Professional Documents
Culture Documents
D (G) 15S, 18S, 20SC-5 Sb4239e
D (G) 15S, 18S, 20SC-5 Sb4239e
form SB4239E
sb4240e04
Jul. 2014
NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers are listed with mark(*), they are not available for the initial
release of the manual. When items are updated, or supplements are added,
they will be provided separately.
ENGINE
POWER TRAIN
VEHICLE SYSTEM
SAFETY
WARNING WARNING
The proper and safe lubrication and Do not operate this machine unless you have
maintenance for this machine, recommended read and understand the instructions in the
by DOOSAN, are outlined in the OPERATION OPERATOR'S GUIDE. Improper machine
& MAINTENANCE GUIDE for this machine. operation is dangerous and could result in
injury or death.
Improper performance of lubrication or
maintenance procedures is dangerous and 5. Use steps and grab handles (if applicable) when
could result in injury or death. Read and mounting or dismounting a machine. Clean any
understand the OPERATION & mud or debris from steps, walkways or work
MAINTENANCE GUIDE before performing any platforms before using. Always face machine when
lubrication or maintenance. using steps, ladders and walkways. When it is not
possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
The service man or mechanic may be unfamiliar perform safe repair operations.
with many of the systems on this machine. This
makes it important to use caution when performing 6. To avoid back injury, use a hoist when lifting
service work. A knowledge of the system and/or components which weigh 23 kg (50 lb.) or more.
components is important before the removal or Make sure all chains, hooks, slings, etc., are in
disassembly of any component. good condition and are of the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes are
Because of the size of some of the machine not to be side loaded during a lifting operation.
components, the serviceman or mechanic should
check the weights noted in this Manual, Use proper 7. To avoid burns, be alert for hot parts on machines
lifting procedures when removing any components. which have just been stopped and hot fluids in lines,
tubes and compartments.
Following is a list of basic precautions that should
always be observed.
8. Be careful when removing cover plates. Gradually
1. Read and understand all Warning plates and back off the last two bolts or nuts located at
decals on the machine before operating, opposite ends of the cover or device and pry cover
lubricating or repairing the product. loose to relieve any spring or other pressure, before
removing the last two bolts or nuts completely.
2. Always wear protective glasses and protective
shoes when working around machines. In 9. Be careful when removing filler caps, breathers and
particular, wear protective glasses when plugs on the machine. Hold a rag over the cap or
pounding on any part of the machine or its plug to prevent being sprayed or splashed by
attachments with a hammer or sledge. Use liquids under pressure. The danger is even greater
welders gloves, hood/goggles, apron and other if the machine has just been stopped because fluids
protective clothing appropriate to the welding job can be hot.
being performed. Do not wear loose-fitting or torn
clothing. Remove all rings from fingers when 10. Always use tools that are in good condition and be
working on machinery. sure you understand how to use them before
performing any service work.
3. Do not work on any machine that is supported
only by lift jacks or a hoist. Always use blocks or 11. Reinstall all fasteners with same part number. Do
jack stands to support the machine before not use a lesser quality fastener if replacements
performing any disassembly. are necessary. Do not mix metric fasteners with
standard nuts and bolts.
4. Lower the forks or other implements to the
ground before performing any work on the
12. If possible, make all repairs with the machine
machine. If this cannot be done, make sure the
forks or other implements are blocked correctly parked on a level, hard surface. Block machine so
to prevent them from dropping unexpectedly. it does not roll while working on or under machine.
1 of 2
13. Disconnect battery and discharge any capacitors 21. Do not operate a machine if any rotating part is
(electric trucks) before starting to work on damaged or contacts any other part during
machine. Hang "Do Not Operate" tag in the operation. Any high speed rotating component
Operator's Compartment. that has been damaged or altered should be
checked for balance before reusing.
14. Repairs, which require welding, should be
performed only with the benefit of the appropriate 22. On LP equipped lift trucks, be sure to close the
reference information and by personnel valve on the LP tank before service work is
adequately trained and knowledgeable in welding performed. Always close the valve on the LP
procedures. Determine type of metal being tank when the lift truck is being stored. Do not
welded and select correct welding procedure and check for LP leaks with an open flame.
electrodes, rods or wire to provide a weld metal
strength equivalent at least to that of parent 23. Caution should be used to avoid breathing dust
metal. that may be generated when handling
components containing asbestos fibers. If this
15. Do not damage wiring during removal operations. dust is inhaled, it can be hazardous to your
Reinstall the wiring so it is not damaged nor will it health. Components in DOOSAN products that
be damaged in operation by contacting sharp may contain asbestos fibers are brake pads,
corners, or by rubbing against some object or hot brake band and lining assemblies, clutch plates
surface. Do not connect wiring to a line and some gaskets. The asbestos used in these
containing fluid. components is usually bound in a resin or sealed
in some way. Normal handling is not hazardous
16. Be sure all protective devices including guards as long as airborne dust which contains asbestos
and shields are properly installed and functioning is not generated.
correctly before starting a repair. If a guard or
shield must be removed to perform the repair If dust which may contain asbestos is present, there
work, use extra caution. are several common sense guidelines that should be
followed.
17. Always support the mast and carriage to keep
carriage or attachments raised when a. Never use compressed air for cleaning.
maintenance or repair work is performed, which
requires the mast in the raised position. b. Avoid brushing or grinding of asbestos containing
materials.
18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not c. For clean up, use wet methods or a vacuum
bend or strike high pressure lines or install ones equipped with a high efficiency particulate air
which have been bent or damaged. Inspect lines, (HEPA) filter.
tubes and hoses carefully. Do not check for leaks
with your hands. Pin hole (very small) leaks can d. Use exhaust ventilation on permanent machining
result in a high velocity oil stream that will be jobs.
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use e. Wear an approved respirator if there is no other
cardboard or paper to locate pin hole leaks. way to control the dust.
19. Tighten connections to the correct torque. Make f. Comply with applicable rules and regulations for
sure that all heat shields, clamps and guards are the work place (for example in the U.S.A., OSHA
installed correctly to avoid excessive heat, requirements as set forth in 29 CFR 1910. 1001).
vibration or rubbing against other parts during
operation. Shields that protect against oil spray g. Follow environmental rules and regulations for
onto hot exhaust components in event of a line, disposal of asbestos.
tube or seal failure must be installed correctly.
h. Avoid areas where asbestos particles may be in
20. Relieve all pressure in air, oil or water systems the air.
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
2 of 2
SB2004E00
Dec.1998
Specifications
TORQUE
SPECIFICATIONS
STANDARD TORQUE FOR METRIC FASTENERS
NOTE : Take care to avoid mixing metric and inch dimensioned fasteners.
Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or
possible injury. Exceptions to these torques are given in the Service Manual where
needed.
NOTE : Prior to installation of any hardware, be sure components are in near new
condition. Bolt and nut threads must not be worn or damaged. Hardware must be
free of rust and corrosion. Clean hardware with a non-corrosive cleaner and apply
engine oil to threads and bearing face. If thread lock or other compounds are to be
applied, do not apply engine oil.
1 of 7
STANDARD TORQUE FOR INCH FASTENERS
2 of 7
O-RING FACE SEAL FITTINGS
3 of 7
FITTING INSTALLATION
HYDRAULIC LINE INSTALLATION 1. Put locknut (3), backup washer (4) and O-ring seal
(5) as far back on fitting body (2) as possible. Hold
these components in this position. Turn the fitting
1. For a metal tube to hose installation, install the tube into the part it is used on until backup washer (4) just
and tighten all bolts finger tight. makes contact with the face of the part it is used on.
2. Tighten the bolts at the rigid end. 2.To put the fitting assembly in its correct position, turn
3. Install the hose and tighten all bolts finger tight. the fitting body (2) out (counterclockwise) a
maximum of 359û. Tighten locknut (3) to the torque
4. Put the hose in a position so that it does not make shown in the correct chart for the fitting used.
contact with the machine or another hose.
NOTE: If the fitting is a connector (straight fitting), the
5. Tighten the bolts on both connections. hex on the body takes the place of the locknut. To
6. Start the engine. install this type fitting, tighten the hex against the face
of the part it goes into.
7. Move the implement control levers to all positions.
8. Look at the hose during movement of the
implement. Make sure hose is not in contact with TORQUES FOR FLARED AND O-RING FITTINGS
the machine or other hoses.
The torques shown in the charts that follow are to be
9. Shut off the engine.
used on the nut part of 37û Flared, 45û Flared and
10. If necessary, put the hose in a new position where it Inverted Flared fittings (when used with steel tubing),
will not make contact when the implement is moved. O-ring plugs, O-ring fittings and swivel nuts when
used in applications to 3000 psi (20 700 kPa).
2
1 IDAS003B
4 of 7
37û FLARED AND STRAIGHT THREAD O-RING FITTINGS
Hi Seal Fittings
Put nut and sleeve over the tubing with the short
heavy end of the sleeve facing the end of tubing. Put
the tube end against the counterbore in the body of
the fitting and tighten until nut is over the last thread IDAS006B
on the body. The remainder of space is used
whenever the fitting is removed and installed again.
5 of 7
45û FLARED AND 45û INVERTED FLARE FITTINGS
INVERTED
45û FLARED 45û FLARED
IDAS007B
Flex Fittings
Put nut and sleeve over the tubing and push tube in
to counterbore of fitting body as far as possible.
Tighten the nut until it is against the hex part of the
fitting body.
IDAS009B
6 of 7
AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS
IDAS010B
7 of 7
SB4106E01
Oct.2003
Service Manual
A2300 Diesel Engine
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section or the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this
publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.
1
Index
The left column of the charts indicates a probable cause. The right column provides a brief description of the
corrective action with a reference to the repair procedure or diagnostic discussion when appropriate.
If the problem occurs with a new engine or after repair of the engine, the diagnostics discussion for each major
system will provide guidance for sorting out the cause of the problem.
Warning – Serious personal injury or extensive property damage can result if the warning
instructions are not followed.
Causion – Minor personal injury can result or a part, an assembly or the engine can be
damaged if the caution instructions are not followed.
The component weighs 23kg [50lb] or more. To avoid personal injury, use a hoist or get
assistance to lift the component.
INSPECTION is required.
Refer to another location in this manual or another publication for additional information.
Check Examine a component or system for damage, excessive wear, accuracy, safety, or
performance.
Inspect Examine a component or dimension to make sure it meets the required specifications.
Adjust Complete the necessary steps to set or adjust the component, assemblies, or system in
the required setting or position.
Note Only the easiest and simplest repairs will be made to a component or assembly. If a
component or assembly must be rebuilt; it must be replaced with a new or Cummins
Diesel Recon, Inc. replacement or be rebuilt at a Cummins authorized repair location.
Replace Install a new, properly rebuilt, or Cummins Diesel Recon, Inc. component or assembly
in place of one which is removed.
Star Pattern
Torque
Sequence
Unacceptable
Acceptable
Direction of Movement
(Action)
The illustrations used in the Replacement Sections are intended to show replacement procedures when the engine
is installed in a chassis. The illustration may differ from your application, but the procedure given will be the same.
Engine Diagrams
A schematic of each of the major engine systems is provided at the beginning of the section of the manual devoted
to troubleshooting and repairing that particular system.
The diagrams depict flow through the various engine systems. The information and configuration of the
components illustrated in the drawings are of a general nature. Some items for specific applications and
installations may be different.
Each Section also contains a discussion regarding diagnosing malfunctions for that specific system.
Knowledge of the systems can help you troubleshoot and repair the engine.
Be sure to consider any maintenance or repair action that could have caused the problem.
If the engine surges or runs rough initially after not being used for 2 months or more, do not assume that the
engine has a malfunction. Varnish can form on the internal parts of the injection pump and the oil film can drain
from the piston rings. Operate the engine for at least 5 minutes before troubleshooting.
36 Coolant Loss
46 Compression Knocks
43 Contaminated Coolant
49 Excessive Vibration
26 Low Power
OK
OK
OK
OK
OK
OK
OK
Injection Pump Not Getting Fuel or Check Fuel Flow/Bleed Fuel System.
Fuel is Aerated Refer to Page 83
OK
OK
OK
Cold Starting Aids Not Working or Verify the Aids are Operating. Refer
Are Needed To O&M Manual.
OK
OK
OK
(Continued)
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
Idle Speed Too Low for the Check/Adjust Low Idle Screw.
Accessories Refer to Page 73
OK
OK
OK
OK
(Continued)
OK
Cause Correction
OK
OK
OK
Check/Time Pump.
Injection Pump Timing Incorrect
Refer to Page 77
OK
OK
(Continued)
OK
OK
OK
Inspect Camshaft.
Damaged Camshaft or Tappets
Refer to Page 182
OK
OK
OK
High Speed Stop Screw Incorrectly Check/Set High Speed Stop Screw.
Adjusted Refer to Page 74, 225
OK
OK
(Continued)
Cause Correction
OK
Replace Pump.
Malfunctioning Injection Pump
Refer to Page 94
OK
OK
OK
Incorrect External Injection Pump Verify Pump Timing Marks are Aligned.
Timing Refer to Page 77, 96
OK
(Continued)
OK
OK
OK
OK
OK
(Continued)
OK
OK
Inspect/Replace Turbocharger.
Malfunctioning Turbocharger
Refer to Page 101, 105, 109
OK
OK
OK
(Continued)
OK
OK
OK
OK
OK
Inspect/Replace Turbocharger.
Malfunctioning Turbocharger
Refer to Page 101
OK
OK
Replace Injectors.
Malfunctioning Injectors
Refer to Page 88
OK
(Continued)
OK
OK
OK
OK
Check/Replace Hose.
Collapsed Radiator Hose
Refer to Page 58
OK
(Continued)
OK
OK
OK
OK
OK
Incorrect External Injection Pump Verify Pump Timing Marks are Aligned.
Timing Refer to Page 77, 83
OK
OK
(Continued)
OK
OK
OK
OK
OK
OK
If Equipped with a Water Cooled Look for Coolant in the Oil. Check/Replace
Air Compressor, Leaking Head or Head or Gasket. Refer to the Equipment
Head Gasket Manufacturer’s Procedures.
OK
(Continued)
OK
OK
OK
OK
Check/Replace Valve.
Relief Valve Stuck Open
Refer to Page 116
OK
(Continued)
Cause Correction
OK
OK
OK
OK
OK
OK
Check/Replace Valve.
Relief Valve Stuck Closed
Refer to Page 116
OK
OK
Incorrect Oil
Make Sure the Correct Oil is Being Used.
(Specification or Viscosity)
OK
OK
OK
(Continued)
OK
OK
OK
OK
OK
Oil Leaks from Oil Cooler, Head Refer to Troubleshooting Logic for
Gasket, Head and Cylinder Block Lube Oil Loss.
OK
OK
OK
OK
OK
OK
Check/Replace Turbocharger.
Turbocharger Seals Leaking Oil
Refer to Page 102
Cause Correction
OK
OK
OK
OK
Replace Injectors.
Malfunctioning Injectors
Refer to Page 88.
Cause Correction
OK
OK
OK
OK
OK
Check/Replace Injectors.
Worn or Malfunctioning Injectors
Refer to Page 88.
OK
Check/Adjust Valves.
Valves Not Seating
Refer to Page 179
OK
OK
(Continued)
OK
Engine Running on Fumes Drawn Check the Air Intake Ducts for Source of
into the Air Intake the Fumes.
OK
OK
OK
OK
OK
OK
(Continued)
Cause Correction
OK
Drive Belt Squeal, Insufficient Check the Tensioner and Inspect the Drive
Tension or Abnormally High Belt. Make Sure Water Pump, Tensioner
Loading Pulley, Fan Hub and Alternator Turn Freely.
OK
OK
OK
OK
OK
OK
OK
Replace Alternator.
Malfunctioning Alternator
Refer to Page 144
As the coolant flows across the head toward the 1. Radiator. 2. Thermostat. 3. Water Temperature Gauge. 4.
thermostat housing, it provides cooling for the injector Water Pump. 5. Water Manifold. 6. Cylinder Head
nozzle. When the engine is below operating 7. Piston. 8. Cylinder Block. 9. Oil Cooler (Optional).
temperature, the thermostat is closed, and the A. From Oil Pump (Oil)
coolant flow bypasses the radiator and goes to the
water pump inlet via internal drillings in the block and
cylinder head.
Pressure Caps
The system is designed to use a pressure cap to
prevent boiling of the coolant.
Different caps are specified for the two recommended
systems:
System Cap
A- 104 °C [220°F] 103kPa [15 PSI]
B- 99 °C [210°F] 48kPa [7 PSI]
Thermostat
The thermostat controls the coolant temperature.
When the coolant temperature is below the operating
range, coolant is bypassed back to the inlet of the
water pump.
When the coolant temperature reaches the operating
range, the thermostat opens, sealing off the bypass,
forcing coolant to flow to the radiator.
12mm
Remove the capscrew and replace the tensioner.
Torque Valve: 25.5 Nm [19ft-lbs]
12mm
Remove the four capscrews and replace the fan
hub.
Torque Valve: 25.5 Nm [19ft-lbs]
Coolant – Draining
The coolant is 50% mixture of water and ethylene-
glycol base antifreeze; a 20 liter (4 U.S. gallons)
drain pan will contain the coolant in most
applications.
12mm
Remove the four capscrews and water pump, and
complete the following steps.
Thermostat - Replacement
Preparatory Steps:
z Drain the coolant.
z Remove the drive belt.
z Disconnect negative battery cable.
z Disconnect the upper radiator hose.
12mm
14mm
Remove the alternator mounting capscrew and lower
the alternator.
Torque Valve:
(Alternator Link) 25.5 Nm [19 ft-lbs]
(Alternator Mounting) 49Nm [37 ft-lbs]
(Thermostat Mounting) 25.5 Nm [19 ft-lbs]
The most usual place for air to enter the fuel system
is between the inlet of the lift pump and the suction
tube in the tank. Fuel tanks that have the outlet fitting
at the top will have a suction tube that extends down
in the tank.
Cracks or pin holes in the weld that joins the tube to
the fitting can let air enter the fuel system.
Governor Malfunctions
Balance between the flyweight governor and control
lever position controls the metering of the amount of
fuel to be injected.
The pump governor performance and setting can
affect engine power. Special equipment and qualified
personnel are required to verify governor
performance. If the seals are broken on the external
Robert Bosch VE adjustment screw, the fuel rate
may be out of adjustment.
A
VE Pump Adjustment Screws
B A – Idle Screw
B – High Idle Screw
Robert Bosch
Resistance Peak
Shut Down
Ohms Amperes
Values
Bleed the air from the high pressure line at the fitting
that connects the injector. Bleed one line at a time
until the engine runs smooth.
If the air cannot be removed, check the pump and
supply line for suction leaks.
Injectors
Caution: Use only the specified injector for the
engine.
Install the filter(s) and tighten it 1/2 turn after its seal
contacts the filter head.
10mm
Assemble the lines in the reverse order of removal.
Torque Value: 11Nm [8 ft-lbs]
Start the engine and vent one line at a time until the
engine runs smoothly.
17mm
Remove the head cap nuts.
17mm
Assemble the high pressure fuel line and fuel drain
manifold in the reverse order of disassembly.
Torque Value: 49Nm [37 ft-lbs]
Hit the injector body with the drift pin to loosen any
rust.
17mm
24mm
Tighten the solenoid securely.
Connect the electric wire.
Torque Value: 20 Nm [15 ft-lbs]
14mm
Remove the delivery valve holder and sealing
washer.
14mm
Tighten the holder to 49 Nm [37 ft-lbs].
17mm
Start the engine and vent one line at a time until the
engine runs smoothly.
12mm
Remove the retaining nuts on the fuel injection pump
mounting on the rear of the gear housing.
Remove the access cover and gasket from the front
of the gear housing.
Rotate the engine to line up the “B” mark on the fuel
pump gear to the “B” mark on the idler gear. This can
take a number of crankshaft revolutions to
accomplish
17mm.
Remove the nut from the fuel injection pump shaft
inside the housing.
Remove the fuel injection pump support bracket and
mounting capscrews.
Remove the gear with a gear puller.
If the gear housing is in place, use the arms of the
puller to push against the inside front of the housing
and force the pump shaft rearward out of the gear.
12mm
Remove the fuel injection pump.
12mm
Align the shaft key to the gear keyway and install the
fuel injection pump on the rear of the gear housing.
17mm
Install the gear, washer, and nut on the fuel injection
pump shaft. Tighten the nut.
Torque Value : 88 n.m [65 ft-lb ]
12mm
Install the access cover. Tighten the cover
capscrews.
Torque Value : 26 n.m [19 ft-lb ]
12mm
12mm
Re-rating
The pump governor performance and setting can
affect engine power. Special equipment and qualified
personnel are required to verify governor
performance. The fuel rate change is not allowed
Exhaust System
1. Exhaust valve port. 2. Exhaust manifold
3. Turbocharger turbine
Exhaust Restriction at Rated Speed and Load – kPa [mmAq] 7.65 [780]
Debris drawn into the air suction side can damage the
compressor blades causing and imbalance resulting in
a bearing failure.
To verify a bearing failure or damaged compressor,
remove the intake and exhaust piping and check for
contact. The rotor assembly must rotate freely.
Measurement of axial and radial clearance is
described in this Section.
Malfunctioning Turbocharger
Failure of the internal components of the turbocharger
can reduce its effectiveness and also cause excess
smoke and low power. A bearing failure can produce
friction which will slow the speed of the rotor assembly.
Failed bearings can also allow the blades of the rotor
assembly to rub the housings, thus reducing the rotor
assembly speed.
Turbocharger Noise
It is normal for the turbocharger to emit a “whine”
sound that varies in intensity depending on engine
speed and load. The sound is caused by the very high
rotational speed of the rotor assembly. Consequently,
the sound will be more audible at full speed.
Note: If possible, operate the engine at full speed to
verify the noise level.
12mm
Install the gasket and cover.
Torque Value : 25.5Nm [19 ft-lbs]
10mm
Remove the oil drain tube capscrews and complete the
following steps.
14mm
Remove the oil supply line.
12mm
Use a new gasket and connect drain line.
Torque Value : 25.5Nm [19 ft-lbs]
14mm
Install the oil supply line.
After installing the air intake and exhaust piping,
operate the engine to check for leaks.
12mm
Remove the manifold and gasket.
12mm
Install the manifold and gaskets.
Torque Value : 25.5Nm [19 ft-lbs]
Follow the sequence shown in the illustration.
Lubricating System Flow The engine use trochoid type oil pumps (1). The
machined cavity in the block is the same for all
engines.
Oil Filters
After the oil is cooled, it flows through the full flow oil filter.
Oil Level
Low oil level can cause low oil pressure.
Caution: Never operate the engine with the oil level
below the low (L) mark.
Oil Gauge
Check the oil gauge and sending unit to make sure
they are operating correctly by verifying the pressure
with a manual gauge.
Oil Dilution
Caution: Diluted oil can cause severe engine damage.
Oil Leaks
Various gaskets, seals and plugs are used to contain
the oil. Most leaks can be identified during routine
inspection of the engine and vehicle.
12mm
17mm
Install the drain plug.
Torque Value: 78 Nm [59 ft-lbs]
Fill the engine with oil. Run the engine and check for
leaks.
Stop the engine and check the oil level with the
dipstick.
12mm
Remove the front cover.
Backlash Limits
A
0.11 to 0.19mm
[0.0043 to 0.0075 inch
12mm
Install the front cover and gasket.
19mm
Torque Value : 113Nm [98 ft-lbs]
Fill the engine with oil. Run the engine and check for
leaks.
Stop the engine and check the oil level with the
dipstick.
12mm
Remove the battery cable from the solenoid.
17mm
Remove the starting motor.
Install the starting motor in the reverse order of
removal.
Torque Value : 78Nm [59 ft-lbs]
Alternator - Replacement
Preparatory Steps:
z Disconnect the ground cable from the
battery terminal.
z Remove the drive belt from the alternator
pulley.
14mm
Remove the alternator mounting nuts.
12mm, 14mm
Install the alternator by tightening the 12mm bolts
before the 14mm bolts. Reconnect all wires.
24mm
Torque Value :
(Installed into Cast Iron)
16Nm [12 ft-lbs]
17mm
Remove the temperature sensor.
17mm
Apply liquid Teflon sealant to the threads when
installing the temperature sensor.
Reconnect the wiring.
Torque Value:
(Installed into Aluminum)
39Nm [29 ft-lbs]
Definition
For the purpose of this manual, Base Engine
Components are defined as mechanical functions not
included in the other major engine systems. The
components include:
z Valve Train and Cylinder Gear Head
z Front Gear Housing and Gear Train
z Camshaft, Tappets and Push Rods
z Piston and Connecting Rod Assemblies
z Crankshaft and Main Bearings
z Cylinder Block
The ball end of the push rod fits into a ball socket in
the tappet.
The other end of the push rod is fitted with a socket
into which the ball end of the rocker lever adjusting
screw operates.
The piston ring sets are also different. While both sets
consist of three rings; two compression rings and one
oil ring.
Oversize service rod bearings are available for use with re-
ground crankshafts.
Cylinder Block
We have discussed the cylinder block relative to cooling and lubrication in those respective systems. We have also
discussed the interfaces of some of the above power functions with the block. This discussion will cover the
remaining interfaces including the cylinder bores.
Mark
Cylinder block L
M
S
Cylinder Liner L
M
S
Valve Sealing
If the compression is low on one or more non-
adjacent cylinders and the pressure cannot be
increased by oiling the rings, poor valve sealing is
to be suspected.
Cylinder Block
Diagnosis of cylinder block malfunctions relative to
cooling and lubrication has been discussed in those
respective systems.
The potential problems with cylinder, the camshaft
bore and the crankshaft main journals have also been
discussed in this Section.
Valve Clearance
z - Intake 0.3mm [0.012 in]
z - Exhaust 0.3mm [0.012 in]
Gear Train
z Gear Backlash
Crankshaft, Injection pump drive, camshaft:
0.07 to 0.15mm [0,0027 to 0.006 in]
Oil pump:
0.11 to 0.119mm [0,0043 to 0.0075 in]
Camshaft
z Journal Diameter
44.964 to 44.95 mm [1.7702 to 1.7697 in]
Worn Limit: 44.89 mm [1.767 in]
z Valve Lobes
Standard: 37. 935 to 38.065 mm
[1.4935 to 1.4986 in]
Worn Limit: 37.83 mm [1.4893 in]
Tappets
z Stem Diameter
Standard: 14.238 to 14.210 mm
[0.5606 to 0.5598 in]
Worn Limit: 14.18 mm [0.5583 in]
Crankshaft
z Main Bearing Journal Diameter
Standard: 53.964 to 53.95 mm
[2.2146 to 2.1240 in]
Worn Limit: 53.91 mm [2.122 in]
Cylinder Block
z Top Surface Flatness
(Maximum Overall Variation
Standard: 0.03 mm [0.00118 in]
Worn Limit: 0.15 mm [0.0059 in]
Cylinder Bore
z Cylinder Bore Diameter
Standard: 88.0 to 88.02 mm
[3.464 to 3.465 in]
z Out of Round
0.34mm [0.0012 in]
Preparatory Step:
17mm
z Remove the valve covers.
Removal
12mm
Loosen the adjusting screw locknuts. Loosen the
adjusting screws until they stop.
19mm
Remove the 19mm nuts from the rocker lever
pedestals. Remove the pedestals. Remove the
pedestals and rocker lever assemblies.
Four-Cylinder Engine
Step A
12mm
Adjust the clearance for the valves shown in the
illustration.
Clearance: 0.3 mm [0.012 in]
Tighten the locknut and check the clearance.
12mm
Remove the capscrews from the thrust plate.
Camshaft Inspection
Inspect the lift pump lobe, valve lobes and bearing
journals for wear, cracking, pitting and other damage.
Tappet Inspection
Inspect the socket, stem and face for excessive wear,
cracks and other damage.
Limit
(A) - Normal wear
(B) and (C) - Abnormal wear – Do not reuse
Camshaft Installation
Apply a coat of Lubriplate 105 to the camshaft bores.
Verify the camshaft has proper back lash and end play.
12mm
Remove the gear housing and gasket.
12mm
Caution : If a new housing or other than the original
housing is installed, the timing pin assembly
must be accurately located.
19mm
Remove the Flywheel.
Use the drift pin to drive the ring gear from the
flywheel.
Flywheel – Installation
Caution : Never use the timing pin to hold the crank-
shaft.
17 mm
Remove the cylinder head bolts in the sequence
shown.
Limits
Variance: Standard: 0.03 mm [0.0012 in]
Worn Limit: 0.15 mm [0.006 in]
Use the pin to push the bearing shell into position. Use
the pin to push against the end of the bearing with the
tang. Push the bearing in slowly being sure it is
aligned with the block. Make sure the tang on the
bearing sets into the notch.
Note : Make sure the tang on the bearing sets into the
notch in the bearing saddle.
19mm
Limits
Minimum Clearance
Top groove: 2.006 mm [0.079 in]
Oil Control: 3.002mm [0.1102 in]
Diameter
30.008 mm [1.1814 in]
Worn Limit: 29.9 mm [1.177 in]
Diameter
30.0 mm [1.181 in]
Maximum Diameter
30.038 mm [1.1826 in]
Worn Limit: 30.1 mm [1.185 in]
Limits
Ring Minimum Maximum
Top:
0.20 mm [0.0079 in.] 0.35 mm [0.0138 in.]
Intermediate:
0.25mm [0.0100 in.] 0.70 mm [0.0276 in.]
Oil Control:
0.20 mm [0.0079 in.] 0.40mm [0.0157 in.]
Install the oil control ring with the end gap opposite the
ends on the expander.
Push the piston into the bore until the top of the piston
is approximately 50mm [2 inches] below the top of the
bore.
Then, pull the connecting rod onto the crankshaft
journal.
Torque Value:
Step 1 – 20 Nm [15 ft-lbs]
Step 2 – 34 Nm [26 ft-lbs]
Step 3 – 49 Nm [37 ft-lbs]
Install the suction tube and oil pan (refer to page 6-19).
17mm
Torque Value:
Step 1 – 29 Nm [22 ft-lbs]
Step 2 – 59 Nm [44 ft-lbs]
Step 3 – 93 Nm [70 ft-lbs]
19mm
OK
z Correct injectors for the engine rating used and only one copper sealing washer
installed?
z Sealant applied to the capscrews that attach the intake manifold cover or aftercooler?
z Turbocharger pre-lubed?
z Engine filled with oil; oil filter filled with oil prior to installation so the engine has an
immediate supply of oil?
z Fuel filter (s) filled with fuel and the injection pump primed using the lever on the lift
pump?
Caution : It is extremely important that all air is vented prior to operating the engine.
Valves – Grind
Re-face all reused valves. Check/replace bent valves.
Intake: 30 Degrees
Exhaust: 45 Degrees
Dimension (GD)
0.20 mm [0.008 in]
Valve Depth
Standard: 0.69 to 0.70 mm [0.0271 to 0.0279 in]
Worn Limit: 1.0 mm [0.0394 in]
Limits
Approx. Free Length (L): 46.1 mm [1.815 in.]
Balancer - Remove
Check the gear backlash before removing balancer.
Refer to Section 1.
Remove the mounting capscrews.
Remove the balancer and shim or shim plate (1).
Remove the o-ring (2) in the oil passage.
Make sure that the oil supply passage is open and the
o-ring (2) is installed..
Engine Replacement
If the engine cannot be repaired in chassis, use the following guidelines for removal and installation of the engine.
Engine Removal
Preparatory Steps:
z Disconnect the air intake and exhaust pipes.
z Disconnect the throttle linkage from the control lever.
z Do not remove the control lever from the injection pump.
z Disconnect all engine driven accessories.
z Disconnect the drive units from the flywheel.
z Drain the coolant.
z Drain the lubricating oil.
z Remove the chassis parts as necessary to lift the engine from the equipment
Note : Check the oil level after the engine has run for
2 to 3 minutes. Oil held in the oil filter and oil
passages will cause the oil level in the oil pan
to lower.
Engine Testing
Verify engine performance by performing an in-chassis check.
Operating Conditions for Run-In and Test
Smoke
Bosch Smoke Meter ּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּ 2.5 Units Maximum
Celsco Smoke Meter ּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּּ 4% Opacity Maximum
Fuel System
Maximum Fuel Inlet Restriction to Injection Pump (Clean FIlter) 76.3 mm-Hg [3 in-Hg]
Maximum Fuel Drain Restriction 381 mm-Hg [15 in-Hg]
Maximum Fuel Inlet Temperature 65°C [149°F]
Minimum Engine Cranking Speed 180 rpm
Exhaust System
Maximum Allowable Exhaust Restriction
- A2000, and A2300 75 mm-Hg [3 in-Hg]
Electrical System
Recommended Battery Capacity
- A2000, and A2300
- 12 Volt Battery with Light Accessories 500 Cold Cranking Amps
- 12 Volt Battery with Heavy Accessories 650 Cold Cranking Amps
- 24 Volt Battery with Light Accessories 250 Cold Cranking Amps
- 24 Volt Battery with Heavy Accessories 325 Cold Cranking Amps
Maximum 12 Volt Starting System Resistance 0.001 ohm
Maximum 24 Volt Starting System Resistance 0.002 ohm
Minimum Cranking Speed 180 rpm
NOTES:
1. Always use the torque values listed in the
following tables when specific torque values
are not available.
2. Do not use the torque values in place of
those specified in other sections of this
manual.
3. The torque values in the table are based on
the use of lubricated threads.
Capscrew
Cast Iron Aluminum Cast Iron Aluminum
Body Size
N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
1/4 - 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
3/8 - 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480
In Cast Iron or
Thread Actual Thread O.D. In Aluminum Components
Steel Components
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
From
From U.S.
Metric
Customary
Quantity U.S. Customary Metric To U.S.
To Metric
Customary
Multiply By
Multiply By
Unit Name Abbreviation Unit Name Abbreviation
kilometers per
miles per gallon mpg km/l 0.4251 2.352
liter
Fuel
Performance
liters per
gallons per mile gpm l/km 2.352 0.4251
kilometer
millimeters of
Pressure inches of mercury in Hg mm Hg 25.40 0.039370
mercury
millimeters of
inches of water in H2O mm H2O 25.40 0.039370
water
millimeters of
bars bars mm Hg 750.06 0.001333
mercury
ST 1111-3 Manometer
Service Manual
V2403 Diesel Engine
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication. Specific safety
warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
Indicates that equipment or property damage could result if instructions are not followed.
Safety Working
• Do not work on the machine while under the
influence of alcohol, medication, or other
substances or while fatigued.
1.1. Specifications
Model V2403-M
Number of Cylinders 4
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.)
Total Displacement 2434 cm3 (148.5 cu.in.)
SAE Gross Intermittent 34.1 kW @ 2400 rpm
(46.4 ps @ 2400 rpm)
High Idle Speed @ Dynamo 2670 ±50 rpm
Low Idle Speed @ Dynamo 775 ~ 825rpm (for D18G)
875 ~ 925rpm (for D18S)
Combustion Chamber Spherical Type (E-TVCS)
Fuel Injection Pump PFR 4M Type Mini Pump (DENSO)
Governor Mechanical all speed governor
Direction of Rotation Counter-clockwise (viewd from flywheel side)
Injection Nozzle OPD Mini Nozzle (DENSO)
Injection Timing 15.25 Before T.D.C
Firing Order 1-3-4-2
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)
Compression Ratio 23.8 : 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 2.0 kW
Starting Support Device By glow plug in combustion chamber
EGR NONE
Recommended Battery 12 V, 92 AH equivalent
Charging Alternator 12V, 40A
Recommended Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
Lubricating Oil Capacity For details on recommended lubricating oils, see page G-7, 10
9.5 L (2.5 U.S.gals)
Weight (Dry) 184 kg (406 lbf)
• Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name and Serial Number
The emission controls previously implemented in various countries to prevent air pollution will be stepped up
as Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road
Emission regulations depends on the engine output classification.
Over the past several years, Kubota has been supplying diesel engines that comply with regulations in the
respective countries affected by Non-Road Emission regulations. For Kubota Engines, E3B will be the
designation that identifies engine models affected by the next emission phase (See the table below).
When servicing or repairing ###-E3B series engines, use only replacement parts for that specific E3B engine,
designated by the appropriate E3B Kubota Parts List and perform all maintenance services listed in the
appropriate Kubota Operator's Manual or in the appropriate E3B Kubota Workshop Manual. Use of incorrect
replacement parts or replacement parts from other emission level engines (for example: E2B engines), may
result in emission levels out of compliance with the original E3B design and EPA or other applicable
regulations.Please refer to the emission label located on the engine head cover to identify Output
classification and Emission Control Information. E3B engines are identified with "ET" at the end of the Model
designation, on the US EPA label. Please note : E3B is not marked on the engine.
Categ EU
Engine output classification
ory (1) regulation
K From 19 to less than 37 kW STAGE ΙΙΙA
J From 37 to less than 75 kW STAGE ΙΙΙA
I From 75 to less than 130 kW STAGE ΙΙΙA
Categ EPA
Engine output classification
ory (2) regulation
Less than 19kW Tier 4
From 19 to less than 56 kW Interim Tier 4
ET
From 56 to less than 75 kW Tier 3
From 75 to less than 130 kW Tier 3
(1) EU regulation engine output classification category
(2) “E3B” engines are identified with “ET” at the end of
the Model designation, on the US EPA label.
“E3B” designates Tier 3 and some Interim Tier 4 /
Tier 4 models, depending on engine output
classification.
To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by
following the table below.
Service Interval
Item Every
50 100 150 200 400 500 1 or 2 1 800 1500 3000 2
hrs hrs hrs hrs hrs hrs months year hrs hrs hrs years
* Checking fuel hoses and clamp
☆
bands
Changing (1) Oil pan depth
★ ☆
engine oil (90 mm, 3.5 in.)
(depending
(2) Oil pan depth
on the oil ★ ☆
(124 mm, 4.88 in.)
pan)
*Cleaning air cleaner element
(replace the element after 6-times ☆
cleanings)
*Cleaning fuel filter (Element type) ☆
Checking battery electrolyte level ☆
Checking fan belt tension and
☆
damage
(1) Oil pan depth
Replacing oil ★ ☆
(90 mm, 3.5 in.)
filter
(2) Oil pan depth
cartridge ★ ☆
(124 mm, 4.88 in.)
Checking radiator hoses and clamp
☆
bands
* Checking intake air line ☆
Replacing fuel filter cartridge ☆
Cleaning water jacket and radiator
☆
interior
Replacing fan belt ☆
Recharging battery ☆
* Replacing air cleaner element ☆
Checking valve clearance ☆
* Checking injection nozzle
☆
condition
* Checking turbocharger ☆
* Checking injection pump ☆
* Replacing intake air line ☆
Replacing battery ☆
Replacing radiator hoses and
☆
clamp bands
* Replacing fuel hoses and clamps ☆
Changing radiator coolant (L.L.C.) ☆
★ Change engine oil and replace oil filter cartridge after the first 50 hours of operation.
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA nonroad emission
regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the
above instruction.
NOTE
Engine Oil :
Refer to the following table for the suitable American Petroleum Institute (API) classification of engine
oil according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type
Used : (Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).
CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change -
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))
• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and
is Not Recommended for use in Kubota E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according
to the ambient temperatures where the engine is operated.
• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been
developed for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine
runs on high sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high
Total Base Number (a minimum TBN of 10 is recommended).
Fuel :
• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than
50 is preferred, especially for ambient temperatures below .20 °C (.4 °F) or elevations above 1500 m
(5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all
applicable emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel,
change the engine oil and oil filter at shorter intervals. (approximately half)
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE
J313 JUN87)
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4
standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when
operated in US EPA regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an
alternative to No.2-D, and use No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient
temperatures below .10 °C (14 °F).
2) EN : European Norm
5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
2.4.1. Check Point When Required Draining the Water from the Fuel Filter
2. To check the oil level, draw out the dipstick (1), wipe
it clean, reinsert it, and draw it out again.
Check to see that the oil level lies between the two
notches.
IMPORTANT
When using an oil of different maker or viscosity
from the previous, drain old oil. Never mix two
different types of oil.
NOTE
• Be sure to inspect the engine, locating it on a
horizontal place. If placed on gradients, accurately,
oil quantity may not be measured.
CAUTION
Do not remove the radiator cap until coolant
temperature is below its boiling point. Then loosen
the cap slightly to relieve any excess pressure
before removing the cap completely.
IMPORTANT
• During filling the coolant, air must be vented from
the engine coolant passages. The air vents by
jiggling the radiator upper and lower hoses.
• Be sure to close the radiator cap securely. If the
cap is loose or improperly closed, coolant may
leak out and the engine could overheat.
• Do not use an antifreeze and scale inhibitor at the
same time.
• Never mix the different type or brand of L.L.C..
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5
minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at
the bottom of the engine and drain the oil
completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).
IMPORTANT
• When using an oil of different maker or viscosity
from the previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API
classification CF (See page G-7).
• Use the proper SAE Engine Oil according to
ambient temperature.
CAUTION
• Be sure to stop the engine before replacing filter
cartridge.
1. Remove the oil filter cartridge (1) with the filter
wrench.
2. Apply a slight coat of oil onto the new cartridge
gasket.
3. To install the new cartridge, screw it in by hand.
Over tightening may cause deformation of rubber
gasket.
4. After the new cartridge has been replaced, the
engine oil normally decrease a little. Thus see
that the engine oil does not leak through the seal
and be sure to read the oil level on the dipstick.
Then, replenish the engine oil up to the specified
level.
IMPORTANT
To prevent serious damage to the engine,
replacement element must be highly efficient. Use
only a KUBOTA genuine filter or its equivalent.
CAUTION
Stop the engine when attempting the check and
change prescribed above.
NOTE
• The air cleaner uses a dry element. Never apply oil
to it.
• Do not run the engine with filter element removed.
• Change the element once a year or every 6th
cleaning.
IMPORTANT
If dust and dirt enter the fuel, the fuel injection
pump and injection nozzle will wear quickly. To
prevent this, be sure to clean the fuel filter cup (5)
periodically.
2. If the level is below than lower level line (2), and the
distilled water to pour level of each cell.
7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.
(A) Deflection
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5
minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at
the bottom of the engine and drain the oil
completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).
IMPORTANT
• When using an oil of different maker or viscosity
from the previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API
classification CF (See page G-7).
• Use the proper SAE Engine Oil according to
ambient temperature.
CAUTION
• Be sure to stop the engine before replacing filter
cartridge.
1. Remove the oil filter cartridge (1) with the filter
wrench.
2. Apply a slight coat of oil onto the new cartridge
gasket.
3. To install the new cartridge, screw it in by hand.
Over tightening may cause deformation of rubber
gasket.
4. After the new cartridge has been replaced, the
engine oil normally decrease a little. Thus see
that the engine oil does not leak through the seal
and be sure to read the oil level on the dipstick.
Then, replenish the engine oil up to the specified
level.
IMPORTANT
To prevent serious damage to the engine,
replacement element must be highly efficient. Use
only a KUBOTA genuine filter or its equivalent.
IMPORTANT
To prevent serious damage to the engine, keep out
any dust inside the intake air line.
WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
Turn the disconnect switch OFF if fitted or
disconnect the battery when changing fuel filters.
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to
fuel system parts.
CAUTION
• Do not remove the radiator cap when the engine is
hot. Then loosen cap slightly to the stop to
relieve any excess pressure before removing cap
completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug
(2) and remove the radiator cap (1). Then radiator
cap (1) must be removed to completely drain the
coolant. And open the drain cock (3).
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-
freeze until the coolant level is just below the port.
Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the
recovery tank (4).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level
of radiator and recovery tank (4) and add coolant
if necessary.
IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill
the radiator and recovery tank.
• When the anti-freeze is mixed with fresh, soft
water, the antifreeze mixing ratio must be less
than 50 %.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the
engine could overheat.
• Mix the anti-freeze with fresh, soft water, and then fill
into the radiator.
IMPORTANT
When the anti-freeze is mixed with fresh, soft water,
the antifreeze mixing ratio must be less than 50 %.
NOTE
• The above data represents industrial standards
that necessitate a minimum glycol content in the
concentrated anti-freeze.
• When the coolant level drops due to evaporation,
add fresh, soft water only to keep the anti-freeze
mixing ratio less than 50 %. In case of leakage,
add anti-freeze and fresh, soft water in the
specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-
freeze in a tightly sealed container.
• Do not use radiator cleaning agents when anti-
freeze has been added to the coolant.
(Anti-freeze contains an anti-corrosive agent,
which will react with the radiator cleaning agent
forming sludge which will affect the engine parts.)
7.0 to 9.0 mm / 98 N
Deflection (A) Factory spec. 0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
Recharging
CAUTION
• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely
explosive. Keep open sparks and flames away from the battery at all times, especially when
charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with the negative terminal first. When
connecting the cable to the battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across the posts.
Use a voltmeter or hydrometer.
1) Slow Charging
1. Add distilled water if the electrolyte level is low. When charging, the amount of electrolyte should be slightly
lower than the specified level to prevent overflow.
2. Connect the battery to the charging unit, following the manufacture’s instructions.
3. As the electrolyte generates gas while charging, remove all port caps.
4. The electrolyte temperature must not exceed 40 °C (104 °F) during charging. If it exceed 40 °C (104 °F),
decrease the charging amperage or stop charging for a while.
5. When charging several batteries in series, charge at the rate of the smallest battery in the line.
2) Quick Charging
1. Determine the proper charging current and charging time with the tester attached to the quick charger.
2. Determine the proper charging current as 1/1 of the battery capacity. If the battery capacity exceeds 50 Ah,
consider 50 A as the maximum.
NOTE
• Hold the hydrometer tube vertical without
removing it from the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the
hydrometer at eye level.
• The hydrometer reading must be taken at the
highest electrolyte level.
(Reference)
NOTE
• The air cleaner uses a dry element. Never apply
oil to it.
• Do not run the engine with filter element
removed.
Valve Clearance
IMPORTANT
Valve clearance must be checked and adjusted
when engine is cold.
CAUTION
• Check the injection pressure and condition after confirming that there is nobody standing in the
direction the fume goes.
• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood
poisoning may be caused.
(Reference)
No fuel leak at
Valve seat 12.75 MPa
Factory spec. 2
tightness 130.0 kgf/cm
1849 psi
Nozzle Holder
(When reassembling)
35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf·m
26 to 28 lbf·ft
20 to 24 N·m
Tightening Overflow pipe
2.0 to 2.5 kgf·m
torque retaining nut
15 to 18 lbf·ft
49 to 68 N·m
Nozzle holder
5.0 to 7.0 kgf·m
assembly
37 to 50 lbf·ft
13.73 MPa
2
Fuel tightness of pump element Allowable limit 140.0 kgf/cm
1991 psi
10 seconds
13.73 → 12.75 MPa
Factory spec. 2
140.0 → 130.0 kgf/cm
1991 → 1849 psi
Fuel tightness of delivery valve
5 seconds
13.73 → 12.75 MPa
Allowable limit 2
140.0 → 130.0 kgf/cm
1991 → 1849 psi
NOTE : Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to
contact a Kubotaauthorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle
3. Replace new intake air hose (1) and new clamp (2).
Replacing Battery
CAUTION
• When the battery is being activated, hydrogen and
oxygen gases in the battery are extremely
explosive. Keep open sparks and flames away
from the battery at all times, especially when
charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery,
start with the negative terminal first. When
connecting the cable to the battery, start with the
positive terminal first.
• Never check battery charge by placing a metal
object across the posts.
CAUTION
Do not remove the radiator cap when the engine is
hot. Then loosen cap slightly to the stop to relieve
any excess pressure before removing cap
completely.
1. Loosen the clamp (2) and remove the fuel hose (1).
CAUTION
Stop the engine when attempting the check and
[B] change prescribed above.
CAUTION
Do not remove the radiator cap when the engine is
hot. Then loosen cap slightly to the stop to relieve
any excess pressure before removing cap
completely.
IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill
the radiator and recovery tank.
• When the anti-freeze is mixed with fresh, soft
water, the antifreeze mixing ratio must be less
than 50 %.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the
engine could overheat.
(Anti-freeze)
IMPORTANT
When the anti-freeze is mixed with fresh, soft water,
the antifreeze mixing ratio must be less than 50 %.
NOTE
• The above data represents industrial standards
that necessitate a minimum glycol content in the
concentrated anti-freeze.
• When the coolant level drops due to evaporation,
add fresh, soft water only to keep the anti-freeze
mixing ratio less than 50 %. In case of leakage,
add anti-freeze and fresh, soft water in the
specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-
freeze in a tightly sealed container.
• Do not use radiator cleaning agents when anti-
freeze has been added to the coolant.
(Anti-freeze contains an anti-corrosive agent,
which will react with the radiator cleaning agent
forming sludge which will affect the engine
parts.)
1. Extracting tool
2. Inserting tool
A 24 mm (0.94 in.)
B 10 mm dia. (0.39 in. dia.)
C 0.5 mm radius (0.02 in. radius)
D M20 x Pitch 2.0
E 10 mm (0.39 in.)
F 20 mm (0.79 in.)
G 5 mm (0.2 in.)
H 95 mm (3.7 in.)
I 125 mm (4.92 in.)
J 0.87 rad (50 °)
K 5 mm (0.2 in.)
L 60 mm radius (2.4 in. radius)
M M20 x Pitch 2.0
N 30 mm (1.2 in.)
O 10 mm (0.39 in.)
P 10 mm (0.39 in.)
Q 10 mm (0.39 in.)
R 35.5 mm (1.40 in.)
S 4.5 mm radius (0.18 in. radius)
T 40 mm (1.6 in.)
U 40 mm (1.6 in.)
V 12 mm (0.47 in.)
W 120 mm (4.72 in.)
C2 Chamfer 2.0 mm (0.079 in.)
3.1.1. Piston
3.3.1. Governor
4.1. Troubleshooting
Engine Body
Item Factory Specification Allowable Limit
0.18 to 0.22 mm
Valve Clearance (When Cold)
0.0071 to 0.0086 in.
3.24 to 3.72 MPa / 290 2.55 MPa / 290
min-1 (rpm) -1
min (rpm)
2 2
Compression Pressure 33.0 to 38.0 kgf/cm / 290 26.0 kgf/cm / 290
-1 -1
(When Cranking with Starting Motor) min (rpm) min (rpm)
-1 -1
470 to 540 psi / 290 min 370 psi / 290 min
(rpm) (rpm)
0.575 to 0.675 mm
Top Clearance -
0.0227 to 0.0265 in.
0.05 mm / 500 mm
Cylinder Head Surface Flatness
0.002 in. / 19.7 in.
0.05 mm
Protrusion
0.002 in.
Valve Recessing
(Protrusion to Recessing) Recessing
0.15 mm 0.40 mm
0.0059 in. 0.016 in.
Valve Recessing Recessing 0.65 to 0.85 mm -
[D1803-M-DI], [V2403-M-DI] 0.026 to 0.033 in.
[V2403-M-DI-T]
Tilt - 1.0 mm
0.039 in.
Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.10 mm
0.00063 to 0.0017 in. 0.0039 in.
0.25 mm
Push Rod Alignment -
0.0098 in.
Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.036 mm 0.15 mm
0.00056 to 0.0014 in. 0.0059 in.
Lubricating System
Item Factory Specification Allowable Limit
Engine Oil Pressure At Idle Speed More than 98 kPa 50 kPa
2 2
1.0 kgf/cm 0.5 kgf/cm
14 psi 7 psi
Cooling System
Item Factory Specification Allowable Limit
Fan Belt Tension 7.0 to 9.0 mm (0.28 to -
0.35 in.) deflection at 98
N (10 kgf, 22 lbf) of force
Thermostat Valve Opening 69.5 to 72.5 °C -
Temperature (At 157.1 to 162.5 °F
Beginning)
Valve Opening 85 °C -
Temperature 185 °F
(Opened
Completely)
Radiator Water Tightness No leak at specified -
pressure
Radiator Cap Pressure Falling More than 10 seconds -
Time for pressure fall from 90
to 60 kPa from 0.9 to 0.6
2
kgf/cm from 10 to 9 psi
Electrical System
Item Factory Specification Allowable Limit
Starter
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts
and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper
torque.
4.3.1. Tightening Torques For General Use Screws, Bolts And Nuts
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
Unit
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to
tightening, be sure to check out the numbers as shown below.
NOTE
For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size
is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm
between two threads.
Engine Body
Compression Pressure
5. After making sure that the stop lever is set at the stop position (non-injection).
6. While cranking the engine with the starter, measure the compression pressure.
8. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the
nozzle hole and measure the compression pressure again.
9. If the compression pressure is still less than the allowable limit, check the top clearance, valve and cylinder
head.
10. If the compression pressure increases after applying oil, check the cylinder wall and piston rings.
NOTE
• Check the compression pressure with the specified valve clearance.
IMPORTANT
Valve clearance must be checked and adjusted
when engine is cold.
NOTE
• The “1TC” mark line on the flywheel is just for No.
1 cylinder.
There is no “TC” marking for the other cylinders.
• No. 1 piston comes to the top dead center
position when the “TC” marking is aligned with
the projection (2) in the window on flywheel-
housing. Turn the flywheel 0.26 rad (15 °)
clockwise and counterclockwise to see if the
piston is at the compression top dead center or
the overlap position. Now referring to the table
below, readjust the valve clearance (1). (The
piston is at the top dead center when both the IN.
and EX. valves do not move; it is at the overlap
position when both the valves move.)
• Finally turn the flywheel 6.28 rad (360 °) and align
the “1TC” mark line and the projection (2)
perfectly. Adjust all the other valve clearance as
required.
• After turning the flywheel counterclockwise twice
or three times, recheck the valve clearance (1).
• After adjusting the valve clearance (1), firmly
tighten the lock nut of the adjusting screw.
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.
15 to 19 N·m
Tightening torque Oil pressure switch 1.5 to 2.0 kgf·m
11 to 14 lbf·ft
7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.
(A) Deflection
(A) Good
(B) Bad
CAUTION
When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water may gush out, scalding nearby people.
Injection Timing
(Reference)
13.73 MPa
Fuel tightness of 2
Allowable limit 140.0 kgf/cm
pump element
1991 psi
6. Stop the starter when the fuel jets from the injection
nozzle. After that, turn the flywheel by the hand and
raise the pressure to approx. 13.73 MPa (140.0
2
kgf/cm , 1991 psi).
7. Now turn the flywheel back about half a turn (to keep
the plunger free). Maintain the flywheel at this
position and clock the time taken for the pressure to
drop from 13.73 to 12.75 MPa (140.0 to 130.0
2
kgf/cm , 1991 to 1849 psi).
10 seconds
Factory 13.73 → 12.75 MPa
2
spec. 140.0 → 130.0 kgf/cm
Fuel tightness 1991 → 1849 psi
of delivery
valve 5 seconds
Allowable 13.73 → 12.75 MPa
2
limit 140.0 → 130.0 kgf/cm
1991 → 1849 psi
(Reference)
No fuel leak at
12.75 MPa
Valve seat tightness Factory spec. 2
130.0 kgf/cm
1849 psi
Nozzle Holder
(When reassembling)
35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf•m
26 to 28 lbf•ft
20 to 24 N·m
Tightening Overflow pipe
2.0 to 2.5 kgf•m
torque retaining nut
15 to 18 lbf•ft
49 to 68 N•m
Nozzle holder
5.0 to 7.0 kgf•m
assembly
37 to 50 lbf•ft
CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away
completely with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
IMPORTANT
If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
Battery Voltage
NOTE
• Hold the hydrometer tube vertical without
removing it from the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the
hydrometer at eye level.
• The hydrometer reading must be taken at the
highest electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be
exact, the specific gravity decreases by 0.0007 with an
increase of 1 °C (0.0004 with an increase of 1 °F) in
temperature, and increases by 0.0007 with a
decreases of 1 °C (0.0004 with a decrease of 1 °F).
CAUTION
Secure the starter to prevent it from jumping up
and down while testing the motor.
NOTE
• B terminal : It is the terminal which connects the
cable from the battery to the starter.
• C terminal : It is the terminal which connects the
cable from the motor to the magnet switch.
NOTE
• B terminal : It is the terminal which connects the
cable from the battery to the starter.
• S terminal : It is the terminal which connects the
cable from the starter switch to the magnet switch.
(Before testing)
5. When switch (4) is turn on, the plunger pull into the
solenoid body and then turn off the switch (4), the
plunger comes out.
6. Turn on the switch (3) then turn on the switch (4), the
plunger pull into the solenoid body and it keep in
holding position after turn off the switch (4).
IMPORTANT
Never apply the current for pulling coil more than
two seconds when inspecting.
(Reference)
• The procedure of confirming the solenoid’s movement
Alternator
(1) Alternator
(2) Terminal L (Harness Side)
ON 0Ω
Resistance
OFF Infinity
ON 0Ω
Resistance
OFF Infinity
ON 0Ω
Resistance
OFF Infinity
Battery
(1) Battery
(When refilling)
IMPORTANT
• Never mix two different types of oil.
• Use the proper SAE Engine Oil according to
ambient temperature.
Draining Coolant
CAUTION
Never remove radiator cap while operating or
immediately after stopping. Otherwise, hot water
will spout out from the radiator. Wait for more than
ten minutes to cool the radiator, before opening the
cap.
2. Remove the fan (1), fan belt (4), alternator (2) and
starter (3).
(When reassembling)
IMPORTANT
• After reassembling the fan belt, be sure to adjust
the fan belt tension.
• Do not confuse the direction of the fan.
(1) Fan
(3) Starter
(2) Alternator
(4) Fan Belt
(When reassembling)
Injection Pipes
(When reassembling)
25 to 34 N·m
Tightening Injection pipe
2.5 to 3.5 kgf·m
torque retaining nut
18 to 25 lbf·ft
(When reassembling)
49 to 68 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
20 to 24 N·m
Tightening torque Overflow pipe assembly retai ning nut 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
20 to 24 N·m
Glow plug 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
(1) Lead (2) Glow Plug (3) Overflow Pipe Assembly (4) Nozzle Holder Assembly (5) Heat Seal
IMPORTANT
Use a plus (phillips head) screw driver (1) that has
a diameter which is bigger than the heat seal hole
(Approx. 6 mm (1/4 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.
(When reassembling)
• Heat seal and injection nozzle gasket must be
changed when the injection nozzle is removed for
cleaning or for service.
(When reassembling)
• When putting the push rods (2) onto the tappets (3),
check to see if their ends are properly engaged with
the grooves.
IMPORTANT
After installing the rocker arm, be sure to adjust the
valve clearance.
24 to 27 N•m
Tightening Rocker arm bracket
2.4 to 2.8 kgf•m
torque screw
18 to 20 lbf•ft
(When reassembling)
IMPORTANT
To replace the cylinder head gasket (4), in advance
make sure the marking (5) of cylinder head gasket
in the original engine, and replace the same
marking as the original cylinder head gasket.
IMPORTANT
When replacing piston, piston pin, small end
bushing, connecting rod, or crankpin bearings,
measure piston head’s protrusion or recessing
from the level of crankcase cylinder face (average
of all pistons) after installing the pistons, and
select the cylinder head gasket following the below
table.
0.500 to 0.540 mm
15
0.0197 to 0.0212 in.
0.550 to 0.590 mm
20
0.0217 to 0.0232 in.
0.600 to 0.640 mm
25
0.0237 to 0.0251 in.
0.650 to 0.690 mm
30
0.0256 to 0.0271 in.
0.700 to 0.740 mm
35
0.0276 to 0.0291 in.
(When reassembling)
IMPORTANT
Do not change the combination of tappet and
tappet guide.
(1) Tappet
Valves
(When reassembling)
• Wash the valve stem and valve guide hole, and apply
engine oil sufficiently.
IMPORTANT
Do not change the combination of valve and valve
guide.
(When reassembling)
(When reassembling)
IMPORTANT
Before removing the injection pump assembly (2),
be sure to remove the solenoid (4), hi-idling body
(1), engine stop lever (3) and solenoid guide (6).
(When reassembling)
• Before fitting the stop lever (3) to the gear case, install
the solenoid guide (6) first into position. Then attach
the stop lever and use it to see if it functions well.
45 to 49 N·m
Tightening Hi-idling body 4.5 to 5.0 kgf·m
torque
33 to 36 lbf·ft
IMPORTANT
Before removing the injection pump assembly (1),
be sure to remove the boost compensator
assembly (2), hi-idling body (4), solenoid (3) and
solenoid guide (5).
(When reassembling)
IMPORTANT
If you replace new boost compensator, it is
necessary to adjust it.
Get the adjustment procedure from KUBOTA.
45 to 49 N·m
Tightening
Hi-idling body 4.5 to 5.0 kgf·m
torque
33 to 36 lbf·ft
NOTE
Specific tool (1) :
1.2 mm diameter hard wire with its end hooked,
overall length 200 mm (7.87 in.).
The tip of wire is bent like the hook to hang
governor springs.
6. Take out the speed control plate (6) with care not to
let the large (3) and small (4) governor springs come
off this plate and fall in to the gear case.
(When reassembling)
• Hook the small spring (4) first and then the large
governor spring (3) on the speed control plate (6).
• Put the specific tool (1) from the injection pump side to
catch the large governor spring (3). Keep this spring
slightly extended and place the speed control plate (6)
in its specified position.
NOTE
• Be careful not to stretch the small governor
spring (4) too long because otherwise it may get
deformed permanently.
• Using the specific tool (1), hook the large
governor spring (3) onto the fork lever (2).
• Make sure both the governor springs (3), (4) are
tight on the fork lever (2).
• Apply and tighten up the two bolts and two nuts
on the speed control plate (6).
• Check that the speed control lever (5) positions
low idle, after assembling governor springs.
• Check that the speed control lever (5) returns to
the high idle position rather than the low idle
position, after moving the lever to the maximum
speed position.
• Finally attach the injection pump cover in position.
3. Remove the fan drive pulley (2) with gear puller (4).
(When reassembling)
(When reassembling)
24 to 27 N·m
Idle gear 2 shaft
2.4 to 2.8 kgf·m
set screw
Tightening 18 to 20 lbf·ft
torque Idle gear 2 49 to 55 N·m
stopper set 5.0 to 5.7 kgf·m
screw 37 to 41 lbf·ft
(When reassembling)
• Apply a thin film of engine oil to the oil seal, and install
it, noting the lip come off.
Gear Case
(When reassembling)
• Apply a thin film of engine oil to the oil seal (3), and
install it, noting the lip come off.
(When reassembling)
Idle Gear
(When reassembling)
Camshaft
(When reassembling)
24 to 27 N·m
Tightening Camshaft set
2.4 to 2.8 kgf·m
torque screw
18 to 20 lbf·ft
4. Draw out the fuel camshaft assembly (5), (6) and fork
lever assembly (3), (4), (7) at the same time.
(When reassembling)
Oil Pump
2. Draw out the oil pump drive gear (2) with gear puller
(1).
Crank Gear
(When reassembling)
• After cleaning the oil strainer (1), check to see that the
filter mesh in clean, and install it.
Pistons
(When reassembling)
IMPORTANT
• Do not change the combination of cylinder and
piston. Make sure of the position of each piston
by marking. For example, mark “1” on the No. 1
piston.
• Place the piston rings with their gaps at 0.79 rad
(45 °) from the piston pin’s direction as shown in
the figure.
• Carefully insert the pistons using a piston ring
compressor (6).
• When inserting the piston in place, be careful not
to get the molybdenum disulfide coating torn off
its skirt. This coating is useful in minimizing the
clearance with the cylinder liner. Just after the
piston pin has been press-fitted, in particular, the
piston is still hot and the coating is easy to peel
off. Wait until the piston cools down.
45 to 49 N·m
Tightening Connecting rod
4.5 to 5.0 kgf·m
torque screw
33 to 36 lbf·ft
(When reassembling)
• When installing the oil ring (3) onto the piston (6),
place the expander joint (10) on the opposite side of
the oil ring gap (11).
Flywheel
(When reassembling)
IMPORTANT
The length of inside screws (5) and outside screws
(3) are different. Do not take a mistake using inside
screws and outside screws.
(When reassembling)
• Fit the bearing case gasket (1) and the bearing case
cover gasket (2) with correct directions.
Crankshaft
(When reassembling)
IMPORTANT
• Install the crankshaft sub assembly, aligning the
screw hole of main bearing case 2 (2) with the
screw hole of cylinder block.
• When tightening the main bearing case screw 2
(1), apply oil to the screw and screw by hand
before tightening the specific torque.
If not smooth to screw by hand, align the screw
holes between the cylinder block and the main
bearing case.
69 to 73 N·m
Tightening Main bearing
2 7.0 to 7.5 kgf·m
torque case screw
51 to 54 lbf·ft
(When reassembling)
• Install the thrust bearing with its oil groove (8) facing
outward.
46 to 50 N·m
Tightening Main bearing
1 4.7 to 5.2 kgf·m
torque case screw
34 to 37 lbf·ft
(1) Through Bolt (2) Brush (3) C Terminal Nut (4) Yoke
(5) Armature (6) Overrunning Clutch (7) Idle Gear (8) End Frame
(9) Brush Holder (10) Magnet Switch Cover (11) Plunger (12) B Terminal Nut
(13) Housing
1. Unscrew the C terminal nut (3), and disconnect the connecting lead.
2. Remove the two through bolts (1).
3. Detach the motor.
4. Remove the end frame (8).
5. Remove the brush from the brush holder while holding the spring up.
6. Remove the brush holder (9).
7. Draw out the armature (5) from the yoke (4).
8. Remove the housing (13).
9. Remove the idle gear (7) and the overrunning clutch (6).
10. Remove the magnet switch cover (10).
11. Remove the plunger (11).
(When reassembling)
• Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.
5.9 to 11 N·m
Tightening torque B terminal nut 0.60 to 1.2 kgf·m
4.4 to 8.6 lbf·ft
(1) Pulley (2) Drive End Frame (3) Stator (4) Bearing
(5) Retainer Plate (6) Rotor (7) Bearing (8) Rear End Frame
(9) Rectifier (10) IC Regulator (11) Brush Holder (12) Rear End Cover
(When reassembling)
Top Clearance
0.575 to 0.675 mm
Top clearance Factory spec.
0.0227 to 0.0265 in.
(1) Piston
(2) Fuse
IMPORTANT
• Do not place the straightedge on the combustion
chamber.
• Be sure to check the valve recessing after
correcting.
0.05 (protrusion) to
0.15 (recessing) mm
Factory spec.
0.002 (protrusion) to
Valve recessing 0.0059 (recessing) in.
0.40 (recessing) mm
Allowable limit
0.016 (recessing) in.
(When removing)
(When installing)
IMPORTANT
Do not hit the valve guide with a hammer during
replacement.
1. Coat the valve face lightly with prussian blue and put
the valve on its seat to check the contact.
2. If the valve does not seat all the way around the
valve seat or the valve contact is less than 70 %,
correct the valve seating as follows.
2.12 mm
Valve seat width Factory spec.
0.0835 in.
NOTE
• Before correcting the valve and seat, check the
valve stem and the I.D. of valve guide section, and
repair them if necessary.
• After correcting the valve seat, be sure to check
the valve recessing.
1) Correcting Valve
1.0 rad
IN.
Valve face Factory 60 °
angle spec. 0.79 rad
EX.
45 °
Valve Lapping
2. Insert the valve into the valve guide. Lap the valve
onto its seat with a valve flapper or screwdriver.
IMPORTANT
When valve lapping is performed, be sure to check
the valve recessing and adjust the valve clearance
after assembling the valve.
1.0 mm
Tilt (A) Allowable limit
0.039 in.
41.7 to 42.2 mm
Factory spec.
1.65 to 1.66 in.
Free length (B)
41.2 mm
Allowable limit
1.62 in.
118 N / 35.0 mm
Factory spec. 12.0 kgf / 35.0 mm
Setting load / 26.5 lbf / 1.38 in.
Setting length 100 N / 35.0 mm
Allowable
10.2 kgf / 35.0 mm
limit
22.5 lbf / 1.38 in.
1. Set a dial indicator (lever type) with its tip on the gear
tooth.
0.04150 to 0.1122 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004417 in.
crank gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1154 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004543 in.
cam gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1154 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004543 in.
injection pump gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1090 mm
Factory spec.
Backlash between crank gear and 0.001634 to 0.004291 in.
oil pump gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1154 mm
Factory spec.
Backlash between crank gear and 0.001634 to 0.004543 in.
idle gear 2 0.15 mm
Allowable limit
0.0059 in.
0.03080 to 0.1062 mm
Factory spec.
Backlash between idle gear 2 and 0.001213 to 0.004181 in.
hydraulic pump drive gear 0.15 mm
Allowable limit
0.0059 in.
Camshaft Alignment
33.90 mm
Factory spec.
Cam height of 1.335 in.
intake 33.85 mm
Allowable limit
1.333 in.
33.90 mm
Factory spec.
Cam height of 1.335 in.
exhaust 33.85 mm
Allowable limit
1.333 in.
(When removing)
(When installing)
(When removing)
(When installing)
1. Insert the piston ring into the lower part of the liner
(the least worn out part) with the piston.
0.25 to 0.40 mm
Factory spec.
0.0099 to 0.015 in.
Top ring
1.25 mm
Allowable limit
0.0492 in.
0.30 to 0.45 mm
Factory spec.
0.012 to 0.017 in.
Second ring
1.25 mm
Allowable limit
0.0492 in.
0.25 to 0.45 mm
Factory spec.
0.0099 to 0.017 in.
Oil ring
1.25 mm
Allowable limit
0.0492 in.
1. Clean the rings and the ring grooves, and install each
ring in its groove.
0.20 mm
Top Ring Allowable limit
0.0079 in.
0.0930 to 0.128 mm
Factory spec.
0.00367 to 0.00503 in.
Second ring
0.20 mm
Allowable limit
0.0079 in.
0.020 to 0.060 mm
Factory spec.
0.00079 to 0.0023 in.
Oil ring
0.15 mm
Allowable limit
0.0059 in.
(Reference)
0.2 mm 0.4 mm
Oversize
0.008 in. 0.02 in.
54.50 to 54.70 mm 54.60 to 54.80 mm
Dimension A
2.146 to 2.153 in. 2.150 to 2.157 in.
26.20 to 26.25 mm 26.40 to 26.45 mm
Dimension B
1.032 to 1.033 in. 1.040 to 1.041 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension C
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
Crankshaft Alignment
Crankshaft 0.02 mm
Allowable limit
alignment 0.0008 in.
NOTE
• Never insert the plastigage into the crankpin oil
hole.
• Be sure not to move the crankshaft while the
connecting rod screws are tightened.
(Reference)
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
3.3 to 3.7 mm radius 3.3 to 3.7 mm radius
Dimension A
0.13 to 0.14 in. radius 0.13 to 0.14 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
46.759 to 46.775 mm dia. 46.559 to 46.575 mm dia.
Dimension C
1.8409 to 1.8415 in. dia. 1.8331 to 1.8336 in. dia.
(0.4S)
The crankpin must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
(Reference)
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C
2.3513 to 2.3519 in. dia. 2.3434 to 2.3440 in. dia.
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
(When removing)
(When installing)
4.20 to 4.50 mm
Dimension (A) Factory spec.
0.166 to 0.177 in.
0.0400 to 0.104 mm
Factory spec.
Oil clearance between crankshaft 0.00158 to 0.00409 in.
and crankshaft bearing 2 0.20 mm
Allowable limit
0.0079 in.
59.921 to 59.940 mm
Crankshaft journal O.D. Factory spec.
2.3591 to 2.3598 in.
59.980 to 60.025 mm
Crankshaft bearing 2 I.D. Factory spec.
2.3615 to 2.3631 in.
(Reference)
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C, D
2.3513 to 2.3519 in. dia. 2.3434 to 2.3440 in. dia.
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
NOTE
• Mount the sleeve with its largely chamfered
surface facing outward.
• Should heating is not enough, a sleeve might stop
halfway, so careful.
Cylinder Wear
87.000 to
87.022 mm
Factory spec.
3.4252 to
Cylinder I.D. 3.4260 in.
87.170 mm
Allowable limit
3.4319 in.
83.250 to 83.272 mm
3.2776 to 3.2784 in.
Factory spec.
Oversize 87.250 to 87.272 mm
cylinder 3.4351 to 3.4359 in.
V2403-M- 83.420 mm
BG I.D. 3.2843 in.
Allowable limit
87.420 mm
3.4417 in.
Hone to 2.2 to 3.0 μmRz
Finishing (0.000087 to 0.000118 in.Rz)
∇∇∇.
Overrunning Clutch
35.0 mm
Factory spec.
Commutator 1.38 in.
O.D. Allowable 34.0 mm
limit 1.34 in.
0.45 to 0.75 mm
0.018 to 0.029 in.
Factory spec.
Mica under 0.55 to 0.85 mm
cut 0.022 to 0.033 in.
0.20 mm
Allowable limit
0.0079 in.
15.0 mm
Factory spec.
0.591 in.
Brush length (A)
9.0 mm
Allowable limit
0.35 in.
Brush Holder
Field Coil
Bearing
Stator
Rotor
14.4 mm
Factory spec.
0.567 in.
Slip ring O.D.
14.0 mm
Allowable limit
0.551 in.
Brush Wear
10.5 mm
Factory spec.
0.413 in.
Brush length
8.4 mm
Allowable limit
0.33 in.
IC Regulator
Service Manual
G420FE LP/Dual Fuel Engine
G420F LP/Gasoline Dual Fuel Engine
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
1
Index Inspect Battery System ..................................25
Inspect Ignition System..................................25
Inspection of Ignition Timing ..........................25
G420F LPG System Inspection and Repair..... 222 Customer Problem Analysis Sheet ...............251
G420F Fuel System Connections ......... 223 Connector Inspection Procedure ..................253
Appendix
Special Tool
When oil seal, O-ring, packing and gasket have When the part is to be replaced, be sure to use
been removed, be sure to replace them with new genuine part.
parts. For selection of appropriate parts, refer to the Parts
However, rocker cover gasket may be reused if it is Catalog.
not damaged.
Electrical System
Rubber Parts
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.
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
NOTE: The torques shown in the table are standard 1. When spring washers, toothed washers and the
vales under the following conditions. like are inserted.
1. Nuts and bolt are made of steel bar and 2. If plastic parts are fastened.
galvanized.
3. If oil is applied to threads and surfaces.
2. Galvanized plain steel washers are inserted.
NOTE: If you reduce the torques in the table to the
3. All nuts, bolts, plain washers are dry. percentage indicated below under the
following conditions, it will be the standard
NOTE: The torques shown in the table are not value.
applicable,
1. If spring washers are used : 85%
Recommended Lubricants
Lubricant Capacities
Engine Emission
Fuel Type
Model Regulation
EPA/CARB*
G420FE LP/Dual Fuel 2007
Compliant
LP/Gasoline/Dual
G420F
Fuel
* EPA: Environmental Protection Agency
* CARB: California Air Resources Board
G420FE Engine
• Comply with EPA 2007 Emission Regulation Engine Model Engine Serial Number
• Certified LP/Dual Fuel System available Features and Benefits of G420FE/G420F Engine
• Standard LP/Gas/DF/Dual Fuel System available • Distributorless Ignition system (coil on plug)
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.
In order to preserve the environment, used oil
and used oil filter must be disposed of only at
designated disposal sites.
2) Remove the oil drain plug, and drain the oil into
a container.
1. Check that the oil level is between “MIN” and 6) Tighten it an additional 3/4 turn.
“Max” marks on the engine oil level gauge.
3. Refill with engine oil filter.
2. If the oil level is below “MIN” mark, add oil until
the level is within the specified ranges. 1) Clean and install the oil drain plug with a new
gasket.
3. Check the engine for oil contamination and
viscosity and replace if necessary.
39.2~44.1N.m(4.0~4.5kgf.m,
Torque
28.9~32.5lb-ft)
Capacity Drain
4.0L(4.23US qts, 3.52Lmp qts)
and refill
Oil filter 0.3L(0.32US qts, 0.26Lmp qts)
CAUTION
1. Prior to inspection, check that the engine oil,
If a large amount of incomplete combustion
starter motor and battery are normal.
gaso-line comes into the catalytic converter,
emergency such as a fire can occur due to
2. Start the engine and run it until the engine coolant
overheating. So this job should be done quickly
temperature reaches 80 ~ 95°C.
with the engine not operated.
3. Stop the engine and disconnect the ignition coil
and air cleaner element.
CAUTION
At this time, necessarily screen the spark plug
hole with a rag. Because hot coolant, oil, fuel,
and other foreign material, being penetrated in
the cylinder through cracks can come into the
spark hole during checking compressed
pressure.
When cranking the engine to test compressed
pressure, necessarily open the throttle valve be-
fore cranking.
CAUTION
If it is turned in reverse direction, be sure that
the tensioner may function abnormally.
Acceptable Water
Water Content Limits (pps)
Chlorides (CI) 40 maximum
Sulfates (SO4) 50 maximum
Total Hardness 80mg/ℓ maximum
Total Solids 250 maximum
pH 6.0 ~ 8.0
ppm = parts per million
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.
When removing the tester, take care not to spill
the coolant.
When removing/installing the tester as well as
testing, take care not to deform the filler neck.
1. Checking tension
Standard
Item
New belt Used belt 1) Type
Drive belt deflection (L) 4.0~4.4mm 5.1~5.7mm
• BORROUGHS BT - 33 - 73F
2. Using a tension gauge • NIPPONDENSO BTG – 2
2) How to use
Standard
Tension(T) New belt Used belt
65~75kg 40~50kg
CAUTION
The belt used over 5 minutes should be ad-
justed as used belt of standard
Check that the belt is installed correctly.
When the belt is loosened, slip noise is heard.
Crank
pulley
1. Loosen the alternator support bolt “A” nut and Check the following items and replace the belt if
adjusting lock bolt “B”. defective.
2. Adjust the belt tension by moving the alternator 1. Check the belt surface for damage, wear and
brace adjusting bolt to “T” direction. 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. Check the rubber part for wear or hardening.
3. Tighten the bolt “A” and then tighten “B” to the
4. Check the pulley surface for crack or damage.
specified torque.
CAUTION
If the belt tension is too excessive, noise as well
as early wear of belt occurs and the water pump
bearing and alternator bearing are damaged.
