal and then the connector (A). Loosen the clip (B). 2. Loosen 3 mounting bolts (A) and disconnect the brush holder assembly (B). 3. Loosen the alternator tension adjusting bolt (A) and the alternator fixing bolt (B). 3. Remove the slip ring guide (A). 4.
Inspection Rotor 4. Remove the nut, pulley and spacer. 1. Inspect the rotor coil for continuity and check for continuity between slip rings. If resistance is too low, circuit is short and if the resistance is too high, circuit is opened. So replace the rotor assembly in both cases. Resistance value 2.5 ~ 3.0Ω(20Ω) 5. Loosen 4 through bolts. 2. Inspect the rotor coil ground and check continuity between the slip ring and the core, If there is continuity, replace the rotor assembly. 6.
Stator 2. (-) rectifier When inspecting continuity between (-) rectifier and stator coil lead connecting terminal using an ohmmeter, there must have only one direction continuity. If there is both direction continuity, replace the rectifier assembly owing to short circuit of diode. 1. Inspect the stator coil for continuity and check continuity between the coil leads. If there is no continuity, replace the stator assembly. Brush Replacemement 2.
Installation Installation is the reverse order of disassembly. Take care of the following items. 1. Before installing the rotor to the bracket, insert the wire into the small bore of rear bracket and fix the brush. 2. After installing the rotor, remove the wire. Installation 1. After placing the alternator, insert the support bolt. (At this time do not insert the nut.) 2. After pressing forward the alternator, Contact the alternator front bracket with front case (A) as shown in the illustration. 3.
STARTING SYSTEM General Description The starting motor is used to turn the engine flywheel lfast enough to make the engine run. The starting motor has a solenoid. When the ignition switch is activated, voltage from the electrical system will cause the solenoid to move the pinion toward the flywheel ring gear of the engine. The electrical contacts in the solenoid close the circuit between the battery and the starting motor just before the pinion engages the ring gear.
Diagnosis Procedure 2. Is a high current switch rated about 1000 amps that actually turns on the starting motor. The following simplified procedure is intended to help the serviceman determine if a starting motor needs to be removed and replaced or repaired. It is not intended to cover all possible problems and conditions, but to serve only as a guide. The most common 12 volt circuit is shown and discussed. General Information All starting systems are made up of four elements.
The result of these switches and relays is to permit a 5 amp dash-mounted switch to turn on a 500 to 1000amp motor used to crank an engine. Battery voltage (power) available during cranking varies according to the temperature of the batteries. The following chart is a guide as to what to expect from a normal system. NOTICE Do not operate the starting motor for more than 30seconds at a time. After 30 seconds, the cranking must be stopped for two minutes to allow the starting motor to cool.
• If the starting motor voltage is correct, the battery and starting motor cables down to the motor are within specifications. Go to Step 8. Start Relay Tests • If the starting motor voltage is low, the voltage drop between the battery and the starting motor is too great. Go to Step 6. 1. Put the multimeter on the 200 ohm scale. 6. Measure the voltage drops in the cranking circuits with the multimeter. Compare the results with maximum voltage drops allowed in Figure 2. 3.
Troubleshooting Starting system problem can be classified into “Start motor is not operating”, “Start motor is operating but engine is not starting” , and “There is a lot of time taken to start engine”. When the starting system has problems, before removing the start motor, find where the problem happens. Generally if it is difficult to start, there are problems in ignition system, fuel system, and electrical system. In this case, necessarily inspect and repair step by step, or the same problem will happen.
Starter Components 11 8 7 9 6 4 1 14 15 13 12 19 10 5 3 2 20 18 17 16 L4GC343A 1. Screw 2. Front bracket 3. Stop ring 4. Stopper 5. Overrunning clutch 6. Lever 7. Plate 8. Packing B 9. Shim 10. Internal gear G420F(FE) Service Manual 11. Magnetic switch 12. Planetary gear holder 13. Planetary gear 14. Ball 15. Packing A 144 16. Yoke assembly 17. Armature 18. Brush holder 19. Through bolt 20. Rear bracket Chapter 4.
Removal and Installation CAUTION This test should be done as soon as possible not to damage the coil (in 10 seconds). 1. Disconnect the battery ground cable. 2. Remove the speedometer cable. 3. Separate the start motor connector and terminal. 4. Measure clearance between the pinion and stopper using a feeler gauge. If the measured value is out of the standard, adjust clearance by adding or removing the washer between the magnetic switch and front bracket. 4. Remove the start motor assembly. 5.
Hold in Test of Solenoid Performance Test (with NO-LOAD) 1. Disconnect the connector from “M” terminal. 1. Connect a 12V battery to the start motor. 2. Connect a 12V battery between “S” terminal and “M” terminal. 2. To operate the start motor with no load, turn the switch ON. If the operating speed and current measured are identified with the standard, the start motor is normal. If the operating speed is insufficient or the current is excessive, it is because of excessive friction resistance.
Disassembly 2. Short Circuit Test of Armature Coil. Inspect the armature coil in the growler and if there is short circuit, replace the coil. During core rotation, if the blade attached in the core is vibrated, the armature is short. To remove the overrunning clutch from the armature shaft, remove the stop ring. Remove the stop ring by moving it to the pinion side, and then remove the stop ring from the shaft. Inspection (After Disassembly) 3. Open Circuit Test of Armature Coil.
4. Open Circuit Test of Field Coil. Check continuity of the field coil using a circuit tester. If there is no continuity, replace the field coil assembly owing to open circuit of the field coil. 7. Brush Holder Check continuity between the (+) side brush holder and the base. If there is continuity, replace the brush holder assembly. 5. Ground Test of Field Coil. With the yoke field coil installed, inspect continuity between the field coil and the yoke, if there is continuity, replace the field coil. 8.
Assembly 9. Bruch Replacement 1) Remove the worn brush taking care not to damage the pigtail. 1. Install the overrunning clutch to the armature shaft front end. 2) For better welding, correct the pigtail end with a sand paper. 2. Install the stop ring and snap ring to the armature shaft front end and completely press the stop ring toward the snap ring. 3) Weld the pigtail end. 3. When installing the lever to the front bracket, take care of the direction.
Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS) General Information Specifications SECM and Sensor/Switch Inputs Q’ty Components G420FE Environmental / Electrical Specifications None Items Specifications G420F None Ambient Operating Temperature -20 °F to 221°F [-29 °C to 105 °C] 8-16 Vdc Operating Voltage Engine Control Module (SECM 48) 1 1 Operating Temperature -20 °F to 221°F [-29 °C to 105 °C] Operating Voltage 8-16 Vdc SECM microprocessor may reset at voltages below 6.
Q’ty Components Ground speed limit switch Items G420FE G420F option option Type Actuation Pressure Specifications Normal Open 145 ± 28 kPa Electronic Throttle System Q’ty Components Electronic Throttle System Items G420FE G420F 1 1 Minimum Electrical Resistance of Throttle Actuator Specifications 1.
LP Fuel Components Specification Q’ty Components G420FE Items Specifications G420F LP Fuel System Requirements Operating Temperature -20 °F to 221°F [-29 °C to 105 °C] - - LPG Composition Requirements HD5 / HD10 LPG. Failure to use fuel compliant with HD5 or HD10 standards will void the user warranty. LP Fuel Filter 1 1 Fuel Filter Micron Size 40 micron LP Fuel Lock-off 1 1 Electrical Resistance 20~25Ω Fuel Supply Pressure 10 psi to 250 psi (68.95 kPa to 1723.
Q’ty Components G420FE Items N-2001 LP Regulator For G420F None 1 CA100 Mixer For G420FE 1 G420F(FE) Service Manual Specifications G420F None Fuel Supply Pressure 10 psi to 250 psi (69 kPa to 1724 kPa) Fuel Inlet Fitting 1/4” NPT Fuel Outlet Fitting One 3/4” NPT and one 1/8” NPT fitting with plug Fuel Supply Temperature At Tank Outlet -20 °F to 120 °F [-29 °C to 49 °C] Primary Pressure Tap 1/8” NPT with plug Max Flow 50 lbm/hr LPG Coolant Flow to Vaporizer >1.