If the belt is too loose, due to early wear of belt
and insufficient power of alternator, battery and
water pump become inefficient and finally en-
gine is overheated or damaged.
• Remove battery cables and clean, repair and/or NOTE: Affective ECU input to lgnition timing control
replace as necessary.
• Coolant temperature sensor
• Oxygen sensor
Inspect Ignition System
• Battery voltage
• MAP sensor (Engine load)
• Remove and inspect the spark plugs. Replace as • Crankshaft position sensor
required. • Throttle position sensor
• Intake Air Temperature sensor
• Inspect the ignition coil for cracks and heat
deterioration. Visually inspect the coil heat sink 5) Check that actual ignition timing is changed
fins. If any fins are broken replace as required. with engine RPM increased.
1. Inspection condition
Parking brake : ON
2. Inspection
2) Measure RPM.
RPM
Low Idle 750±15rpm
BTDC 5˚±5˚
1) Insulator broken
2) Terminal worn
3) Carbon deposit
Replace LP Fuel Filter Element 9. Install the cover retaining screws, tightening the
screws in an opposite sequence across the cover.
Park the lift truck in an authorized refueling area with
the forks lowered, parking brake applied and the 10. Open the fuel valve by slowly turning the valve
transmission in Neutral. counterclockwise.
12. Check the filter housing, fuel lines and fittings for
leaks. Repair as necessary.
The length of time the engine runs on trapped fuel • To ensure a valve is not leaking a blow-by test can
vapor increases with any increase in distance be performed.
between the fuel lock-off and the pressure
regulator/converter. 1. With the engine off, disconnect the electrical
connector to the FTVs.
• Turn the ignition key switch off and re-connect the 2. Disconnect the vacuum line from the FTVs to the
fuel lock-off connector. pressure regulator/converter at the converter’s
tee connection.
• Visually inspect the throttle assembly motor • Ensure that wire routing for the oxygen sensors is
housing for coking, cracks, and missing cover- still keeping wires away from the exhaust system.
retaining clips. Repair and/or replace as Visually inspect the oxygen sensors to detect any
necessary. damage.
5. Turn the crankshaft, and align its groove with 11. Remove the idler.
timing mark “T”
12. Remove the crankshaft sprocket.
TIMING BELT
CAUTION
Do not bend or twist the timing belt.
Take care not to contact the timing belt with oil,
water, grease and steam.
7. Tooth is missing
CAUTION
When no.1 piston is at TDC, if the camshaft
sprocket mark is not aligned with head mark,
interference between piston and valve occurs.
So take care of timing aligning.
3. Install the idler and tighten the bolt to the 6) Install the timing belt not to loosen in the
specified torque. following order.
9) Insert a hexagonal wrench to the adjuster 14) Install the crankshaft pulley (A) together with
groove as below, rotate it counterclockwise to the flange, tighten the bolt (B).
place the arm indicator in the middle of base When installing, align the crankshaft key with
groove. the pulley groove.
CAUTION
Tightening torque 16.0 ~ 17.0kgf·m
Do not rotate the wrench clockwise, or the auto
tensioner is not normally functioned.L4GC144A
15) Install the timing belt upper cover.
Engine condition Proper operating Engine condition High speed and overload
PCV valve Proper operating PCV valve Light operating
Vacuum path Big Vacuum path Very big
REMOVAL
INSPECTION
Components
COMPONENTS
MAP sensor
1. Disconnect the map sensor and the connector. 1. After replacing the intake manifold gasket, install
it to the cylinder head and then to the intake
2. Remove the P.C.V valve hose. manifold.
3. Disconnect the fuel injector connector and the 2. Install the delivery pipe and injector assembly to
wiring harness. the intake manifold.
5. Remove the intake manifold stay. 4. Connect the high-pressure fuel hose.
6. Remove the intake manifold and gasket. 5. Connect the P.C.V valve hose.
1. Intake manifold
Check each component for damage and crack.
2. Air hose
Check each component for damage and crack.
COMPONENTS
CAUTION
Do not tighten parts excessively, observe the
specified torque.
INSPECTION
INSTALLATION
CAUTION
Do not reuse the exhaust manifold nut.
Water pump (10) is installed on the front of the thermostat (2) is open the coolant will go through
cylinder block. The water pump is driven by a single radiator top hose (5) and into the top tank of radiator
V belt from the crankshaft pulley. The inlet opening (8). Coolant then goes through the cores of the
of the water pump is connected to the radiator lower radiator. The air from the fan will make the coolant
hose (9). The outlet flow from the water pump goes cool as the coolant flows to the bottom of the
through passages inside the cylinder block. radiator and out hose (9) where the coolant returns
The coolant from the water pump through the to water pump (10).
cylinder block passages has primary coolant flow to The radiator is equipped with a shroud to increase
and around the seats for the exhaust valves. This the efficiency of the fan and cause the air to be
method gives the coolant with the coolest pushed through the radiator and away from the lift
temperature flow to the hottest area during engine truck.
operation. If the coolant is hot and the cooling system pressure
Cylinder walls (7) are cooled by the coolant flow is too high, some coolant flows to the top of radiator
through the block. After the coolant goes through the (8) through the tube to recovery tank (3). The
cylinder block it flows through cylinder head (1) to cooling system pressure is controlled by cap (6).
the thermostat housing, where the bypass type When the cooling system pressure goes above its
thermostat (2) is installed. The thermostat controls rated pressure, a valve opens in pressure cap (6)
the opening to radiator (8) to control the temperature which releases the cooling system pressure to the
in the cooling system. atmosphere. After the engine is at normal
If the coolant is cold (cool), the thermostat will be temperature for operation, a development of vacuum
closed. The coolant circulates (makes a complete is present in the cooling system. Pressure cap (6)
circuit) from the water pump and through the permits air in the radiator to remove the vacuum at
cylinder block until the temperature of the coolant is the same time coolant from recovery tank (3) is
warm enough to make the thermostat open. When pulled back into the radiator.
Adhere to the following warnings when performing 6. Check for damage to the fan blades.
any tests or adjustments while the engine is running:
7. Look for air or combustion gas in the cooling
system.
WARNING
Work carefully around an engine that is running. 8. Inspect the filler cap and the surface that seals
Engine parts that are hot, or parts that are the cap. This surface must be clean.
moving, can cause personal injury.
9. Look for a large amount of dirt in the radiator core
and on the engine.
WARNING
10. Check for loose or missing fan shrouds that
Exhaust fumes contain carbon monoxide (CO) cause poor flow of cooling air.
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 Cooling System Tests
the outside.
WARNING
Do not loosen the filler cap or pressure cap on a
hot engine. Steam or hot coolant can cause
severe burns. Remember that temperature and pressure work
together. When making a diagnosis of a cooling
1. After the engine is cool, loosen the filler cap (on a system problem, temperature and pressure must
radiator with a pressure cap, turn it to the first both be checked. Cooling system pressure will have
stop) to let pressure out of the cooling system. an effect on cooling system temperatures. For an
Then remove filler or pressure cap. example, look at the chart to see the effect of
pressure and height above sea level on the boiling
2. Check coolant level in the cooling system. (steam) point of water.
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.
Pressure Cap Diagram 2. Make sure the radiator is full (hot) or nearly full
(A) Sealing surface of cap and radiator. (cold) of coolant.
One cause for a pressure loss in the cooling system 3. Attach the Cooling System Pressurizing Pump
can be a bad seal on the pressure cap of the system. Tool to the radiator filler neck.
Inspect the pressure cap carefully. Look for damage
to the seal or the sealing surface. Any foreign 4. Pump the pressure to 20 kPa (3 psi) more than
material or deposits on the cap, seal or seal or the rated pressure of the cap.
sealing surface must be removed.
5. Check the radiator for outside leakage.
To check the pressure cap opening pressure, do the
following procedure. 6. Check all connections and hoses of the cooling
system for outside leakage.
WARNING
7. If there is no outside leakage and the pressure
If the engine has been in operation and the reading on the gauge is still the same after 5
coolant is hot, slowly loosen the pressure cap to minutes, the radiator and cooling system do not
the first stop and let the pressure out of the have leakage. If the reading on the gauge goes
cooling system, then remove the pressure cap. down and there is no outside leakage, there is
leakage on the inside of the cooling system.
Make repairs as necessary
1. Remove pressure cap from the radiator.
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.
Operation
b. Coolant boils out (comes out because of too The engine cooling system is provided with a
much heat) of the cooling system during mixture of 50% ethylene glycol anti-freeze and 50%
operations. water (For the vehicles of tropical area, the engine
cooling system is provided with a mixture of 40%
c. Coolant boils out on the floor when the engine is ethylene glycol anti-freeze and 60% water at the
stopped. time of manufacture.)
Since the cylinder head and water pump body are
d. Coolant must be added at the end of each shift made of aluminum alloy casting, be sure to use a 30
but Steps b and c are not present. to 60% ethylene glycol antifreeze coolant to assure
corrosion protection and freezing prevention.
2. If indication in Step 1 a is only present. It is
possible the problem is only a damaged gauge,
light or sender. Make a replacement of the WARNING
defective part. If the concentration of the antifreeze is below
30%, the anticorrosion property will be adversely
3. If indication in Step 1b is present, do the affected. In addition, if the concentration is
procedure that follows: above 60%, both the antifreeze and engine
cooling properties will decrease, adversely
a. Run the engine at medium idle (1200 rpm) for affecting the engine. For these reasons, be sure
three minutes after high idle operation. This cools to maintain the concentration level within the
off the hottest parts of the engine before it is specified range.
stopped.
b. Install a coolant recovery system on the truck, if To prevent damage to your engine, never add
not already equipped. coolant to an overheated engine. Allow the engine to
cool first.
4. If indications in Step 1b, 1c or 1d are present, but If the lift truck is to be stored in, or shipped to, an
Step 1a is not and the high temperature indicator area with freezing temperatures, the cooling system
light does work, the problem can be a damaged must be protected to the lowest expected outside
radiator cap seal or there can be a leak in the (ambient) temperature.
cooling system. Complete the procedure that
follows: The engine cooling system is protected with a
commercially available automotive antifreeze, when
a. Do the Pressure Cap Test, Cooling System Leak shipped from the factory.
Check, Thermostat Test and Belt Adjustment in
the Testing And Adjusting. Check the specific gravity of the coolant solution
frequently in cold weather to ensure adequate
b. Clean the radiator with hot water (steam clean) at protection.
low pressure and use detergent or air according
to the different types of debris that caused the
radiator to be dirty (plugged). Clean the cooling system if it is contaminated, if the
engine overheats or if foaming is observed in the
c. Check the engine high idle setting. radiator.
Acceptable Water
Water Content Limits (ppm)
Chlorides (CI) 40 maximum
Sulfates (SO4) 50 maximum
Total Hardness 80mg/ℓ maximum
Total Solids 250 maximum
pH 6.0 ~ 8.0
ppm = parts per million
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 connect-
ing part with sand or dust.
Press-fit the coolant intake pipe completely.
COMPONENTS
INSTALLATION
B
A
B
1. Drain the engine coolant.
CAUTION
A 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 1. Clean the gasket surface of the water pump body
engine is cool. and cylinder block.
2. Remove drive belts. 2. After getting water around new O-ring, install it
the groove in the coolant intake pipe front end.
3. Remove the timing belt. Do not apply oil or grease to the O-ring.
4. Remove the timing belt idler. 3. Install a new water pump gasket and water pump
assembly. Tighten it to the specified torque.
5. Remove the water pump.
WATERPUMP AND CYLINDER BLOCK
1) Remove the 4 bolts and pump pulley.
A 2.0 ~ 2.7 kg·m
2) Remove the 3 bolts (C), then remove the
alternator brace (A). B 2.0 ~ 2.4 kg·m
3) Remove the water pump (B) and gasket. 4. Install the timing belt tensioner and timing belt.
Adjust the timing belt tension and install the timing
INSPECTION belt cover.
COMPONENTS
INSPECTION INSTALLATION
3. Add coolant.
Open 82°C
COMPONENTS
REMOVAL
INSPECTION
INSTALLATION
Cylinder Head
Valve margin
Flatness of cylinder Standard 0.03mm or less
Head gasket surface Limit 0.06mm Intake 1.15mm
Standard
Exhaust 1.35mm
Exhaust 1.0mm
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
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 NOTE: In normal case, the recommended engine oil
and operate the engine in a well ventilated area for G420F(E) engine is SAE 10W - 30.
only. In an enclosed area, vent the exhaust to
the outside.
But, if the excessive valve noise occurs up to five
minutes after a cold start and if the maximum
Engine Oil ambient temperature is lower than 10°C (50°F), it is
recommended to change engine oil to SAE 5W - 30
Engine Oil Recommendation for that application.
Prior to changing oil, select an oil based on the One of the problems in the list that follows will
prevailing daytime temperature in the area in which
generally be an indication of a problem in the
the engine is operated. The chart in figure is a guide
to selection the proper crankcase oil. lubrication system for the engine.
IMPORTANT: Oils containing “solid” additives, non- • Too much oil consumption.
detergent oils, or low-quality oils are not
• Low oil pressure.
recommended for use in G420F(E) Engine.
• High oil pressure.
Oil leakage into the combustion area of the cylinders 4. Leakage at the oil line connections.
can be the cause of blue smoke. There are three
possible ways for oil leakage into the combustion 5. Worn connecting rod or main bearings. Worn
area of the stems. gears in the oil pump.
1. Oil leakage between worn valve guides and valve 6. Oil pressure relief valve worn or stuck in the
stems. OPEN position.
2. Worn or damaged piston rings, or dirty oil return 7. Oil filter bypass valve stuck open. Oil filter is
holes. restricted. Replace oil filter.
Instrument Panel
(1) Engine Oil Light
After applying sealant to the spiral portion, install the 3. When applying a negative pressure of 0.3kg/cm2
oil pres-sure switch. through the oil hole, it an electric current is not
measured, the switch is normal. If the switch is not
NOTE: Do not tighten the oil pressure switch too normal, check for air leak. If air is leaked, replace
tight. the switch because it means damage of the
diaphragm.
Oil pressure switch 1.3 ~ 1.5㎏∙m
COMPONENTS
5. Remove the oil pan and oil screen 6. Remove the front case.
B 20mm(0.787in)
Body length
C 38mm(1.496in)
D 45mm(7.771in)
19.6~26.5N.m
Tightening torque
(2.0~2.7kgf.m, 14.5~19.5lb-ft)
5.9~8.8N.m
Tightening torque 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.
INSPECTION
0.025~0.069mm
Tip clearance
(0.0010~0.0027in.)
43.8mm
Free height
Standard (1.724in.)
value 3.7kg/40.1mm
Load
(8.14lb/1.579in.)
0.12~0.185mm
Body clearance
(0.0047~0.0073in.)
REASSEMBLY
39.2~49.0kgf.m
Tightening torque
(28.9~36.2lb-ft)
Components
L4GC043A
1. Check the oil seal surface for wear and if the seal
lip portion is worn, replace it.
1. Check the camshaft journal for wear and if the 2) Warm-up the engine.
journal is seriously worn, replace the camshaft.
3) If the valve noise is heard at engine warm-up,
2. Check the cam lobe for damage and if the lobe is air-bleed the system.
severely damaged or worn, replace the camshaft.
4) How to air-bleed
Items Standard Limit
a) During remaining it for 10 minutes at
Intake 43 42.9 3,000 rpm and over 5 minutes at idle, check
Cam that the valve noise is heard.
height Exhaust 43 42.9
b) Repeat the above step(a) only once or twice.
3. Check the cam surface for abnormal wear and
damage and replace it if necessary.
CAUTION
Because HAL is precision parts, take care not to
come foreign materials such as a dust from
outside.
Do not disassemble HLA. 1. Install HLA
When cleaning HLA, use clean diesel oil.
Take care not to make scratches and sharp 2. After Installing the intake and exhaust camshaft
edges to O.D of HLA. by aligning it with the timing mark on the timing
With HLA filled with engine oil, grasp A and chain sprocket, install the camshaft to the cylinder
press B by hand as shown in the illustration, if head.
the HLA is moving, replace the HLA.
CAUTION
Apply engine oil to the camshaft journal and
cam.
There a detective pin for TDC sensor in the in-
take camshaft rear end and a dowel pin in the
intake camshaft front end.
CAUTION
Align the timing marks on the camshaft sprocket
and the crankshaft sprocket. At this time piston
no.1 cylinder should be placed on the
compression dead point.
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
7. Place the cylinder no.1 to the dead point. deformed resulting in oil leaks and the head
cover bolt can be broken resulting in cylinder
head replacement.
1) Rotate the crankshaft pulley so as to align it When installing after head cover removing,
with “T” mark on the timing belt low cover. necessarily apply sealant to the head cover rear
and front portion.
Because the head cover is made of plastic, take
care not to drop tools on the head cover upper
portion when removing/installing the engine
parts.
When installing after head cover removing, after
checking the head gasket for damage, re-use it if
it is normal.
When applying/draining engine oil, take care not
to spill oil on the head cover upper surface, if oil
is spilled, wipe it out completely with a paper
and a rag.
3. Disconnect the connecting rod cap. Journal oil clearance 0.028 ~ 0.048mm
4. Remove the main bearing cap. (Arrange it in Pin oil clearance 0.024 ~ 0.044mm
order)
2.7 ~ 3.3kg·m+
Main bearing cap bolt
5. Remove the crankshaft. (60°~ 65°)
Connecting rod cap bolt 5.0 ~ 5.3kg·m
6. Disassemble the crankshaft position sensor wheel.
Inspection
1. Crankshaft
CAUTION
Sensor wheel as one of the electronic control
affects performance if deformed or damaged, so
be careful when handling it.
Removal
Inspection
1. Remove the flywheel.
1. Check the ring gear for damage and crack and
2. Remove the flywheel housing. replace it if necessary.
Assembly
Piston Ring
Specified
Item Limit
value
1. Remove the cylinder head assembly. Side clearance No.1 0.04 ~ 0.08mm 0.1mm
of piston ring No.2 0.03 ~ 0.07mm 0.1mm
NOTE: Put an identification mark on the connecting
rod and cap before disassembly to refer to the
original position and direction.
1) Remove the piston ring. 2. To measure the end gap of piston ring, insert the
piston ring to the cylinder bore. At this time,
2) When placing the assembly on a press, face smoothly insert the ring to the piston so as to
the front mark on the piston upward. place the ring and cylinder wall to right position.
After this, smoothly insert the ring to the piston.
3) Using the press, remove the piston pin. And then, pull out the piston upward and measure
gap using a feeler gauge. When the gap exceeds
the limit, re-place the piston ring.
Connecting Rod
Front mark
Component
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
6. Remove oil level gauge assembly (A). from the top of the cylinder.
Connecting Rod and Crankshaft 5) Place plastigage across the crank pin.
Tightening torque
50~53 Nm(500~530kgf.cm,36.9~39lbf.ft)
1. Check the connecting rod end play. Using feeler 7) Remove the 2 nuts, connecting rod cap and
gauge, measure the end play while moving the bearinghalf.
connecting rod back and forth.
8) Measure the plastigage at its widest point.
• If out-of-tolerance, install a new connecting rod 9) If the plastigage measures too wide or too
narrow, remove the upper half of the bearing,
• If still out-of-tolerance, replace the crankshaft. install a new, complete bearing with the same
color mark (select the color as shown in the
next column), and recheck the clearance.
CAUTION
Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
2. Check the connecting road bearing oil clearance. NOTE: If the proper clearance cannot be obtained
by using the appropriate larger or smaller
1) Check the matchmarks on the connecting rod bearings, replace the crankshaft and start over.
and cap are aligned to ensure correct
reassembly. CAUTION
2) Remove the 2 connecting rod cap nuts. If the marks are indecipherable because of an
accumulation of dirt and dust, do not scrub them
3) Remove the connecting rod cap and bearing with a wire brush or scraper. Clean them only
half. with solvent or deter gent.
OUTSIDE
CLASS MARK
DIAMETER OF PIN
44.960~44.966mm
Ⅰ WHITE
(1.7700~1.7703in.)
44.955~44.960mm
Ⅱ NONE
(1.7698~1.7700in.)
44.948~44.955mm
Ⅲ YELLOW
(1.7696~1.7698in.)
a (WHITE) B (NONE)
CAUTION
III(WHITE) b (NONE) A (BLACK) Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
c (YELLOW) AA (BLUE)
3. Check the crankshaft bearing oil clearance. 7) If the plastigage shows the clearance is still
incorrect, try the next larger or smaller bearing
(the color listed above or below that one), and
check clearance again.
CAUTION
If the marks are indecipherable because of an
accumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only
with solvent or detergent.
1) To check main bearing-to-journal oil clearance,
remove the main caps and bearing halves.
1. When reinstalling, make sure that cylinder CLASS MARK INSIDE DIAMETER
numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod i 59.000~59.006mm
a A
s installed, make sure that the notches for holding (2.3228~2.3230in.)
the bearing in place are on the same side. 59.006~59.012mm
b B
(2.3230~2.3233in.)
2. Replace the connecting rod if it is damaged on
the thrust faces at either end. Also if step wear or 59.012~59.018mm
c C
a severely rough surface of the inside diameter of (2.3233~2.3235in.)
the small end is apparent, the rod must be
replaced aswell. Crankshaft journal mark location
Letters have been stamped on the end of the block Discrimination of crankshaft
as a mark for the size of each of the 5 main journal
bores. OUTSIDE
CLASS MARK DIAMETER OF
Use them, and the numbers or bar stamped on the JOURNAL
crank (marks for main journal size), to choose the 54.956~54.962mm
correct bearings. Ⅰ YELLOW
(2.1636~2.1638in.)
54.950~54.956mm
Ⅱ NONE
(2.1633~2.1636in.)
54.944~54.950mm
Ⅲ WHITE
(2.1631~2.1633in.)
THICKNESS OF
CLASS MARK
BEARING
2.014~2.017mm
AA BLUE
(0.0793~0.0794in.)
2.011~2.014mm
A BLACK
(0.0791~0.0793in.)
2.008~2.011mm
B NONE
(0.0790~0.0791in.)
2.005~2.008mm
C GREEN
(0.0789~0.0790in.) If the end play is greater than maximum, replace the
2.002~5.005mm thrust bearings as a set.
D YELLOW
(0.0788~0.0789in.)
c (C) B(NONE)
a (A) C (GREEN)
c (C) A (BLACK)
a (A) B (NONE)
c (C) AA (BLUE)
1. Clean piston
1. Oversize pistons should be selected according to 1) Using a gasket scraper, remove the carbon
the largest bore cylinder. from the piston top.
NOTE: The size of piston is stamped on top of the NOTE: Do not use a wire brush.
piston.
Standard diameter
CAUTION 81.97 ~ 82.00 mm(3.2272 ~ 3.2283in.)
To prevent distortion that may result from
temperature rise during honing, bore the
cylinder holes in the firing order.
Piston-to-cylinder clearance
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
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
Piston pin diameter oil seals with new parts.
20.001~20.006 mm (0.7874 ~ 0.7876in.)
1. Assemble piston and connecting rod.
2. Measure the piston pin-to-piston clearance. 1) Use a hydraulic press for installation.
2) Install the bearings (A) in the 6. Place crankshaft on the cylinder block.
connecting rod and connecting rod cap (B).
7. Place main bearing caps on cylinder block.
Tightening torque
30Nm (300kgf.cm, 22lbf.ft)
Tightening torque
Main bearing cap bolt:
30Nm (300kgf.cm,22lbf.ft)+60˚~65˚
Tightening torque
10~12Nm (100~120kgf.cm, 7.3~8.8lbf.ft)
2) Install the ring compressor, check that the 12. Install rear oil seal.
bearing is securely in place, then position the
piston in the cylinder, and tap it in using the 1) Apply engine oil to a new oil seal lip.
wooden handle of a hammer.
2) Using SST (09231-21000) and a hammer, tap
3) Stop after the ring compressor pops free, and in the oil seal until its surface is flush with the
check the connecting rod-to-check journal rear oil seal retainer edge.
alignment before pushing the piston into place.
13. Install front case.
4) Apply engine oil to the bolt threads. Install the
rod caps with bearings, and torquethenuts:
50~53Nm(500~530kgf.cm,36.9~39lbf.ft)
Tightening torque
10~12Nm (100~120kgf.cm, 7.3~8.8lbf.ft)
Tightening torque
12~15Nm (120~150kgf.cm,9~11lbf.ft)
Tightening torque
15~22Nm (150~220kgf.cm, 11~16lbf.ft)
Tightening torque
12~15Nm (120~150kgf.cm, 9~11lbf.ft)
19. Install cylinder head.
Tightening torque
120~130Nm (1200~1300kgf.cm,89~96lbf.ft)
Specifications
Ignition Coil
Item Specification
Spark Plug
Item Specification
NGK PFR6N
Type
CHAMPION RC8PYPB
Spark plug gap 0.7 ~ 0.8mm
Starter Motor
Item Specification
Alternator
Item Specification
COP problems can include many of the same Individual ignition coils can be tested with an
ailments as other ignition systems such as misfiring, ohmmeter the same as those on a conventional
hard starting, or a no start. Spark plugs can still be distributor or DIS ignition system. Measure primary
fouled by oil or fuel deposits, as well as pre-ignition and secondary resistance and compare to
and detonation. specifications. If resistance is out of specifications,
the coil is bad and needs to be replaced.
If the crankshaft position sensor fails, the loss of the
basic timing signal will prevent the system from Also, pay close attention to the tube that wraps
generating a spark and the engine will not start or around the spark pug. Cracks can allow voltage to
run. A failed driver circuit within the SECM can kill jump to ground causing a misfire. The spark plug
an individual coil and prevent that cylinder from firing. terminal should also fit tightly.
But with COP, an individual coil failure will only
cause misfiring in one cylinder. If a COP coil tests bad and is replaced, cleaning the
COP connector and wiring harness terminals can
It is important to remember that ignition misfire can often avoid future problems. Corrosion at either
also be caused by other factors such as worn or place can cause intermittent operation and loss of
fouled spark plugs, loose or damaged coil connector continuity, which may contribute to component
or terminals, dirty fuel injectors, low fuel pressure, failure. Applying dielectric grease to these
intake vacuum leaks, loss of compression in a connections can help prevent corrosion and assure
cylinder, even contaminated fuel. These other a good electrical connection.
possibilities should all be ruled out before a COP
unit is replaced. Magnetic crankshaft position sensors can be tested
with an ohmmeter, and the sensor output voltage
A COP engine that cranks but fails to start, in many and waveform can be read with an oscilloscope. The
cases, will often have a problem in the crankshaft or output voltage of a Hall Effect crankshaft position
camshaft position sensor circuits. Loss of sensor sensor can be checked with a voltmeter. On most
signals may prevent the SECM from properly vehicles, a defective crank position sensor will
synchronizing, thereby preventing the engine from usually set a fault code that can be read with the
starting and running. Service Tool.
Circuit Diagram
SECM
CAUTION
Take care not to disconnect the connector.
3) Measure RPM.
RPM
Low Idle 750 ± 15 rpm
BTDC 5˚ ± 5˚
5) If ignition timing is out of the standard, inspect (1) Power TRs (2) SECM
sensors concerned with ignition timing.
CAUTION
Because ignition timing is fixed by set data
value in ECU, it is impossible to control on
purpose.
Fisrt, check that sensors send output properly to
help determine ignition timing control.
Description
The operation of the ignition system is essentially
the same as any other ignition system. Each coil has
a low primary resistance (0.4 to 0.6 ohms) and steps
up the primary system voltage from 12 volts to as
much as 40,000 volts to produce a spark for the
IB (Terminal #3), OC (Terminal #1), GND (Terminal spark plug.
#2)
The primary difference between COP and other
ignition systems is that each COP coil is mounted
directly atop the spark plug so the voltage goes
directly to the plug electrodes without having to pass
through a distributor or wires. It is a direct
connection that delivers the hottest spark possible.
Resistor plugs are generally used to suppress
electromagnetic interference (EMI).
CAUTION
1st Coil Resistance : 0.71 ± 9 % (Ω) Take care not to come foreign materials into
spark-plug mounting hole.
3. Inspection of battery voltage at idling (At this time charge battery only)
Result
Preparation 4. After test, adjust the engine speed at idle and turn
the light and ignition switch OFF.
1. Turn the ignition switch OFF.
5. Disconnect the battery ground cable.
2. Disconnect the battery ground cable.
6. Disconnect the ammeter and voltmeter.
3. Disconnect the alternator output wire from the
alternator “B” terminal. 7. Connect the alternator output lead wire to the
alternator “B” terminal.
4. Connect a DC ampere meter (0-100A) between
the terminal and the disconnected output wire. 8. Connect the battery ground cable.
Connect (+) lead wire to the terminal “B” and (-)
lead wire to the disconnected output wire. Output Current Test
NOTE: In case of using a clamp type ammeter, it is This test is to check that the alternator output
possible to measure current without disconnecting current is identified with the rated current.
the harness.
Preparation
5. Connect a digital voltmeter between the alternator
“B” terminal and the battery (+) terminal. 1. Prior to test, inspect the following items and repair
Connect (+) lead wire to the terminal and (-) lead if necessary.
wire to the battery (+) terminal.
1) Be sure that the battery installed in the vehicle
6. Connect the battery ground cable. is normal.(See “Battery”)
7. Be sure that the hood is opened. NOTE: When measuring output current, necessarily
use a slightly discharged battery. Fully charged
battery is not enough to use for correct test owing to
insufficient load.
4. Disconnect the alternator output wire from the NOTE: This test should be done as soon as
alternator “B” terminal. possible to measure the exact maximum current
because output current drops rapidly after starting
the engine.
Result
7. Connect the engine tachometer and then battery 2. After test, adjust the engine speed at idle and turn
ground cable. the light and ignition switch OFF.
8. Be sure that the hood is opened. 3. Disconnect the battery ground cable.
1. Be sure that voltmeter reading is identified with 5. Connect the alternator output lead wire to the
battery voltage. alternator “B” terminal.
If voltmeter reading is 0V, it means short circuit of
wire between “B” terminal and the battery (-) 6. Connect the battery ground cable.
terminal, fusible link cut off or ground fault.
1. Disconnect the battery (A) terminal. 1. After removing the mounting nuts (B), remove the
generator cover (A) using a screwdriver.
Rotor
2. (-) rectifier
When inspecting continuity between (-) rectifier
1. Inspect the stator coil for continuity and check and stator coil lead connecting terminal using an
continuity between the coil leads. If there is no ohmmeter, there must have only one direction
continuity, replace the stator assembly. continuity. If there is both direction continuity,
replace the rectifier assembly owing to short
circuit of diode.
Brush Replacemement
Rectifier If the brush is worn out to the limit, replace the brush
as the following order.
1. (+) 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.
Installation
Components
MAXIMUM ACCEPTABLE SYSTEM VOLTAGE • If the battery voltage is too low, Charge or replace
DROPS DURING CRANKING the battery.
Circuit
12V System NOTE: Alow battery can be caused by battery
Battery(-) post to starting motor (-) condition or a shorted starting motor.
terminal 0.7 Volts
3. Measure current draw on the (+) battery cable
Battery (+) post to solenoid (+) between the battery and the starting motor
terminal 0.5 Volts solenoid with the clamp-on ammeter. The
maximum current draw allowed is 350 Amp. At
Solenoid Bat terminal to solenoid temperatures below27°C (80°F), the voltage will
Mtr terminal 0.4 Volts be less and the current draw will be higer. If
current draw is too much, the starting motor has a
problem and must be removed for repair or
Figure 2 replacement.
Voltages greater than those shown are most often
caused by loose and/or corroded connections or NOTE: If voltage at the battery post is within
defective switch contacts. approximately 2 volts of the lowest value in the
applicable temperature range of Figure1 and if the
Diagnosis Procedure large starting motor cables get hot, then the starting
motor has a problem and the Ammeter test is not
needed.
TOOLS NEEDED
Digital Multimeter or Equivalent 4. Measure starting motor voltage from test point (4)
1
to (5) with the multimeter while cranking or
DC Clamp-On Ammeter or Equivalent attempting to crank the engine.
1
5. Is voltage equal to or greater than shown in
Figure1?
• If the starting motor voltage is low, the voltage 1. Put the multimeter on the 200 ohm scale.
drop between the battery and the starting motor
is too great. Go to Step 6. 2. Put the multimeter lead to the 85 and 86 terminals.
6. Measure the voltage drops in the cranking circuits 3. The indication on the meter must be 82 5 ohms. If
with the multimeter. Compare the results with the indication is not correct, the start relay must
maximum voltage drops allowed in Figure 2. be replaced.
7. Are all the voltages within specifications ? 4. Put the multimeter leads to the 30 and 87
terminals.
• If the voltage drops are correct, go to Step 8, to
check the engine. 5. The indication must be "OL"(Over Load). If the
indication is not correct, the start relay must be
• If the voltage drops are too high, repair and/ or replaced.
replace the faulty electrical component.
6. Connect WH wire to 86 and BK wire to 85
8. Rotate the crankshaft by hand to make sure it is terminal with the ignition switch to start position.
not locked up. Check oil viscosity and any Put the meter lead to 30 and 87 terminal.
external loads that would affect engine rotation.
7. The indication must be Zero ohm. If the indication
9. Is the engine locked up or hard to turn ? is not correct the start relay must be replaced.
Components
11
8
7 9
14
15
13
12
19
10
3
2
20
18
17
16
L4GC343A
3. Separate the start motor connector and terminal. 4. Measure clearance between the pinion and
stopper using a feeler gauge. If the measured
4. Remove the start motor assembly. value is out of the standard, adjust clearance by
adding or removing the washer between the
5. Installation is the reverse of removal. magnetic switch and front bracket.
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 2. To operate the start motor with no load, turn the
“M” terminal. switch ON. If the operating speed and current
measured are identified with the standard, the
start motor is normal. If the operating speed is
CAUTION insufficient or the current is excessive, it is
This test should be done as soon as possible not to because of excessive friction resistance. And the
damage the coil (in 10 seconds). low current or lack of operating speed is because
of faulty contact or open circuit between the brush
and the rectifier or between the welding points.
3. If the pinion is moving outward, the coil is normal,
if the pinion is moving inward, replace the
magnetic switch owing to open-circuit. Speed Minimum 3,000rpm
CAUTION
This test should be done as soon as possible not to
damage the coil (in 10 seconds).
6. Brush.
If the brush is worn out to the limit, replace the
brush.
9. Bruch Replacement
1) Remove the worn brush taking care not to 1. Install the overrunning clutch to the armature
damage the pigtail. shaft front end.
2) For better welding, correct the pigtail end with a 2. Install the stop ring and snap ring to the armature
sand paper. shaft front end and completely press the stop ring
toward the snap ring.
3) Weld the pigtail end.
General Information
Specifications
Q’ty
Components Items Specifications
G420FE G420F
Environmental / Ambient Operating -20 °F to 221°F [-29 °C to 105 °C]
Electrical Temperature
None None
Specifications 8-16 Vdc
Operating Voltage
Engine Control Module Operating Temperature -20 °F to 221°F [-29 °C to 105 °C]
(SECM 48)
8-16 Vdc
Operating Voltage SECM microprocessor may reset at
1 1
voltages below 6.3 Vdc
Q’ty
Components Items Specifications
G420FE G420F
Q’ty
Components Items Specifications
G420FE G420F
Q’ty
Components Items Specifications
G420FE G420F
LP Fuel System Operating Temperature -20 °F to 221°F [-29 °C to 105 °C]
Requirements
LPG Composition HD5 / HD10 LPG. Failure to use fuel
- -
Requirements compliant with
HD5 or HD10 standards will void the
user warranty.
LP Fuel Filter 1 1 Fuel Filter Micron Size 40 micron
LP Fuel Lock-off 1 1 Electrical Resistance 20~25Ω
N-2007 LP Regulator Fuel Supply Pressure 10 psi to 250 psi (68.95 kPa to
For G420FE 1723.69 kPa)
Fuel Outlet Fitting Two 3/4” NPT fittings with one plugged
and one 1/8” NPT fitting with plug
Fuel Outlet Fitting One 3/4” NPT and one 1/8” NPT fitting
with plug
Q’ty
Components Items Specifications
G420FE G420F
Gasoline System Gasoline Unleaded gasoline of 87 octane or
None None
Requirements Requirements higher is recommended
Gasoline Fuel Pump 1 1 Type Electrical, In-Tank
Gasoline Fuel Filter Type High pressure type (built in Fuel Pump
1 1
Assembly)
Gasoline Pressure Pressure 350 kPa (49.8 psi)
1 1
Regulator built in Fuel Pump Assembly
Fuel Injector Type Electric-magnetic
4 4
Coil resistance 14.5 +/- 0.35 ohms
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 ~ 11.8 1.1 ~ 1.2 8.0 ~ 8.7
Camshaft Position Sensor (CMPS) 4~6 0.4 ~ 0.6 2.9 ~ 4.3
Engine Coolant Temperature Sensor (ECTS) 15 ~ 20 1.5 ~ 2.0 10.8 ~ 14.5
Delivery pipe installation 19 ~ 28 1.9 ~ 2.8 13.7 ~ 20.3
General Description
MI-07 control system provides a complete, fully MI-07 is a closed loop system utilizing a catalytic
integrated engine management system that meets muffler to reduce the emission level in the exhaust
or exceeds 2007 emission standards for Large gas. In order to obtain maximum effect from the
Spark Ignited (LSI) engines established by the catalyst, an accurate control of the air fuel ratio is
California Air Resources Board (CARB) and the required. A small engine control module (SECM)
Environmental Protection Agency (EPA). uses two heated exhaust gas oxygen sensors
(HEGO) in the exhaust system to monitor exhaust
The control system is applicable to naturally gas content. One HEGO is installed in front of the
aspirated engines running on LPG and/or gasoline. catalytic muffler and one is installed after the
It provides accurate, reliable, and durable control of catalytic muffler.
fuel, spark, and air over the service life of the engine
in the extreme operating environment found in
heavy-duty, under hood, on-engine electronic
controls.
[Figure 1] MI-07 Dual Fuel System for G420FE Engine on Certified Systems
The SECM makes any necessary corrections to the wire (DBW) system connecting the accelerator pedal
air fuel ratio by controlling the inlet fuel pressure to to the electronic throttle through the electrical
the air/fuel mixer by modulating the dual fuel trim harness; mechanical cables are not used. A throttle
valves (FTV) connected to the regulator. Reducing position sensor (TPS) monitors throttle position in
the fuel pressure leans the air/fuel mixture and relation to the accelerator pedal position sensor
increasing the fuel pressure enriches the air/fuel (APP) command. Even engine coolant temperature
mixture. To calculate any necessary corrections to and adequate oil pressure are monitored by the
the air fuel ratio, the SECM uses a number of SECM. The SECM controller has full adaptive
different sensors to gain information about the learning capabilities, allowing it to adapt control
engine’s performance. Engine speed is monitored function as operating conditions change. Factors
by the SECM through a Hall Effect sensor. Intake such as ambient temperature, fuel variations,
manifold air temperature and absolute pressure are ignition component wear, clogged air filter, and other
monitored with a TMAP sensor. MI-07 is a drive-by- operating variables are compensated.
INPUT OUTPUT
Crank Sensor Throttle body
TMAP sensorv
2 Fuel trim valves
Coolant Temp
LP fuelock valve
A dual fuel system operates on either LPG or MPI (multi-point injection) system is used for
gasoline. The fuel type can be switched while the G420FE dual fuel engine and G420F gasoline/dual
engine is stopped or running at low speeds and low fuel engine. On gasoline, the camshaft sensor along
loads. The fuel selection switch is a three-position with the crankshaft sensor is used to control the fuel
type where the center position is fuel off. injectors and feedback from oxygen sensor is used
by the SECM to adjust the gasoline delivery based
on the exhaust emissions.
SECM
The Small Engine Control Module (SECM) controls
the LPG lock-off solenoid valve and the FTVs. The
lock-off solenoid is energized when fueling with LPG
and the engine is turning. FTV modulation frequency Figure 4. Electric Fuel Lock Assembly
will be varied as a function of rpm by the SECM in
order to avoid resonance phenomena in the fuel In the MI-07 design, power is supplied to the fuel
system. FTV commands will be altered by the lock-off via the main power relay with the SECM
SECM in order to maintain a stoichiometric air-fuel controlling the lock-off ground (earth) connection.
ratio. Commands are based primarily on feedback The lock-off remains in a normally closed (NC)
from the exhaust gas oxygen sensor, with an offset position until the key switch is activated.
for fuel temperature. This supplies power to the lock-off and the SECM,
but will not open the lock-off via the main power
MI-07 LP Fuel Filter relay until the SECM provides the lock-off ground
connection. This design gives the SECM full control
After exiting the fuel tank, liquid propane passes
of the lock-off while providing additional safety by
through a serviceable inline fuel filter to the electric
closing the fuel lock-off in the unlikely event of a
fuel lock off. Figure 3 shows a typical inline type LP
power failure, wiring failure or module failure.
fuel filter manufactured by Century. The primary
function of the fuel filter is to remove particles and
When the liquid service valve in the fuel container is
sediments that have found their way into the tank.
opened, liquid propane flows through the LP filter
The LP fuel filter will not remove heavy end solids
and through the service line to the fuel lock-off.
and paraffins that build up in LPG fuel systems as a
Liquid propane enters the lock-off through the 1/4”
result of vaporization.
NPT liquid inlet port and stops with the lock-off in the
normally closed position. When the engine is
cranked over the main power relay applies power to
the lock-off and the SECM provides the lock-off
ground causing current to flow through the windings
of the solenoid creating a magnetic field. The
strength of this magnetic field is sufficient to lift the
lock-off valve off of its seat against spring pressure.
When the valve is open liquid propane, at tank
pressure, flows through the lock-off outlet to the
pressure regulator/converter. A stall safety shutoff
feature is built into the SECM to close the lock-off in
case of a stall condition. The SECM monitors three
engine states: Crank, when the crankshaft position
Figure 3. Inline LP Fuel Filter
sensor detects any engine revolutions; Stall, when
the key is in the ON position but the crankshaft
position sensor detects no engine revolutions; and
the Run state, when the engine reaches pre-idle rpm.
A higher flow pressure regulator is required on A small port connects the expansion chamber to the
larger engines. primary diaphragm chamber. At the outlet of the
expansion chamber is the secondary valve (6). The
secondary valve is held closed by the secondary
spring on the secondary valve lever (7). The
secondary diaphragm controls the secondary lever.
When the pressure in the expansion chamber
reaches 1.5 psig (10.342 kPa) it causes a
pressure/force imbalance across the primary
diaphragm (8). This force is greater than the primary
diaphragm spring pressure and will cause the
diaphragm to close the primary valve.
CA100 Mixer
The mixer is installed above the throttle body and
meters gaseous fuel into the airstream at a rate that
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel
flow is controlled by the shaping of the mixer fuel
cone and biased by the controllable fuel supply
pressure delivered by the pressure regulator. Fuel
flow must be metered accurately over the full range
of airflows. Pressure drop across the mixer air valve
must be minimized to assure maximum power
output from the engine.
Figure 8. CA100 Mixer Attached to Throttle Body
The mixer fuel inlet is fitted with a thermistor-type
temperature sensor. This permits the SECM to (Refer to Figure 98.)
correct fuel pressure to compensate for variations in The air/fuel mixer is mounted in the intake air stream
fuel temperature. Left uncorrected, fuel temperature between the air cleaner and the throttle. The design
variations can cause significant variations in air fuel of the main body incorporates a cylindrical bore or
ratio. mixer bore, fuel inlet (1) and a gas discharge jet (2).
In the center of the main body is the air valve
assembly, which is made up of the air valve (3), the
gas-metering valve (4), and air valve diaphragm (5)
Figure 9. Parts View of CA100 Mixer Figure 11. CA100 Mixer Installed with Electronic
Throttle
A pressure/force imbalance begins to build across
the air valve diaphragm between the air valve A main mixture adjustment valve on the fuel inlet of
vacuum (AVV) chamber (above the diaphragm) and the CA100 is not used in the MI-07 system, however
atmospheric pressure below the diaphragm. an idle mixture adjustment is incorporated into the
Approximately 6 inH2O (14.945 mbar) of negative mixer (Figure 12). The idle mixture adjustment is an
pressure is required to overcome the air valve spring air bypass port, adjusting the screw all the way in,
force and push the air valve assembly upward off blocks off the port and enriches the idle mixture.
the valve seat. Approximately 24 inH2O (59.781 Backing out the idle adjustment screw opens the
mbar) pulls the valve assembly to the top of its travel port and leans the idle mixture. The idle mixture
in the full open position. screw is a screw with locking threads that is factory
set with a tamper proof cap installed after
The amount of negative pressure generated is a adjustment. Accurate adjustment of the idle mixture
direct result of throttle position and the amount of air can be accomplished by adjusting for a specific fuel
flowing through the mixer to the engine. At low trim valve (FTV) duty cycle with the Service Tool
engine speeds, low AVV causes the air valve software or with a voltmeter.
diaphragm assembly to move upward a small
amount, creating a small venturi. At high engine NOTE: Adjustments should only be performed by
speeds, high AVV causes the air valve diaphragm trained service technicians.
assembly to move much farther creating a large
venturi. The variable venturi air/fuel mixer constantly
matches venturi size to engine demand.
Use of unleaded gasoline of 87 octane or higher is recommended for optimal performance of the MI-07
system.
Picture courtesy of Robert Bosch GmbH Coil-On-Plug (Coil Pack) Ignition System
Coil-on-plug (COP) is a type of distributorless
Figure 15. Throttle Body Assembly Exploded View ignition system where individual ignition coils are
mounted directly over each spark plug. No spark
plug wires are used. On most engines, the plugs
and coils are located on top of the cylinder head for
easy mounting of the coils. A topside location is best
because it keeps the coils away from the heat of the
exhaust.
Misfires
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
Figure 18. HEGO (O2) Sensor
fouled by oil or fuel deposits, as well as pre-ignition
and detonation.
Once a HEGO sensor reaches approximately 600°F
(316°C), it becomes electrically active. The
If the crankshaft position sensor fails, the loss of the
concentration of oxygen in the exhaust stream
basic timing signal will prevent the system from
determines the voltage produced. If the engine is
generating a spark and the engine will not start or
running rich, little oxygen will be present in the
run. A failed driver circuit within the SECM can kill
exhaust and voltage output will be relatively high.
an individual coil and prevent that cylinder from firing.
Conversely, in a lean situation, more oxygen will be
But with COP, an individual coil failure will only
present and a smaller electrical potential will be
cause misfiring in one cylinder.
noticed.
It is important to remember that ignition misfire can
In order for the sensor to become active and create
also be caused by other factors such as worn or
an electrical signal below 600°F (316°C) a heated
fouled spark plugs, loose or damaged coil connector
element is added to the sensor housing. Two wires
or terminals, dirty fuel injectors, low fuel pressure,
provide the necessary 12 Vdc and ground signal for
intake vacuum leaks, loss of compression in a
the heater element. A fourth wire provides an
cylinder, even contaminated fuel. These other
independent ground for the sensor. The pre-catalyst
possibilities should all be ruled out before a COP
sensor heater is powered by the main power relay
unit is replaced.
and is always powered. The post-catalyst sensor
heater is powered from an additional relay that is
A COP engine that cranks but fails to start, in many
controlled by the SECM. This relay is only energized
cases, will often have a problem in the crankshaft or
when the SECM calculates that water condensation
camshaft position sensor circuits. Loss of sensor
in the exhaust system and catalytic muffler prior to
signals may prevent the SECM from properly
the sensor should be evaporated. This is to avoid
synchronizing, thereby preventing the engine from
thermal shock of the sensor that could prematurely
starting and running.
fail the sensor.
CAUTION
CAUTION—PROPER WIRING
General Description
MI-07 control system provides a complete, fully Engine speed is monitored by the SECM through a
integrated engine management system for naturally Hall Effect sensor. Intake manifold air temperature
aspirated engines. and absolute pressure are monitored with a TMAP
sensor. MI-07 is a drive-by-wire (DBW) system
It provides accurate, reliable, and durable control of connecting the accelerator pedal to the electronic
spark and air over the service life of the engine in throttle through the electrical harness; mechanical
the extreme operating environment found in heavy- cables are not used. A throttle position sensor (TPS)
duty, under hood, on-engine electronic controls. monitors throttle position in relation to the
accelerator pedal position sensor (APP) command.
The SECM monitors the engine through a number of Even engine coolant temperature and adequate oil
different sensors to ensure optimal performance. pressure are monitored by the SECM
The LPG regulator and the mixer operate as an crank position sensor and throttle position is used by
open loop system since no mixture adjustments are the SECM to calculate load. Feedback from the
made by the SECM. The mixer does have an idle electronic throttle is provided to the SECM by the
mixture adjustment and a power valve adjustment. throttle position sensors (TPS).
Manifold pressure from the TMAP, rpm from the
INPUT OUTPUT
Crank Sensor Throttle body
TMAP sensor
Coolant Temp
LP fuelock valve
Oxygen sensor
(Gasoline only)
• Fuel delivery system • Open-loop fuel control with fuel specific controls
• Spark-ignition control system for LPG
• Air throttle • Closed-loop fuel control with fuel specific controls
• Sensors/Switches/Speed inputs for gasoline (MPI)
The chart below lists the MI-07 components required • Speed-load spark control with tables for dwell,
for a G420F engine operating on LP fuel. timing, and fuel type
• Speed-load throttle control with table for maximum
Key Components TPS limiting
The MI-07 system functions primarily on engine • Min/max governing
components that affect engine • All-speed isochronous governing
• Fixed-speed isochronous governing with three
Q’ty DESCRIPTION switch-selectable speeds
G420FE G420F • Spark timing modifiers for temperature and fuel
-LP -LP type
1 1 Engine Control Module • Transient wall wetting compensation for gasoline
(SECM 48-pin) • Input sensor selection and calibration
1 1 Camshaft Position Sensor • Auxiliary device control for fuel pump, fuel lock-off
1 1 Crankshaft Position Sensor solenoid, tachometer, MIL, interlocks, vehicle
1 1 TMAP Sensor speed limiting, etc.
1 None Fuel Temperature Sensor • CANBus data transfer for speed, torque, etc.
1 1 Transmission Oil
Temperature Switch
2 None Oxygen Sensors
1 1 Coolant Temperature
Sensor
1 1 Engine Oil Pressure Switch
2 None Fuel Trim Valve
4 4 Ignition Coils
4 4 Power TR
1 1 Fuel Lock Off Solenoid
N-2007 N-2001 LP Regulator
CA-100 CA-100 LP Mixer
(Certified)
1 1 Electronic Throttle Body
emissions and performance. These key components
include the following:
CA100 Mixer
The mixer is installed above the throttle body and
meters gaseous fuel into the airstream at a rate that
Figure 8. CA100 Mixer Attached to Throttle Body
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel
(Refer to Figure 98.)
flow is controlled by the shaping of the mixer fuel
The air/fuel mixer is mounted in the intake air stream
cone and biased by the controllable fuel supply
between the air cleaner and the throttle. The design
pressure delivered by the pressure regulator. Fuel
of the main body incorporates a cylindrical bore or
flow must be metered accurately over the full range
mixer bore, fuel inlet (1) and a gas discharge jet (2).
of airflows. Pressure drop across the mixer air valve
In the center of the main body is the air valve
must be minimized to assure maximum power
assembly, which is made up of the air valve (3), the
output from the engine.
gas-metering valve (4), and air valve diaphragm (5)
and air valve spring (6). The gas-metering valve is
A higher flow mixer is required on larger engines. A
permanently mounted to the air valve diaphragm
lower flow mixer is required on smaller engines.
assembly with a face seal mounted between the two
parts.
The MPI Gasoline System of G420F engine is the The SECM of G420F engine is the same as that of
same as that of G420FE engine. See, “MPI Gaso- G420FE engine. See, “SECM of G420FE EMS over-
line System Operation of G420FE EMS overview” view”
Ignition System
Exhaust System
• Camshaft position
Variable reluctance (2-wire, 200 Vpp max) or 0-5
V Hall Effect with calibration selectable pull-up
resistor for open collector sensors.
Digital Inputs
• CANBus
CAN 2.0b serial communication for J1939 com-
munications, programming and diagnostics.
Requires proper termination resistance per CAN
2.0b.
Component Location
3 2 1
[CIRCUIT DIAGRAM]
CMPS
ECM
3 B1 - GND
2 B10 - CMPS
SIGNAL
1 After Main
Relay
A23_DRVP
[HARNESS CONNECTORS]
3 2 1
C14
CMPS
Component Location
[CIRCUIT DIAGRAM]
CKPS
ECM
3 B1 - GND
2 B5 - CKPS
SIGNAL
1 After Main Relay
A23_DRVP
[HARNESS CONNECTORS]
Description
3 2 1
The Crankshaft Position Sensor (CKPS) is a hall
effect type sensor that generates voltage using a C13
sensor and a target wheel mounted on the CKPS
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, Sensor Inspection
the sensor voltage out put slow.
When the metal (tooth) in the wheel aligns with the
sensor, the sensor voltage out puts high.
During one crankshaft rotation there are 58
rectangular signals and one longer signal. The ECM
calculates engine RPM by using the sensor’ signal
and controls the injection duration and the ignition
timing. Using the signal differences caused by the
longer slot, the ECM identifies which cylinder is at
3 2 1
top dead center.
Ciruit Diagram
3 2 1 4
ECM
IG.SW.ON Temperature
Resistance(kΩ)
℃ (°F)
0 (32) 4.5 ~ 7.5
20 (68) 2.0 ~ 3.0
40 (104) 0.7 ~ 1.6
80 (176) 0.2 ~ 0.4
Ciruit Diagram
3 2 1 4
ECM
Component Location
[CIRCUIT DIAGRAM]
HO2S (B1/S1) ECM
4
2
B1 - HO2S GND
[HARNESS CONNECTORS]
Description
Specification
[CIRCUIT DIAGRAM]
HO2S (B1/S2) ECM
3
1 B1 - HO2S GND
[HARNESS CONNECTORS]
1 2
3 4
C22
Component Location
[CIRCUIT DIAGRAM]
ECTS ECM
1
B15 - ECTS SIGNAL
2
to Cluster
3
B1 - GND
[HARNESS CONNECTORS]
3 2 1
C11
ECTS
Installation
Tightning torque
Location
Inspection
1. Remove the LP fuel temperature sensor from the
Description adapter connected to LP mixer.
The LP Fuel Temperature Sensor (FTS) is located in
2. With the temperature sensing portion of the LP
the LP fuel passage of the LP mixer for detecting the
engine fuel temperature immersed in hot water,
LP fuel temperature. The FTS uses a thermistor
check resistance.
whose resistance changes with the temperature.
The electrical resistance of the FTS decrease as the
Temperature °C (°F) FTS Resistance (Ohms)
temperature increase, and increase as the
temperature decrease. The reference 5V in the ECM -20(-4) 15462
is supplied to the FTS by way of a resister in the 0(32) 5896
ECM. That is, the resistor in the ECM and the 20(68) 2498
thermistor in the FTS are connected in series. When 40(104) 1175
the resistance value of the thermistor in the FTS 60(140) 596
changes according to the LP fuel temperature, the 80(176) 323
output voltage also change.
3. If the resistance deviates from the standard value
[Circuit Diagram] greatly, replace the sensor.
Location
Inspection
1. Disconnect the Accelerator Pedal’s connector
Description from the main engine harness.
Angle Sensor-Accelerator is located in the
2. Inspect the electrical conditions with a follow
accelerator pedal assembly. The engine speed
basic specification.
management deals with a Drive-by-wire system.
Drive-by-wire refers to the fact that the MI-07 control
Signal output is on condition that input voltage
system has no throttle cable from the foot pedal to
is 5V±0.5%
the throttle body. Instead, the ECM is electronically
Rated current : 20Ma,
connected both to the foot pedal assembly and the
Power : 100mW,
throttle body. The SECM monitors the foot pedal
Wire width : 20AWG
position and controls the throttle plate by driving a
- At start point : Signal ’A’ 0.4V±0.1V
DC motor connected to the throttle. The DC motor
Signal ‘B’ 4.5V±0.1V
actuates the throttle plate to correspond to the foot
- At end point(Push for end) :
pedal position when the operator depresses the
Signal ’A’ 3.60V±0.15V
pedal. The SECM will override the pedal command
Signal ‘B’ 1.39V±0.15V
above a maximum engine speed and below a
minimum idle speed. The foot pedal assembly uses
two potentiometers to detect pedal position. These
3. If the result value is out of the specification,
two signals, accelerator pedal position 1 (APP1) and
replace the Accelerator Pedal.
accelerator pedal position 2 (APP2) are sent directly
to the SECM. The SECM uses a series of algorithms
to self calibrate and cross check the signals from the
pedal assembly.
[Circuit Diagram]
Location
Inspection
1. Remove the Transmission Oil Temperature
Description Switch from the transmission.
Transmission Oil Temperature Switch is located in
2. Use an ohmmeter to check the continuity between
the adapter on transmission (T/M) for operating by
the 1 terminal and the 2 terminal. If there is
the transmission (T/M) oil temperature change. This
continuity, replace the Transmission Oil
switch is normally open, and then it is closed as the
Temperature Switch.
T/M oil temperature Increases to the 125±3°C.
Actually if the switch is closed by high T/M oil
3. The Transmission Oil Temperature Switch is the
temperature, the ECM makes engine shutdown with
‘ON/OFF’ switch. So during the normal status the
fault set. If the T/M oil temperature decreases to the
switch circuit should be open.
118°C, the switch is open again and the engine also
can run. This function can protect the engine of Tier-
3 and Non cert folk lift trucks from damage as
overheating.
[Circuit Diagram]
Location
Inspection
1. Remove the Ground Speed Limit Switch from the
Description transmission.
Ground Speed Limit Switch is located in the
2. Use an ohmmeter to check the continuity between
pressure port on transmission (T/M) for operating by
the 1 terminal and the 2 terminal. If there is
the transmission (T/M) oil pressure change. This
continuity, replace the Ground Speed Switch.
switch is normally opened, and then it is closed as
the T/M oil pressure increases. Actually the switch is
3. The Ground Speed Limit Switch is the ‘ON/OFF’
closed by increasing of the T/M oil pressure after
switch. So during the normal status the switch
engine cranking. And if the inching pedal is pushed
circuit should be open.
by a driver the switch is opened again by decreasing
of the T/M oil pressure. ECM can control the travel
speed of the folk lift trucks with this switch. Also the
maximum travel speed of Tier-3 and Non cert fork lift
trucks is an optional feature that can be easily
activated using the MotoView Service Tool. This
feature may be of particular interest to customers
with indoor warehouse operations.
[Circuit Diagram]
Location
Inspection
1. Check for loose, dirty or damaged connectors and
Description wires on the harness
The MI-07 system uses electronic throttle control
2. Check the throttle assembly motor housing for
(ETC). The SECM controls the throttle valve based
coking, cracks, and missing cover-retaining clips
on engine RPM, engine load, and information
received from the foot pedal. Two potentiometers on
3. Check the resistance of TPS sensor. (refer as
the foot pedal assembly monitor accelerator pedal
blow chart)
travel. The electronic throttle used in the MI-07
system is a Bosch 32mm electronic throttle body
EXPECTED
DV-E5. The DV-E5 is a single unit assembly, which SENSOR POINT TO POINT
RANGE
includes the throttle valve, throttle-valve actuator
(DC motor) and two throttle position sensors (TPS). TPS PIN 2(GND) TO 1.25KΩ +/-
The SECM calculates the correct throttle valve TPS PIN 6(TPS1 SIGNAL) 30%
opening that corresponds to the driver’s demand, (Throttle TPS PIN 3(PWR) TO 1.25KΩ +/-
makes any adjustments needed for adaptation to the Position PIN 6(TPS1 SIGNAL) 30%
engine’s current operating conditions and then Sensor) TPS PIN 1(+DRIVER) ~3.0KΩ +/-
generates a corresponding electrical (driver) signal TO PIN 4(-DRIVER) 30%
to the throttle-valve actuator.
[Circuit Diagram]
CAUTION
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.
Diagram Notes
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. Close the liquid outlet valve in the forklift cylinder
or fuel storage container. 4. Install the four rear-mounting bolts that hold the
regulator to the support bracket. Use a torque
2. Purge the system of fuel by starting the engine wrench and tighten each bolt to 60-70 lbf-in (6.78-
and running until all trapped fuel in the system is 7.91 N-m).
exhausted and the engine shuts down.
5. Install the fuel inlet line (1) to the lock-off, the two
3. Key switch in “OFF” position. vacuum lines (2) to the branch-tee fitting in the
regulator vent and re-connect the lock-off
connector (3).
4. Remove the fuel inlet line (1) from the lock-off, the
two vacuum lines (2) from the branch-tee fitting in
6. Open the liquid outlet valve in the forklift cylinder
the regulator vent and disconnect the lock-off
or fuel storage container.
connector (3).
CA100 Certified Mixer Removal Steps 4. Remove the air cleaner hose (1).
3. Install the fuel temperature sensor to the adapter • Gas vapor may reduce oxygen available for
(6). breathing, cause headache, nausea, dizziness
and unconsciousness and lead to injury or
4. Install the four mount screws that attach the
death. Always operate the forklift in a well
throttle adaptor to the mixer. See Figure 32.
ventilated area
Torque bolts to 30-40 lbf-in (3.39-4.52 N-m).
5. Install the mixer/adapter assembly to the throttle • Liquid propane may cause freezing of tissue or
by gently pushing downwards. frostbite. Avoid direct contact with skin or
tissue; always wear appropriate safety
6. Install the four bolts that mount the throttle protection including gloves and safety glasses
adapter to the electronic throttle body (5). when working with liquid propane.
Break-Off Test
Figure 34. Secondary Stage Test Connection
Secondary Stage Test Hardware
Pressure Test
1. Hand vacuum pump
Primary Stage Test Hardware
2. Regulator vapor outlet test fitting 3/4” NPT x 1/4”
hose barb 1. Shop air pressure regulator adjusted to 100 psi
3. Union Tee 1/4” NPT with three 1/4” NPT x 1/4” 2. Shop air hose fitting (1/4” NPT to air hose)
hose barb
3. Air hose
4. Vacuum hose
4. Test gauge fitting (1/16” NPT x 1/4” hose barb)
5. 0-3” WC Magnehelic gauge (inches of water
column) 5. Vacuum hose or vinyl tubing
1. Union Tee fitting, 1/4” (6.35mm) NPT with three Idle Mixture Adjustment
1/4” (6.35mm) NPT x 1/4” (6.35mm) hose barbs
The CA100 mixer requires adjustment of the idle
2. Vacuum hose mixture screw to assure optimal emissions and
performance. This adjustment accounts for minor
3. 0-20” H2O differential pressure Magnehelic gauge 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
AVV Test tamper proof cap, after which it need not be
adjusted for the life of the vehicle.
1. Install Union Tee fitting in the hose between the
FTVs and the AVV fitting. Connect this fitting to Therefore, the only situations in which the idle
the low pressure port of the Magnehelic gauge mixture screw needs to be adjusted are when the
(Figure 37). engine is initially fitted with a fuel system at the
factory and following the field replacement of the
2. Leave high pressure port of the Magnehelic mixer. Under these situations, follow the procedures
gauge exposed to ambient pressure (Figure 37). below for adjustment of the idle mixture screw.
3. With the engine fully warmed up and running at Factory Test Preparation:
idle (750 rpm) place the transmission in Neutral.
The AVV should be between 5” and 8” H2O of 1. Install the MI-07 fuel system, wiring harness and
pressure vacuum.
SECM-48 control module on the engine.
4. If the measured pressure drop is excessively high,
2. All coolant hoses should be attached, filled with
check for sticking or binding of the diaphragm air
coolant and bled to remove any air.
valve assembly inside the mixer. Replace mixer if
necessary.
3. Attach LPG fuel lines.
5. If the measured pressure drop is low, check for
4. Attach wiring harness to battery power.
vacuum leaks in the manifold, throttle, mixer,
TMAP sensor and attached hoses.
5. Attach exhaust system.
1. Operating the engine on LPG fuel, start the NOTE : If the FTV Duty Cycle reading is NOT
engine and permit it to warm up until the coolant between 25-60%, check for possible
temperature (ECT on Mototune display) is vacuum leaks, manifold leaks, or a faulty
approximately 167°F (75 oC). mixer.
2. Adjust the load until MAFPort equals 3.3 to 3.5
g/sec. 9. Turn the ignition key to the OFF position to shut
3. Mototune display parameter LP Fuel Control must down the engine.
display “Closed Loop”. 10. Install the tamper proof cap on the idle mixture
4. Use the Mototune Service Tool to monitor Duty screw adjustment port using a large pin punch,
Cycle % on the Mototune display. so that no further adjustments can be made
5. To adjust the idle mixture screw, use a hex or (Figure 42).
Allen-type wrench. Turning the screw in
(clockwise) should increase the duty cycle; turning
the screw out (counterclockwise) should decrease
the duty cycle.
6. Adjust the idle mixture screw on the mixer until a
reading of 35-55% is reached for the FTV Duty
Cycle in Closed Loop Idle (Figure 41). If engine
idle performance is unstable, screw the idle screw
in slightly to see if stability is obtained, but in no
case should duty cycle exceed 60%.
WARNING
• ASSEMBLY TOOLS
Use proper size and type of tool for assembly
and disassembly. Any damaged screws
cannot be properly torqued and can cause
unexpected hardware problems or gas leakage,
which could lead to serious injury or loss of
life.
REF
DESCRIPTION QTY
NO
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
Dowel Pin Ø 0.094” x 1” L (Ø
6 2.39mm x 25.4mm L) Hardened 1
Steel
7 Diaphragm, Secondary Assembly 1
8 Lever, Secondary 1
9 Seat, Secondary 1
10 Valve Primary 1
Fillister Head Screws SEMS Split
11 6
Lockwasher #12-24 x 5/8”
Pan Head Screw SEMS Ext. Tooth
12 1
Lockwasher #12-24 x 1/4”
13 Body Gasket 1
14 Back Plate 1
15 O-ring, Size 107 GLT Viton® 1
16 Bottom Plate Gasket 1
17 Plate Cover 1
Fillister Head Screws SEMS Split
18 6
Lockwasher #12-24 x 1-3/8”
Hex Head Screws SEMS Split
19 4
Lockwasher 1/4-20 x 5/8”
20 Plug, Socket Head Pipe (T-086) 1
21 Cover, Secondary Diaphragm 1
Lockwasher, Int. Tooth (T-210) #8
22 6
SST
23 Torx Screws (T-15) #8-32 x 5/8” 6
Figure 2 Figure 5
PRIMARY INLET
PORT CLOSING
Figure 6
Figure 3
CAUTION
DIAGRAM NOTES
1
Only one 90 fitting permissible on vapor fuel line between mixer and regulator
3 Vapor fuel fittings (regulator and mixer) must have minimum ID of 0.46” (11.68mm)
4 Vapor hose length to be as short as possible and have no restrictions for best regulator
performance
5
Fuel outlet must be positioned vertically in the down position
Follow the procedures below for removal and 2. Purge the system of fuel by starting the engine
reinstallation of the CA100 mixer in non-certified and running until all trapped fuel in the system is
systems. exhausted and the engine shuts down.
6. Remove the vapor fuel inlet line from the mixer (3).
1. Mixer-Non Cert
2. Fitting-To Regulator 11. Remove the four mounting screws that attach
3. Fitting-To Regulator the throttle adapter to the mixer.
4. Apollo Adapter-ITB, Mixer
5. ITB
6. O-Ring Spacer 12. Remove the vapor fuel inlet fitting from the
7. O-Ring mixer.
8. Bolt-ITB.Conn
9. Gasket-ITB
10. Bolt
Break-Off Test
4. Vacuum hose
Primary Stage Test Hardware 1. Remove the primary test port plug from the side
of the regulator and install the 1/16” NPT hose
1. Hand vacuum pump barb fitting (Figure 31).
2. Regulator fuel inlet test fitting 1/4 NPT standard 2. Connect a compressed air line (shop air ~100 psi)
air coupling) to the liquid propane fuel inlet of the N-2001
regulator (Figure 31).
3. Test gauge fitting (1/4” NPT X 1/4” hose b)
1. The power valve should only be adjusted after the 1. The power valve should only be adjusted after the
idle screw has been adjusted properly. The idle screw has been adjusted properly. The
engine and vehicle drive train and hydraulics engine and vehicle drive train and hydraulics
should also be at normal operating temperatures. should also be at normal operating temperatures.
2. Apply a load to the engine while the engine is 2. Apply a load to the engine while the engine is
operating above idle speed. Torque converter stall operating above idle speed. Torque converter stall
is the preferred operating mode for this test. If a is the preferred operating mode for this test. If a
torque converter speed test cannot be performed, torque converter speed test cannot be performed,
the engine can be run at another speed (max the engine can be run at another speed (max
governor), but a load must be applied by using governor), but a load must be applied by using
hydraulics. hydraulics.
The power valve should be adjusted to obtain
NOTE : While adjusting the power valve, do not hold maximum torque converter stall speed.
engine at load point for longer than 5-10
seconds. Holding for a longer period of time NOTE : While adjusting the power valve, do not hold
will cause the fuel temperature to drop, engine at load point for longer than 5-10
which could adversely affect the power seconds. Holding for a longer period of time
valve setting. will cause the fuel temperature to drop,
which could adversely affect the power
3. Monitor the output of the UEGO or HEGO sensor valve setting.
while the engine is at the higher speed with the
load applied (phi = 1.00 to 1.05 is optimal). 3. Once the power valve is set, bring the engine
back to idle and verify the idle screw setting.
4. If the phi reading is not at the desired level, bring
the engine back to idle and adjust the power valve.
WARNING
• ASSEMBLY TOOLS
Use proper size and type of tool for assembly
and disassembly. Any damaged screws
cannot be properly torqued and can cause
unexpected hardware problems or gas leakage,
which could lead to serious injury or loss of
life.
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
9 the top of the mixer (Figure M4).
3 14
2
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
10
spring shown in (Figure M5).
11
Figure M6
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
Figure M7
will need to be replaced.
NOTE
For re-assembly of the CA100
reverse the disassembly steps.
Figure M8
WARNING
5. Place the alignment mark on top of the air valve DO NOT spray car carburetor cleaner or
assembly toward the fuel inlet of the mixer; this solvent into the mixer while installed on
places the small notches in the fuel metering valve the engine. These chemicals may damage
(fuel cone) inline with the fuel inlet and the large the oxygen sensor and cause pre-mature
notches of the fuel metering valve “cone”, failure of the catalytic muffler.
perpendicular to the fuel inlet of the mixer. Now
reinstall the air-valve spring and diaphragm cover
(Figure M8).
Figure M9
Parts List
N-2001-RSA Regulator
REF
DESCRIPTION QTY
NO.
1 Cover Screws 8-32 x 5/8” SEMS 4
Torx Screws (T-15) 8-32 x 5/8” Tamper
2 2
Resistant
3 Lockwasher #8 Internal Tooth 2
4 Secondary Cover 1
5 Secondary Diaphragm Assembly 1
Pan Head Screw 10-24 x 1/4” w/Star
6 1
Washer
7 Secondary Lever 1
8 Secondary Valve 1
9 Secondary Lever Fulcrum Pin 1
10 Red Secondary Spring 1
11 Pilot Valve Lever 1
12 Pilot Valve Lever Fulcrum Pin 1
13 Internal Hex Head Set Screw 8-32 x 1/4” 1
14 Cover Screws 12-24 x 5/8” SEMS 6
15 Primary Diaphragm Cover 1
16 Primary Regulator Springs 2
17 Primary Diaphragm Assembly 1
18 1/8 NPT Hex Pipe Plug Fitting 1
19 Body Assembly 1
20 Body Seal O-ring 1
21 Body Gasket 1
22 Regulator Back Plate 1
23 Primary Seal O-Ring 1
24 Primary Regulator Valve 1
25 Cover Screws 12-24 x 5/8” SEMS 6
26 Inlet Seal O-Ring 1
27 Inlet Plug 1
Hex Head Screws 1/4-20 UNC-2A x 5/8”
28 2
SEMS
4
1
Figure R5
Figure R3
Figure R5
Figure R6
11
Figure R7
Figure R8
Figure R9
5. Turn the regulator body over with the rear fuel inlet
plate facing up. Remove the primary valve access
plug (7), the primary valve (8) and the primary valve
o-ring seal (9). The primary valve goes through
the inlet plate, then through the body assembly
and is retained by the primary diaphragm
(Figure R9).
Figure R11
Special Tools
Tool
Illustration Application
(Numberandname)
G420F(E) Service Manual 241 Chapter 7. MPI Gasoune Fuel Delivery System
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(E) Service Manual 242 Chapter 7. MPI Gasoune Fuel Delivery System
Fuel Pressure Test Install The Special Service Tool (SST)
For Measuring The Fuel Pressure
Release The Internal Pressure
CAUTION
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by residual
pressure in the fuel line.
G420F(E) Service Manual 243 Chapter 7. MPI Gasoune Fuel Delivery System
Inspect Fuel Leakage On Connection • Observing the declination of the fuel pressure
when the gage reading drops and perform the
1. Connect the battery negative (-) terminal. necessary repairs using the table below.
4. Start the engine and measure the fuel pressure at Release The Internal Pressure
idle.
Supected
Condition Probable Cause
Area
G420F(E) Service Manual 244 Chapter 7. MPI Gasoune Fuel Delivery System
Remove The Special Service Tool (SST) Injector
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).
CAUTION
Description
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by residual Based on information from various sensors, the
pressure in the fuel line. ECM measures the fuel injection amount. The fuel
injector is a solenoid-operated valve and the fuel
injection amount is controlled by length of time the
5. Conenct the fuel feed hose to the delivery pipe. fuel injector is held open. The ECM controls each
injector by grounding the control circuit. When the
Inspect Fuel Leakage On Connection ECM energizes the injector by grounding the control
circuit, the circuit voltage should be low (theoretically
1. Connect the battery negative (-) terminal. 0V) and the fuel is injected. When the ECM de-
energizes the injector by opening control circuit, the
2. Apply battery voltage to the fuel pump terminal fuel injector is closed and circuit voltage should be
and activate the fuel pump. With fuel pressure peak for a moment.
applied, check that there is no fuel leakage from
the fuel pressure gauge or connection part.
G420F(E) Service Manual 245 Chapter 7. MPI Gasoune Fuel Delivery System
Specification
Schematic diagram
G420F(E) Service Manual 246 Chapter 7. MPI Gasoune Fuel Delivery System
Injector Inspection Resistance Measurement Between
Terminals
Operation check
CAUTION
Cover the hose connection with rags to prevent
splashing of fuel that could be caused by
residual pressure in the fuel line.
CAUTION
Be careful not to drop any injectors when
removing the delivery pipe.
Be aware that fuel may flow out when removing
the injector.
G420F(E) Service Manual 247 Chapter 7. MPI Gasoune Fuel Delivery System
Inspection
1. Measure the resistance of the injectors between
the terminals using an ohmmeter.
Installation
G420F(E) Service Manual 248 Chapter 7. MPI Gasoune Fuel Delivery System
Fuel Pump
Removal (Including Fuel Filter And Fuel
Pressure Regulator)
CAUTION
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by residual
pressure in the fuel line.
G420F(E) Service Manual 249 Chapter 7. MPI Gasoune Fuel Delivery System
Chapter 8. BASIC TROUBLESHOOTING
Preliminary Checks Visual/Physical check
MI-07 systems are equipped with built-in fault Several of the procedures call for a “Careful
diagnostics. Detected system faults can be Visual/Physical Check” which should include:
displayed by the Malfunction Indicator Lamp (MIL)
and are covered in Chapter 9, Advanced • SECM grounds for being clean and tight
Diagnostics. However, items such as fuel level,
plugged fuel lines, clogged fuel filters, and • Vacuum hoses for splits, kinks, and proper
malfunctioning pressure regulators may not set a connection.
fault code and usually can be corrected with the
basic troubleshooting steps described on the • Air leaks at throttle body mounting and intake
following pages. manifold
1. Forklift Information
(I) VIN:
(II) ProductionDate:
2. Symptoms
3. Environment
4. MIL/DTC
MIL (Malfunction Indicator Lamp) □ Remains ON □ Sometimes lights up □ Does not light
WARNING
DO NOT heat components to the point where
they may be damaged.
DO NOT heat the ECM directly.
WARNING
DO NOT sprinkle water directly into the engine
compartment or electronic components.
● Simulatingelectricalload
1. Clear Diagnostic Trouble Code (DTC).
1) Turn on all electrical systems to simulate
2. Inspect connector connection, and check terminal
excessive electrical loads (Radios, fans, lights,
for poor connections, loose wires, bent, broken or
etc.).
corroded pins, and then verify that the connectors
are always securely fastened.
Handling of Connector
Specification (Resistance)
1Ω or less → Normal Circuit
1㏁ or Higher → Open Circuit
3. Voltage Check Method
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1㏁ or Higher → Normal Circuit
Corrective Action
Most intermittent problems are caused by faulty
electrical connections or wiring. Perform careful
visual/physical check for:
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.
The fuel management should maintain a stoichiometric air-fuel ratio under all
Oxygen sensor steady state operating conditions following engine warmup. Failure of the Pre-
malfunction catalyst O2 sensor should cause an O2 sensor fault that can be diagnosed with
the MIL lamp or Service Tool.
Preliminary Checks
Repair/replace as required.
Clogged fuel filter
See Chapter 2 Fuel Filter replacement.
Check connection
Faulty vapor connection between the
• Verify no holes in hose.
pressure regulator/converter and the
• Clamps must be tight.
mixer
• Look for kinked, pinched and/or collapsed hose.
Repair/replace fuel lock-off.
Fuel lock-off malfunction
See Chapter 2 Fuel Lock-off.
Pressure regulator/converter Test regulator/converter operation and pressure.
malfunction See Chapter 6 Tests and Adjustments.
Incorrect air/fuel or ignition/spark
See Chapter 8 Advanced Diagnostics.
control
Verify the crankshaft position signal is present
No crankshaft position sensor signal
See Chapter 8 Advanced Diagnostics.
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
SECM / control system of this section.
malfunction Verify that there is no code for ETC spring check fault.
Check for 0% APP during cranking.
Cycle key ON and OFF and listen for throttle check (movement) on key OFF.