Q’ty Components G420FE Items CA100 Mixer For G420F None Fuel Trim Valve (FTV) Specifications G420F 1 2 None Fuel LPG Fuel Inlet Fitting 1/2” NPT Fuel inlet fitted with Delphi temperature sensor Air Intake Flange 2.25” (57.15mm) ID inlet, four #1024 screws in 1.94” (49.28mm) square pattern Mixer Mounting Flange 1.87” (47.49mm ID outlet, four #1224 screws arranged in a rectangular pattern Reference Pressure Ports 1/4-1/8 NPT ports. Pressure readings must be identical within 0.25 inH2O (0.
Service Standard Basic Idle rpm (After warm up) No Load Ignition Timing (After warm up, at idle) 750±15 rpm BTDC 5°±5° Sealants Engine Coolant Temperature Sensor (ECTS) assembly LOCTITE 962T or equivalent Tightening Torques Items N∙m kgf∙m 1bf∙ft Heated Oxygen Sensor (HO2S, Sensor 1) 50 ~ 60 50 ~ 60 36. 2 ~ 43.4 Heated Oxygen Sensor (HO2S, Sensor 2) 50 ~ 60 5.0 ~ 6.0 36.2 ~ 43.4 Crankshaft Position Sensor (CKPS) 4~6 0.4 ~ 0.6 2.9 ~ 4.3 CKPS target wheel installation screw 10.8 ~ 11.
Component Location Engine Control Module (SECM48) Camshaft Position Sensor Crankshaft Position Sensor TMAP Sensor LP Fuel Temperature Sensor Coolant Temperature Sensor G420F(FE) Service Manual 156 Chapter 5.
Pre-Catalyst Oxygen Sensor Electronic Throttle Body Pedal Angle Sensor Post-Catalyst Oxygen Sensor Transmission Oil Temperature Switch Engine Oil Pressure Switch G420F(FE) Service Manual 157 Chapter 5.
Ground speed limit switch (option) Fuel Trim Valve (FTV) Power TR Gasoline Injectors and fuel rall N-2007 LP Regulator LP Fuel Lock-off G420F(FE) Service Manual 158 Chapter 5.
CA100 Mixer Gasoline Fuel Pump Ass`y G420F(FE) Service Manual 159 Chapter 5.
G420FE EMS (Engine Management System) Overview General Description MI-07 is a closed loop system utilizing a catalytic muffler to reduce the emission level in the exhaust gas. In order to obtain maximum effect from the catalyst, an accurate control of the air fuel ratio is required. A small engine control module (SECM) uses two heated exhaust gas oxygen sensors (HEGO) in the exhaust system to monitor exhaust gas content.
Dual Fuel System of G420FE (certified engine system) INPUT OUTPUT Crank Sensor Throttle body CAM sensor 4 Power TRs 4 Ignition coils TMAP sensorv 2 Fuel trim valves Coolant Temp LP fuelock valve EG oil pressure switchv T/M Temp switch 4 Injectors SECM Accel pedal angle sensor Fuel Pump CAN communication Throttle position sensor Pre Oxygen sensor Post Oxygen sensor LP fuel temp sensor T/M Inching pressure switch MPI (multi-point injection) system is used for G420FE dual fuel engine and G420F
• LPG mixer • LPG pressure regulator • Fuel trim valves • Fuel trim orifices • Small engine control module (SECM), firmware and calibration † • Fuel system sensors and actuators • Ignition system including spark plugs, cables, coils and drivers • Gasoline injectors and fuel pressure regulator (dual-fuel systems only) MI-07 System Components The MI-07 control system provides electronic control to the following subsystems on mobile industrial engines: • Fuel delivery system • Spark-ignition control system •
LPG Fuel System Operation Other system features include: The principles outlined below describe the operation of MI-07 on an LPG fuel system. Tamper-Resistance Special tools, equipment, knowledge, and authorization are required to effect any changes to the MI-07 system, thereby preventing unauthorized personnel from making adjustments that will affect performance or emissions.
pressure regulator outlet pressure changes by the same amount and in the same direction. The end result is that a change in FTV modulation changes the outlet pressure of the regulator/fuel inlet pressure of the mixer, and thus the AFR. A major benefit of this trim system results from the use of mixer inlet pressure and AVV as the reference pressure extremes. The pressure differential across the mixer fuel valve is related to these same two pressures, and thus so is fuel flow.
the propane is reduced, the liquid propane vaporizes and refrigeration occurs inside the regulator due to the vaporization of liquid propane. To replace heat lost to vaporization, engine coolant is supplied by the engine driven water pump and pumped through the regulator. Heat provided by this coolant is transferred through to the fuel vaporization chamber.
A higher flow mixer is required on larger engines. A lower flow mixer is required on smaller engines. Figure 6. Parts View of N-2007 Regulator Because vapor propane has now left the expansion chamber, the pressure in the chamber will drop, causing the primary diaphragm spring force to reopen the primary valve allowing liquid propane to enter the regulator, and the entire process starts again.
and air valve spring (6). The gas-metering valve is permanently mounted to the air valve diaphragm assembly with a face seal mounted between the two parts. When the engine is not running this face seal creates a barrier against the gas discharge jet, preventing fuel flow with the aid (downward force) of the air valve spring. When the engine is cranked over it begins to draw in air, creating a negative pressure signal. This negative pressure signal is transmitted through four vacuum ports in the air valve.
exists across the diaphragm, reducing fuel flow and leaning the air/fuel mixture. Figure 12. Idle Mixture Adjustment Screw (with tamper proof cap removed) Fuel Trim Valve (FTV) The Fuel Trim Valve (FTV) is a two-way electric solenoid valve and is controlled by a pulse-width modulated (PWM) signal provided by the SECM.
the balance line and referencing atmospheric pressure. The other side of the branch-tee fitting connects to the FTV inlet (small housing side). The FTV outlet (large housing connector side) connects to the AVV port. When the FTVs are open AVV is sent to the atmospheric side of the N-2007 secondary diaphragm, which lowers the reference pressure, closing the N-2007 secondary valve and leaning the air/fuel mixture. The MI-07 system is calibrated to run rich without the FTV.
is solenoid valve which supplies exactly calculated fuel as a spray to engine to best combustion under the condition of various engine load and speed. MPI Gasoline System Operation MPI (multi-point injection) system is used for G420FE dual fuel engine and G420F gasoline/dual fuel engine. An electric fuel pump in gasoline fuel tank supplies the fuel and generates the injection pressure. The gasoline fuel pressure regulator is a one-way, non-return configuration.
Electronic Throttle System MI-07 Electronic Throttle Conventional throttle systems rely on a mechanical linkage to control the throttle valve. To meet fluctuating engine demands a conventional system will typically include a throttle valve actuator designed to readjust the throttle opening in response to engine demand, together with an idle control actuator or idle air bypass valve.
There are multiple limp-home modes available with electronic throttle control: 1. If the throttle itself is suspected of being inoperable, the SECM will remove the power to the throttle motor. When the power is removed, the throttle blade returns to its “default” position, approximately 7% open. 2. If the SECM can still control the throttle but some other part of the system is suspected of failure, the SECM will enter a “Reduced Power” mode.
Exhaust System COP Components In a typical COP ignition system, a crankshaft position sensor generates a basic timing signal by reading notches on the crankshaft, flywheel, or harmonic balancer. The crank sensor signal goes to the small engine control module (SECM), where it is used to determine firing order and turn the individual ignition coils on and off. Heated Exhaust Gas Oxygen Sensors (HEGO) The MI-07 system utilizes two HEGO (O2) sensors.
converter. It reduces the unburned hydrocarbons and carbon monoxide by burning (oxidizing) them over a platinum and palladium catalyst. Cerium is also used to promote oxygen storage and improve oxidation efficiency. The HEGO stoichiometric air-fuel ratio voltage target is approximately 500 mV and changes slightly as a function of speed and load. When the pre-catalyst HEGO sensor sends a voltage signal less than 450 mV the SECM interprets the air-fuel mixture as lean.