Check for oil pressure switch faults.
Check for sensor “sticking” faults.
Check TPS for stuck binding or a high TPS voltage with the throttle closed.
Check fuel lock off (propane) or fuel pump relay gasoline operation: actuator
should turn “ON” for 2 seconds when ignition is turned “ON”.
Check fuel pressure.
Check for contaminated fuel.
Check both gasoline injector and lock off fuses (visually inspect).
Fuel system malfunction
Check propane tank valve & pickup. A faulty
in-tank fuel pump check valve will allow the fuel in the lines to drain back to the
tank after engine is stopped. To check for this condition, perform fuel system
diagnosis.
Check FTV system for proper operation.
PRELIMINARY CHECKS
Check spark advance for excessive retarded ignition timing. Use Service Tool.
Check secondary voltage using an oscilloscope or a spark tester to check for a
Ignition system malfunction weak coil.
Check spark plug condition.
Check poor spark plug primary and secondary wire condition.
PRELIMINARY CHECKS
Check for excessive oil in the combustion chamber and/or blow by from
excessive PCV flow.
Engine mechanical Check combustion chambers for excessive carbon build up.
Check combustion chamber pressure by performing a compression test.
Check for incorrect basic engine parts such as cam, heads, pistons, etc.
PRELIMINARY CHECKS
Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.
Simulate condition by reviewing operation procedure practiced by vehicle operator.
Dieseling, Run-on
Engine continues to run after key is turned “OFF,“ but runs very roughly. If engine runs smoothly, check
ignition switch and adjustment.
PRELIMINARY CHECKS
Fuel lock off valve Make sure lock off valve is closing properly.
Related MIL Faults: EST faults / ETC faults / Pre-catalyst O2 sensor faults
PRELIMINARY CHECKS
PRELIMINARY CHECKS
Check fuel system specifically for plugged fuel filter, low pressure.
Check for contaminated fuel.
Check injector drivers. Disconnect all injector harness connectors. Use
injector test light or equivalent 6-volt test light between the harness terminals
Fuel system
of each connector and observe if light blinks while cranking. If test light fails
malfunction
to blink at any connector, it is a faulty injector drive circuit harness, connec-
tor, or terminal.
Check lock off intermittent connection.
Check dither valve operation.
PRELIMINARY CHECKS
PRELIMINARY CHECKS
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.
If the Service tool indicates a very high coolant temperature and the system
is running lean:
Cooling system • Check engine coolant level.
malfunction • Check engine thermostat for faulty part (always open) or for wrong heat
range.
• Check fan operation
If the system is running rich, refer to “Diagnostic Aids” chart on the next
page.
Fuel system If the system is running lean refer to “Diagnostic Aids” chart on the next
malfunction page.
Check for properly installed fuel system components.
Check fuel pressure.
Fuel injector pulse width at idle * < 1.0 msec > 8 msec.
• Pre-catalyst O2 sensor failed
Malfunction codes • Pre-catalyst O2 sensor failed rich
lean
Closed loop operation • Pre-catalyst O2 sensor high • Pre-catalyst O2 sensor low
(*) The duty cycle injector pulse width criteria for lean or rich operation apply only if the O2 sensor is
functioning properly. If the sensor is not operating properly the criteria may be reversed.
• Inspect in-line orifices for blockages (in wye), • Check system voltage
replace as necessary
• Check fuel pressure
• Check trim valves for proper operation, replace as
necessary • Check injectors for sticking or obstructions
Lean Operation
Illustration Notes
1. Backpressure gage
3. Exhaust manifold
Diagnosis:
LPG And LPG Fuel Tanks The same principle is applied to LPG in a container,
commonly referred to as an LPG tank or cylinder.
LPG Fuel Supply Typically an LPG tank is not filled over 80% capacity
allowing for a 20% vapor expansion space. Outside
Liquefied petroleum gas (LPG) consists mainly of air temperature effect’s an LPG tank and must be
propane, propylene, butane, and butylenes in considered when using an LPG system. (Figure 2)
various mixtures. LPG is produced as a by-product shows the relationship between pressure and
of natural gas processing or it can be obtained from temperature in a LPG tank at a steady state
crude oil as part of the oil refining process. LPG, like condition.
gasoline, is a compound of hydrogen and carbon,
commonly called hydrocarbons. LPG Tank Pressure VS Temperature
300
In its natural state, propane is colorless and
odorless; an odorant (ethyl mercaptan) is added to 250
Pressure, psig
currently three grades of propane available in the 150
United States. A propane grade designation of HD5
(not exceeding 5% propylene), is used for internal 100
CAUTION
When empty, the tank is exchanged with a pre-
filled replacement tank. When exchanging a tank,
Figure 4 safety glasses and gloves should be worn.
4
6 12 10
11
5
Figure 5
Figure 8
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.
ECM Engine control module
FPP Foot pedal position
FPV Fuel primer valve
FTS Fuel temperature sensor
FTV Fuel trim valve
GPM Gallons per minute of flow
HEGO Heated exhaust gas oxygen (sensor)
LAT Limited-angle torque motor
LPG Liquified petroleum gas
MAP Manifold absolute pressure
MAT Manifold air temperature
MIL Malfunction indicator lamp
MOR Manufacturer of record for emissions certification on the engine
OEM Original equipment manufacturer
PHI Relative fuel-air ratio or percent of stoichiometric fuel
(actual fuel-air ratio / stoichiometric fuel-air ratio)
RPM Revolutions per minute
SECM Small engine control module
TMAP Temperature and manifold absolute pressure
TPS Throttle position sensor
VDC Voltage of direct current type
VE Volumetric efficiency
WOT Wide open throttle
Service Manual
DAC CS-121
Series Alternators
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 train-
ing, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publica-
tion.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubri-
cation, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information avail-
able.
1
Index
Specifications
Alternator................................................................. 5
Systems Operation
Alternator................................................................. 6
CS-121 Alternator Operation ........................... 6
Alternator Components ............................ 7
Alternator Operation Schematic ............... 9
Introduction ...................................................... 6
Troubleshooting..................................................... 10
Troubleshooting Problem List ................ 10
Troubleshooting Problems ..................... 10
Alternator
IDAS012B
ALTERNATOR SPECIFICATIONS
DAEWOO Part No. D167411
DAC Series CS-121
Voltage Rating 12V
Polarity Neg. Gnd.
Rotation CW
2 Test Speed 6500 rpm
Rated Output (Cold) 61A
IDAS011B
Output Voltage 14.0L0.5V
CS-121 Alternator Cross-Sectional View Rotor Field Winding
Resistance [At 27C(80°F)] -
Field Current [At 14.0V or -
27.5V and 27C(80°F)]
Stator Winding -
Resistance
Turn On Speed (Max.) -
Slip Rings (3) : -
Maximum Runout (TIR)
Minimum Diameter -
Brush Length (Measured
On Longest Side) : -
New
Minimum
Pulley Nut (2) Torque 100 L 7 N I m
(75 L lb I ft)
Thru Bolt (1) Torque -
Terminal Torques :
Bat 3.6 L 0.8 N I m
(32 L 7 lb I in)
Gnd -
IDAS001C
3 5 6
1 2 4
10
IDAS002C
7
The major components of the alternator are stator
(4), rotor (3), rectifier (10), regulator (9), brush holder
(7) and frames (2) and (5). The CS-121 alternators
8 feature a high ampere output per pound of weight,
IDAS013B with a totally new and different regulator. A diode trio
is not used. A delta wound stator, rectifier bridge,
Alternator Components-Cross-Sectional View rotor with slip rings and brushes are electrically
(1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive similar to the SI series. alternators. The CS stands
end frame. (6) External fan. (7) Brush holder. (8) Internal for Charging System. The 121 denotes the outside
fan. diameter in millimeters of the stator laminations. This
series of alternators has two fans for cooling the
alternator.
IDAS014B
Stator
(4) Stator.
IDAS003C 8
Rotor
(1) Slip rings. (3) Rotor. (8) Internal fan.
7
IDAS015B
Brush Holder
(7) Brush holder. (11) Brushes.
Probable Cause:
Troubleshooting
1. Loose Drive Belt For Alternator:
Adjust the alternator drive belt.
Troubleshooting can be difficult. On the page that 2. Loose Alternator Drive Pulley:
follows is a list of possible problems. To make a repair Check the pulley for wear. If it is worn, install a
to a problem, make reference to the probable cause. new pulley. Tighten the pulley nut to the correct
torque shown in Specifications.
This list of problems and probable causes will only
give an indication of where a possible problem can 3. Charging Or Ground Return Circuit Or Battery
be and what repairs are needed. Sometimes more or Connections Defective:
other repair work is needed beyond the Inspect all cables and connections. Clean and
recommendations in the list. Remember that a tighten all connections. Replace defective parts.
problem is not normally caused by one part, but by
4. Regulator Is Defective:
the relation of one part with other parts. This list
Replace the regulator.
cannot give all possible problems and probable
causes. The serviceman must find the problem and 5. Rectifier Is Defective:
its source, then make the necessary repairs. Replace the rectifier.
2. Regulator Is Defective:
Install a new regulator.
Troubleshooting Problems
Problem 4: Alternator Is Noisy
Problem 1: Alternator Does Not Charge
Probable Cause:
Probable Cause:
1. Drive Belt For Alternator Is Worn Or Defective:
1. Loose Drive Belt For Alternator : Install a new drive belt for the alternator.
Adjust the alternator drive belt.
2. Loose Alternator Drive Pulley:
2. Loose Alternator Drive Pulley : Check the pulley for wear. If it is worn, install a
Check the pulley for wear. If it is worn, install a new pulley. Tighten the pulley nut to the correct
new pulley. Tighten the pulley nut to the correct torque shown in Specifications.
torque shown in Specifications. 3. Drive Belt And Drive Pulley For Alternator Are Not
3. Charging Or Ground Return Circuit Or Battery In Alignment:
Connection Are Defective: Make an adjustment to put the drive belt and drive
Inspect all cables and connections. Clean and pulley in correct alignment.
tighten all connections. Replace defective parts. 4. Alternator Bearings Are Worn:
4. Rotor Field Winding Or Regulator Is Defective: Install new bearings in the alternator.
Install a new rotor or regulator.
Tools Needed
Digital Multimeter or Equivalent 1
AC/DC Clamp-On Ammeter 1
Machine Test
* Some models that have the CS-121 alternator do not have a resistor in the ignition of key start switch circuit, if the indicator
lamp is burned out, the alternator cannot turn on. Also, if a machine is jump started because the battery is too low, the
alternator may not have any output. This is because the battery may be too low to send current to the alternator. The
alternator needs current to start the charging process.
Service Manual
CS-105D Series
Alternator
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index
Specifications
Alternator........................................................ 5
Systems Operation
Alternator............................................................... 6
CS-105D Alternator Operation ........................ 6
Alternator Components ............................ 7
Alternator Operation Schematic ............... 9
Introduction..................................................... 6
Troubleshooting....................................................10
Troubleshooting Problem List..................10
Troubleshooting Problems ......................10
DOOSAN Supplier
Series Voltage
Part No. Part No.
ALTERNATOR SPECIFICATIONS
DOOSAN Part No. A274017
Series CS-105D
Voltage Rating 12V
Polarity Neg. Gnd.
Rotation CW
Test Speed 6500 rpm
Rated Output (cold) 50A
Output Voltage 14.5 ± 0.3V
Rotor Field Winding
Resistance [At 27℃ 2.97 ~ 3.05 OHMS
(80℉)0
CS-105D Alternator View
Field Current [At 14.0V
or 27.5V and -
27℃(80℉)0
Stator Winding
-
Resistance
Turn On Speed (Max.) -
Slip Rings (3) :
0.08
Maximum Runout (TIR)
Minimum Diameter -
Brush Length (Measured
17.0 ± 0.3 mm
On Longest Side) : New
Minimum
100 ± 10 N•m
Pulley Nut (2) Torque
(900 ±90 lb•ft)
Thru Bolt (1) Torque
10 ± 1.0 N•m
Terminal Torques : Bat
(90 ± 10 lb•ft)
Gnd -
CS-105D Alternator
Stator
(4) Stator.
Rotor (3) consists of a core, coils and slip rings (1). Rectifier (10) contains three positive (+) and three
The rotor provides the magnetic field between the negative (-) diodes to form the full wave rectifier
rotor field winding and the stator. Slip rings (1) bridge which is connected to the stator. Rectifier (10)
provide the surfaces for brush contact. Internal fan changes or rectifies three phase AC to DC.
(8) pulls air through the rear frame to cool the
rectifier bridge and regulator.
Regulator
(9) Regulator.
Troubleshooting can be difficult. On the page that 1. Loose Drive Belt For Alternator:
follows is a list of possible problems. To make a Adjust the alternator drive belt.
repair to a problem, make reference to the probable
cause. 2. Loose Alternator Drive Pulley:
This list of problems and probable causes will only Check the pulley for wear. If it is worn, install a
give an indication of where a possible problem can new pulley. Tighten the pulley nut to the correct
be and what repairs are needed. Sometimes more torque shown in Specifications.
or other repair work is needed beyond the
recommendations in the list. Remember that a 3. Charging Or Ground Return Circuit Or Battery
problem is not normally caused by one part, but by Connections Defective:
the relation of one part with other parts. This list Inspect all cables and connections. Clean and
cannot give all possible problems and probable tighten all connections. Replace defective parts.
causes. The serviceman must find the problem and
its source, then make the necessary repairs. 4. Regulator Is Defective:
Replace the regulator.
Probable Cause:
Troubleshooting Problems
1. Alternator Or Regulator Has Loose Connections:
Problem 1: Alternator Does Not Charge Tighten all connections to alternator or regulator.
Probable Cause: 2. Regulator Is Defective:
Install a new regulator.
1. Loose Drive Belt For Alternator :
Adjust the alternator drive belt. Problem 4: Alternator Is Noisy
2. Loose Alternator Drive Pulley : Probable Cause:
Check the pulley for wear. If it is worn, install a
new pulley. Tighten the pulley nut to the correct 1. Drive Belt For Alternator Is Worn Or Defective:
torque shown in Specifications.
Install a new drive belt for the alternator.
3. Charging Or Ground Return Circuit Or Battery
2. Loose Alternator Drive Pulley:
Connection Are Defective:
Check the pulley for wear. If it is worn, install a
Inspect all cables and connections. Clean and
new pulley. Tighten the pulley nut to the correct
tighten all connections. Replace defective parts.
torque shown in Specifications.
4. Rotor Field Winding Or Regulator Is Defective:
3. Drive Belt And Drive Pulley For Alternator Are Not
Install a new rotor or regulator.
In Alignment:
Make an adjustment to put the drive belt and drive
pulley in correct alignment.
Tools Needed
Digital Multimeter or Equivalent 1
AC/DC Clamp-On Ammeter 1
Machine Test
1. Put the multimeter positive (+) lead on the Bat
terminal of the alternator. Put the negative (-) lead
on the ground terminal or the frame of the
alternator. Put the clamp-on ammeter around the
positive output wire of the alternator.
*Some models that have the CS-105D alternator do not have a resistor in the ignition of key start switch circuit,
if the indicator lamp is burned out, the alternator cannot turn on. Also, if a machine is jump started because
the battery is too low, the
alternator may not have any output. This is because the battery may be too low to send current to the
alternator. The
alternator needs current to start the charging process.
Service Manual
G424I(E) LP/Gasoline Engine
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
1
Chapter 3. ENGINE MECHANICAL
Index SYSTEM
General Information........................................... 36
Specifications ............................................... 36
Chapter 1. GENERAL INFORMATION
Tightening Torque ........................................ 39
Compression ................................................ 40
Precautions before Service ................................. 7
Valve Clearance ........................................... 41
Tightening Torque ............................................. 10
Troubleshooting ............................................ 45
Recommended Lubricants and Capacities ....... 11
Special service tools ..................................... 48
Engine Model and Engine Serial Number ......... 12
General Specification ........................................ 13
Timing System ................................................... 49
Engine Power and Torque ................................. 15
Component ................................................... 49
Removal ....................................................... 51
Inspection ..................................................... 53
Chapter 2. RECOMMENDED
Installation .................................................... 54
MAINTENANCE
Cylinder Head Assembly ................................... 59
General Maintenance ......................................... 20
Components ................................................. 59
Test Fuel System for Leaks........................... 20
Removal ....................................................... 60
Inspect Engine for Fluid Leaks ...................... 20
Inspection ..................................................... 62
Inspect Vacuum Lines and Fittings ................ 20
Installation .................................................... 66
Inspect Electrical System .............................. 20
Inspect Foot Pedal Operation ........................ 20
Cylinder Block Assembly .................................. 70
Engine Oil Classification................................ 21
Components ................................................. 70
Checking Engine Oil Level ............................ 22
Disassembley ............................................... 72
Replacing Engine Oil and Filter ..................... 23
Inspection ..................................................... 74
Reassembly.................................................. 81
Cooling System Maintenance............................ 24
Coolant Recommendation ............................. 24
Cooling System ................................................. 86
Check Coolant Level ..................................... 24
Components ................................................. 86
Inspect Coolant Hoses .................................. 24
Water pump / Thermostat ............................. 87
Checking coolant leaks ................................. 25
Troubleshooting ............................................ 89
Specific gravity test ....................................... 25
Relation between Coolant concentration and
Lubrication System ........................................... 91
Specific Gravity ............................................. 25
Component ................................................... 91
Checking and Adjusting Drive Belt ................ 26
Oil pump ....................................................... 92
Adjusting ....................................................... 27
Inspection ..................................................... 93
Checking Belt for Damage ............................ 27
Engine Oil..................................................... 95
Ignition System Maintenance ............................ 28
Manifold System ................................................ 96
Inspect Battery System ................................. 28
Intake manifold ............................................. 96
Inspect Ignition System ................................. 28
Exhaust manifold .......................................... 99
Inspection of Ignition Timing .......................... 28
Inspection of Spark Plug ............................... 29
Engine Electrical System ................................ 101
Specification ............................................... 101
Fuel System Maintenance ................................. 31
Trouble Shooting ........................................ 102
Replace LP Fuel Filter Element ..................... 31
Ignision System .......................................... 104
Testing Fuel Lock-off Operation .................... 32
Repair procedures ...................................... 104
Pressure Regulator/Converter Inspection ...... 32
On-vehicle Inspection ................................. 106
Inspect Air/Fuel Valve Mixer Assembly.......... 33
Emission control system ............................. 107
Inspect for Intake Leaks ................................ 33
Emission..................................................... 108
Inspect Throttle Assembly ............................. 33
Checking the TMAP Sensor .......................... 33
Fuel System ..................................................... 109
Actuators .................................................... 109
Exhaust System Maintenance ........................... 33
Tightening torques ...................................... 109
Inspect Engine for Exhaust Leaks ................. 33
Troubleshooting .......................................... 110
Maintenance Schedule ...................................... 34
Special Tool
When oil seal, O-ring, packing and gasket have When the part is to be replaced, be sure to use
been removed, be sure to replace them with new genuine part.
parts. For selection of appropriate parts, refer to the Parts
However, rocker cover gasket may be reused if it is Catalog.
not damaged.
Electrical System
Rubber Parts
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.
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
NOTE: The torques shown in the table are standard 1. When spring washers, toothed washers and the
vales under the following conditions. like are inserted.
1. Nuts and bolt are made of steel bar and 2. f plastic parts are fastened.
galvanized.
3. f oil is applied to threads and surfaces.
2. Galvanized plain steel washers are inserted.
NOTE: If you reduce the torques in the table to the
3. All nuts, bolts, plain washers are dry. percentage indicated below under the
following conditions, it will be the standard
NOTE: The torques shown in the table are not value.
applicable,
1. f spring washers are used : 85%
Recommended Lubricants
Lubricant Capacities
Engine Emission
Fuel Type
Model Regulation
EPA/CARB*
G424iE LP/Dual Fuel 2007
Compliant
G424iE Engine
Engine Model Engine Serial Number
• Comply with EPA 2007 Emission Regulation
G424iE/G424i T1101001D~/T21101001D
• Electronic Control by ECM
Features and Benefits of G424iE/G424i Engine
• Certified LP/Dual Fuel System available
• Al head with valve seat inserts
– Closed loop LP Carburetion system
– Closed loop MPI Gasoline system – Aluminum head and valve seat system
• 3-way Catalytic Muffler is standard • DOHC 16 valve system
G424i Engine • Durable timing chain system
• Not comply with EPA 2007 Emission Regulation – Durable timing chain material and rubber-
sealed cover
• Electronic Control by ECM
• Distributorless Ignition system (coil on plug)
• Standard LP/Gas/DF/Dual Fuel System available
• Electronic control system by ECM
– Open loop LP Carburetion system (Engine control module)
– Closed loop MPI Gasoline system – Drive-by-wire system
• Muffler is standard – Higher efficiency and lower fuel consumption
LP FUEL SYSTEM
LP FUEL SYSTEM Closed loop LP Carburetion System
MIXER: Diaphragm Type Air Valve Assembly inside. Downdraft (Model: CA-100)
REGULATOR: Two-Stage Negative Pressure Regulator (Model: N-2007)
FUEL FILTRATION: 40 Microns Maximum
GASOLINE FUEL SYSTEM
GASOLINE FUEL SYSTEM Closed loop MPI System and In-Tank Fuel Pump System
Electric Fuel Pump (12V)
FUEL PUMP MODULE Fuel Filter (10Micron) & Strainer
Gasoline Pressure Regulator (3.5 bar)
FUEL INJECTOR ASS’Y Electric Fuel Injector (12V)
ENGINE ELECTRIC
ENGINE CONTROL
12 V operation volt, 48 pins I/O
MODULE(ECM):
CRANK SENSOR Hall sensor
CAM SENSOR MRE
TMAP: Intake Air Temp. & Manifold Absolute Pressure Sensor
PEDAL ANGLE SENSOR: Two-Output Signals (Installed on Accelerator Pedal)
Heated Exhaust Gas Oxygen Sensor(HEGO)
OXYGEN SENSOR:
Dual Oxygen Sensor System
ECT-ECM: Engine Coolant Temperature Sensor for ECM
ECT-GAUGE Engine Coolant Temp. Sensor for GAUGE on Instrument Panel
TPS: Throttle Position Sensor (Built in Throttle Body)
THROTTLE BODY: Electronic Throttle Body
FUEL TRIM VALVE(FTV): Dual Dither System
LP FUEL LOCK-OFF: 12 V operation volt
ENGINE OIL PR. S/W: 29.4 kPa (4.3 psi)
STARTING MOTOR: 12 V-1.4 kW
ALTERNATOR: 13.5 V-90 A
EXHAUST SYSTEM
CATALYTIC MUFFLER: Three-way catalyst with durable metal substrate
G424iE-LP & DF(LPG) ENGINE POWER & TORQUE CURVE FOR G30E-5
G424i-LP & DF(LPG) ENGINE POWER & TORQUE CURVE FOR G18S-5
G424i-LP & DF(LPG) ENGINE POWER & TORQUE CURVE FOR G30E-5
• Obtain a leak check squirt bottle or pump spray • Repair and/or replace as necessary.
bottle.
• Fill the bottle with an approved leak check solution. Inspect Foot Pedal Operation
• Spray a generous amount of the solution on the • Verify foot pedal travel is smooth without sticking.
fuel system fuel lines and connections, starting at
the storage container.
• Wait approximately 15-60 seconds, then perform a
visual inspection of the fuel system. Leaks will
cause the solution to bubble.
• Listen for leaks
• Smell for LPG odor which may indicate a leak
• Repair any leaks before continuing.
• Crank the engine through several revolutions. This
will energize the fuel lock-off and allow fuel to flow
to the pressure regulator/converter. Apply
additional leak check solution to the regulator/
converter fuel connections and housing. Repeat
leak inspection as listed above.
• Repair any fuel leaks before continuing.
2) Remove the oil drain plug, and drain the oil into
a container.
39.2~44.1N.m(4.0~4.5kgf.m,
Torque
28.9~32.5lb-ft)
Capacity Drain
5.1L(4.23US qts, 3.52Lmp qts)
and refill
Oil filter 0.4L(0.32US qts, 0.26Lmp qts)
Acceptable Water
Water Content Limits (pps)
Chlorides (CI) 40 maximum
Sulfates (SO4) 50 maximum
Total Hardness 80mg/ℓ maximum
Total Solids 250 maximum
pH 6.0 ~ 8.0
ppm = parts per million
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.
When removing the tester, take care not to spill
the coolant.
When removing/installing the tester as well as
testing, take care not to deform the filler neck.
1. Checking tension
Standard
Tension(T) New belt Used belt
65~75kg 40~50kg
CAUTION
The belt used over 5 minutes should be ad-
justed as used belt of standard
Check that the belt is installed correctly.
When the belt is loosened, slip noise is heard.
Crank
pulley
1. Loosen the alternator support bolt “A” nut and Check the following items and replace the belt if
adjusting lock bolt “B”. defective.
2. Adjust the belt tension by moving the alternator 1. Check the belt surface for damage, wear and
brace adjusting bolt to “T” direction. 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. Check the rubber part for wear or hardening.
3. Tighten the bolt “A” and then tighten “B” to the
4. Check the pulley surface for crack or damage.
specified torque.
CAUTION
If the belt tension is too excessive, noise as well
as early wear of belt occurs and the water pump
bearing and alternator bearing are damaged.
If the belt is too loose, due to early wear of belt
and insufficient power of alternator, battery and
water pump become inefficient and finally en-
gine is overheated or damaged.
Parking brake : ON
2. Inspection
2) Measure RPM.
RPM
LP: 750±15rpm
Low Idle
Gasoline: 830±15rpm
LP: -8˚±5˚
BTDC
Gasoline: -5˚±5˚
1) Insulator broken
2) Terminal worn
3) Carbon deposit
12. Check the filter housing, fuel lines and fittings for
leaks. Repair as necessary.
• The engine should run out of fuel and stop within a • Refer to Chapter 5 if the pressure
short period of time. regulator/converter requires replacement.
NOTE : The length of time the engine runs on Fuel Trim Valve Inspection (FTV)
trapped fuel vapor increases with any
increase in distance between the fuel lock- • Visually inspect the fuel trim valves (C) for
off and the pressure regulator/converter. abrasions or cracking. Replace as necessary.
• To ensure a valve is not leaking a blow-by test can
• Turn the ignition key switch off and re-connect the be performed.
fuel lock-off connector.
1. With the engine off, disconnect the electrical
connector to the FTVs.
• Visually inspect the intake throttle assembly (E), • Perform visual inspection of exhaust system from
and intake manifold for looseness and leaks. the engine all the way to the tailpipe. Any leaks,
Repair as necessary. even after the post-catalyst oxygen sensor, can
cause the sensor output to be effected (due to
Inspect Throttle Assembly exhaust pulsation entraining air upstream). Repair
any/all leaks found. Ensure the length from the
• Visually inspect the throttle assembly motor post-catalyst sensor to tailpipe is the same as
housing for coking, cracks, and missing cover- original factory.
retaining clips. Repair and/or replace as necessary.
• Ensure that wire routing for the oxygen sensors is
NOTE: Refer to Chapter 5 for procedures on still keeping wires away from the exhaust system.
removing the mixer and inspecting the throttle plate. Visually inspect the oxygen sensors to detect any
damage.
Checking the TMAP Sensor
• Verify that the TMAP sensor (F) is mounted tightly
into the manifold or manifold adapter (E), with no
leakage.
Inspection
Compression pressure :
3. Remove ignition coils(B).
1,283kPa (13.0kgf/cm², 185psi)
Remove spark plugs.
Using a 16mm plug wrench, remove the 4 s/plugs.
Minimum pressure :
1,135kPa (11.5kgf/cm², 164psi)
4. Check cylinder compression pressure. • If adding oil helps the compression, it is likely
that the piston rings and/or cylinder bore are
1) Insert a compression gauge into the spark worn or damaged.
plug hole. • If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage
past the gasket.
B. Disconnect the P.C.V hose(A). A. Turn the crankshaft pulley and align its groove
with the timing mark "T" of the lower timing chain
cover.
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A-0.30mm (0.0118in.)]
Tightening torque
11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lb-ft)
Valve clearance
(Engine coolant temperature : 20°C)
Spcification
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.32~0.38mm (0.0126~0.0149in.)
1. Inspect crankshaft.
Broken crankshaft
2. Repair as required.
(09214-3K000) A : 09214-3K000
(09231-H1100) B : 09231-H1100
Flywheel stopper
Holds flywheel so that engine
dosen't turn/move.
(09231-3K000)
53.9 ~ 63.7
(5.5~6.5, 39.76~46.99)
9.8 ~ 11.76
(1.0~1.2, 7.23~8.67)
18.62 ~ 22.54
(1.9~2.3, 13.74~16.63)
9.8 ~ 11.76
7.84 ~ 9.8 (1.0~1.2, 7.23~8.67) 9.8 ~ 11.76
(0.8~1.0, 5.78~7.23) (1.0~1.2,
7.84 ~ 9.8
(0.8~1.0, 5.78~7.23) 7.23~8.67)
9.8 ~ 11.76
(1.0~1.2, 7.23~8.67) 26.46 ~ 30.38 (2.7~3.1, 19.52~22.41)
TORQUE : N.m (kgf.m, Ibf.ft)
CAUTION
Place wooden block between the jack and 11. Remove the ignition coils (A).
engine oil pan.
CAUTION
Be careful not to damage the contact surfaces of
cylinder block and oil pan.
CAUTION
Be careful not to damage the contact surfaces of
cylinder block, cylinder head and timing chain
cover.
2. Install the timing chain oil jet (A). The timing mark of each sprockets should be
matched with timing mark (color link) of timing
chain at installing timing chain.
Tightening torque
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Tightening torque
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
14. Install the PCV hose (A). 17. Install the idler (C).
Tightening torque
53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)
Tightening torque
42.14 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 30.96 ~ 39.60lb-
ft)
Tightening torque
18.6 ~ 22.5N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)
Tightening torque
18.6 ~ 22.5N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)
Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 690~880 N (70~90 kgf, 150~200 lbf)
10.78 ~ 12.74
(1.1~1.3, 7.95~9.39)
27.44 ~ 31.36
(2.8~3.2, 20.24~23.14)
53.9 ~ 63.7
(5.5~6.5, 39.7~47.0)
34.3(3.5, 25.3)+90°+90°
CAUTION
• To avoid damaging the cylinder head, wait until
the engine coolant temperature drops below
normal temperature before removing it.
• When handling a metal gasket, take care not to
fold the gasket or damage the contact surface
of the gasket.
• To avoid damage, unplug the wiring
connectors carefully while holding the
connector portion. 4. Disconnect the ignition coil connectors (A).
NOTE:
• Mark all wiring and hoses to avoid
misconnection.
• Turn the crankshaft pulley so that the No1 piston
is at top dead center(See page timing)
9. Remove the cam shaft. 1) Using triple square wrench, uniformly loosen
and remove the 10 cylinder head bolts, in
1) Remove the front cam shaft bearing cap (A). several passes, in the sequence shown.
Remove the 10 cylinder head bolt and plat
washers
CAUTION
Head warpage or crack could result from
removing bolts in an incorrect order.
CAUTION
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block.
2. Remove valves.
Flatness of manifold gasket surface
Standard : Less than 0.10mm(0.004in.)
1) Using SST(09222-3K000, 09222-3K100),
compress the valve spring and remove
retainer lock.
Margin
Standard
2) Using a micrometer, measure the diameter of Intake : 1.02mm(0.0401in.)
the valve stem. Exhaust : 1.09mm(0.0429in.)
Valve length
3) Subtract the valve stem diameter
measurement from the valve guide inside Standard
diameter measurement. Intake : 113.18mm (4.456in.)
Exhaust : 105.79mm (4.165in.)
Limit
Intake : 112.93mm (4.446in.)
Valve stem-to-guide clearance Exhaust : 105.64mm (4.159in.)
Standard
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.) 5) Check the surface of the valve stem tip for
Limit wear.
Intake : 0.07mm (0.0027in.) If the valve stem tip is worn, replace the
Exhaust : 0.09mm (0.0035in.) valve.
Standard value
Intake : 42.6~42.8mm (1.6771 ~ 1.1.6850in.)
Exhaust : 45.3~45.5mm (1.7834 ~ 1.7913in.)
MLA
If the cam lobe height is less than standard,
1. Inspect MLA. replace the camshaft.
Using a micrometer, measure the MLA outside
diameter. 2. Inspect camshaft journal clearance.
CAUTION
Do not turn the camshaft.
Standard value
Intake If the end play is greater than maximum, replace
No.1.2,3,4,5, journal : 0.045 ~ 0.082mm (0.0018 ~ the camshaft. If necessary, replace cylinder head
0.0032in.)
Exhaust 3) Remove the camshafts.
No.1. 2,3,4,5, journal : 0.045 ~ 0.082mm (0.0017
~ 0.0032in.)
Limit
Intake / Exhaust
No.1.2,3,4,5 journal : 0.12mm (0.0047in.)
CAUTION
• Do not reuse old valve stem seals.
• Incorrect installation of the seal could result
in oil leakage past the valve guides.
CAUTION
Keep the OCV filter clean.
CAUTION
Apply a light coat of engine oil on camshaft
journals.
Tightening torque :
34.3N.m (3.5kgf.m, 25.3lb-ft) + 90° + 90°
Tightening torque :
Step 1 : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-
15. Install the water temp control assembly (A).
ft)
Step 2 : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-
ft)
Tightening torque :
Bolt : 14.7 ~21.56Nm
1.5~2.2kgf.m.10.84~15.9lbf.ft)
Nut : 19.6 ~ 26.4N.m (2.0 ~ 2.7 kgf.m,14.46 ~
19.52lb-ft)
Tightening torque :
Bolt : 18.6~ 27.4Nm (1.9 ~ 2.8kgf.m.13.7 ~
20.2lbf.ft)
16. Install the ignition coils (A).
Nut : 18.6~ 27.4Nm (1.9 ~ 2.8kgf.m.13.7 ~
20.2lbf.ft)
Tightening torque :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
14. Install the exhaust manifold(B)
Tightening torque :
Nut : 49~ 53.9Nm(5.0~ 5.5kgf.m.36.2 ~ 39.8lbf.ft)
Tightening torque :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
3. Crankshaft
NOTE:
• Keep the bearings, connecting rod and cap
together.
• Arrange the piston and connecting rod
12. Remove the water pump(A). assemblies in the correct order.
A) If out-of-tolerance, install a new connecting 9) If the plastigage measures too wide or too
rod. narrow, remove the upper half of the bearing,
install a new, complete bearing with the
B)If still out-of-tolerance, replace the crankshaft. same color mark (select the color as shown
in the next column), and recheck the
2. Check the connecting road bearing oil clearance.
clearance.
2) Remove 2 connecting rod cap bolts. 10) If the plastigage shows the clearance is still
incorrect, try the next larger or smaller
3) Remove the connecting rod cap and bearing bearing (the color listed above or below that
half. one), and check clearance again.
4) Clean the crank pin and bearing. NOTE: If the proper clearance cannot be obtained
by using the appropriate larger or smaller
5) Place plastigage across the crank pin. bearings, replace the crankshaft and start
over.
6) Reinstall the bearing half and cap, and
torque the bolts.
CAUTION
7) Remove 2 bolts, connecting rod cap and If the marks are indecipherable because of an
bearing half. accumulation of dirt and dust, do not scrub them
with a wire brush or scraper.
Clean them only with solvent or detergent.
CAUTION
If the marks are indecipherable because of an
accumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only
with solvent or detergent.
Selection
Crankshaft
Crankshaft Assembling
Bore
Identification Classification of
Identification
Mark Bearing
Mark
a (A) D (YELLOW)
Ⅰ(1) b (B) C (GREEN)
c (C) B (NONE)
a (A) C (GREEN)
Ⅱ(2) b (B) B (NONE)
c (C) A (BLACK)
NOTE: Conform to read stamping order as shown a (A) B (NONE)
arrow direction from #1. Ⅲ(3) b (B) A (BLACK)
c (C) AA (BLUE)
Discrimination Of Crankshaft
Class Mark outside Diameter of Pin 4. Check crankshaft end play.
51.954 ~ 51.960mm
Ⅰ 1 Using a dial indicator, measure the thrust
(2.0454 ~ 2.0456in.)
clearance while prying the crankshaft back and
51.948 ~ 51.954mm
Ⅱ 2 forth with a screwdriver.
(2.0452 ~ 2.0454in.)
51.942 ~ 51.948mm
Ⅲ 3
(2.0449 ~2.0452in.)
Standard end play
0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)
Place Of Identification Mark (Crankshaft Bearing) Limit : 0.30mm (0.0118in.)
Discrimination Of Crankshaft Bearing
1. Remove gasket material. 6. Check the cylinder bore size code on the
Using a gasket scraper, remove all the gasket cylinder block.
material from the top surface of the cylinder block.
7. Check the piston size code on the piston top Standard diameter
face. 87.975 ~ 88.005mm (3.4635 ~ 3.4647in.)
Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
No.2 : 0.37 ~ 0.52m (0.0145 ~ 0.0204in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)
NOTE: Thoroughly clean all parts to assembled. 1) Align the bearing claw with the groove of the
Before installing the parts, apply fresh connecting rod or connecting rod cap
engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals 2) Install the bearings(A) in the connecting rod
with new parts. and connecting rod cap(B).
Tightening torque :
NOTE: Maintain downward force on the ring Step 1 : 7.8 ~ 8.8N.m
compressor to prevent the rings from (0.8 ~ 0.9kgf.m, 5.8 ~ 6.5lb-ft)
expanding before entering the cylinder Step 2 : 15.7 ~18.6N.m
bore. (1.6 ~ 1.9kgf.m, 11.6 ~ 13.7lb-ft)
Step 3 : 23.5 ~ 27.5N.m
(2.4 ~ 2.8kgf.m, 17.4 ~ 20.3lb-ft)
Tightening torque :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
1) Apply adhesive to 2 or 3 threads. 1) Install a new O-ring on the oil level gauge.
Adhesive : MS 721-39(B) or equivalent.
2) Apply engine oil on the O-ring.
2) Install the oil pressure sensor (A).
3) Install the oil level gauge assembly(A) with
the bolt.
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
14.7 ~ 21.56
(1.5~2.2, 10.8~15.8)
18.6 ~ 23.5
(1.9~2.4, 13.7~17.4)
19.6 ~ 26.5
(2.0~2.7, 14.2~9.5)
1. Remove the water inlet fittingt(A) If the valve opening temperature is not as
specified, replace the thermostat.
Installation
Inspection
1. Install the water pump (A) with a new gasket.
Water pump
Tightening torque :
7.8 ~ 11.08N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)
Water pump
Check again
- Check interference of - Exchange the water
- Impeller after
body body and impeller pump in case of
interference removing
of water pump occurring interference
water pump
Tightening torque :
Tightening torque :
8.8(1'st) -> 16.7(2'nd) -> 25.5(3'rd)N.m
(0.9 + 1.7 + 2.6kgf.m, 6.5 + 12.3 + 18.8lb-ft)
Bolting order
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
1) Remove the oil filler cap. 4. Start engine and check for oil leaks and check
the oil gauge or light for an indication of oil
2) Remove the oil drain plug, and drain the oil pressure.
into a container.
5. Recheck the engine oil level.
2. Replace the oil filter.
Inspection
1) Remove the oil filter.
1. Check the engine oil quality.
2) Check and clean the oil filter installation Check the oil deterioration, entry of water,
surface. discoloring of thinning. If the quality is visibly
poor, replace the oil.
3) Check the part number of the new oil filter is
as same as old one. 2. Check the engine oil level.
After engine warm up stop the engine wait 5
4) Apply clean engine oil to the gasket of a new minutes then check the oil level.Oil level should
oil filter. be befween the "L" and "F" marks on the
dipstick. If low check for leakageand add oil up
5) Lightly screw the oil filter into place, and to the "F" mark.
tighten it until the gasket contacts the seat.
Tightening torque :
11.8 ~ 15.7N.m (1.2 ~ 1.6kgf.m, 8.7 ~ 11.6lb-ft)
NOTE:
For best performance and maximum protection of all types of operation, select only those lubricants which :
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API service classification on the container
should not be used.
Component
18.6 ~ 23.5
(1.9~2.4, 10.8~14.5)
9.8 ~ 11.76
(1.0~1.2, 7.2~8.7)
18.6 ~ 23.5
(1.9~2.4, 10.8~14.5)
TORQUE : N.M(kgf.m, Ib-ft)
Installation
Tightening torque :
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m,13.7 ~ 17.4lb-ft)
4. Remove the sensor connectors (A) from the 3. Install the intake manifold stay (B) and then
bracket and then remove the intake manifold install the sensor connectors (A).
stay (B).
Tightening torque :
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m,13.7 ~ 17.4lb-ft)
Components
2. Exhaust manilod
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Installation
Tightening torque :
39.2 ~ 44.1N.m (4.0 ~ 4.5kgf.m, 28.9 ~ 32.5lb-ft)
Ignition System
ITEM SPECIFICATION
NGK LFR6A
Spark plug Leaded
Gap 0.8 ~ 0.9㎜(0.0315~0.354 in)
Starting System
ITEM SPECIFICATION
Voltage 11.5v
No-load
Starter Ampere 90A, MAX
charateristics
Speed 2600rpm, MIN
Charging System
ITEM SPECIFICATION
Ignition System
Starting System
Starter Replace
Starter keeps running
Ignition switch Replace
Repair procedures
6. Check if spark occurs while engine is being
Spark Test
cranked.
1. Remove the ignition coil connector(A).
NOTE: To prevent fuel being injected from
injectors while the engine is being
cranked, remove the fuel pump relay
from the fuse box.
Crank the engine for no more than 5 ~
10 seconds.
OK
BAD
Check connection of ignition coil connector Connect securely
OK
BAD
Check the ignition coil Replace the ignition coil
OK
Check power supply to ignition coil BAD Check wiring between ignition switch and
1. Turn ignition switch to ON ignition coil
2. Check that there is battery voltage
at ignition coil positive (+) terminal
OK
BAD
Check the camshaft position seneor Replace the camshaft position sensor
OK
BAD
Check the crankshaft position seneor Replace the crankshaft position sensor
OK
BAD
Check ignition signal from ECM Check wiring between ECM and ignition
coil, and then try another ECM
OK
Standard value
Leaded : 0.8 ~ 0.9 mm (0.0275 ~ 0.0315 in.)
Inspection
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV
valve from the rocker cover and reconnect it to the ventilation hose.
NOTE: The plunger inside the PCV valve will move back and forth.
Operation
Intake manifold side (No vacuum) Intake manifold side (High vacuum)
Intake manifold side (Moderate vacuum) Intake manifold side (Low vacuum)
Engine condition Nomal operation Engine condition Accelerating and high load
PCV valve Properly operating PCV valve Slightly operating
Vacuum passage Large Vacuum passage Very large
1. Disconnect the vacuum hose and remove the - Type: Piezo-resistive pressure sensor type
PCV valve(A) - Specification
Items Specification
Capacitance (pF) 1,480 ~ 2,200
Resistance(㏁) 1
Tightening torques
Manifold absolute pressure sensor installation bolt 1.0 ~ 1.2 9.8 ~11.8 7.2 ~ 8.7
Engine coolant temperature sensor installation 3.0 ~ 4.0 29.4 ~39.2 21.7 ~ 28.9
Crankshaft position sensor installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Knock sensor installation bolt 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.4
Heated oxygen sensor installation 3.5 ~ 4.5 34.3 ~ 44.1 25.3 ~32.6
Ignition coil assembly installation bolts 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~4.3
CAUTION
DO NOT sprinkle water directly into the engine
compartment or electronic components.
1. Handling of Connector
NOTE:
- Use a fine wire to prevent damage to the
terminal.
- Do not damage the terminal when inserting the
tester lead.
C) Listen for a click when locking connectors.
This sound indicates that they are securely 2. Checking Point for Connector
locked.
A. While the connector is connected:
Hold the connector, check connecting condition
and locking efficiency.
A. Clean the contact points using air gun and/or NOTE: When measuring for resistance, lightly
shop rag. shake the wire harness above and below
or from side to side.
NOTE: Never use sand paper when polishing the
contact points, otherwise the contact point
may be damaged.
Specification (Resistance)
Wire harness inspection procedure 1Ω or less → Normal Circuit
1MΩ or Higher → Open Circuit
1. Before removing the wire harness, check the
wire harness position and crimping in order to
restore it correctly. A. Disconnect connectors (A), (C) and measure
resistance between connector (A) and (C) as
2. Check whether the wire harness is twisted, shown in [FIG. 2].
pulled or loosened. In [FIG.2.] the measured resistance of line 1
and 2 is higher than 1MΩ and below 1 Ω
3. Check whether the temperature of the wire respectively.
harness is abnormally high. Specifically the open circuit is line 1 (Line 2 is
normal).
4. Check whether the wire harness is rotating, To find exact break point, check sub line of line
moving or vibrating against the sharp edge of a 1 as described in next step.
part.
A. Continuity Check
B. Voltage Check
Specification
Component inspection
Specifications
Ignition Coil
Item Specification
Spark Plug
Item Specification
NGK PLFR6A
Starter Motor
Item Specification
Alternator
Item Specification
COP problems can include many of the same Individual ignition coils can be tested with an
ailments as other ignition systems such as misfiring, ohmmeter the same as those on a conventional
hard starting, or a no start. Spark plugs can still be distributor or DIS ignition system. Measure primary
fouled by oil or fuel deposits, as well as pre-ignition and secondary resistance and compare to
and detonation. specifications. If resistance is out of specifications,
the coil is bad and needs to be replaced.
If the crankshaft position sensor fails, the loss of the
basic timing signal will prevent the system from Also, pay close attention to the tube that wraps
generating a spark and the engine will not start or around the spark pug. Cracks can allow voltage to
run. A failed driver circuit within the SECM can kill jump to ground causing a misfire. The spark plug
an individual coil and prevent that cylinder from firing. terminal should also fit tightly.
But with COP, an individual coil failure will only
cause misfiring in one cylinder. If a COP coil tests bad and is replaced, cleaning the
COP connector and wiring harness terminals can
It is important to remember that ignition misfire can often avoid future problems. Corrosion at either
also be caused by other factors such as worn or place can cause intermittent operation and loss of
fouled spark plugs, loose or damaged coil connector continuity, which may contribute to component
or terminals, dirty fuel injectors, low fuel pressure, failure. Applying dielectric grease to these
intake vacuum leaks, loss of compression in a connections can help prevent corrosion and assure
cylinder, even contaminated fuel. These other a good electrical connection.
possibilities should all be ruled out before a COP
unit is replaced. Magnetic crankshaft position sensors can be tested
with an ohmmeter, and the sensor output voltage
A COP engine that cranks but fails to start, in many and waveform can be read with an oscilloscope. The
cases, will often have a problem in the crankshaft or output voltage of a Hall Effect crankshaft position
camshaft position sensor circuits. Loss of sensor sensor can be checked with a voltmeter. On most
signals may prevent the SECM from properly vehicles, a defective crank position sensor will
synchronizing, thereby preventing the engine from usually set a fault code that can be read with the
starting and running. Service Tool.
Circuit Diagram
SECM
2. Inspection
Inspection of Ignition Coil Drivers
1) Connect the timing light. (Power TR)
2) After inserting the clip backward the Four Power Transistors are used for G420i(E)
connector, connect the tachometer with the engine. Its function is ignition coil driver, and it is
special tool (09273-24000) located near to SECM.
CAUTION
Location of Components
Take care not to disconnect the connector.
3) Measure RPM.
RPM
CAUTION
Because ignition timing is fixed by set data
value in ECU, it is impossible to control on
purpose.
First, check that sensors send output properly to
help determine ignition timing control.
Description
The operation of the ignition system is essentially
the same as any other ignition system. Each coil has
a low primary resistance (0.4 to 0.6 ohms) and steps
up the primary system voltage from 12 volts to as
IB (Terminal #3), OC (Terminal #1), GND (Terminal #2) much as 40,000 volts to produce a spark for the
spark plug.
1. 1st Coil Resistance Measurement 3. Remove all spark plugs from the cylinder head
Measure resistance between no.1 (Ba+) using a spark plug wrench.
and no.3 (ECU) terminals of ignition coil.
CAUTION
1st Coil Resistance : 0.62 ± 10 % (Ω)
Take care not to come foreign materials into
spark-plug mounting hole.
3. Inspection of battery voltage at idling (At this time charge battery only)
Result
6. Connect the battery ground cable. 1) Be sure that the battery installed in the vehicle
is normal.(See “Battery”)
7. Be sure that the hood is opened.
NOTE: When measuring output current, necessarily
use a slightly discharged battery. Fully
charged battery is not enough to use for
correct test owing to insufficient load.
4. Disconnect the alternator output wire from the NOTE: This test should be done as soon as possible
alternator “B” terminal. to measure the exact maximum current
because output current drops rapidly after
starting the engine.
Result
1. Disconnect the battery (A) terminal. 1. After removing the mounting nuts (B), remove
the generator cover (A) using a screwdriver.
3. Loosen the alternator tension adjusting bolt (A) 3. Remove the slip ring guide (A).
and the alternator fixing bolt (B).
Rotor
1. Inspect the stator coil for continuity and check 2. (-) rectifier
continuity between the coil leads. If there is no When inspecting continuity between (-) rectifier
continuity, replace the stator assembly. 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.
Brush Replacement
Rectifier
1. (+) 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.
Installation
Components
Disassembly
4. Remove the brush holder assembly (A), yoke
1. Disconnect the M-terminal (A) on the magnet (b) and armature (C).
switch assembly (B).
7. Disconnect the planet gear (A). 11. Disconnect the stop ring (A), overrunning
clutch (B), internal gear (C) and planet shaft
(D).
1. Slide the overrunning clutch along the shaft. 1. Remove the starter relay
Replace it if does not slide smoothly.
2. Using an ohmmeter, check that there is
2. Rotate the overrunning clutch both ways. continuity between each terminal.
Does it lock in one direction and rotate
smoothly in reverse? If it does not lock in either
direction or it locks in both directions, replace it. Terminal Continuity
30 - 87 NO
85 - 86 YES
Cleaning
1. Do not immerse parts in cleaning solvent. 4. If there is no continuity, replace the starter relay.
Immersing the yoke assembly and/or armature
will damage the insulation. Wipe these parts
with a cloth only.
General Information
Specifications
Q’ty
Components Items Specifications
G424iE G424i
Environmental / Ambient Operating -20 °F to 221°F [-29 °C to 105 °C]
Electrical Temperature
None None
Specifications
Operating Voltage 8-16 Vdc
Engine Control Operating Temperature -20 °F to 221°F [-29 °C to 105 °C]
Module (SECM 48)
Q’ty
Components Items Specifications
G424iE G424i
Minimum Electrical Resistance
Electronic Throttle System 1 1 1.5 ohms
of Throttle Actuator
Q’ty
Components Items Specifications
G424iE G424i
Q’ty
Components Items Specifications
G424iE G424i
LP Fuel System LPG Composition HD5 / HD10 LPG. Failure to use fuel
- -
Requirements Requirements compliant with
HD5 or HD10 standards will void the
user warranty.
LP Fuel Filter 1 1 Fuel Filter Micron Size 40 micron
Fuel Outlet Fitting One 3/4” NPT and one 1/8” NPT
fitting with plug
Fuel Inlet Fitting 1/2” NPT Fuel inlet fitted with Delphi
temperature sensor
Fuel LPG
Q’ty
Components Items Specifications
G424iE G424i
Sealants
Tightening Torques
CKPS target wheel installation screw 10.8 ~ 11.8 1.1 ~ 1.2 8.0 ~ 8.7
General Description
MI-07 control system provides a complete, fully MI-07 is a closed loop system utilizing a catalytic
integrated engine management system that meets muffler to reduce the emission level in the exhaust
or exceeds 2007 emission standards for Large gas. In order to obtain maximum effect from the
Spark Ignited (LSI) engines established by the catalyst, an accurate control of the air fuel ratio is
California Air Resources Board (CARB) and the required. A small engine control module (SECM)
Environmental Protection Agency (EPA). uses two heated exhaust gas oxygen sensors
(HEGO) in the exhaust system to monitor exhaust
The control system is applicable to naturally gas content. One HEGO is installed in front of the
aspirated engines running on LPG and/or gasoline. catalytic muffler and one is installed after the
It provides accurate, reliable, and durable control of catalytic muffler.
fuel, spark, and air over the service life of the engine
in the extreme operating environment found in
heavy-duty, under hood, on-engine electronic
controls.
Figure 1. MI-07 Dual Fuel System for G424iE Engine on Certified Systems
The SECM makes any necessary corrections to the wire (DBW) system connecting the accelerator pedal
air fuel ratio by controlling the inlet fuel pressure to to the electronic throttle through the electrical
the air/fuel mixer by modulating the dual fuel trim harness; mechanical cables are not used. A throttle
valves (FTV) connected to the regulator. Reducing position sensor (TPS) monitors throttle position in
the fuel pressure leans the air/fuel mixture and relation to the accelerator pedal position sensor
increasing the fuel pressure enriches the air/fuel (APP) command. Even engine coolant temperature
mixture. To calculate any necessary corrections to and adequate oil pressure are monitored by the
the air fuel ratio, the SECM uses a number of SECM. The SECM controller has full adaptive
different sensors to gain information about the learning capabilities, allowing it to adapt control
engine’s performance. Engine speed is monitored function as operating conditions change. Factors
by the SECM through a Hall Effect sensor. Intake such as ambient temperature, fuel variations,
manifold air temperature and absolute pressure are ignition component wear, clogged air filter, and other
monitored with a TMAP sensor. MI-07 is a drive-by- operating variables are compensated.
INPUT OUTPUT
Crank Sensor Throttle body
TMAP sensorv
2 Fuel trim valves
Coolant Temp
LP fuelock valve
A dual fuel system operates on either LPG or MPI (multi-point injection) system is used for G424iE
gasoline. The fuel type can be switched while the dual fuel engine and G424i gasoline/dual fuel engine.
engine is stopped or running at low speeds and low On gasoline, the camshaft sensor along with the
loads. The fuel selection switch is a three-position crankshaft sensor is used to control the fuel injectors
type where the center position is fuel off. and feedback from oxygen sensor is used by the
SECM to adjust the gasoline delivery based on the
exhaust emissions.
SECM
The Small Engine Control Module (SECM) controls
the LPG lock-off solenoid valve and the FTVs. The
lock-off solenoid is energized when fueling with LPG
and the engine is turning. FTV modulation frequency Figure 4. Electric Fuel Lock Assembly
will be varied as a function of rpm by the SECM in
order to avoid resonance phenomena in the fuel In the MI-07 design, power is supplied to the fuel
system. FTV commands will be altered by the lock-off via the main power relay with the SECM
SECM in order to maintain a stoichiometric air-fuel controlling the lock-off ground (earth) connection.
ratio. Commands are based primarily on feedback The lock-off remains in a normally closed (NC)
from the exhaust gas oxygen sensor, with an offset position until the key switch is activated.
for fuel temperature. This supplies power to the lock-off and the SECM,
but will not open the lock-off via the main power
MI-07 LP Fuel Filter relay until the SECM provides the lock-off ground
After exiting the fuel tank, liquid propane passes connection. This design gives the SECM full control
through a serviceable inline fuel filter to the electric of the lock-off while providing additional safety by
fuel lock off. Figure 3 shows a typical inline type LP closing the fuel lock-off in the unlikely event of a
fuel filter manufactured by Century. The primary power failure, wiring failure or module failure.
function of the fuel filter is to remove particles and
sediments that have found their way into the tank. When the liquid service valve in the fuel container is
The LP fuel filter will not remove heavy end solids opened, liquid propane flows through the LP filter
and paraffins that build up in LPG fuel systems as a and through the service line to the fuel lock-off.
result of vaporization. Liquid propane enters the lock-off through the 1/4”
NPT liquid inlet port and stops with the lock-off in the
normally closed position. When the engine is
cranked over the main power relay applies power to
the lock-off and the SECM provides the lock-off
ground causing current to flow through the windings
of the solenoid creating a magnetic field. The
strength of this magnetic field is sufficient to lift the
lock-off valve off of its seat against spring pressure.
When the valve is open liquid propane, at tank
pressure, flows through the lock-off outlet to the
pressure regulator/converter. A stall safety shutoff
feature is built into the SECM to close the lock-off in
case of a stall condition. The SECM monitors three
Figure 3. Inline LP Fuel Filter engine states: Crank, when the crankshaft position
sensor detects any engine revolutions; Stall, when
the key is in the ON position but the crankshaft
position sensor detects no engine revolutions; and
the Run state, when the engine reaches pre-idle rpm.
CA100 Mixer
The mixer is installed above the throttle body and
meters gaseous fuel into the airstream at a rate that
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel
flow is controlled by the shaping of the mixer fuel
cone and biased by the controllable fuel supply
pressure delivered by the pressure regulator. Fuel
flow must be metered accurately over the full range
of airflows. Pressure drop across the mixer air valve
must be minimized to assure maximum power
output from the engine. Figure 8. CA100 Mixer Attached to Throttle Body
The mixer fuel inlet is fitted with a thermistor-type (Refer to Figure 98.)
temperature sensor. This permits the SECM to The air/fuel mixer is mounted in the intake air stream
correct fuel pressure to compensate for variations in between the air cleaner and the throttle. The design
fuel temperature. Left uncorrected, fuel temperature of the main body incorporates a cylindrical bore or
variations can cause significant variations in air fuel mixer bore, fuel inlet (1) and a gas discharge jet (2).
ratio. In the center of the main body is the air valve
assembly, which is made up of the air valve (3), the
gas-metering valve (4), and air valve diaphragm (5)
and air valve spring (6). The gas-metering valve is
permanently mounted to the air valve diaphragm
Use of unleaded gasoline of 87 octane or higher is recommended for optimal performance of the MI-07
system.
The electronic throttle system controls engine output Conventional throttle systems rely on a mechanical
(speed and torque) through electronic control of linkage to control the throttle valve. To meet
mass airflow to the engine. Any DC motor-actuated fluctuating engine demands a conventional system
or Limited Angle Torquemotor (LAT)-actuated will typically include a throttle valve actuator
throttle with less than 5A peak and 2A steady state designed to readjust the throttle opening in response
can be controlled. The TPS must be directly coupled to engine demand, together with an idle control
to the throttle shaft for direct shaft position actuator or idle air bypass valve.
measurement.
In contrast, the MI-07 system uses electronic throttle
A commonly used throttle is the Bosch DV-E5. This control (ETC). The SECM controls the throttle valve
throttle is available in a variety of bore sizes to meet based on engine RPM, engine load, and information
specific engine needs: 32mm, 40mm, and 54mm are received from the foot pedal. Two potentiometers on
readily available throttle bore sizes; other sizes are the foot pedal assembly monitor accelerator pedal
possible. The Bosch throttle is a fully validated travel. The electronic throttle used in the MI-07
automotive component incorporating a brushed DC system is a Bosch 32mm or 40mm electronic throttle
motor with gear reduction, dual throttle position body DV-E5 (Figure 14). The DV-E5 is a single unit
sensors, throttle plate, and cast aluminum housing. assembly, which includes the throttle valve, throttle-
In the event of an electrical disconnection or other valve actuator (DC motor) and two throttle position
related failure, the throttle plate returns to a limp- sensors (TPS). The SECM calculates the correct
home idle position at a no-load engine speed above throttle valve opening that corresponds to the
curb idle speed. This provides sufficient airflow for driver’s demand, makes any adjustments needed for
the engine to move the vehicle on level ground. Any adaptation to the engine’s current operating
throttle bodies used for MI-07 meet or exceed the conditions and then generates a corresponding
specification for the Bosch throttle bodies. electrical (driver) signal to the throttle-valve actuator.
Figure 15. Throttle Body Assembly Exploded View Coil-On-Plug (Coil Pack) Ignition System
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. On most engines, the plugs
and coils are located on top of the cylinder head for
easy mounting of the coils. A topside location is best
because it keeps the coils away from the heat of the
exhaust.
Misfires
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. Figure 18. HEGO (O2) Sensor
If the crankshaft position sensor fails, the loss of the Once a HEGO sensor reaches approximately 600°F
basic timing signal will prevent the system from (316°C), it becomes electrically active. The
generating a spark and the engine will not start or concentration of oxygen in the exhaust stream
run. A failed driver circuit within the SECM can kill determines the voltage produced. If the engine is
an individual coil and prevent that cylinder from firing. running rich, little oxygen will be present in the
But with COP, an individual coil failure will only exhaust and voltage output will be relatively high.
cause misfiring in one cylinder. Conversely, in a lean situation, more oxygen will be
present and a smaller electrical potential will be
It is important to remember that ignition misfire can noticed.
also be caused by other factors such as worn or
fouled spark plugs, loose or damaged coil connector In order for the sensor to become active and create
or terminals, dirty fuel injectors, low fuel pressure, an electrical signal below 600°F (316°C) a heated
intake vacuum leaks, loss of compression in a element is added to the sensor housing. Two wires
cylinder, even contaminated fuel. These other provide the necessary 12 Vdc and ground signal for
possibilities should all be ruled out before a COP the heater element. A fourth wire provides an
unit is replaced. independent ground for the sensor. The pre-catalyst
sensor heater is powered by the main power relay
A COP engine that cranks but fails to start, in many and is always powered. The post-catalyst sensor
cases, will often have a problem in the crankshaft or heater is powered from an additional relay that is
camshaft position sensor circuits. Loss of sensor controlled by the SECM. This relay is only energized
signals may prevent the SECM from properly when the SECM calculates that water condensation
synchronizing, thereby preventing the engine from in the exhaust system and catalytic muffler prior to
starting and running. the sensor should be evaporated. This is to avoid
thermal shock of the sensor that could prematurely
fail the sensor.
Recommendations
In order to prevent the possibility of any SECM
malfunctions due to EMI/RFI emissions, engine
packagers and OEMs should follow industry “best
practices” and the SECM mounting and harness
recommendations listed below:
General Description
MI-07 control system provides a complete, fully Engine speed is monitored by the SECM through a
integrated engine management system for naturally Hall Effect sensor. Intake manifold air temperature
aspirated engines. and absolute pressure are monitored with a TMAP
sensor. MI-07 is a drive-by-wire (DBW) system
It provides accurate, reliable, and durable control of connecting the accelerator pedal to the electronic
spark and air over the service life of the engine in throttle through the electrical harness; mechanical
the extreme operating environment found in heavy- cables are not used. A throttle position sensor (TPS)
duty, under hood, on-engine electronic controls. monitors throttle position in relation to the
accelerator pedal position sensor (APP) command.
The SECM monitors the engine through a number of Even engine coolant temperature and adequate oil
different sensors to ensure optimal performance. pressure are monitored by the SECM
The LPG regulator and the mixer operate as an crank position sensor and throttle position is used by
open loop system since no mixture adjustments are the SECM to calculate load. Feedback from the
made by the SECM. The mixer does have an idle electronic throttle is provided to the SECM by the
mixture adjustment and a power valve adjustment. throttle position sensors (TPS).
Manifold pressure from the TMAP, rpm from the
INPUT OUTPUT
Crank Sensor Throttle body
TMAP sensor
Coolant Temp
LP fuelock valve
Oxygen sensor
(Gasoline only)
A dual fuel system operates on either LPG or MPI (multi-point injection) system is used for G424iE
gasoline. The fuel type can be switched while the dual fuel engine and G424i gasoline/dual fuel engine.
engine is stopped or running at low speeds and low On gasoline, the camshaft sensor along with the
loads. The fuel selection switch is a three-position crankshaft sensor is used to control the fuel injectors
type where the center position is fuel off. and feedback from oxygen sensor is used by the
SECM to adjust the gasoline delivery based on the
exhaust emissions.
CA100 Mixer
The mixer is installed above the throttle body and
meters gaseous fuel into the airstream at a rate that Figure 8. CA100 Mixer Attached to Throttle Body
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel (Refer to Figure 98.)
flow is controlled by the shaping of the mixer fuel The air/fuel mixer is mounted in the intake air stream
cone and biased by the controllable fuel supply between the air cleaner and the throttle. The design
pressure delivered by the pressure regulator. Fuel of the main body incorporates a cylindrical bore or
flow must be metered accurately over the full range mixer bore, fuel inlet (1) and a gas discharge jet (2).
of airflows. Pressure drop across the mixer air valve In the center of the main body is the air valve
must be minimized to assure maximum power assembly, which is made up of the air valve (3), the
output from the engine. gas-metering valve (4), and air valve diaphragm (5)
and air valve spring (6). The gas-metering valve is
A higher flow mixer is required on larger engines. A permanently mounted to the air valve diaphragm
lower flow mixer is required on smaller engines. assembly with a face seal mounted between the two
parts.
A pressure/force imbalance begins to build across A main mixture adjustment valve on the fuel inlet of
the air valve diaphragm between the air valve the CA100 is not used in the MI-07 system, however
vacuum (AVV) chamber (above the diaphragm) and an idle mixture adjustment is incorporated into the
atmospheric pressure below the diaphragm. mixer (Figure 12). The idle mixture adjustment is an
Approximately 6 inH2O (14.945 mbar) of negative air bypass port, adjusting the screw all the way in,
pressure is required to overcome the air valve spring blocks off the port and enriches the idle mixture.
force and push the air valve assembly upward off Backing out the idle adjustment screw opens the
the valve seat. Approximately 24 inH2O (59.781 port and leans the idle mixture. The idle mixture
mbar) pulls the valve assembly to the top of its travel screw is a screw with locking threads that is factory
in the full open position. set with a tamper proof cap installed after
adjustment. Accurate adjustment of the idle mixture
The amount of negative pressure generated is a can be accomplished by adjusting for a specific fuel
direct result of throttle position and the amount of air trim valve (FTV) duty cycle with the Service Tool
flowing through the mixer to the engine. At low software or with a voltmeter.
engine speeds, low AVV causes the air valve
diaphragm assembly to move upward a small NOTE: Adjustments should only be performed by
amount, creating a small venturi. At high engine trained service technicians.
speeds, high AVV causes the air valve diaphragm
assembly to move much farther creating a large
venturi. The variable venturi air/fuel mixer constantly
matches venturi size to engine demand.
Ignition System
Exhaust System
y Camshaft position
Variable reluctance (2-wire, 200 Vpp max) or 0-5 V
Hall Effect with calibration selectable pull-up
resistor for open collector sensors.
y CANBus
CAN 2.0b serial communication for J1939
communications, programming and diagnostics.
Requires proper termination resistance per CAN
2.0b.
Troubleshooting Waveform
Harness Connector
Troubleshooting
Circuit Diagram
Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the surge tank.
This MAPS senses absolute pressure in surge tank and transfers this analog signal proportional to the
pressure to the PCM.
The PCM calculates the intake air quantity and engine speed based on this signal. This MAPS consists of
piezo-electric element and hybrid IC that amplifies the element output signal. The element is silicon diaphragm
type and adapts pressure sensitive variable resistor effect of semi-conductor. 100% vacuum and the manifold
pressure applies to both sides of it respectively. That is, this sensor outputs the silicon variation proportional to
pressure change by voltage.
Specification
Component inspection
Intake Air Temperature Sensor (IATS) is installed Temperature [℃(℉)] Resistance (㏀)
inside the Manifold Absolute Pressure Sensor
(MAPS) and detects the intake air temperature. To -40 (-40) 40.93 ~ 48.35
calculate precise air quantity, correction of the air -30 (-22) 23.43 ~ 27.34
temperature is needed because air density varies
according to the temperature. So the PCM uses not -20 (-4) 13.89 ~ 16.03
only MAPS signal but also IATS signal. This sensor -10 (14) 8.50 ~ 9.71
has a Negative Temperature Coefficient (NTC) and
0 (32) 5.38 ~ 6.09
its resistance is in inverse proportion to the
temperature. 10 (50) 3.48 ~ 3.90
20 (68) 2.31 ~ 2.57
Circuit Diagram
25 (77) 1.90 ~ 2.10
30 (86) 1.56 ~ 1.74
40 (104) 1.08 ~ 1.21
60 (140) 0.54 ~ 0.62
80 (176) 0.29 ~0.34
Component Inspection
[CIRCUIT DIAGRAM]
HO2S (B1/S1) ECM
4
2
B1 - HO2S GND
L4GC215A
Specification
1 B1 - HO2S GND
[HARNESS CONNECTORS]
1 2
3 4
C22
Specification
Harness Connector
Location
Inspection
Description 1. Remove the LP fuel temperature sensor from the
The LP Fuel Temperature Sensor (FTS) is located in adapter connected to LP mixer.
the LP fuel passage of the LP mixer for detecting the
LP fuel temperature. The FTS uses a thermistor 2. With the temperature sensing portion of the LP
whose resistance changes with the temperature. engine fuel temperature immersed in hot water,
The electrical resistance of the FTS decrease as the check resistance.
temperature increase, and increase as the
temperature decrease. The reference 5V in the ECM Temperature °C (°F) FTS Resistance (Ohms)
is supplied to the FTS by way of a resister in the
-20(-4) 15462
ECM. That is, the resistor in the ECM and the
thermistor in the FTS are connected in series. When 0(32) 5896
the resistance value of the thermistor in the FTS
20(68) 2498
changes according to the LP fuel temperature, the
output voltage also change. 40(104) 1175
60(140) 596
[Circuit Diagram]
80(176) 323
Location
Inspection
Description 1. Disconnect the Accelerator Pedal’s connector
Angle Sensor-Accelerator is located in the from the main engine harness.
accelerator pedal assembly. The engine speed
management deals with a Drive-by-wire system. 2. Inspect the electrical conditions with a follow
Drive-by-wire refers to the fact that the MI-07 control basic specification.
system has no throttle cable from the foot pedal to
the throttle body. Instead, the ECM is electronically Signal output is on condition that input
connected both to the foot pedal assembly and the voltage is 5V±0.5%
throttle body. The SECM monitors the foot pedal Rated current : 20Ma,
position and controls the throttle plate by driving a Power : 100mW,
DC motor connected to the throttle. The DC motor Wire width : 20AWG
actuates the throttle plate to correspond to the foot - At start point : Signal ’A’ 0.4V±0.1V
pedal position when the operator depresses the Signal ‘B’ 4.5V±0.1V
pedal. The SECM will override the pedal command - At end point(Push for end) :
above a maximum engine speed and below a Signal ’A’ 3.60V±0.15V
minimum idle speed. The foot pedal assembly uses Signal ‘B’ 1.39V±0.15V
two potentiometers to detect pedal position. These
two signals, accelerator pedal position 1 (APP1) and 3. If the result value is out of the specification,
accelerator pedal position 2 (APP2) are sent directly replace the Accelerator Pedal.
to the SECM. The SECM uses a series of algorithms
to self calibrate and cross check the signals from the
pedal assembly.
[Circuit Diagram]
Location
Description Inspection
Transmission Oil Temperature Switch is located in 1. Remove the Transmission Oil Temperature
the adapter on transmission (T/M) for operating by Switch from the transmission.
the transmission (T/M) oil temperature change. This
switch is normally open, and then it is closed as the 2. Use an ohmmeter to check the continuity
T/M oil temperature Increases to the 125±3°C. between the 1 terminal and the 2 terminal. If
Actually if the switch is closed by high T/M oil there is continuity, replace the Transmission Oil
temperature, the ECM makes engine shutdown with Temperature Switch.
fault set. If the T/M oil temperature decreases to the
118°C, the switch is open again and the engine also 3. The Transmission Oil Temperature Switch is the
can run. This function can protect the engine of Tier- ‘ON/OFF’ switch. So during the normal status the
3 and Non cert folk lift trucks from damage as switch circuit should be open.
overheating.
[Circuit Diagram]
Location
Inspection
Description 1. Remove the Ground Speed Limit Switch from the
Ground Speed Limit Switch is located in the transmission.
pressure port on transmission (T/M) for operating by
the transmission (T/M) oil pressure change. This 2. Use an ohmmeter to check the continuity
switch is normally opened, and then it is closed as between the 1 terminal and the 2 terminal. If
the T/M oil pressure increases. Actually the switch is there is continuity, replace the Ground Speed
closed by increasing of the T/M oil pressure after Switch.
engine cranking. And if the inching pedal is pushed
by a driver the switch is opened again by decreasing 3. The Ground Speed Limit Switch is the ‘ON/OFF’
of the T/M oil pressure. ECM can control the travel switch. So during the normal status the switch
speed of the folk lift trucks with this switch. Also the circuit should be open.
maximum travel speed of Tier-3 and Non cert fork lift
trucks is an optional feature that can be easily
activated using the MotoView Service Tool. This
feature may be of particular interest to customers
with indoor warehouse operations.
[Circuit Diagram]
Location
Inspection
Description 1. Check for loose, dirty or damaged connectors
The MI-07 system uses electronic throttle control and wires on the harness
(ETC). The SECM controls the throttle valve based
on engine RPM, engine load, and information 2. Check the throttle assembly motor housing for
received from the foot pedal. Two potentiometers on coking, cracks, and missing cover-retaining clips
the foot pedal assembly monitor accelerator pedal
travel. The electronic throttle used in the MI-07 3. Check the resistance of TPS sensor. (refer as
system is a Bosch 32mm electronic throttle body blow chart)
DV-E5. The DV-E5 is a single unit assembly, which
includes the throttle valve, throttle-valve actuator EXPECTED
SENSOR POINT TO POINT
(DC motor) and two throttle position sensors (TPS). RANGE
The SECM calculates the correct throttle valve TPS PIN 2(GND) TO 1.25KΩ +/-
opening that corresponds to the driver’s demand, PIN 6(TPS1 SIGNAL) 30%
TPS
makes any adjustments needed for adaptation to the
(Throttle TPS PIN 3(PWR) TO 1.25KΩ +/-
engine’s current operating conditions and then
Position PIN 6(TPS1 SIGNAL) 30%
generates a corresponding electrical (driver) signal
Sensor) TPS PIN 1(+DRIVER) ~3.0KΩ +/-
to the throttle-valve actuator.
TO PIN 4(-DRIVER) 30%
[Circuit Diagram]
CAUTION
The regulator/converter and mixer are part of a
certified system complying with EPA and CARB
2007 requirements. Only trained, certified
technicians should perform disassembly,
service or replacement of the regulator/
converter or mixer.
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.
Diagram Notes
N-2007 Removal Steps 10. Install the fuel vapor outlet hose (5) to the
regulator.
Refer to Figure 28.
11. Install the two cooling lines (4) to the regulator.
1. Close the liquid outlet valve in the forklift cylinder
or fuel storage container. 12. Install the four rear-mounting bolts that hold the
regulator to the support bracket. Use a torque
2. Purge the system of fuel by starting the engine wrench and tighten each bolt to 60-70 lbf-in
and running until all trapped fuel in the system is (6.78-7.91 N-m).
exhausted and the engine shuts down.
13. Install the fuel inlet line (1) to the lock-off, the two
3. Key switch in “OFF” position. vacuum lines (2) to the branch-tee fitting in the
regulator vent and re-connect the lock-off
4. Remove the fuel inlet line (1) from the lock-off, connector (3).
the two vacuum lines (2) from the branch-tee
fitting in the regulator vent and disconnect the 14. Open the liquid outlet valve in the forklift cylinder
lock-off connector (3). or fuel storage container.
CA100 Certified Mixer Removal Steps 4. Remove the air cleaner hose (1).
Break-Off Test
Figure 34. Secondary Stage Test Connection
Secondary Stage Test Hardware
Pressure Test
1. Hand vacuum pump
Primary Stage Test Hardware
2. Regulator vapor outlet test fitting 3/4” NPT x 1/4”
hose barb 1. Shop air pressure regulator adjusted to 100 psi
3. Union Tee 1/4” NPT with three 1/4” NPT x 1/4” 2. Shop air hose fitting (1/4” NPT to air hose)
hose barb
3. Air hose
4. Vacuum hose
4. Test gauge fitting (1/16” NPT x 1/4” hose barb)
5. 0-3” WC Magnehelic gauge (inches of water
column) 5. Vacuum hose or vinyl tubing
4. Make sure there is no leakage at any of the y Gas vapor may reduce oxygen available for
fittings. The static pressure should read between breathing, cause headache, nausea, dizziness
40-60” of water column on the Magnehelic gauge and unconsciousness and lead to injury or
and maintain a constant pressure for 60 seconds. death. Always operate the forklift in a well
ventilated area
1. Union Tee fitting, 1/4” (6.35mm) NPT with three Idle Mixture Adjustment
1/4” (6.35mm) NPT x 1/4” (6.35mm) hose barbs
The CA100 mixer requires adjustment of the idle
2. Vacuum hose mixture screw to assure optimal emissions and
performance. This adjustment accounts for minor
3. 0-20” H2O differential pressure Magnehelic part-to-part variations in the fuel system and assures
gauge 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
AVV Test adjusted for the life of the vehicle.
1. Install Union Tee fitting in the hose between the Therefore, the only situations in which the idle
FTVs and the AVV fitting. Connect this fitting to mixture screw needs to be adjusted are when the
the low pressure port of the Magnehelic gauge engine is initially fitted with a fuel system at the
(Figure 37). factory and following the field replacement of the
mixer. Under these situations, follow the procedures
2. Leave high pressure port of the Magnehelic below for adjustment of the idle mixture screw.
gauge exposed to ambient pressure (Figure 37).
Factory Test Preparation:
3. With the engine fully warmed up and running at
idle (750 rpm) place the transmission in Neutral. 1. Install the MI-07 fuel system, wiring harness and
The AVV should be between 5” and 8” H2O of SECM-48 control module on the engine.
pressure vacuum.
2. All coolant hoses should be attached, filled with
4. If the measured pressure drop is excessively coolant and bled to remove any air.
high, check for sticking or binding of the
diaphragm air valve assembly inside the mixer. 3. Attach LPG fuel lines.
Replace mixer if necessary.
4. Attach wiring harness to battery power.
5. If the measured pressure drop is low, check for
vacuum leaks in the manifold, throttle, mixer, 5. Attach exhaust system.
TMAP sensor and attached hoses.
6. If present, set fuel select switch to LPG fuel.
WARNING
• ASSEMBLY TOOLS
Use proper size and type of tool for assembly
and disassembly. Any damaged screws
cannot be properly torqued and can cause
unexpected hardware problems or gas leakage,
which could lead to serious injury or loss of
life.