The SECM provides a transducer ground for all the sensors, and a low side driver signal controlling the fuel lock-off, MIL, gasoline injectors, gasoline fuel pump, and FTVs. SECM General Description The Small Engine Control Module (SECM) controller has full authority over spark, fuel and air. Utilizing a Freescale micro controller, the SECM has 48 pins of I/O and is fully waterproof and shock hardened.
NOTE : The DV-E5 throttle is not a serviceable assembly. If a TPS sensor fails, the assembly should be replaced. Speed Management Drive-by-wire refers to the fact that the MI-07 control system has no throttle cable from the foot pedal to the throttle body. Instead, the SECM is electronically connected both to the foot pedal assembly and the throttle body. The SECM monitors the foot pedal position and controls the throttle plate by driving a DC motor connected to the throttle.
Ignition Management In the normal course of events, with the engine operating at the correct temperature in defined conditions, the SECM will use load and engine speed to derive the correct ignition timing. In addition to load and speed there are other circumstances under which the SECM may need to vary the ignition timing, including low engine coolant temperature, air temperature, start-up, and idle speed control.
SECM Wiring Diagrams for G420FE CAUTION—PROPER WIRING To prevent system faults be sure to follow good wiring practices. Poor wiring may cause unexpected or intermittent failures not related to MI-07 components. Figure 23. SECM Wiring Diagram for G420FE Engine Systems G420F(FE) Service Manual 178 Chapter 5.
Figure 23. SECM Wiring Diagram for G420FE Engine Systems G420F(FE) Service Manual 179 Chapter 5.
G420F EMS (Engine Management System) Overview General Description Engine speed is monitored by the SECM through a Hall Effect sensor. Intake manifold air temperature and absolute pressure are monitored with a TMAP sensor. MI-07 is a drive-by-wire (DBW) system connecting the accelerator pedal to the electronic throttle through the electrical harness; mechanical cables are not used. A throttle position sensor (TPS) monitors throttle position in relation to the accelerator pedal position sensor (APP) command.
Dual Fuel System of G420F INPUT OUTPUT Crank Sensor Throttle body CAM sensor 4 Power TRs 4 Ignition coils TMAP sensor Coolant Temp LP fuelock valve EG oil pressure switch T/M Temp switch 4 Injectors SECM Accel pedal angle sensor Fuel Pump CAN communication Throttle position sensor Oxygen sensor (Gasoline only) T/M Inching pressure switch A dual fuel system operates on either LPG or gasoline. The fuel type can be switched while the engine is stopped or running at low speeds and low loads.
MI-07 System Components The MI-07 control system provides electronic control to the following subsystems on mobile industrial engines: MI-07 System Features The MI-07 system uses an advanced speed-density control strategy for fuel, spark, and air throttle control. Key features include the following. • Fuel delivery system • Spark-ignition control system • Air throttle • Sensors/Switches/Speed inputs The chart below lists the MI-07 components required for a G420F engine operating on LP fuel.
Other system features include: LPG Fuel System Operation Tamper-Resistance Special tools, equipment, knowledge, and authorization are required to effect any changes to the MI-07 system, thereby preventing unauthorized personnel from making adjustments that will affect performance or emissions. The principles outlined below describe the operation of MI-07 on an LPG fuel system.
secondary (2nd stage) valve and the primary (1st stage) valve closes. Unlike most other regulator/converters, the N-2001 primary valve closes with fuel pressure rather than against pressure, extending primary seat life and adding additional safety. N-2001 Operation Refer to Figure 6. Liquid propane, at tank pressure, enters the N-2001 through the fuel inlet port (1). Propane liquid then flows through the primary valve (2).
imbalance on the secondary diaphragm, which overcomes the secondary spring force, opening the secondary valve and allowing vapor propane to flow out of the expansion chamber, through the secondary chamber to the mixer. CA100 Mixer Operation Vapor propane fuel is supplied to the CA100 mixer by the N-2001 pressure regulator/converter. The mixer uses a diaphragm type air valve assembly to operate a gas-metering valve inside the mixer.
Figure 9. Parts View of CA100 Mixer Figure 11. CA100 Mixer Installed with Electronic Throttle A pressure/force imbalance begins to build across the air valve diaphragm between the air valve vacuum (AVV) chamber (above the diaphragm) and atmospheric pressure below the diaphragm. Approximately 6 inH2O (14.945 mbar) of negative pressure is required to overcome the air valve spring force and push the air valve assembly upward off the valve seat. Approximately 24 inH2O (59.
MPI Gasoline System Operation SECM The MPI Gasoline System of G420F engine is the same as that of G420FE engine. See, “MPI Gasoline System Operation of G420FE EMS overview” The SECM of G420F engine is the same as that of G420FE engine. See, “SECM of G420FE EMS overview” Electronic Throttle System The electronic throttle system of G420F engine is the same as that of G420FE engine.
SECM Wiring Diagrams for G420F G420F(FE) Service Manual 188 Chapter 5.
• Fuel Temperature Sensor (FTS) -40°F to 266°F (-40ºC to 130ºC) range, 48K ohm to 57 ohm sensor range EMS Inspection and Repair Engine Control Module (SECM) • HEGO (3) 0 to 1 V The 48-pin Small Engine Control Module (SECM) and sensors provide the computational power, algorithm logic, sensor inputs and control outputs to control the system.
Outputs • Saturated injector drivers (4) 10A peak, 45 V max, 1 injector per channel capable of continuous on-time Driver circuit designed for minimum turn-on/turnoff delay Minimum pulse width resolution of 1 usec • FTV drivers (2) 10A peak, 45V max.
Camshaft Position Sensor Sensor Inspection Component Location 3 2 1 1. Turn ignition switch to OFF position and then disconnect CMPS connector. 2. Remove the CMPS from the engine. Description 3. Turn ignition switch to ON position. The Camshaft Position Sensor (CMPS) is a sensor that detects the compression TDC of the NO.1 cylinder. The CMPS consists of a hall type sensor and a target on the end of the in take camshaft. When the target triggers the sensor, the sensor voltage is 5V.
Crank Shaft Position Sensor Schematic Diagram Component Location [CIRCUIT DIAGRAM] CKPS ECM 3 B1 - GND 2 B5 - CKPS SIGNAL 1 After Main Relay A23_DRVP [HARNESS CONNECTORS] Description 3 The Crankshaft Position Sensor (CKPS) is a hall effect type sensor that generates voltage using a sensor and a target wheel mounted on the crankshaft; there are 58 slots in the target wheel where one is longer than the others. When the slot in the wheel aligns with the sensor, the sensor voltage out put slow.
Sensor Inspection MAP (Manifold Absolute Pressure) Sensor 1. Measure the voltage between terminals 1 and 4 of the MAP sensor connectors. Terminal 4 : MAP sensor ground Terminal 1 : MAP sensor output Engine state Ignition SW. ON At idle Test specification 4~5V 0.5~2.0V 2. If the voltage deviates from the standard value, replace the MAP sensor assembly. The manifold absolute pressure (MAP) sensor is a pressure sensitive variable resistor.
IAT (Intake Air Temperature) Sensor Sensor Inspection 1. Using a multimeter, measure the IAT sensor resistance between terminals 3 and 4. IG.SW.ON Temperature ℃ (°F) Resistance(kΩ) 0 (32) 4.5 ~ 7.5 20 (68) 2.0 ~ 3.0 40 (104) 0.7 ~ 1.6 80 (176) 0.2 ~ 0.4 2. If the resistance deviates from the standard value, replace the intake air temperature sensor assembly. The intake air temperature sensor (IAT Sensor), built in to the MAT sensor, is a resistor-based sensor detect the intake air temperature.