REF
DESCRIPTION QTY
NO
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
Dowel Pin Ø 0.094” x 1” L (Ø
6 2.39mm x 25.4mm L) Hardened 1
Steel
7 Diaphragm, Secondary Assembly 1
8 Lever, Secondary 1
9 Seat, Secondary 1
10 Valve Primary 1
Fillister Head Screws SEMS Split
11 6
Lockwasher #12-24 x 5/8”
Pan Head Screw SEMS Ext. Tooth
12 1
Lockwasher #12-24 x 1/4”
13 Body Gasket 1
14 Back Plate 1
15 O-ring, Size 107 GLT Viton® 1
16 Bottom Plate Gasket 1
17 Plate Cover 1
Fillister Head Screws SEMS Split
18 6
Lockwasher #12-24 x 1-3/8”
Hex Head Screws SEMS Split
19 4
Lockwasher 1/4-20 x 5/8”
20 Plug, Socket Head Pipe (T-086) 1
21 Cover, Secondary Diaphragm 1
Lockwasher, Int. Tooth (T-210) #8
22 6
SST
23 Torx Screws (T-15) #8-32 x 5/8” 6
Figure 5
Figure 2
PRIMARY INLET
PORT CLOSING Figure 6
Figure 3
CAUTION
The regulator/converter and mixer are part of a
certified system complying with EPA and CARB
2007 requirements. Only trained, certified
technicians should perform disassembly,
service or replacement of the
regulator/converter or mixer.
DIAGRAM NOTES
1 Only one 90 fitting permissible on vapor fuel line between mixer and regulator
2 Vapor fuel fittings (regulator and mixer) must have minimum ID of 0.46” (11.68mm)
4 Vapor hose length to be as short as possible and have no restrictions for best regulator performance
Follow the procedures below for removal and 2. Purge the system of fuel by starting the engine
reinstallation of the CA100 mixer in non-certified and running until all trapped fuel in the system is
systems. exhausted and the engine shuts down.
1. Mixer-Non Cert 11. Remove the four mounting screws that attach the
2. Fitting-To Regulator throttle adapter to the mixer.
3. Fitting-To Regulator
4. Apollo Adapter-ITB, Mixer 12. Remove the vapor fuel inlet fitting from the mixer.
5. ITB
6. O-Ring Spacer
7. O-Ring
8. Bolt-ITB.Conn
9. Gasket-ITB
10. Bolt
1. Install the vapor fuel inlet fitting onto the mixer. CAUTION
The 1/8” NPT x 1/4” hose barb fitting that is
2. Install the four mounting screws that attach the installed in the mixer housing uses a specific
throttle adapter to the mixer. (See Figure 32). machined orifice size through the fitting. This
Torque bolts to 30-40 lbf-in (3.39-4.52 N-m). orifice fitting is part of the mixer assembly and is
an integral part of the MI-07 control. If this fitting
3. Position the mixer/adapter assembly onto the is damaged the mixer will need to be replaced.
throttle body (4), then drop in the four mounting DO NOT replace this fitting with a standard hose
bolts and gently push down on the assembly until barb fitting or use a drill bit to clean out the
it rests on the throttle body. Be careful not to fitting passage way.
pinch the O-ring.
NOTE : A plastic O-ring spacer and an O-ring are
4. Attach the mixer/throttle body assembly to the inside the mixer/adapter assembly. Be
intake manifold, making sure gasket is in place. careful not to lose these items when
Tighten the four mounting bolts. removing the assembly from the throttle
(Figure 31).
5. Connect the wiring harness to the throttle body.
Break-Off 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
1. Hand vacuum pump barb fitting (Figure 31).
2. Regulator fuel inlet test fitting 1/4 NPT standard 2. Connect a compressed air line (shop air ~100
air coupling) psi) to the liquid propane fuel inlet of the N-2001
regulator (Figure 31).
3. Test gauge fitting (1/4” NPT X 1/4” hose b)
1. Install Union Tee fitting in the hose between the 2. After the mixer is installed, start and warm up the
FTVs and the AVV fitting. Connect this fitting to engine to normal operating temperature
the low pressure port of the Magnehelic gauge (ECT>167°F [75°C]). Also ensure that the vehicle
(Figure 37). drive train and hydraulic systems are at normal
operating temperatures per vehicle manufacturer
2. Leave high pressure port of the Magnehelic recommendations.
gauge exposed to ambient pressure (Figure 37).
3. Allow the engine to reach steady state at idle.
3. With the engine fully warmed up and running at
idle (750 rpm) place the transmission in Neutral. 4. While monitoring the output of the UEGO or
The AVV should be between 5” and 8” H2O of HEGO sensor adjust the idle screw using a
pressure vacuum. standard screwdriver until the desired phi reading
is achieved (phi = 1.00 to 1.01 is optimal). To
4. If the measured pressure drop is excessively make the mixture richer, turn the screw
high, check for sticking or binding of the clockwise; to make the mixture leaner, turn the
diaphragm air valve assembly inside the mixer. screw counter-clockwise.
Replace mixer if necessary.
5. Rev the engine to take it off of idle and let it
5. If the measured pressure drop is low, check for return to idle.
vacuum leaks in the manifold, throttle, mixer,
TMAP sensor and attached hoses. 6. Once the engine has reached steady state at idle,
verify the phi reading. Adjust further as needed.
1. The power valve should only be adjusted after 1. The power valve should only be adjusted after
the idle screw has been adjusted properly. The the idle screw has been adjusted properly. The
engine and vehicle drive train and hydraulics engine and vehicle drive train and hydraulics
should also be at normal operating temperatures. should also be at normal operating temperatures.
2. Apply a load to the engine while the engine is 2. Apply a load to the engine while the engine is
operating above idle speed. Torque converter operating above idle speed. Torque converter
stall is the preferred operating mode for this test. stall is the preferred operating mode for this test.
If a torque converter speed test cannot be If a torque converter speed test cannot be
performed, the engine can be run at another performed, the engine can be run at another
speed (max governor), but a load must be speed (max governor), but a load must be
applied by using hydraulics. applied by using hydraulics.
The power valve should be adjusted to obtain
NOTE : While adjusting the power valve, do not hold maximum torque converter stall speed.
engine at load point for longer than 5-10
seconds. Holding for a longer period of time NOTE : While adjusting the power valve, do not hold
will cause the fuel temperature to drop, engine at load point for longer than 5-10
which could adversely affect the power valve seconds. Holding for a longer period of time
setting. will cause the fuel temperature to drop,
which could adversely affect the power
3. Monitor the output of the UEGO or HEGO sensor valve setting.
while the engine is at the higher speed with the
load applied (phi = 1.00 to 1.05 is optimal). 3. Once the power valve is set, bring the engine
back to idle and verify the idle screw setting.
4. If the phi reading is not at the desired level, bring
the engine back to idle and adjust the power
valve.
WARNING
• ASSEMBLY TOOLS
Use proper size and type of tool for assembly
and disassembly. Any damaged screws
cannot be properly torqued and can cause
unexpected hardware problems or gas leakage,
which could lead to serious injury or loss of
life.
5
Figure M4
4
1. With the mixer/adapter assembly removed from
the engine, and the throttle adapter removed
9 from the mixer, remove the four cover retaining
14 screws from the top of the mixer (Figure M4).
3
2
7
Figure M5
1 15
2. Gently remove the diaphragm cover from the top
10 of the mixer. Take care not to loose the air-valve
spring shown in (Figure M5).
11
Figure M6
Figure M9
Parts List
N-2001-RSA Regulator
REF
DESCRIPTION QTY
NO.
1 Cover Screws 8-32 x 5/8” SEMS 4
Torx Screws (T-15) 8-32 x 5/8”
2 2
Tamper Resistant
3 Lockwasher #8 Internal Tooth 2
4 Secondary Cover 1
5 Secondary Diaphragm Assembly 1
Pan Head Screw 10-24 x 1/4”
6 1
w/Star Washer
7 Secondary Lever 1
8 Secondary Valve 1
9 Secondary Lever Fulcrum Pin 1
10 Red Secondary Spring 1
11 Pilot Valve Lever 1
12 Pilot Valve Lever Fulcrum Pin 1
Internal Hex Head Set Screw 8-32
13 1
x 1/4”
14 Cover Screws 12-24 x 5/8” SEMS 6
15 Primary Diaphragm Cover 1
16 Primary Regulator Springs 2
17 Primary Diaphragm Assembly 1
18 1/8 NPT Hex Pipe Plug Fitting 1
19 Body Assembly 1
20 Body Seal O-ring 1
21 Body Gasket 1
22 Regulator Back Plate 1
23 Primary Seal O-Ring 1
24 Primary Regulator Valve 1
25 Cover Screws 12-24 x 5/8” SEMS 6
26 Inlet Seal O-Ring 1
27 Inlet Plug 1
Hex Head Screws 1/4-20 UNC-2A x
28 2
5/8” SEMS
Figure R3 Figure R5
2
5
3
Figure R4 Figure R5
1. Remove the six secondary cover screws (1), the 3. Remove the six primary diaphragm cover screws
secondary cover (2) and the secondary (4) and the primary cover assembly (5).
diaphragm (3).
Figure R6
11
Figure R7
Figure R8
Figure R9
Figure R11
Special Tools
Tool
Illustration Application
(Numberandname)
G424i(E) Service Manual 236 Chapter 7. MPI Gasoline Fuel Delivery System
- Specification / Special Tools
Components Location
1. Fuel Tank
2. Fuel Pump (Including full pressure regulator and fuel filter)
3. Fuel Hose Assy
4. Fuel Rail
5. Injector
G424i(E) Service Manual 237 Chapter 7. MPI Gasoline Fuel Delivery System
- Components Location
Fuel Pressure Test Install The Special Service Tool (SST)
For Measuring The Fuel Pressure
Release The Internal Pressure
CAUTION
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by residual
pressure in the fuel line.
G424i(E) Service Manual 238 Chapter 7. MPI Gasoline Fuel Delivery System
- Fuel Pressure Test
Inspect Fuel Leakage On Connection • Observing the declination of the fuel pressure
when the gage reading drops and perform the
1. Connect the battery negative (-) terminal. necessary repairs using the table below.
4. Start the engine and measure the fuel pressure at Release The Internal Pressure
idle.
Supected
Condition Probable Cause
Area
Clogged fuel filter Fuel filter 1. Disconnect the fuel pump connector.
Fuel leak on the 2. Start the engine and wait until fuel in fuel line is
Fuel fuel-pressure exhausted.
Pressure too regulator that is
low assembled on fuel Fuel Pressure 3. After the engine stalls, turn the ignition switch to
pump because of Regulator OFF position and diconnect the negative (-)
poor seating of the terminal from the battery.
fuel-pressure
regulator. NOTE: Be sure to reduce the fuel pressure before
Fuel disconnecting the fuel feed hose, otherwise
Sticking fuel Fuel Pressure fuel will spill out.
Pressure too
pressure regulator Regulator
High
G424i(E) Service Manual 239 Chapter 7. MPI Gasoline Fuel Delivery System
- Fuel Pressure Test
Remove The Special Service Tool (SST) Injector
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).
CAUTION
Description
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by residual Based on information from various sensors, the
pressure in the fuel line. ECM measures the fuel injection amount. The fuel
injector is a solenoid-operated valve and the fuel
injection amount is controlled by length of time the
5. Conenct the fuel feed hose to the delivery pipe. fuel injector is held open. The ECM controls each
injector by grounding the control circuit. When the
Inspect Fuel Leakage On Connection ECM energizes the injector by grounding the control
circuit, the circuit voltage should be low (theoretically
1. Connect the battery negative (-) terminal. 0V) and the fuel is injected. When the ECM de-
energizes the injector by opening control circuit, the
2. Apply battery voltage to the fuel pump terminal fuel injector is closed and circuit voltage should be
and activate the fuel pump. With fuel pressure peak for a moment.
applied, check that there is no fuel leakage from
the fuel pressure gauge or connection part.
G424i(E) Service Manual 240 Chapter 7. MPI Gasoline Fuel Delivery System
- Injector
Function and operation principle Connection Information
Injector #1
Terminal Connected Function
1 Main Relay Power Supply (B+)
Each pin no
2 of ecu Injector Control
(SECM)
Injector #2
Terminal Connected Function
1 Main Relay Power Supply (B+)
Each pin no
Based on information from various sensors, the 2 of ecu Injector Control
SECM measures the fuel injection amount. The fuel (SECM)
injector is a solenoid-operated valve and the fuel
injection amount is controlled by length of time that Injector #3
the fuel injector is held open. Terminal Connected Function
The SECM controls each injector by grounding the
1 Main Relay Power Supply (B+)
control circuit. When the SECM energizes the
Each pin no
injector by grounding the control circuit, the circuit
2 of ecu Injector Control
voltage s hould be low (theoretically 0V) and the fuel
(SECM)
is injected. When the SECM de-energizes the
injector by opening control circuit, the fuel injector is
closed and circuit voltage should momentarily peak. Injector #4
Terminal Connected Function
Specification 1 Main Relay Power Supply (B+)
Each pin no
Item Specification 2 of ecu Injector Control
Coil Resistance 14 ~ 15.4 at 20℃(68℉) (SECM)
Haness Connector
G424i(E) Service Manual 241 Chapter 7. MPI Gasoline Fuel Delivery System
- Injector
Injector Inspection Resistance Measurement Between
Terminals
Operation check
NOTE: Ensure that the sound from an adjacent 2. Re-connect the connector to the injector.
injector is not being transmitted along the
delivery pipe to an inoperative injector. Removal
CAUTION
Cover the hose connection with rags to prevent
splashing of fuel that could be caused by
residual pressure in the fuel line.
CAUTION
Be careful not to drop any injectors when
removing the delivery pipe.
Be aware that fuel may flow out when removing
the injector.
G424i(E) Service Manual 242 Chapter 7. MPI Gasoline Fuel Delivery System
- Injector Inspection
Inspection
1. Measure the resistance of the injectors between
the terminals using an ohmmeter.
Installation
G424i(E) Service Manual 243 Chapter 7. MPI Gasoline Fuel Delivery System
- Injector Inspection
Fuel Pump
Removal (Including Fuel Filter And Fuel
Pressure Regulator)
CAUTION
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by residual
pressure in the fuel line.
G424i(E) Service Manual 244 Chapter 7. MPI Gasoline Fuel Delivery System
- Fuel Pump
Chapter 8. BASIC TROUBLESHOOTING
Preliminary Checks Visual/Physical check
MI-07 systems are equipped with built-in fault Several of the procedures call for a “Careful
diagnostics. Detected system faults can be Visual/Physical Check” which should include:
displayed by the Malfunction Indicator Lamp (MIL)
and are covered in Chapter 9, Advanced • SECM grounds for being clean and tight
Diagnostics. However, items such as fuel level,
plugged fuel lines, clogged fuel filters, and • Vacuum hoses for splits, kinks, and proper
malfunctioning pressure regulators may not set a connection.
fault code and usually can be corrected with the
basic troubleshooting steps described on the • Air leaks at throttle body mounting and intake
following pages. manifold
1. Forklift Information
(I) VIN:
(II) ProductionDate:
2. Symptoms
3. Environment
4. MIL/DTC
MIL (Malfunction Indicator Lamp) □ Remains ON □ Sometimes lights up □ Does not light
WARNING
DO NOT heat components to the point where
they may be damaged.
DO NOT heat the ECM directly.
WARNING
DO NOT sprinkle water directly into the
enginecompartment or electronic components.
● Simulatingelectricalload
1. Clear Diagnostic Trouble Code (DTC). 1) Turn on all electrical systems to simulate
excessive electrical loads (Radios, fans, lights,
2. Inspect connector connection, and check etc.).
terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
connectors are always securely fastened.
Handling of Connector
Specification (Resistance)
1Ω or less → Normal Circuit
1㏁ or Higher → Open Circuit
3. Voltage Check Method
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1㏁ or Higher → Normal Circuit
13.0kg/cm ²
13.0kg/cm
-5°± 5°/830rpm
²
Corrective Action
Most intermittent problems are caused by faulty
electrical connections or wiring. Perform careful
visual/physical check for:
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.
The fuel management should maintain a stoichiometric air-fuel ratio under all
Oxygen sensor steady state operating conditions following engine warmup. Failure of the Pre-
malfunction catalyst O2 sensor should cause an O2 sensor fault that can be diagnosed with
the MIL lamp or Service Tool.
Preliminary Checks
Repair/replace as required.
Clogged fuel filter
See Chapter 2 Fuel Filter replacement.
Check connection
Faulty vapor connection between the
• Verify no holes in hose.
pressure regulator/converter and the
• Clamps must be tight.
mixer
• Look for kinked, pinched and/or collapsed hose.
Repair/replace fuel lock-off.
Fuel lock-off malfunction
See Chapter 2 Fuel Lock-off.
Pressure regulator/converter Test regulator/converter operation and pressure.
malfunction See Chapter 6 Tests and Adjustments.
Incorrect air/fuel or ignition/spark
See Chapter 8 Advanced Diagnostics.
control
Verify the crankshaft position signal is present
No crankshaft position sensor signal
See Chapter 8 Advanced Diagnostics.
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
SECM / control system of this section.
malfunction Verify that there is no code for ETC spring check fault.
Check for 0% APP during cranking.
Cycle key ON and OFF and listen for throttle check (movement) on key OFF.
Check for oil pressure switch faults.
Check for sensor “sticking” faults.
Check TPS for stuck binding or a high TPS voltage with the throttle closed.
Check fuel lock off (propane) or fuel pump relay gasoline operation: actuator
should turn “ON” for 2 seconds when ignition is turned “ON”.
Check fuel pressure.
Check for contaminated fuel.
Check both gasoline injector and lock off fuses (visually inspect).
Fuel system malfunction
Check propane tank valve & pickup. A faulty
in-tank fuel pump check valve will allow the fuel in the lines to drain back to the
tank after engine is stopped. To check for this condition, perform fuel system
diagnosis.
Check FTV system for proper operation.
PRELIMINARY CHECKS
Check spark advance for excessive retarded ignition timing. Use Service Tool.
Check secondary voltage using an oscilloscope or a spark tester to check for a
Ignition system malfunction weak coil.
Check spark plug condition.
Check poor spark plug primary and secondary wire condition.
PRELIMINARY CHECKS
Check for excessive oil in the combustion chamber and/or blow by from
excessive PCV flow.
Engine mechanical Check combustion chambers for excessive carbon build up.
Check combustion chamber pressure by performing a compression test.
Check for incorrect basic engine parts such as cam, heads, pistons, etc.
PRELIMINARY CHECKS
Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.
Simulate condition by reviewing operation procedure practiced by vehicle operator.
Dieseling, Run-on
Engine continues to run after key is turned “OFF,“ but runs very roughly. If engine runs smoothly, check
ignition switch and adjustment.
PRELIMINARY CHECKS
Fuel lock off valve Make sure lock off valve is closing properly.
Related MIL Faults: EST faults / ETC faults / Pre-catalyst O2 sensor faults
PRELIMINARY CHECKS
PRELIMINARY CHECKS
Check fuel system specifically for plugged fuel filter, low pressure.
Check for contaminated fuel.
Check injector drivers. Disconnect all injector harness connectors. Use
injector test light or equivalent 6-volt test light between the harness terminals
Fuel system
of each connector and observe if light blinks while cranking. If test light fails
malfunction
to blink at any connector, it is a faulty injector drive circuit harness, connec-
tor, or terminal.
Check lock off intermittent connection.
Check dither valve operation.
PRELIMINARY CHECKS
PRELIMINARY CHECKS
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.
If the Service tool indicates a very high coolant temperature and the system
is running lean:
Cooling system • Check engine coolant level.
malfunction • Check engine thermostat for faulty part (always open) or for wrong heat
range.
• Check fan operation
If the system is running rich, refer to “Diagnostic Aids” chart on the next
page.
Fuel system If the system is running lean refer to “Diagnostic Aids” chart on the next
malfunction page.
Check for properly installed fuel system components.
Check fuel pressure.
Fuel injector pulse width at idle * < 1.0 msec > 8 msec.
• Pre-catalyst O2 sensor failed
Malfunction codes • Pre-catalyst O2 sensor failed rich
lean
Closed loop operation • Pre-catalyst O2 sensor high • Pre-catalyst O2 sensor low
(*) The duty cycle injector pulse width criteria for lean or rich operation apply only if the O2 sensor is
functioning properly. If the sensor is not operating properly the criteria may be reversed.
Rich Operation
• Check trim valves for proper operation, replace as
LP (Trim valve duty cycle>90%) necessary
• Inspect hoses from AVV port (port on bottom of • Check regulator out pressure, replace if out of
mixer) to trim valves and regulator for leaks or spec
blockages, replace as necessary.
Gasoline (Injector Pulse Width>8 msec)
• Inspect in-line orifices for blockages (in wye),
replace as necessary • Check system voltage
• Check trim valves for proper operation, replace as • Check fuel pressure
necessary
• Check injectors for sticking or obstructions
• Check regulator out pressure, replace if out of
spec
Lean Operation
Illustration Notes
1. Backpressure gage
3. Exhaust manifold
Diagnosis:
Power Train
Specification
System Operation
Testing & Adjusting
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index
Specification
Forward / Reverse Clutch Elements ................... 5
Torque Converter ................................................ 5
Valve Block Elements (On top of transmission) .. 6
Valve Spring in Transmission Bearing Plate ....... 7
Tightening Torques - Transmission..................... 8
Final Drives and Wheel ....................................... 9
Wheel Bearing Adjustment................................ 10
System Operation
General Information .......................................... 11
Torque Converter .............................................. 12
Transmission ..................................................... 13
Transmission Power Flow - Forward................. 14
Transmission Power Flow - Reverse ................ 15
Transmission Lubrication Schematic ................ 16
Transmission Hydraulic System ........................ 17
Control Valve..................................................... 26
Drive axle .......................................................... 30
Differential – Pneumatic Shoe Type.................. 30
Differential – Pneumatic ODB Type & Cushion Type
.......................................................................... 31
Maintenance
Transmission ................................................... 42
Drive axle .......................................................... 43
Electric Control System Test ............................. 44
Inching Pedal Adjustment ................................. 48
Adjustments on Drive axle ................................ 51
c) Bend Plate
Inside Diameter………..60mm (2.36 in)
Outside Diameter………..122.5mm (4.82 in)
Torque Converter
a) Outer clultch disc, b) Inner clultch disc
c) Bend plate, d) Spring
b) Inner clutch Plate (1) Torque for six bolts that hold torque converter drive
plate to the flywheel 45 ± 7 N·m (33 ±5 lb·ft)
C) Spring (outer)
Length under test force ............... 26.6 mm (1.05 in)
Test force ...................... 75.6 ± 6.0N (17.0 ± 1.3 lb)
Free length after test (nominal) .. 52.6 mm (2.07 in)
Outside diameter ...................... 15.24 mm (0.60 in)
A
2-Springs
Tighten to 45 N·m (33.2 Ib·ft)
Converter Inlet Valve
Tighten to 45 N·m (33.2 Ib·ft)
Converter Outlet Valve
A) Spring
Length under test force .................. 30 mm (1.18 in)
Test force ..................... 18.1 ± 1.8 N (4.07 ± 0.4 lb)
Free length after test (nominal)..43.25 mm (1.70 in)
Outside diameter…………………10.7 mm (0.42 in)
Power Train
Axle Lube Pump Bolt 12 N m (8.9 Ib ft)
Bearing Plate
Bolt 55 N m (40.6 Ib ft)
Pump Housing
Bolt 32 N m (23.6 Ib ft)
8
Tightening Torques - Transmission
Bearing Shims
See Instructions
Bearing Shims
See Instructions Bolt 40 N m (29.5 Ib ft)
Housing Bolt 55 N m
Plug 50 N m (36.9 Ib ft)
(40.6 Ib ft)
Specifications
Final Drives and Wheel
Pneumatic – Shoe Pneumatic – ODB & Cushion
(1) Torque for bolts that hold brake assembly to drive (1) Apply LOCTITE NO.271 Thread Lock to threads of
axle arm .................... 176 ± 29 N•m (130 ± 21 lb•ft) spindle bolts. Torque for bolts that hold spindle to
drive axle housing is .................... 100.5 ± 12.3 N•m
(2) Tighten nut slowly until torque required to turn (74.2 ± 9.1 lb•ft)
bearings is ........ 2.45 ± 0.49 N•m (1.80 ± 0.35 lb•ft)
(2) Tighten nut slowly until torque required to turn
bearings is..............10.8 ± 2.0 N•m (8.0 ± 1.5 lb•ft)
(3) Torque for bolts that hold drive shaft to hub ...........
..................................... 71 ± 12 N•m (52.5 ± 9 lb•ft)
(3) Apply Loctite No.271 Thread Lock to threads of
drive shaft bolts. Torque for bolts that hold drive
(4) Torque for drive wheel mounting nuts ....................
shaft to hub is .............. 71 ± 12 N•m (52.5 ± 9 lb•ft)
.................................. 176 ± 20 N•m (130 ± 14 lb•ft)
(4) Pneumatic - ODB
Apply Loctite No.271 Thread Lock to threads of
stud bolts. Torque for stud bolts is ...... 88 ± 10 N•m
Pneumatic - ODB (65 ± 7.4 lb•ft)
Cushion
Torque for wheel mounting bolts is ... 135 ± 15 N•m
(100 ± 10 lb•ft)
(1) Tighten nut (3) slowly until torque required to turn (1) Tighten nut (3) slowly until torque required to turn
bearings is 2.5 N•m (1.8 lb•ft), while hub (1) is bearings is 2.5 N•m (1.8 lb•ft), while hub (1) is
turned to put the bearings in position. turned to put the bearings in position.
(2) Tighten the bolts to hold the nut in position. (Apply (2) Tighten the bolts to hold the nut in position.
Loctite No. 272) (Apply Loctite No. 272)
Tightening Torque ......................... 7.9 to 11.7 N•m Tightening Torque .......................... 7.9 to 11.7 N•m
(5.8 to 8.6 lb•ft) (5.8 to 8.6 lb•ft)
Pneumatic - ODB
Power Flow
(1) Drive axle. (2) U-joint. (3) Transmission. (4) Engine.
The basic components of the power train are engine Power from yoke of drive axle is sent through a spiral
(4), Transmission (3), U-Joint (2), Drive axle (1) and bevel gear set to the differential.
the final drives and wheels. The differential sends power out through the axles to
the final drives and wheels.
Two axle shafts connect the differential to two final
drives. The drive wheels are mounted to the final
drives.
5A
(1) TC Housing. (2) TM Bearing Plate. (3) TM Housing. (4) Torque Converter. (5) Input Shaft. (5A) Input Shaft Gear.
(6) Oil Pump. (7) Forward Gear. (8) Forward Clutch. (9) Reverse Shaft. (9A) Reverse Shaft Gear. (10) Reverse Clutch. (11)
Reverse gear. (12) Output gear. (13) U-joint. (14) Quill Shaft. (14A) Coupling. (15) PTO Pump.
The Transmission consists of 3 sections: The reverse shaft (9) carries the reverse shaft gear
(9A), the reverse clutch (10) and the reverse gear (11)
a) TC housing (1) which contains torque converter (4) which is in mesh and drives the output gear (12) when
and the oil pump (6) and its housing. Tangs on the the reverse clutch (10) is selected.
TC neck engage in and drive the pump. The quill shaft (14) is splined to the torque converter
and therefore rotates with engine speed and direction.
b) Bearing plate (2) which contains the rear bearings A coupling (14A) connects the PTO pump (15) to the
of input, reverse shaft and output gear and the oil quill shaft (14).
supply channels. The oil channels are sealed by
the front TC housing wall.
Power Train
Orifice
Oil Pump
Transmission Hydraulic System
17
Transmission Oil Sump
Systems Operation
Pump, Filter, Torque Converter And Oil Cooler
Systems
Spool will move left and right to maintain 895 kPa (130
psi). Oil can also bypass the torque converter through
converter bypass orifice (16). The purpose of orifice
(16) is to prevent too much of a pressure load being
put on the torque converter.
Oil will flow from the main relief valve to inching valve
(6). Without inching (inching pedal up and valve in), oil
flows around and through the center of reducing spool
(6A) to the bottom of the spool. The oil, at the bottom,
pushes the spool up to the position shown. Oil flows
around the lands of the spool and through a passage
to modulating valve group (7).
Power Train
Orifice
Oil Pump
21
Transmission Oil Sump
Systems Operation
Reverse Direction
Oil will flow from the main relief valve to inching valve
(6). Without inching (inching pedal up and valve in), oil
flows around and through the center of reducing spool
(6A) to the bottom of the spool. The oil, at the bottom,
pushes the spool up to the position shown. Oil flows
around the lands of the spool and through a passage
to modulating valve group (7).
Power Train
Orifice
Oil Pump
23
Transmission Oil Sump
Systems Operation
Forward Direction During Inching
Power Train
Orifice
Oil Pump
25
Transmission Oil Sump
Systems Operation
Control Valve
Basic Control Schematic
DR DR DR
FWD REV
CLUTCH CLUTCH
SOLENOID
SOLENOID
DR DR DR
PUMP
DR DR DR
Figure 1
The modulating valve consists of 5 basic elements: pressure to drain, and reducing Force 2.
1. Orifice If Force 1 is too large then the valve would be forced
2. Springs to the right, opening the clutch circuit to supply,
3. Load piston and increasing the value of Force 2 so it balances
4. Modulating valve Force 1. By regulating clutch pressures between
5. Reaction slug supply and drain, valve forces are balanced.
The function of the modulating valve is to control
clutch pressure during a shift. It allows the clutch
pressure to raise gently to the maximum transmission
pressure in order to provide a smooth clutch
engagement and a good shift feel for the vehicle
operator.
There are two forces acting on the modulation valve:
Figure 3
Figure 2
MODULA TION
When a new direction is selected by the operator, the
selector spools open up a circuit to the new clutch
piston. System pressure drops as the new clutch
piston is stroking. This drop in supply pressure causes
a force imbalance on the modulating valve / reaction
slug pressure becomes smaller. Since Force 1 is still
the same, Force 1 forces the modulating valve to the
right until the end of the modulating valve opens the
load piston cavity to drain.
Figure 4
The load piston oil dumps to drain and the load piston
immediately moves to the right (shown in fig.2).
This action is called "load piston reset". It happens
very quickly in comparison to the time needed for the
clutch piston to fully stroke. Therefore the modulating As long as reaction slug pressure is greater than load
valve and load piston are ready to start controlling the piston pressure, oil will flow across the orifice from
clutch pressure in a smooth upward manner once the Area 2 to Area 1. As oil flows to the load piston the
clutch piston finishes stroking. springs will continue to compress, allowing the load
piston to move to the left. As the load piston moves to
the left the spring force increases and load piston
pressure increases.
Figure 5
(1) Spider. (2) Pinion. (3) Gear. (4) Differential case. (5) Nut. (6) Tube. (7) Drum. (8) Hub. (9) Shaft.
The location of the differential is in the front of the lift During a turn, the force (traction) that is on the drive
truck. The differential is a part of the drive axle. It is a wheels is different. These different forces are also felt
single reduction unit with a differential drive gear (3) on opposite sides of the differential and cause pinions
fastened on the differential case (4). (2) to turn. The rotation of pinions (2) stops or slows
the inside wheel and lets the outside wheel go faster.
The differential is used to send the power from the This moves the machine through a turn under full
transmission to the wheels. When one wheel turns power.
slower than the other, the differential lets the inside
wheel stop or turn slower in relation to the outside The differential gets lubrication from oil thrown about
wheel. inside the housing.
Case (4) has four differential pinions (2). The pinions The differential turns axle shaft (9). Tube (6) which is
are engaged with two side gears. The side gears are pressed into axle housing is used as a support for hub
splined to the axle shafts (9). (8). The hub (8) and bearings are turned by axle shaft
When the lift truck moves in a forward direction and (9) through a direct connection between the hub and
there is same traction under each wheel, there is also axle shaft. The drive wheel is fastened to hub (8) and
the same torque on each axle and pinions (2) are turns with the hub.
stopped. This gives the same effect as if both wheels
were on the same axle
(1) Spider. (2) Pinion. (3) Gear. (4) Differential case. (5) Nut. (6) Hub. (7) Shaft. (8) Spindle.
The location of the differential is in the front of the lift During a turn, the force (traction) that is on the drive
truck. The differential is a part of the drive axle. It is a wheels is different. These different forces are also felt
single reduction unit with a differential drive gear (3) on opposite sides of the differential and cause pinions
fastened on the differential case (4). (2) to turn. The rotation of pinions (2) stops or slows
the inside wheel and lets the outside wheel go faster.
The differential is used to send the power from the This moves the machine through a turn under full
transmission to the wheels. When one wheel turns power.
slower than the other, the differential lets the inside
wheel stop or turn slower in relation to the outside The differential gets lubrication from oil thrown about
wheel. inside the housing.
Case (4) has four differential pinions (2). The pinions The differential turns axle shaft (7). Spindle (8) is used
are engaged with two side gears. The side gears are as a support for hub (6). The hub (6) and bearings are
splined to the axle shafts (9). turned by axle shaft (7) through a direct connection
When the lift truck moves in a forward direction and between the hub and axle shaft. The drive wheel is
there is same traction under each wheel, there is also fastened to hub (6) and turns with the hub.
the same torque on each axle and pinions (2) are
stopped. This gives the same effect as if both wheels
were on the same axle
Operate the machine in each direction. Make note of Operate the machine in each direction. Make note of
all noises that are not normal and find their source. If noises that are not normal and find their source. If the
the operation is not correct, make reference to the operation is not correct, make reference to the check
troubleshooting chart for "problems" and "probable List During Operation for "problems" and "probable
causes". causes".
Visual Checks
1. Parking brake switch mounting is loose. 3. Reverse clutch components have damage.
Problem: Transmission does not operate in either a. Leakage caused by worn or broken metal sea-
ling rings.
direction or does not shift.
b. Leakage caused by worn or broken clutch piston.
Probable cause:
c. Failure of shaft seal ring.
1. Problems in the electrical circuit (directional con-
trol)
Problem: Transmission operates only in REVERSE.
a. Open circuit between ignition switch and direc-
Probable cause:
tional control switch.
c. Defective wiring harness between directional 2. Forward solenoid valve does not actuate.
control switch and transmission.
3. Forward clutch components have damage.
d. Shorted wiring harness for the solenoids.
a. Leakage caused by worn or broken metal
2. Low oil pressure or no oil pressure caused by: sealing rings
a. Iow oil, no oil or thick oil. b. Leakage caused by worn or broken seal around
clutch piston.
b. Inching control valve linkage loose, broken or
adjustment is not correct. c. Failure of shaft seal ring.
c. Inching valve reducing spool stuck open. Problem: Transmission gets hot.
Problem: Noise at different intervals. d. Pinion oil seal worn or not installed correctly.
2. Side gears tight in differential case. Check List From Pressure Tests
3. Differential pinion or side gears have a defect. Problem: Low pressure to FORWARD and
REVERSE clutches.
4. Thrust washers worn or have damage.
Probable cause:
5. Too much clearance (backlash) between side gears
and pinion. 1. Inching valve linkage adjustment is not correct.
6. Worn axle shaft assembly gear. 2. Inching valve reducing spool stuck open.
8. Wheel bearings worn or out of adjustment. 4. Main relief valve setting too low caused by a
defective relief valve spring.
Problem: Leakage of lubricant. 5. Low oil pressure. See Probable Cause for Low Oil
Pressure.
Probable cause:
6. External oil lines are not connected correctly.
1. Loss through hub seals.
7. Modulating valve assembly stuck.
a. Lubricant above specification level.
3. Main relief valve not adjusted properly. Problem: High converter charge pressure.
1. Clutch piston seal alignment is not correct, oil leaks 2. A restriction inside the converter assembly.
through.
3. A plugged oil flow passage.
2. Seal rings on shaft or clutch piston seals are broken
or worn. Problem: Low converter charge pressure.
a. Failure of the oil pump or a defect in the oil Problem: Low stall speed.
pump.
Probable cause:
b. Restriction in the oil flow circuit such as a dirty
oil screen. 1. Engine performance is not correct.
c. Inching valve reducing spool stuck open. 2. The one-way clutch of the torque converter does not
hold.
d. Leakage inside of transmission caused by com-
ponent defects.
Problem: High stall speed in one direction. Problem: Modulation spool problems.
c. Ports not machined properly 1. The upstream orifice (in the oil supply) is not
installed. (The orifice is located in the valve block)
d. Contamination in solenoid
2. The load piston is only moving a small amount
e. Electrical problem before it sticks. Check the spool to see if it freely
fits in the bore. This check must be made while the
3. Orifice plugged aluminum body is still bolted down to the
transmission.
a. With debris
b. Bad part 3. The plastic orifice is not installed or the hole in the
plastic housing is too large.
4. Modulation valve stuck in "off" position
4. The modulating valve is stuck in an open position.
5. Modulation valve not correctly assembled. Check to see if the valve moves freely while the
aluminum body is still bolted down.
2. Transmission will not shift into or out of 1 gear
Probable cause: 5. The springs are not installed or the pin has jammed
the load piston.
1. Spools mechanically stuck (same as above)
Temperature Sensor
To Cooler
From Cooler
Lubrication Pressure Tap 7
Engine
LIFT TRUCK STALL SPEED
Max.RPM
RPM±100 RPM±100
Engine Without Power With Power -
Brakes Applied Brakes Applied
A2300 1600 1500 2600±50
G420F(E) 1600 1500 2450±25
G424I(E) 1820 1720 2450±25
Change
Filter
Grease Parking
Brake Lever
ATTENTION: When changing oil, replace filter and clean suction strainer.
14
1
Inching Pedal Adjustment
(1) Lug. (2) Bolt. (3) Nut.
Inching Operation Test
(1) Inching pedal.
3. Start the engine and put the transmission
FORWARD.
2. Slowly push down on inching pedal (1) until the
4. With the drive wheels turning, depress inching pedal
movement of the brake pedal causes the brake
until the drive wheels stop.
discs to make contact (small drag) with the brake
plates.
5. Now depress the brake pedal until brake contact is
felt.
3. Increase the engine speed to high idle. The truck
must not move.
6. Loosen nut (3) and adjust bolt (2) to contact lug (1)
that rotates the brake control cross shaft. Tighten
nut (3).
If the operation of the inching valve is not correct, do
the procedure that follows.
7. Check the inching valve operation again.
Backlash Adjustment
(1) Bearing Cone. (2) Spiral Bevel Gear. (3) Bolt.
(4) Bearing Cup. (5) Bearing Cap. (6) Locknut. (7) Plate.
9. Measure the rolling torque. The value of rolling 3. Put the carrier assembly in position in the housing
torque should be 1.5~2.0 N·m (1.1~1.5 lb·ft) assembly. Install bearing caps (5) and four bolts.
Tighten bolts to a torque 150±15 N•m (113±12
10. If the rolling torque exceeds 2 N·m, add one shim Ib•ft.)
and if it is lower than 1.5 N·m, subtract one shim
4. Install locknuts (6). Use tooling (A) to check gear
11. When the adjustment is correct, disassemble the clearance (backlash) between spiral bevel gear (2)
nut and the yoke. and pinion. Adjust locknuts (6) until the clearance
Assemble the oil seal and yoke again and then is 0.18 to 0.23 mm (.007 to .009 in.).
tighten the nut to 180 ±15 N·m (133±11 lb·ft) Adjust the clearance by turning one locknut (6) in
and the other locknut out an equal amount.