Oxygen Sensor (Pre-Catalyst) Schematic Diagram Component Location [CIRCUIT DIAGRAM] HO2S (B1/S1) ECM 4 3 1 2 A23 - HO2S HEATER (B1/S1) B13 - HO2S SIGNAL B1 - HO2S GND After Main Relay L4GC215A [HARNESS CONNECTORS] Description The heated oxygen sensor is mounted on the front side of Catalytic Muffler, which detects the oxygen concentration in the exhaust gas. The heated oxygen sensor produces a voltage that varies between 0V and 1V.
Oxygen Sensor (Post-Catalyst) Signal Wave Form Component Location The amplitude of the signal output of the rear HO2S is small compared to the front HO2S because the rear HO2S detects emission gas purified by the catalytic converter. This illustration is the normal signal waveform of the rear HO2S at idle. Description The rear heated oxygen sensor is mounted on the rear side of the Catalytic Muffler, which detects the catalyst efficiency.
ECT (Engine Coolant Temperature) Sensor Sensor Inspection Component Location 1. Remove the engine coolant temperature sensor from the intake intake manifold. 2. With the temperature sensing portion of the engine coolant temperature sensor immersed in hot water, check resistance. Description The Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting the engine coolant temperature.
Schematic Diagram [CIRCUIT DIAGRAM] ECTS ECM 1 B15 - ECTS SIGNAL 2 to Cluster 3 B1 - GND [HARNESS CONNECTORS] 3 2 1 C11 ECTS Installation 1. Apply sealant LOCTITE 962T or equivalent to threaded portion. 2. 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) 3. Connect the harness connector securely. G420F(FE) Service Manual 198 Chapter 5.
LP Fuel Temperature Sensor [Harness Connectors] Location Inspection 1. Remove the LP fuel temperature sensor from the adapter connected to LP mixer. Description The LP Fuel Temperature Sensor (FTS) is located in the LP fuel passage of the LP mixer for detecting the LP fuel temperature. The FTS uses a thermistor whose resistance changes with the temperature. The electrical resistance of the FTS decrease as the temperature increase, and increase as the temperature decrease.
Angle Sensor-Accelerator [Harness Connectors] Location Inspection 1. Disconnect the Accelerator Pedal’s connector from the main engine harness. Description Angle Sensor-Accelerator is located in the accelerator pedal assembly. The engine speed management deals with a Drive-by-wire system. Drive-by-wire refers to the fact that the MI-07 control system has no throttle cable from the foot pedal to the throttle body.
Transmission Oil Temperature Switch [Harness Connectors] Location Inspection 1. Remove the Transmission Oil Temperature Switch from the transmission. Description Transmission Oil Temperature Switch is located in the adapter on transmission (T/M) for operating by the transmission (T/M) oil temperature change. This switch is normally open, and then it is closed as the T/M oil temperature Increases to the 125±3°C.
[Harness Connectors] Ground Speed Limit Switch (optional) Location Inspection 1. Remove the Ground Speed Limit Switch from the transmission. Description Ground Speed Limit Switch is located in the pressure port on transmission (T/M) for operating by the transmission (T/M) oil pressure change. This switch is normally opened, and then it is closed as the T/M oil pressure increases. Actually the switch is closed by increasing of the T/M oil pressure after engine cranking.
[Harness Connectors] Electronic Throttle Body Location Inspection 1. Check for loose, dirty or damaged connectors and wires on the harness Description The MI-07 system uses electronic throttle control (ETC). The SECM controls the throttle valve based on engine RPM, engine load, and information received from the foot pedal. Two potentiometers on the foot pedal assembly monitor accelerator pedal travel. The electronic throttle used in the MI-07 system is a Bosch 32mm electronic throttle body DV-E5.
Chapter 6. LPG FUEL DELIVERY SYSTEM G420FE LP System Inspection and Repair Removal and Installation WARNING - PROPER USE • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. • Gas vapor may reduce oxygen available for breathing, cause headache, nausea, dizziness and unconsciousness and lead to injury or death.
Hose Connections Proper operation of the closed loop control greatly depends on the correct vacuum hose routing and fuel line lengths. Refer to the connection diagrams below for proper routing and maximum hose lengths when reinstalling system components. Certified System Connections Figure 26. Hose Connections for Certified Systems Diagram Notes G420F(FE) Service Manual 205 Chapter 6.
N-2007 Installation Steps Removal and Installation of N-2007 LP Regulator Refer to Figure 28. Follow the procedures below for removal and reinstallation of the N-2007 regulator in certified systems. 1. Install the nipple extension (6) with the lock-off to the regulator. N-2007 Removal Steps 2. Install the fuel vapor outlet hose (5) to the regulator. Refer to Figure 28. 3. Install the two cooling lines (4) to the regulator. 1.
Removal and Installation of CA100 Mixer for G420FE 2. Purge the system of fuel by starting the engine and running until all trapped fuel in the system is exhausted and the engine shuts down. Follow the procedures below for removal and reinstallation of the CA100 mixer in certified systems. 3. Key switch in “OFF” position. CA100 Certified Mixer Removal Steps 4. Remove the air cleaner hose (1). 5.
CAUTION The 1/8” NPT x 1/4” hose barb fitting that is installed in the mixer housing uses a specific machined orifice size through the fitting. This orifice fitting is part of the mixer assembly and is an integral part of the MI-07 control. If this fitting is damaged the mixer will need to be replaced. DO NOT replace this fitting with a standard hose barb fitting or use a drill bit to clean out the fitting passage way. NOTE : A plastic O-ring spacer and an O-ring are inside the mixer/adapter assembly.
CA100 Certified Mixer Installation Steps Tests and Adjustments Refer to Figure 30. WARNING—PROPER USE 1. Install the vacuum port barb below the idle set screw on the mixer (7). • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. 2. Install the fuel temperature sensor adapter to the mixer. 3. Install the fuel temperature sensor to the adapter (6).
N-2007 Regulator Service Testing For checking the N-2007 regulator/converter operation, the following tests can be performed (See Chapter 5 for removal/installation of the N-2007 regulator). To check the secondary regulation (output) a simple vacuum hand pump can be used to simulate the vacuum signal transmitted from the air/fuel mixer when the engine is running. See listing below for required hardware. Break-Off Test Figure 34.
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. CAUTION •LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. 4.
AVV (Air Valve Vacuum) Testing Ignition Timing Adjustment Purpose of Test With the MI-07 system, ignition-timing advance is controlled by the SECM. Check for excessive or inadequate pressure drop across CA100 mixer. The initial ignition timing needs to be set by the MOR. This setup requires a specific technique for each engine installation. AVV Test Hardware Connection of the MI-07 Service Tool 1. Union Tee fitting, 1/4” (6.35mm) NPT with three 1/4” (6.35mm) NPT x 1/4” (6.
Idle Mixture Adjustment The CA100 mixer requires adjustment of the idle mixture screw to assure optimal emissions and performance. This adjustment accounts for minor part-to-part variations in the fuel system and assures stable performance of the engine at idle. Once adjusted, the idle mixture screw is sealed with a tamper proof cap, after which it need not be adjusted for the life of the vehicle.
measurement at Closed Loop Idle of 25-60% is acceptable if the optimum range of 35-55% cannot be reached through adjustment. If the FTV duty cycle cannot be adjusted below 60%, the mixer is faulty and should be replaced. Factory Adjustment Procedure: NOTE : Be sure engine is fully warm (ECT>167°F [75°C]) before performing the idle mixture adjustment. NOTE : If the FTV Duty Cycle reading is NOT between 25-60%, check for possible vacuum leaks, manifold leaks, or a faulty mixer. 1.
8. If the FTV duty cycle reading is above 55% adjust the idle adjustment screw outward and re-check the duty cycle reading. Continue to do this until the FTV duty cycle reading is within the optimum range (35-55%). DO NOT adjust the screw so far outward that the tamper proof cap cannot be installed. A duty cycle measurement at Closed Loop Idle of 25-60% is acceptable if the optimum range of 35-55% cannot be reached through adjustment.
Parts Description CA100 Mixer for G420FE Engine Parts List of CA100 Mixer (Certified) REF NO DESCRIPTION QTY 1 Torx Screws (T-25) #10-24 x 5/8” 4 2 Lockwashers (T-210) #10 SST 4 3 Mixer Cover 1 4 Mixer Spring 1 5 Diaphragm 1 6 Air Valve Assembly 1 7 Gas Valve Cone (part of air valve assembly) 1 8 Mixer Body 1 9 Expansion Plug Cap Ø 1/2” x 1/16” thick (Ø 12.7mm x 27mm) 1 10 Fuel Inlet 1 11 Air Horn Gasket 1 12 Air Horn Adapter 2-1/16” (52.
Exploded View of CA100 Mixer (Certified) Figure 44. CA100 Certified Mixer Exploded View G420F(FE) Service Manual 217 Chapter 6.
N-2007 Regulator for G420FE Engine Parts List of N-2007 Regulator (Certified) REF NO DESCRIPTION QTY 1 N-2007 Body 1 2 Diaphragm, Primary Assembly 1 3 Springs, Primary Assembly 2 4 Cover, Primary Assembly 1 5 Spring, Secondary Seat, Red 1 6 Dowel Pin Ø 0.094” x 1” L (Ø 2.39mm x 25.
Exploded View of N-2007 Regulator (Certified) Figure 46. N-2007 Certified Regulator Exploded View G420F(FE) Service Manual 219 Chapter 6.
G420F LPG System Inspection and Repair Removal and Installation WARNING – PROPER USE • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. • Gas vapor may reduce oxygen available for breathing, cause headache, nausea, dizziness and unconsciousness and lead to injury or death. Always operate the forklift in a well ventilated area • Liquid propane may cause freezing of tissue or frostbite.
G420F Fuel System Connections Figure 27. Hose Connections for Non-Certified Systems DIAGRAM NOTES 1 3 4 5 Only one 90 fitting permissible on vapor fuel line between mixer and regulator Vapor fuel fittings (regulator and mixer) must have minimum ID of 0.46” (11.
N-2001 Installation Steps Removal and Installation of N-2001 LP Regulator/Converter Refer to Figure 29. Follow the procedures below for removal and reinstallation of the N-2001 regulator. 1. Install the fuel vapor outlet hose (5) from the regulator. N-2001 Removal Steps 2. Install the two cooling lines (4) from the regulator. Refer to Figure 29. 3. Install the two rear-mounting bolts that hold the regulator to the support bracket. Use a torque wrench and tighten each bolt to 50-60 lbf-in (5.656.
Removal and Installation of CA100 Mixer for G420F 1. Close the liquid outlet valve in the forklift cylinder or fuel storage container. Follow the procedures below for removal and reinstallation of the CA100 mixer in non-certified systems. 2. Purge the system of fuel by starting the engine and running until all trapped fuel in the system is exhausted and the engine shuts down. CA100 Mixer Removal Steps 3. Key switch in “OFF” position. 4. Remove the air cleaner hose (1). 1 5.
CA100 Mixer Installation Steps CAUTION 1. Install the vapor fuel inlet fitting onto the mixer. The 1/8” NPT x 1/4” hose barb fitting that is installed in the mixer housing uses a specific 2. Install the four mounting screws that attach the machined orifice size through the fitting. This throttle adapter to the mixer. (See Figure 32). orifice fitting is part of the mixer assembly and is an integral part of the MI-07 control. If this fitting Torque bolts to 30-40 lbf-in (3.39-4.52 N-m).
Secondary Stage (Break-Off) Test Tests and Adjustments 1. Connect the vacuum pump, the Magnehelic gauge and the regulator vapor outlet to the Union Tee fitting (Figure 30). Make sure there is no leakage at any of the fittings. WARNING – PROPER USE • LP gas is highly flammable. To prevent personal injury, keep fire and flammable materials away from the lift truck when work is done on the fuel system. 2. Using the vacuum pump slowly apply enough vacuum to measure above -2” WC on the gauge.
Pressure Test Primary Stage Pressure Test Primary Stage Test Hardware 1. Remove the primary test port plug from the side of the regulator and install the 1/16” NPT hose barb fitting (Figure 31). 1. Hand vacuum pump 2. Connect a compressed air line (shop air ~100 psi) to the liquid propane fuel inlet of the N-2001 regulator (Figure 31). 2. Regulator fuel inlet test fitting 1/4 NPT standard air coupling) 3. Test gauge fitting (1/4” NPT X 1/4” hose b) 4. Vacuum hose or vinyl tubing 5.
AVV (Air Valve Vacuum) Testing Connection of the MI-07 Service Tool Purpose of Test To use the Service Tool, a USB (Universal Serial Bus) to CAN (Controller Area Network) communication adapter by KVaser will be required along with a Crypt Token (Figure 38). The Crypt Token acts as a security key allowing the laptop to retrieve the necessary data from the SECM. Check for excessive or inadequate pressure drop across CA100 mixer. AVV Test Hardware 1. Union Tee fitting, 1/4” (6.35mm) NPT with three 1/4” (6.
Power Valve Adjustment 1. The power valve should only be adjusted after the idle screw has been adjusted properly. The engine and vehicle drive train and hydraulics should also be at normal operating temperatures. 2. Apply a load to the engine while the engine is operating above idle speed. Torque converter stall is the preferred operating mode for this test.
Power Valve Adjustment 1. The power valve should only be adjusted after the idle screw has been adjusted properly. The engine and vehicle drive train and hydraulics should also be at normal operating temperatures. 2. Apply a load to the engine while the engine is operating above idle speed. Torque converter stall is the preferred operating mode for this test.
Parts Description CA100 Mixer for G420F Engine Refer to Figure 45 exploded view on facing page. REF NO.
Exploded View CA100 Mixer Figure 45. CA100 Non-Certified Mixer Exploded View G420F(FE) Service Manual 231 Chapter 6.
CA100 Disassembly and Service 6 5 Figure M4 4 1. With the mixer/adapter assembly removed from the engine, and the throttle adapter removed from the mixer, remove the four cover retaining screws from the top of the mixer (Figure M4). 9 14 2 3 8 7 Figure M5 1 15 2. Gently remove the diaphragm cover from the top of the mixer. Take care not to loose the air-valve spring shown in (Figure M5).
CAUTION The 1/8” NPT X ¼” hose barb fitting that is installed in the mixer housing uses a specific machined orifice size through the fitting. This orifice fitting is part of the mixer assembly and an integral part of the MI-04 control. DO NOT replace this fitting with a standard hose barb fitting or use a drill bit to clean out the fitting passage way. If this fitting is damaged the mixer will need to be replaced. Figure M7 4. Clean the heavy end deposits from the mixer body with solvent.
N-2001 Regulator for G420F Engine Refer to Figure 47 exploded view on facing page. Parts List N-2001-RSA Regulator REF NO.
Exploded View N-2001-RSA Regulator Figure 47. N-2001 Regulator Exploded View G420F(FE) Service Manual 235 Chapter 6.
N2001 Regulator Disassembly Steps: 4 Figure R5 1 Figure R3 5 2 3 Figure R5 Remove the six primary diaphragm cover screws (4) and the primary cover assembly (5). Figure R4 1. Remove the six secondary cover screws (1), the secondary cover (2) and the secondary diaphragm (3). 2. Remove the six primary diaphragm cover screws (4) and the primary cover assembly (5). Figure R6 Remove the primary diaphragm by sliding the diaphragm to one side, releasing the primary valve pin (Figure R6).
10 3 11 Figure R7 6. Remove the body gasket (10), body o-ring seal (11) and the fuel inlet plate, exposing the fuel inlet expansion chamber and the coolant passage. NOTE For re-assembly of the N2001 regulator/converter, reverse the steps for disassembly. Tighten all fasteners to recommended torque values and test the regulator before installing in the vehicle. Torque primary cover screws to (40-50 inch lbs.), secondary cover screws to (1518 inch lbs.).
N2001 Disassembled Service 1. Clean the primary and secondary valves with soap and warm water to remove heavy-end deposits. Inspect the valve seats and o-rings for wear. Replace worn components as necessary. 2. Clean the primary and secondary diaphragms with soap and warm water. Inspect for wear, tears or pinholes and deformations that may cause leaks or poor performance of the regulator/converter. . 3.
Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM Specification Items Specification Fuel Retrun System Type Returnless Fuel Filter Type High pressure type (built in Fuel Pump Assembly) Type Built in fuel pump assembly Fuel Pressure Regulator Fuel Pump Regulated Fuel Pressure Type 350 kpa (3.5kg/cm2, 49.
Components Location 1. Fuel Tank 2. Fuel Pump (Including full pressure regulator and fuel filter) 3. Fuel Hose Assy 4. Fuel Rail 5. Injector G420F(FE) Service Manual 240 Chapter 7.
Fuel Pressure Test Install The Special Service Tool (SST) For Measuring The Fuel Pressure Release The Internal Pressure 1. Disconnect the fuel pump connector. 2. Start the engine and wait until fuel in fuel line is exhausted. 3. After the engine stalls, turn the ignition switch to OFF position and diconnect the negative (-) terminal from the battery. NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel feed hose, otherwise fuel will spill out. 1.
Inspect Fuel Leakage On Connection • Observing the declination of the fuel pressure when the gage reading drops and perform the necessary repairs using the table below. 1. Connect the battery negative (-) terminal. 2. Apply battery voltage to the fuel pump terminal and activate the fuel pump. With fuel pressure applied, check that there is no fuel leakage from the fuel pressure gauge or connection part. Fuel Presure Test 1. Diconnect the negative (-) terminal from the battery. 2.
Injector Remove The Special Service Tool (SST) And Connect the Fuel Line Component Location 1. Disconnect the Fuel Pressure Gage and Hose (09353-24100) from the Fuel Pressure Gage Connector (09353-24000). 2. Disconnect the Fuel Pressure Gage Connector (09353-24000) from the Fuel Pressure Gage Adapter (09353-38000). 3. Disconnect the fuel feed hose from the Fuel Pressure Gage Adapter (09353-38000). 4. Disconnect the Fuel Pressure Gage Adapter (09353-38000) from the delivery pipe.
Specification Temperature Temperature (℃) (℉) Injector Resistance(Ω) (℃) (℉) Injector Resistance(Ω) -20 -4 12.2 ~ 12.3 60 140 16.6 ~ 16.8 0 32 13.3 ~ 13.5 80 176 17.7 ~ 17.9 20 68 14.4 ~ 14.6 100 212 18.8 ~ 19.0 40 104 15.5 ~ 15.7 120 248 19.9 ~ 20.1 Schematic diagram G420F(FE) Service Manual 244 Chapter 7.
Injector Inspection Resistance Measurement Between Terminals Operation check Operation Sound Check 1. Disconnect the connector at the injector and measure the resistance between the two terminals. 1. Using a stethoscope, check the injectors for a clicking sound at idle. Check that the sound is produced at shorter intervals as the engine speed increases. Standard value : 14.5 ± 0.35Ω [at 20℃ (68℉)] 2. Re-connect the connector to the injector.
Inspection 1. Measure the resistance of the injectors between the terminals using an ohmmeter. Resistance : 14.5 ± 0.35Ω [at 20℃ (68℉)] 4. Be sure the injector turns smoothly. NOTE: If it does turn smoothly, the O-ring may be jammed : Remove the injector and re-insert it into the delivery pipe and recheck. 2. If the resistance is not within specifications, replace the injector. Installation 1. Install a new grommet and O-ring to the injector. 2.
Fuel Pump Removal (Including Fuel Filter And Fuel Pressure Regulator) A 1. Release the internal pressure of the fuel lines and hoses as following : a. Disconnect the fuel pump assembly harness connector (A). 4. Remove the fuel pump assembly. b. Start the engine and wait until fuel in fuel line is exhausted. After the engine stalls, turn the ignition switch to OFF position. c. Disconnect the negative (-) terminal from the battery. 2. Disconnect the fuel feed line.
Chapter 8. BASIC TROUBLESHOOTING Preliminary Checks Visual/Physical check MI-07 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) and are covered in Chapter 9, Advanced Diagnostics. However, items such as fuel level, plugged fuel lines, clogged fuel filters, and malfunctioning pressure regulators may not set a fault code and usually can be corrected with the basic troubleshooting steps described on the following pages.
Basic Troubleshooting Guide Customer Problem Analysis Sheet 1. Forklift Information (I) VIN: (II) ProductionDate: (III) Hour meter Reading: (hrs) 2.
4. Repair or replace the component that has a problem. Basic Inspection Procedure Measuring Condition Of Electronic Parts Resistance 5. Verify that the problem has disappeared with the road test. The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient temperature (20℃, 68 ℉), unless there is any notice. ● SIMULATING VIBRATION NOTE: The measured resistance in except for ambient temperature (20℃, 68℉) is reference value.
Connector Inspection Procedure Handling of Connector 4. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side. 1. Never pull on the wiring harness when disconnecting connectors. 5. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side. 2. When removing the connector with a lock, press or pull locking lever. NOTE: Use a fine wire to prevent damage to the terminal.
Wire Harness Inspection Procedure Checking Point for Connector 1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part. 1.
normal). To find exact break point, check sub line of line 1as described in next step. Electrical Circuit Inspection Procedure ● Check Open Circuit b. Disconnect connector (B), and measure for resis tance between connector (C) and (B1) and between (B2) and (A) as shown in [FIG.3]. In this case the measured resistance between connector (C) and (B1) is higher than 1㏁ and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). 1.
● Check Short Circuit b. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground as shown in [FIG.7]. 1. Test Method for Short to Ground Circuit • Continuity Check with Chassis Ground The measured resistance between connector (B1) and chassis groundis1Ω or less. The short to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). If short to ground circuit occurs as shown in [FIG.
Symptom Troubleshooting Guide Chart for MPI Gasoline Engine Engine Is Not Starting Engine Is Difficult To Start(Cranking OK) G420F(FE) Service Manual 255 Chapter 8.
Irregular Idling Or Engine Is Suddenly Stopped G420F(FE) Service Manual 256 Chapter 8.
Engine Hesitation Or Insuffient Accelelation G420F(FE) Service Manual 257 Chapter 8.
G420F(FE) Service Manual 258 Chapter 8.
Troubleshooting Guide for MPI Gasoline Engine • The following number represents inspection order. G420F(FE) Service Manual 259 Chapter 8.
G420F(FE) Service Manual 260 Chapter 8.
Basic Troubleshooting An intermittent “Service Engine Soon” light with no stored diagnostic code may be caused by: Intermittents • Ignition coil shortage to ground and arcing at spark plug wires or plugs An intermittent fault is the most difficult to troubleshoot since the MIL flashes on at random, causing uncertainty in the number of flashes or the conditions present at the time of the fault. Also, the problem may or may not fully turn “ON” the MIL light or store a code.
Surges and/or Stumbles Engine power varies under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the acceleration pedal. Preliminary Checks Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Be sure driver understands vehicle operation as explained in the operator manual.
Engine Cranking but Will Not Start / Difficult to Start Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies. Preliminary Checks Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Be sure driver is using correct method to start engine as explained in operator’s manual. Use “clear flood” mode during cranking by fully depressing the pedal and cranking the engine. If engine does not start, continue troubleshooting.
Engine Cranking but Will Not Start / Difficult to Start (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION SECM / control system malfunction Check Coolant Temperature Sensor using the Service Tool; compare coolant temperature with ambient temperature on cold engine. If coolant temperature reading is 5° greater than or less than ambient air temperature on a cold engine, check resistance in coolant sensor circuit or sensor itself. Compare CTS resistance value to “Diagnostic Aids” chart at end of this section.
Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During Acceleration Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part way. Momentary lack of response as the accelerator is pushed down. Can occur at all vehicle speeds. Usually most severe when first trying to make vehicle move, as from a stop. May cause engine to stall.
Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During Acceleration (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION Component malfunction Check SECM grounds for cleanliness and secure connection. See SECM wiring diagrams. Check alternator output voltage. Repair if less than 9 volts or more than 16 volts. Check for clogged air filter and clean or replace as required. Check exhaust system for possible restriction. Refer to Chart T-1 on later pages.
Detonation / Spark Knock A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with throttle opening (similar to the sound of hail striking a metal roof). PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. PROBABLE CAUSE CORRECTIVE ACTION Fuel system malfunction Check for proper fuel level: • Check for LPG vapor from LPG liquid outlet valve on tank. • Fill fuel container.
Backfire Fuel ignites in intake manifold or in exhaust system, making loud popping noise. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Simulate condition by reviewing operation procedure practiced by vehicle operator.
Rough, Unstable, Incorrect Idle, or Stalling Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies. PRELIMINARY CHECKS Perform the visual checks as described at start of “Basic Troubleshooting” chapter. Check for vacuum leaks. Check that SECM grounds are clean and tight. See SECM wiring diagram PROBABLE CAUSE CORRECTIVE ACTION Fuel system malfunction Monitor oxygen feedback to help identify the cause of the problem.
Rough, Unstable, Incorrect Idle, or Stalling (cont’d.) PROBABLE CAUSE CORRECTIVE ACTION Excess flow valve closed Reset excess flow valve. • Close liquid valve. • Wait for a “click” sound. Slowly open liquid valve. Clogged fuel filter Repair/replace as required See Chapter 4 Fuel Filter Replacement Plugged fuel line Remove obstruction from the fuel line. • Close liquid fuel valve. • Using caution, disconnect the fuel line (some propane may escape). • Clear obstruction with compressed air.
Cuts Out, Misses Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases, sometimes above 1500 rpm. The exhaust has a steady spitting sound at idle or low speed. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. PROBABLE CAUSE CORRECTIVE ACTION Fuel system malfunction Check fuel system specifically for plugged fuel filter, low pressure. Check for contaminated fuel. Check injector drivers.
Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell Fuel economy, as measured during normal operation, is noticeably lower than expected. Also, economy is noticeably lower than what it has been in the past. Propane fuel smell near vehicle sets off carbon monoxide sensors. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. Verify operator complaint: identify operating conditions.
High Idle Speed Engine idles above the range of 700-1000 rpm. PRELIMINARY CHECKS Perform the visual checks as described at start of “ Basic Troubleshooting” chapter. PROBABLE CAUSE Incorrect idle speed control Throttle sticking Foot pedal sticking or incorrect pedal signal Engine mechanical CORRECTIVE ACTION Check all hoses and gaskets for cracking, kinks, or leaks. Verify that there are no vacuum leaks. See Chapter 8 Advanced Diagnostics & Chapter 6 Tests and Adjustments Replace throttle.
Excessive Exhaust Emissions or Odors Vehicle has high CO emissions. NOTE: Excessive odors do not necessarily indicate excessive emissions. PRELIMINARY CHECKS Verify that no stored codes exist. If emission test shows excessive CO and HC, check items that cause vehicle to run rich. If emission test shows excessive NOx, check items that cause vehicle to run lean or too hot.
Diagnostic Aids for Rich / Lean Operation SERVICE TOOL ITEM RICH LEAN Pre-catalyst O2 A/ D counts Consistently > 250 Consistently < 170 Pre-catalyst O2 sensor switching between high and low Always high ADC Always low ADC Trim valve duty cycle > 90% < 10% Fuel injector pulse width at idle * < 1.0 msec > 8 msec.
4. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal damage, split welds, or cracked pipe. Chart T-1 Restricted Exhaust System Check Proper diagnosis for a restricted exhaust system is essential before replacement of any components. The following procedures may be used for diagnosis, depending upon engine or tool used. 5.
Chapter 9. ADVANCED DIAGNOSTICS MI-07 systems are equipped with built-in fault diagnostics. Detected system faults can be displayed by the Malfunction Indicator Lamp (MIL) as Diagnostic Fault Codes (DFC) or flash codes, and viewed in detail with the use of the Service Tool software. When the ignition key is turned on, the MIL will illuminate and remain on until the engine is started. Once the engine is started, the MIL lamp will go out unless one or more fault conditions are present.
Fault Action Descriptions Fault List Definitions Each fault detected by the SECM is stored in memory (FIFO) and has a specific action or result that takes place. Listed below are the descriptions of each fault action. All the analog sensors in the MI-07 system have input sensor range faults. These are the coolant temperature sensor, fuel temperature sensor, throttle position sensors, pedal position sensors, manifold pressure sensor, HEGO sensors, and intake air temperature sensor.
Table 1.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) ECTRangeLow Engine Coolant Temperature Sensor Input is Low. Normally set if the coolant sensor wire has shorted to chassis ground or the sensor has failed.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) EST7_Short EST7 output shorted high or low, EST7 signal shorted to ground or power or defective spark module 437 EST8_Open EST8 output open, possibly open EST8 signal or defective spark module 428 EST8_Short EST8 output shorted high or low, EST8 signal shorted to ground or power or defective spark module 438 FAULT ETCSpringTest Electronic Throttle Control Spring Return Test has Failed.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) FuelTempRangeLow Fuel Temperature Sensor Input is Low. Normally set if the fuel temperature sensor wire has shorted to chassis ground or the sensor has failed.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) HbridgeFault_ETC (Electronic Throttle Control Driver has Failed) Indeterminate fault on Hbridge driver for Electronic Throttle Control.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) Post-catalyst O2 sensor control on gasoline has sensed the O2 sensor is not responding as expected. If any Pre-O2 sensor faults are set, diagnose these first and after correcting these faults recheck if this fault sets. Possible causes for this fault are sensor disconnected, sensor heater failed, sensor element failed, heater relay, or SECM control of heater relay is disconnected or failed.
Table 1. Fault List Definitions (cont’d.
Table 1. Fault List Definitions (cont’d.) DESCRIPTION CODE (MI04 CODE) TPS2 sensor voltage out of range low, normally set if TPS2 signal has shorted to ground, circuit has opened or sensor has failed 222 FAULT TPS2RangeLow TPS sensors differ by more than expected amount. TPS_Sensors_Conflict TransOilTemp NOTE: The TPS is not a serviceable item and can only be repaired by replacing the DV-EV throttle assembly Excessive transmission oil temperature G420F(FE) Service Manual 288 291 933 Chapter 9.
Table 2.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT 161 (16) ECTOverTempFault Engine coolant temperature is high. The sensor has measured an excessive coolant temperature typically due to the engine overheating.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * 341 (34) MAPTimeRangeHigh Manifold Absolute Pressure Sensor Input is High, normally set if the TMAP pressure signal wire has become shorted to power, shorted to the IAT signal, the TMAP has failed or the SECM has failed.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT ACTION * CORRECTIVE ACTION, FIRST CHECK 381 (38) IATRangeHigh Intake Air Temperature Sensor Input is High normally set if the IAT temperature sensor wire has been disconnected or the circuit has opened to the SECM.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT ACTION * CORRECTIVE ACTION FIRST CHECK 424 EST4_Open EST4 output open, possibly open EST4 signal or defective spark module TurnOnMil Check coil driver wiring and connector for open circuit SECM Pin A6 (EST4) to OEM ignition system. See application manual. Verify GND on ignition module Pin A (of both connectors) Verify +12 Vdc on ignition module Pin B (of both connectors) Refer to application manual for specific engine details.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT ACTION * CORRECTIVE ACTION FIRST CHECK TurnOnMil Check coil driver wiring and connector for shorts SECM Pin A10 (EST2) to ignition module Pin D (4-pin connector) Verify GND on ignition module Pin A (of both connectors) Verify +12 Vdc on ignition module Pin B (of both connectors) Refer to application manual for specific engine details.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC 437 438 PROBABLE FAULT EST7_Short EST7 output shorted high or low, EST7 signal shorted to ground or power or defective spark module EST8_Short EST8 output shorted high or low, EST8 signal shorted to ground or power or defective spark module FAULT ACTION * CORRECTIVE ACTION FIRST CHECK None N/A None N/A 461 (26) ETC_Sticking Electronic Throttle Control is sticking.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT 491 (29) HbridgeFault_ETC Electronic Throttle Control Driver has failed. Indeterminate fault on Hbridge driver for electronic throttle control.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTION * CORRECTIVE ACTION FIRST CHECK 731 (73) GasFuelAdaptRangeHi In LPG mode, system had to adapt lean more than expected TurnOnMil Check fuel trim valves, e.g. plugged valve or hose. Check for plugged orifice(s).
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT 842 LiqPostO2NotActive Post-catalyst O2 sensor inactive on gasoline, open O2 sensor signal or heater leads, defective O2 sensor. 843 Reserved 851 LiqO2FailedLean Pre-catalyst O2 sensor indicates extended lean operation on gasoline FAULT ACTION * (1) TurnOnMil (2) DisableLiqPost O2Ctrl CORRECTIVE ACTION FIRST CHECK Check that Post-catalyst O2 sensor connections are OK.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. FAULT ACTION * CORRECTIVE ACTION FIRST CHECK DFC PROBABLE FAULT 911 O2RangeLow Pre-catalyst O2 sensor voltage out of range low, sensor signal shorted to ground (1) TurnOnMil (2) DisableLiquid O2Ctrl (3) DisableGas O2Ctrl Check if O2 sensor installed before the catalyst is shorted to GND or sensor GND.
Table 2. Diagnostic Fault Codes (Flash Codes) cont’d.
Appendix Service Tool Software (MotoView) Service Tool Software Kit Service tool software kit consists of USB-CAN converter, Service tool software (MotoView) and Extension cable.
Service Tool Connection to SECM Communications to the SECM from the Service Tool is through a CAN port using a two wire connection. High-speed CAN reaches 1Mbps and is used for engine control and power-train applications.
Parameters specific to Air/Fuel Ratio Control are displayed in the AFR block. Service Tool Display Service Tool Display consists of Service Screen, Fault Screen, Ground speed select option, Fault list and Override screen. Service Screen Key parameters of a running engine are grouped together for easy reference in the ENGINE block.
Fault Screen Active faults are displayed as they are occurring.
Ground Speed Select Option Speed Limits are set by entering RPM values in the red boxes Values are restricted by Upper and Lower Limits G420F(FE) Service Manual 311 Appendix
Fault List A FAULT LIST screen provides a complete list of faults including Fault Codes with monitored parameters so the technician does not have to refer to the manual for fault descriptions or codes while using the service tool.
Override Screen 1. Click on the Manual Value for the component. 2. Enter a new manual value that will be used when manually overriding the component. 3. Click the Override Select box for the component 4. Select “Pass-Through” for normal operation or “Override” to manually control the component. WARNING Be aware of fuel flow and ignition during manual mode or engine damage may result.
SECM field update with Service Tool SECM controllers can be upgraded in the field using MotoUpdate software. Typically, MotoUpdate and MotoViewer applications are packaged together in the MotoService software application. Software upgrade files may be released to the field to enhance performance, provide additional features, and/or correct software problems. This document provides step-by-step instructions for upgrading a SECM using MotoUpdate software.
STEP 2 - CONNECT THE COMPUTER Prior to launching the MotoUpdate software, a valid Criptoken must be installed in one of the available USB ports on the update computer. A second available USB port will be used by the USB to CAN converter. The USB to CAN coverter must then be connected to the SECM. (A USB hub must be used with computers that do not have two USB ports). STEP 3 - LAUNCH THE MOTOUPDATE APPLICATION Launch the MotoUpdate application. You will see a Welcome scree.
The next screen will provide a list of all of the available software upgrades available for the current engine, based upon what update files have been placed in the “Update” directory (as shown in Step-1 above). Please note that during this process, the software must query the SECM for the current software version, and therefore, the computer must be connected to the SECM and the ignition key must be in the ON position. In general, it is usually best to see the latest revision (e.g.
STEP 4 - PROGRAM THE MODULE Once the desired upgrade is located and highlighted, select Next to upgrade ithe module. Highlight the upgrade option desired, then select Next Follow the on-screen instructions to complete the update process. Once the programming process begins, it must run to completion. If power is interrupted or the process fails, the SECM may be rendered unusable. Several update screens will provide a running status of the upgrade process, as shown below.
Ground Speed Limits (Option) The maximum allowable speed of Doosan forklifts is an optional feature that can be easily activated using the MotoView service tool. This feature is very useful to customers with indoor warehouse operations. Here’s how you can activate the speed-limiting feature. 1) Install Speed control option onto the trucks 2) Set the new speed limit using the MotoView Service tool, if required.
How to Set New Speed Limit Maximum RPM for both the NEUTRAL state (Normal) and IN-GEAR state (Speed Limiting) are configurable using the MotoView Service Tool. [Figure 2] Ground Speed Select Screen of the MotoView Service Tool [Figure 2] shows the Speed Limit screen of the MotoView service tool. The green boxes are configurable for both the NEUTRAL MAX RPM Setpoint and the IN-GEAR MAX RPM Setpoint. The pressure switch state is displayed at the bottom of the screen and labeled NEUTRAL SWITCH STATE.
The same principle is applied to LPG in a container, commonly referred to as an LPG tank or cylinder. Typically an LPG tank is not filled over 80% capacity allowing for a 20% vapor expansion space. Outside air temperature effect’s an LPG tank and must be considered when using an LPG system. (Figure 2) shows the relationship between pressure and temperature in a LPG tank at a steady state condition.
LPG Fuel Tanks Installing LPG Fuel Tanks The two styles of LPG storage containers available for industrial use and lift truck applications are portable universal cylinders and permanently mounted tanks. Portable universal cylinders are used primarily for off-highway vehicles and are constructed in accordance with the DOT-TC (United States Department of Transport – Transport Canada).
Fuel Gauge Service Valve In figure 5 a visual fuel gauge is used to show the fuel level in the tank. A mechanical float mechanism detects the liquid propane level. A magnet on the end of the float shaft moves a magnetic pointer in the fuel gauge. Some units have an electronic sending unit using a variable resistor, installed in place of a gauge for remote monitoring of the fuel level. The gauge may be changed with fuel in the tank.
Most liquid service valves have an internal hydrostatic relief valve and are usually labeled “LIQUID WITH INTERNAL RELIEF”. The hydrostatic relief valve protects the fuel service line between the tank and the lock off from over pressurization. The internal hydrostatic relief valve has a minimum opening pressure of 375 PSIG and a maximum pressure of 500 PSIG.
Regulatory Compliance WARNING—EXPLOSION HAZARD EPA / CARB Emissions Certification Do not connect or disconnect while circuit is live unless area is known to be non-hazardous. When properly applied and calibrated, ’s MI-07 control system is capable of meeting EPA 2007 LSI emission standards (40 CFR Part 1048.101) when operating properly with an approved three-way catalyst.
Abbreviations ACFM Actual cubic feet per minute at the specified suction conditions AFR Air fuel ratio BHP Brake horsepower Bi-Fuel Able to operate on either of two fuels CTS Coolant temperature sensor CNG Compressed natural gas Dual Fuel Able to run simultaneously on two fuels, e.g. diesel and natural gas. Often this term is incorrectly used to describe bi-fuel operation. Spark-ignited engines are typically bi-fuel while compression ignition engines are dual-fuel.