Power Train
Disassembly & Assembly
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional
safety precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where
hazards exist. WARNING labels have also been put on the product to provide instructions and to identify
specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other
persons. Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
1
2
Index
Transmission.......................................... 5
Disassembly of....................................... 5
Transmission Housing................................................ 5
Disassembly of Counter Shaft.................................... 9
Assembly of Counter Shaft....................................... 11
Disassembly of Input Shaft....................................... 14
Assembly of Input Shaft ........................................... 16
Disassembly of Output Shaft.................................... 19
Assembly of Output Shaft......................................... 19
Assembly of Transmission Housing ......................... 20
Differential ................................................................ 28
Drive Axle – Shoe..................................................... 31
Drive Axle – ODB ..................................................... 35
WARNING
Disconnect batteries before performance of
any service work.
4
2. Loosen the screw (1) with socket head wrench
8mm.
2
6. Install 2 jackbolts (M10, 30mm (1.2in)) in
locations (4) until they stop against bearing plate,
alternately tighten bolts to separate the torque
converter housing from the transmission.
13. Turn the adjustment bolt until the strut (1) can 16. Remove the output shaft.
be removed from the brake band.
14. Remove the brake struts from the eccentric 17. Remove the input shaft with forward clutch.
shaft.
2
3
7. Remove the parts - snap ring (1), spring 10. ATTENTION: Open the R-rings before lifting!
retainer(2) and return spring (3)
5
2
4
7. Install snap ring (1) by pressing the return spring. 10. Align the teeth of the clutch disks.
(Tool Ref. No 1)
14. After installing the washer (1), put the ball (2) in 17. After cooling the bearing, the inner bearing ring
he hole. must be tapped to set bearing.
3
5
15. Install the steel-washer (3). 18. Install the R-ring (5).
2
5
7. Remove the snap ring (1) while pressing the 10. ATTENTION : Open the R-rings before lifting.
return spring on the spring retainer with a
hydraulic press. Slowly relieve the tension of the
spring. (Tool Ref. No 1)
1
4. Insert the piston.
2
2. Drive the ring and bearing with an puncher 5. Install snap ring by pressing the return spring.
(Ø25mm, length 400 mm) (Ø 1.0 in X 15.75 in (Tool Ref. No 1)
length) into the shaft.
7. Mount the snap ring (1) on the support disk 10. Align the teeth of the clutch disks and put gear
with the circlip pliers. wheel on the shaft.
9. Install the washer and needle bearings. 12. Put the ball in the hole of the shaft and the
notch in the washer.
13. Heat bearing (1) to a temperature of 120°C 16. Install the heated back bearing (120°C, 248°C)
(248°F) and install it on the shaft. on the shaft.
14. Install the bearing on the shaft. 17. After mounting and cooling, the inner bearing
ring must be tapped into position.
1. ATTENTION: Set the puller on the inner bearing 1. Heat bearing (1) to a temperature of 120°C
ring! (248°F) and install it on the shaft.
2. Remove the shaft with suitable puller device. 2. After cooling, the inner bearing ring must be
This can be done from either end of shaft. tapped into position.
23. Select shim thickness by subtracting B Dim. 26.Tap the outer front bearing ring back.
from A Dim. Shim thickness = A-B-0.05 mm
(0.002 in)
29. Before joining torque converter housing to 32. Install the oil filter screen. Tighten the plug with
bearing plate, apply lubricant to T/C pump ring. an allen head wrench.
30. Install the torque converter housing. 33. Install the torque converter.
5. Loosen lock nut and remove the plate (4). (Tool Ref.
No.:2) 9. Loosen the bolts (8) and remove brake assembly
(9).
10
0
7. Remove the hub and drum (6) from the drive axle.
19
23
20
20
2
23
23
20
22
21
Vehicle System
Specification
Systems Operation
Testing & Adjusting
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety“ section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety“ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index Steering Unit ...................................................... 36
Brake System ........................................................ 38
Master Cylinder .................................................. 38
Specification ............................................ 5 Shoe Type Brakes.............................................. 39
Parking Brake ..................................................... 39
Control Valve ............................................................5
Hydraulic Pump ........................................................6
Sideshift Cylinder ......................................................6 Testing and Adjusting ...........................41
Lift Cylinders .............................................................7
Standard ................................................................7 Troubleshooting ..................................................... 41
Full Free Triple and Full Free Lift Primary ............7 Visual Checks .................................................... 41
Full Free Lift Secondary ........................................8 Performance Tests ............................................. 41
Full Free Triple Lift Secondary ..............................8 Hydraulic System and Mast ............................... 42
Tilt Cylinder ...............................................................9 Steering System ................................................. 47
Steering Wheel .......................................................10 Brake System ..................................................... 48
Priority Valve ...........................................................10 Lift Cylinders Air Removal .................................. 50
Steering Unit ...........................................................11 Hydraulic System ................................................... 51
Forward and Reverse Control Group .....................12 Relief Valve Pressure Check ............................. 51
Brake – SHOE ........................................................12 Lift Relief Valve Check and Adjusment .............. 52
Delayed Engine Shutdown System ........................13 Tilt and Auxiliary Relief Valve Check and
Operation ............................................................13 Adjusment .......................................................... 53
Diagram of Delayed Engine Shutdown System ..14 Steering System .................................................... 53
Trouble shooting of Delayed Engine Shutdown Steer Wheel Bearing Adjustment -Pneumatic.... 53
System ................................................................15 Steer Axle Stop Adjustment-Pneumatic ............. 54
Diagnostic Fault Codes .......................................15 Steer Wheel Bearing Adjustment-Cushion ........ 54
Delayed Engine Shutdown System Schematic ...16 Steer Axle Stop Adjustment-Cushion ................. 55
Delayed Engine Shutdown System Schematic ...16 Steering System Air Removal ............................ 55
Delayed Engine Shutdown System Schematic ...17 Steering System Pressure Check ...................... 56
OSS (Operator Sensing System) ...........................20 Brake System ........................................................ 58
Operation ............................................................20 Brake System Air Removal ................................ 58
Symbols of OSS ..................................................20 Pedal Adjustment for Brake & Inching ............... 58
Operator Sensing System Schematic .................21 Parking Brake Test............................................. 60
Trouble shooting of Operator Sensing System ...22 Parking Brake Adjustment.................................. 60
CONTROL VALVE
RELIEF PRESSURE
MODEL MAST Main Relief Pressure-lift Auxiliary Pressure-tilt,attachment
psi kPa psi kPa
D15S,G(C)15S-5 STD/FF/FFT 2,550±35 17,600±250
D18S,G(C)18S-5 STD/FF/FFT 2,880±35 19,860±250 2,040±50 14,000±350
D20SC,G20SC-5 STD/FF/FFT 3,125±35 21,550±250
(1) Torque for nuts that hold control valve sections together ................................. 24 to 28 N•m (18 to 21 lb•ft)
(2) Torque for nuts that hold control valve sections together ................................. 24 to 28 N•m (18 to 21 lb•ft)
(3) Torque for main and auxiliary relief valve ......................................................... 44 to 49 N•m (32 to 36 lb•ft)
(4) Torque for cap screw that hold spool cap ........................................................... 10 to 15 N•m (7 to 11 lb•ft)
Rotation is counterclockwise when seen from drive (1) Torque for head ...............................270±35 N•m
end. (200±25 lb•ft)
Type of pump : Gear
For test, use SAE 10W oil at 65°C (150°F) (2) Torque for piston nut ........................260±25 N•m
Pump output....................19.5 cm³/rev (1.19 in³/rev) (190±20 lb•ft)
(1) Put Pipe Sealant on the last three threads of (1) Put Pipe Sealant on the last three thread of
bearing. bearing.
(2) Put Pipe Sealant on the last three threads of (2) Put Pipe Sealant on the last three thread of bleed
bleed screw and tighten to a torque of ................ screw and tighten to a torque of ..........................
.......................................... 6±1 N•m (53±9 lb•in) .......................................... 6±1 N•m (53±9 lb•in)
NOTE : All seals to be lubricated with hydraulic oil. NOTE : All seals to be lubricated with hydraulic oil.
(1) Torque for steering wheel nut ........ 75 to 88 N•m Flow ....................................................Load sensing
(55 to 65 lb•in)
Relief valve (no adjustment) opens at:
................................ 8,285±350 kPa (1,200±50 psi)
Once an active fault occurs, the MIL Lamp will illuminate and remain ON. This signals the operator that a fault
has been detected by the SECM. If the MIL Lamp turns on while operating the lift truck, park the lift truck
and stop the engine, and then check the follows.
Delayed Engine shutdown : Some faults, such as low oil pressure, will cause the MIL Lamp to
illuminate for 30 seconds and then shut down the engine
CODE
FAULT DESCRIPTION
(M104 CODE)
Engine Coolant Temperature Sensor Input is High.
ECT Over Range
Normally set if coolant sensor wire has been disconnected or 151(15)
High
circuit has opened to the SECM
ECT Over Engine Coolant Temperature is High.
Temperature The sensor has measured an excessive coolant temperature 161(15)
Fault typically due to the engine overheating
Low Oil Pressure
Low engine oil pressure 521(52)
Fault
Transmission Oil
Excessive transmission oil temperature 933
Temperature
ENG GND
NEAR COILS
E/G OIL PR
E/G CHECK
1. Parking alarm
Alarm warning lights when the operator leaves
the seat without applying parking brake.
21
INDICATOR AS
Operator Sensing System Schematic
Vehicle Systems
Trouble shooting of Operator Sensing System
2. Parking brake 2. Parking brake switch open 2. Check parking brake switch
light
3. Controller defect 3. Check continuity of wire from seat switch to
controller (SW2)
4. Wiring defect
4. Measure the voltage between controller(SW2)
and GND : 12V is no problem
1. Seat belt warning 1. Seat switch open 1. Check seat switch
light
2. Controller defect 2. Check continuity of wire from seat belt switch to
controller (SW3)
3. Wiring defect
3. Measure the voltage between controller(SW3)
and GND : 12V is no problem
1. Buzzer warning 1. Seat switch open 1. Check seat switch
2. Water separator 2. Wiring defect 2. Check continuity of wire from sediment switch to
warning light controller (AUX2)
3. Controller defect
3. Measure the voltage between controller(AUX2)
and GND : 12V is no problem
The levers of control valve move spools in control The speed at which lift cylinders are lowered is
valve. The movement of spool makes a fluid for a lift controlled by the flow regulator valve integrated into
cylinder and/or tilt cylinder (8) and/or side shift lift spool.
cylinder (5).
The return hydraulic fluid from each cylinder flows Flow protector (2) & (4) integrated to lift cylinder acts
through control valve, hydraulic line (17) and a filter- as a fuse valve if the line between control valve (flow
return (14), and back to a hydraulic tank.. regulator) and flow protector is broken when the lift
cylinder is raised or lowered. This prevents the
There is a safety unload function on the first block of sudden fall of mast or carriage if a hydraulic line is
control valve that any function doesn’t work even broken.
though any lever is shifted when operator leaves a
seat for more than 3 seconds. The solenoid valve The tilt backward, forward speed, side shift cylinder
(10) for unload function is electrically connected to speed are controlled by adjustable flow control kit in
the electric on-off switch beneath a seat. When the control valve.
operator leaves a seat for more than 3 seconds, the There is a counter-balance valve (or, tilt lock valve)
solenoid valve (10) is off, which let a system in tilt speed to prevent cavitation (development of air
pressure go down to less than 7 bar. Once the pocket) in tilt cylinder.
operator sits on a seat, the solenoid valve is on and For a complete hydraulic circuit, see the foldout, in
immediately all functions work normally. the back of this module.
Circuit Schematic
• The inlet section contains the pump inlet connection as well as a diagnostic inlet pressure gage port (new
feature to be added).
• When the operator is not seated, the solenoid valve is in the normally open position, which helps divert flow
from the pump directly to the outlet of tank. In this manner, oil pressure is limited and their operation is
prevented.
• The lift section has a single work port to direct flow to the lift cylinder is single-acting (gravity returns the
mast to the lowered position).
• The lift section also contains part of the components which comprise the ISO safety features. There is a
normally closed solenoid valve that works in conjunction with a lift lock check valve. When the operator is
not seated, the solenoid valve is not energized, which ensures that pressures are equalized across the lift
lock valve closed and prevents lowering of the mast.
• Lifting: When the operator shifts the lever backwards, the spool is extended out of the valve and this opens
the internal fluid passages that lift the mast. Oil flows through the high pressure parallel cavity, past the
load check valve, through the spool metering notches, past the lift lock check valve, and to the head side of
the lift cylinder.
• Secondary lowering method: A secondary lowering method is available in the event of the loss of battery
power that is needed to energize the normally closed solenoid valve.
• Important Note: Before opening the secondary needle valve, make sure personnel and equipment are
safely positioned to avoid accidents. Be careful to operate this secondary valve slowly, as heavy loads may
be suspended.
• A manual valve (needle valve) is located on the lift section, and it can be operated by opening the manual
valve (needle valve) counterclockwise with a wrench.
Open the manual valve (needle valve) approximately 2 turn (do not rotate more than 3 turns). Then, shift
the lift spool slowly for controlled lowering. This should be just enough for slow, controlled movement of the
mast.
TILT LOCK
PLUNGER
• The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery power is
off.
• Tilt Forward: When the seated operator shifts the lever forward, pressure is applied to the head of the tilt
cylinder, and the forks tilt forward. Oil is directed from the high pressure parallel passage past the load
check valve, past the spool metering notches, and cylinder head.
• Simultaneously, the high pressure acts on the end of the tilt lock plunger to move it towards the spring end
of the spool. This plunger movement opens additional spool metering notches which control oil flow from
the rod end of the cylinder to the tank return line.
• Tilt Back: When the seated operator shifts the lever back, the high pressure oil from the parallel passage is
directed past the load check valve, past the spool metering notches, and to the rod side of the cylinder.
Exhaust oil from the head side of the cylinder is directed past the spool metering notches to tank.
• In general, one work port is pressurized by high pressure oil from the parallel passage past the load check
valve, past the metering notches, and to the cylinder. Simultaneously, oil from the other work port is
directed across the spool metering notches to tank.
• The outlet section contains the tank port and the secondary relief valve (with built-in anti-cavitation feature).
Relief Valve
(7) Passage for return oil. (11) Piston. (12) Dump valve.
(13) Spring chamber. (14) Pilot valve.
The steering system uses the hydraulic fluid for During a right turn, pilot pressure is increased in
operation. The system has priority valve (12) which load sensing line (7) and the spool of priority valve is
sends the fluid to steering unit (1) as needed before moved to the right. The fluid flows through hydraulic
the requirements of mast operation are filled. line (9) to the steering unit. From the steering unit
The fluid is pulled from a hydraulic tank (11) to a the fluid flows through a hydraulic line (5) for right
hydraulic pump (10). Pump supplies a fluid through turn. The return fluid flows through a hydraulic line
a hydraulic hose (15) to a priority valve (12). (4) back through steering unit, a hydraulic line (2)
When the steering unit (1) is neutral position, pilot and into the hydraulic tank (11).
pressure in load sensing line (7) is reduced and the
spool of priority valve is moved to the left. The fluid
flows though hydraulic line (16) to control valve.
Steering Cylinder
(1) Steering Cylinder
Steering Gear
(1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs.
(8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section.
Lift trucks use the load sensing, closed center (oil Oil from the priority valve goes through inlet (4) into
flow to steering unit only when needed) steering unit. the control section of the steering unit. When the
steering wheel is turned, the control section sends
All lift truck hydraulic lines serve a dual purpose in the oil to and from the metering section and also to
that they serve both the steering and cylinder and from the steering cylinder.
hydraulics through the use of a priority valve. The
priority valve sends oil to the steering unit before the The metering section is a small hydraulic pump. It
needs of the cylinder hydraulics are met. controls (meters) the oil that goes to the steering
cylinder. As the steering wheel is turned faster, there
The steering unit has two main sections: control is an increase in the flow of oil to the steering
section (A), and pump or metering section (B). cylinder. This increased flow causes the main valve
These two sections work together to send oil to the spool to move farther. As the spool moves farther,
steering cylinder. more oil can flow from the priority valve or power
steering pump to the steering cylinder, and a faster
turn is made.
The oil from the priority valve flows through inlet (4).
When the steering wheel is stationary (NEUTRAL),
the oil is stopped by spool (1). The oil can not flow
through the steering unit to the steering cylinder until
the steering wheel is turned.
2. Bend lock (5) away from nut (6). Adjust nut (6) so
lever (4) is against stop (3).
Troubleshooting can be difficult. A list of possible 3. Check all oil lines and connections for damage or
problems and corrections are on the pages that leaks.
follow.
4. Check all the lift chains and mast carriage welds
This list of problems and corrections will only give an for wear or damage.
indication of where a problem can be and what
repairs are needed. Normally, some more or other Performance Tests
repair work is needed beyond the recommendations
on the list. Remember that a problem is not The performance tests can be used to find leakage
necessarily caused only by one part, but by the in the system. They can also be used to find a bad
relation of one part with the other parts. This list can valve or pump. The speed of rod movement when
not give all possible problems and corrections. The the cylinders move can be used to check the
serviceman must find out the problem and its source, condition of the cylinders and the pump.
and then makes the necessary repairs.
Lift, lower, tilt forward and tilt backward the forks
Tools Needed several times.
Fittings Group 1
1. Watch the cylinders as they are extended and
The pressure Gauge Kit or the Tetragauge Group retracted. Movement must be smooth and regular.
can be used to make the pressure tests of the
hydraulic system. Before any test is made, visually 2. Listen for noise from the pump.
inspect the complete hydraulic system for leackage
of oil and for parts that have damage. 3. Listen for the sound of the relief valve. It must not
open except when the cylinders are fully
extended or retracted, when the forks are empty.
WARNING
To prevent personal injury, when testing and Hydraulic Oil Temperature (Too Hot)
adjusting the hydraulic system, move the
machine to a smooth horizontal location and When the temperature of hydraulic oil gets over
lower the mast and carriage to the ground. If the 98.8 °C (210 °F), polyurethane seals in the system
mast and carriage can not be on the ground, start to fail. High oil temperature causes seal failure
make sure they are blocked correctly to keep to become more rapid. There are many reasons why
them from a fall that is not expected. Move away the temperature of the oil will get this hot.
from machines and personnel that are at work.
There must be only one operator. Keep all other 1. Hydraulic pump is badly worn.
personnel away from the machine, or where the
operator can see the other personnel. 2. Heavy hydraulic loads that cause the relief valve
to open.
Before any hydraulic plug, line or component is
removed, make sure all hydraulic pressure in the 3. The setting of the relief valve is too low.
system is released.
4. Too many restrictions in the system.
Visual Checks 5. Hydraulic oil level in the tank is too low.
A visual inspection of the hydraulic system and its 6. High pressure oil leak in one or more circuits.
components is the first step when a diagnosis of a
problem is made. Lower the carriage to the floor and 7. Very dirty oil.
follow these inspections:
8. Air in the hydraulic oil.
1. Measure the oil level. Look for air bubbles in the
oil tank.
a. Return oil to the tank goes in above the level of 4. The priority valve does not work correctly.
the oil in the tank.
5. The load is not correct.
b. Air leaks in the oil suction line between the
pump and the tank. 6. Unload function doesn’t work correctly.
During a diagnosis of the hydraulic system, 1. The mast is not in alignment with the other lifting
remember that correct oil flow and pressure are components and does not move freely.
necessary for correct operation. The output of the
pump (oil flow) increases with an increase in engine 2. Not enough lubricant on the parts of the mast that
speed (rpm) and decreases when engine speed move.
(rpm) is decreased. Oil pressure is caused by
resistance to the flow of oil. 3. The carriage or mast rollers and bearings areworn
and do not move (seized).
Visual checks and measurements are the first step
when troubleshooting a possible problem. Then do 4. Mast is shimmed too tight.
the operation checks and finally, do instrument test
with pressure gauges. Problem: Lift cylinder extends too slowly.
Use the Fittings Group, a stop watch, a magnet, a Probable Hydraulic Cause:
thermometer, and an inch (mm) ruler for basic tests
to measure: 1. Not enough oil supply to lift cylinder.
1. The pressure of the oil to open the relief valve. 2. Defective lift cylinder seals.
Relief valve pressures that are too low will cause
a decrease in the lift and tilt characteristics of the 3. Relief pressure set to low.
lift truck. Pressures that are too high will cause a
decrease in the life of hoses and components. 4. Unload function doesn’t work correctly.
1. There is an air leak, which lets air into the 1. Air in the hydraulic system.
hydraulic system on the inlet side of the hydraulic
pump. 2. Relief valve sticks or defective.
Probable Mechanical Cause: 1. The mast is not in alignment with the other lifting
components and does not move freely.
1. Not enough lubricant on the parts of the mast that
move. 2. Carriage chains need an adjustment.
2. Load rollers defective or not adjusted correctly. 3. Not enough lubricant on the part of the mast that
moves.
3. Mast rollers not shimmed correctly.
4. The carriage or mast rollers and bearings are
4. Mast assembly is damaged or not in alignment. worn and do not move (seized) or shimmed too
tight.
Problem: The mast does not tilt correctly or
moves too slowly.
Problem: Unload function doesn’t work.
Probable Hydraulic Cause:
Unload function: Once the operator leaves a seat
1. There is restriction in the hydraulic tilt lines. more than 3 seconds or a start key is off, any
function (lift, tilt, auxiliary cylinder) doesn’t work even
2. There is an air leak, which lets air into the though each spool is shifted in or out. If the operator
hydraulic system on the inlet side of the hydraulic is seated on a key on, immediately each function will
pump. normally work.
3. The relief valve opens at low oil pressure. Probable Electric Cause:
4. The hydraulic pump has too much wear. 1. The electric switch (on-off) below a seat is
damaged.
5. The internal valve of the tilt spool is stuck.
2. The electric parts (relay and controller) related to
6. Control valve tilt spool has a restriction. a solenoid valve for unload function in lift section
of control valve damaged.
7. The priority valve does not work correctly.
Probable Hydraulic cause:
8. Seals in tilt cylinder are worn or damaged.
1. Hydrostator sleeve in control valve is stuck to a
9. Unload function doesn’t work correctly. housing.
Probable Cause:
1. Lift cylinder damaged or bent. 2. The oil is thick (viscosity too high).
2. Load roller defective (bearing) or not adjusted 3. The pump inlet line has a restriction in it.
4. Worn parts in the pump.
5. Oil is dirty.
6. Air leaks into the inlet line.
1. The oil level is low. 7. The bolts of the pump do not have the correct
torque.
2. There is a restriction in an oil passage.
8. Filter by-pass not working or installed backward.
3. The relief valve setting is too low.
Hydraulic Control Valve
4. The oil is too thin.
Problem: The control spools do not move freely.
5. There is air leakage in the system.
Probable Cause:
6. The pump has too much wear.
1. The temperature of the oil too high.
7. The system operates at too high a pressure.
2. There is foreign material in the fluid.
a. Relief valve setting too high.
3. The fitting connections in the valve body are too
b. Attachment components cause a restriction tight.
during movement.
4. The fastening bolts of the valve assembly do not
c. Restrictions in flow regulator valve, load check have the correct torque and have twisted the
body.
8. Severe hydraulic usage.
5. Linkage of the lift and tilt levers does not operate
Problem: Leakage on the shaft seal. smoothly.
1. The shaft seal is worn. 7. Damage to the return springs of the spools.
2. There is a broken gasket behind the seal. 8. The valve is not at normal temperature for
operation.
3. The inner parts of the pump body are worn.
4. Operation with too low oil level in tank causes Problem: Control valve spools have leakage
suction on the seal. around the seals.
Problem: There is failure of the pump to deliver 3. The seal plates are loose.
the fluid.
4. The seals have damage or are badly worn.
Probable Cause:
1. There is foreign material in the load check valve 1. Cylinder head (bearing) seals are worn.
area.
2. Piston rod is worn, scratched or bent.
2. The load check valve and seat show wear.
Problem: There is leakage of oil inside the
3. Sudden loss of pump oil pressure. cylinder or loss of lift or tilt power.
4. Damage to the relief valve which causes low oil Probable Cause:
pressure.
1. The piston seals are worn and let oil go through.
Problem: Spool do not return to neutral.
2. Cylinder has damage.
Probable Cause:
Problem: The piston rods show wear.
1. The springs are broken.
Probable Cause:
2. The spool is bent.
1. The cylinders are not in correct alignment.
3. The system valve has foreign particles in it.
2. Oil is dirty.
4. The control linkage is not in alignment.
Problem: Foreign material behind the wiper
5. The fastening bolts of the valve have too much rings causing scratches on the cylinder rod.
torque.
Probable Cause:
Problem: No motion or slow, then a too sudden
action of the hydraulic system. 1. The wiper rings show wear and do not remove
dirt and foreign material.
Probable Cause:
3. Steering gear covers are too tight. 4. Oil leakage inside or outside of the system.
5. Priority valve spool is held in one position. Problem: Pump makes noise and the steering
cylinder rod does not move smoothly.
6. Steering gear without lubrication.
Probable Cause:
7. Low fluid level in the hydraulic supply tank.
1. Air in the steering hydraulic circuit.
8. Steer axle damaged.
2. The pump has too much wear.
9. Worn steer cylinder piston seal.
3. Loose connection of the oil line on the inlet side
Problem: Steering wheel does not return to of the pump.
center position correctly.
4. The viscosity of the oil is wrong.
Probable Cause:
5. The oil level in the hydraulic tank is low.
1. Steering gear covers are too tight.
6. Worn steer cylinder piton seal.
2. Steering column is not in correct alignment.
Problem: Lift truck does not turn when steering
3. Valve spool in the steering gear has a restriction. wheel is slowly turned.
4. Priority valve check valve permits lift and tilt Probable Cause:
hydraulic oil to affect steering hydraulic circuit.
1. The oil level of the tank is low.
Problem: Oil leakage at the pump. 2. There is air in the steering system.
2. Air mixed with the oil. 2. Air in the brake hydraulic system.
3. The relief valve is set too high (priority valve). 3. Loose master cylinder mounting.
5. Unit being held in relief mode for long periods of Probable Cause:
time.
1. Mechanical resistance on the pedal or shoe.
Problem: Brakes make noise or pull (grab). 3. Restriction in the brake line.
1. Brake shoe adjustment not correct. 5. Lining surface looks like glass (glazed), or is worn.
2. Lining surface looks like glass (glazed) or is worn. Problem: Pedal gradually goes to the floor.
4. Dirt on the brake drum lining surface. 1. Leakage or low fluid level.
5. Brake drum is badly worn or has grooves (scored). 2. Bad master cylinder.
Problem: Both brake shoes will not release all 1. Leakage or low fluid level.
the way (drag).
2. Air in the brake hydraulic system.
Probable Cause:
3. Bad master cylinder.
1. Brake shoe adjustment not correct.
4. Lining surface looks like glass (glazed), or worn.
2. Brake pedal adjustment not correct.
5. Operation of brake adjuster is not correct.
3. Mechanical resistance at the pedal or shoe.
Probable Cause:
Probable Cause:
4. Loose lining.
WARNING
Hydraulic oil, under pressure can remain in the
hydraulic system after the engine and pump
have been stopped. Personal injury can be
caused if this pressure is not released before
any work is done on the hydraulic system. To
prevent possible injury, lower the carriage to the
ground, turn the key switch off and move the
control levers to make sure all hydraulic
pressure is released before any fitting, plug,
hose or component is loosened, tightened,
removed or adjusted. Always move the lift truck
to a clean and level location away from the travel
of other machines. Be sure that other personnel
are not near the machine when the engine is
running and tests or adjustments are made.
Relief pressure gage point (1)
RELIFE PRESSURE
Auxiliary Relief
Model Mast Main relief pressure-lift Valve
Pressure
Psi Kpa psi Kpa
Remove the plug from elbow (1). Install pressure-checking adapter (4) and, connect pressure-tube (5) and
pressure gage (6). Pressure gage (6) has a range of 2,8000kpa (4,000psi)
(1) Tighten nut (1) slowly to 133 N•m (98 lb•ft) while
turning the wheel.
NOTE : This oil will now flow from the pump, the
Steer Axle Left End. priority valve and the steering gear, then back to the
(1) Setscrew (2) Nut (3) Setscrew (not shown) priority valve, hydraulic control valve, hydraulic tank
(4) Nut (not shown) and finally to the pump again. When no more oil can
be added and oil is clear, do the procedure that
follows :
NOTICE
Be sure to keep the oil level in the hydraulic tank
above the outlet to the pump. Do not hold steer
wheels against stops for an extended period of
time. This will cause the oil to get hot and
damage the components.
Steer Axle Right End
(5) Nut (6) Setscrew (7) Nut (8) Setscrew
(A) 80 +0-2 Cramp angle (reference)
5. Turn the steer wheels until they have reached the
stop in one direction, then quickly turn the
Use the procedure that follows to adjust the steer steering wheel in the opposite direction to the
axle turning angle. opposite stop.
1. Loosen nut (2) and (7) on steer axle ends. Turn 6. This procedure must go on approximately 15 to
setscrew (1) and (8) all the way in. Put left steer 20 times, to remove the air from the system. Add
knuckle in forward cramp until steering cylinder oil as required.
internal stop is reached. Adjust setscrew (1) of
left end of steer axle and setscrew (8) of right
end of steer to contact steer knuckle. Tighten
nuts (2) and (7) to hold the adjustment.
WARNING
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all
hydraulic pressure is released in the steering
system. Move the steer wheels to the left and (4) Pressure-checking adapter. (5) Pressure-tube.
right and then to the straight forward direction. (6) Pressure gauge.
WARNING
5
To prevent personal injury, the operator must be
ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck 6
starts to move.
4
NOTICE
Turn the adjustment screw clockwise to tighten.
Turning the screw too far counterclockwise
could allow parts to fall into the bottom of the
transmission. The transmission would then
require disassembly to remove the parts.
3. Bend lock (5) away from nut (6). Loosen nut (6)
until lever (4) is against stop (3).
7
8
IDCS219S
Vehicle System
Disassembly & Assembly
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
Overhead Guard
WARNING
The hood and seat assembly can fall when nut
(1) is removed from the support cylinder rod. To
avoid personal injury, support the seat and hood
assembly before removing nut (1).
2. Install backup ring (8) and O-ring seal (7) onto the
rod cover.
End By :
WARNING
Before any hydraulic plug, line or component is
removed, make sure all hydraulic pressure in the
system is released.
Disassembly Instruction 1. Loosen the tie rod nuts and remove the tie rods
from the valve sections.
General :
2. Remove o-rings between valve sections and set
• Subassemblies (such as relief valves, check aside to avoid damage.
valves, and spools) may be removed without
having to loosen the tie rods and disassembling 3. Spools, relief valves, load check valves, lift lock
the entire valve. poppets, solenoid valves, and plugs can be
removed from the valve sections. Refer to the
• Disassemble the valve sections on a flat working associated assembly procedures for specific
surface. torque and handling details. Inspect and repair or
replace the assemblies as complete units, as
• Ensure that the disassembly area will be clean may be necessary.
and free of contamination.
4. Valve components are precision items, and care
• Keep the disassembly area neat to avoid loss or must be taken when handing them to avoid
damage of parts. damage or the introduction of contamination that
could adversely affect performance.
• Ensure that the assembly area will be clean and 2. Stack the valve sections such that all the work
free of contamination. ports are facing up, the spool ends are all in
• Use a flat (within 0.2 mm) work surface when the same direction, and they are resting on a
bolting the valve sections together. flat (within 0.2 mm), uniform surface.
• Use calibrated torque wrenches and
instrumentation. 3. Insert all the tie rods through the drilled holes
• The formal Bills of Material, descriptions, and in each of the housings.
views are found in the attached documentation.
• Additional auxiliary valve sections may be added 4. Press the sections together, being careful not
to the main control valve in a similar manner as to damage sealing surfaces or seals.
indicated below, as approved by the O.E.M.
5. Install nuts to both ends of all tie rods and
progressively torque in a circular pattern until
reaching a torque of 2.4 ~2.9 kgf•m on all tie
rods. Periodically, make sure that the valve
remains flat while applying torque.
1. Install the main relief valve assembly into the 1. The spool assembly should already consist of the
lower side cavity of the section, as illustrated. tilt spool (with tilt plunger and spring inserted into
Torque to 4.5 - 5.0 kgf•m. the bore on the spring end), the return spring, one
spring seat on either end of the spring, the seal
2. Install the normally open solenoid valve assembly plate, a spool seal, and a dust wiper. All of these
in the side cavity of the inlet directly above the are assembled on the end of the spool the clevis.
main relief valve. Torque 3.5 - 4.0 kgf•m.
2. Insert the clevis end of the spool into the right -
hand side of the spool bore (the tallest end of the
Lift Section : housing). Place the spool cap over the spool and
spring assembly and connect the cap to the
1. The spool assembly should already consist of the housing using two bolts. Torque both bolts
lift spool, the return spring, one spring seat on alternatively until a torque of 1.0 - 1.5 kgf•m is
either end of the spring, the seal plate, a spool reached on both bolts.
seal, and a dust wiper. All of these are assembled
on the end of the spool opposite the clevis. 3. Install the second spool seal and dust wiper over
the clevis end of the spool and retain with a seal
2. Insert the clevis end of the spool into the right- plate and two bolts. Torque both bolts alternatively
hand side of the spool bore (the tallest end of the until a torque of 1.0 - 1.5 kgf•m is reached on both
housing). Place the spool cap over the spool and bolts.
spring assembly and connect the cap to the
housing using two bolts. Torque both bolts 4. The load check assembly is inserted into the top
alternatively until a torque of 1.0 - 1.5 kgf•m is center cavity. Torque 3.5 - 4.0 kgf•m.
reached on both bolts.
2. Insert the clevis end of the spool into the right- 1. Install the secondary relief valve into the cavity on
hand side of the spool bore (the tallest end of the the clevis end of the housing. Torque to 4.5 - 5.0
housing). Place the spool cap over the spool and kgf•m.
spring assembly and connect the cap to the
housing with two bolts. tighten both bolts
alternatively until a torque of 1.0 - 1.5 kgf•m is
reached on both bolts.
End By:
WARNING
If both tilt cylinders are to be removed at the
same time, make sure that the mast is held
either by a hoist or is securely held in place by
blocks. 3. Remove bolts (4), the washer. Remove rear tilt
cylinder pin (5).
7. Loosen the nut and bolt (6) on the rod eye. 10. Remove wiper seal (12) and U-packing (14) from
Remove cylinder rod. the rod cover.
8. Remove slipper seal (7) and O-ring seal (8) from 11. Remove the DU-bush (15) from the rod cover. If
the piston (9). the DU-bush has a large amount of wear,
replace the DU-bush.
15. Install slipper seal (7) and O-ring seal (8) on the
piston (9).
End By :
5. Remove plate (7) and piston (8). NOTE: Use the following steps to install the steering
wheel.
6. Remove secondary cup (9) from piston.
4. Put the steering wheel on the steering wheel shaft
7. Remove spacer (10) and primary cup (11). in its original position.
8. Remove spring (12) and check valve (13). 5. Install cup (3) and nut (2). Tighten nut (2) to a
torque of 80 ± 7 N•m (60 ± 5 lb•ft).
9. Assemble the master cylinder in the reverse order
of disassembly. 6. Install cap (1).
End By :
NOTICE
Steering unit (5) and column (2) can separate after
bolts (4) have all been removed, causing unit (5) to
fall. To avoid damaging components, support the
1. Open the access cover for the fuse panel.
steering pump while removing bolts (4).
2. Loosen four bolts (1). Slide directional control
switch (3) off of steering column (2). Set switch 5. Support steering unit (5) while removing the
(3) aside, clear of the steering column. remaining two bolts (4). Remove steering unit (5)
and steering column (2).
End By :
1. Use a needle nose pliers to lower check ball 7. Bring spring slots of both parts in line and stand
retainer into check valve hole of housing. Make parts on end of bench. Insert spring installation
sure retainer is straight (not tilted on edge) in tool through spring slots of both parts. Position 2
housing. pairs of centering springs on bench so that
extended edge is down and arched center section
2. Install check ball in housing is together. In this position, insert one end of
entire spring set into spring installation tool, with
3. Lubricate 9.3 mm [.36 in.] ID seal and 7.7 mm [.30 spring notches facing sleeve.
in.] ID seal. Install seals on check ball seat as
shown. 8. Compress extended end of centering spring set
and push into spool sleeve assembly withdrawing
4. Lubricate check ball seat and seals thoroughly installation tool at the same time.
before installing seat in housing. When installing
seat do not twist or damage seals. Install check 9. Center the spring set in the parts so that they
ball seat in housing, insert open end of seat first. push down evenly and flush with the upper
Push check ball seat to shoulder of hole. surface of the spool and sleeve.
5. Install set screw. Use a 1/4 inch hex key to torque 10. Install pin through spool and sleeve assembly
set screw to 11 N•m [100 lb•in]. To prevent until pin is flush at both sides of sleeve.
interference make sure top of set screw in slightly
below housing mounting surface.
13. Install 2 bearing races and the needle thrust 17. Install retaining ring in housing. After installing
bearing in the order shown. ring, tap on ring end or pry with screwdriver
around entire circumference of ring to properly
14. Install 25 mm [1 in.] ID dust seal in seal gland seat ring in groove.
bushing, flat or smooth side must face down
towards bushing.
10. Remove seal (9) and bearing cup (10) from hub b. Loosen nut (5) completely.
(7).
c. Tighten nut (5) again to a torque of 50 ± 5
N•m (37 ± 4 lb•ft).
Tie Rods
Remove Tie Rods
1. Remove the cotter pin (1), pins (2) and seals from
the tie rod.
2. Put seals (1) in position as shown. Install tie rod
2. Remove tie rod (3). (2) with the others seals.
3. Install the pins and retaining rings that hold the tie
rod in position.
WARNING
End By :
1. Put identification marks on steering lines (1).
Disconnect steering lines (1) from the steering a. Install tie rods.
cylinder.
b. Install steer axle.
2. Put a floor jack in position under the steer axle.
Remove bolts (2).
Disassemble & Assemble Steering
3. Lower steer axle with the floor jack to remove it
from under the machine. The weight of the steer
Cylinder
axle is about 150 kg (330 lb).
Steer Cylinder-Cushion
Remove & Install Steering Cylinder
1. Put location marks on end caps (1) as to their
Start By : position on the steer cylinder tube (2).
a. Remove steer axle. 2. Remove end caps (1) from the steer cylinder.
b. Remove tie rods. 3. Remove rod assembly (3) from the tube.
End By :
Steer Axle-Pneumatic
Remove & Install Steer Axle
WARNING
1. Install the seal and bearing in the knuckle. Install
the seal with the sealing lip away from the bearing. Be sure the pressure in the hydraulic system is
released before any lines or hoses have been
NOTE: Prepack bearings with multipurpose EP disconnected.
NLGI NO.2 LITHIUM GREASE prior to assembly.
Typical Example
Typical Example
5. Install cylinder tube (2) on the rod assembly. 2. Remove the links (2).
End By:
End by :
Install Counterweight
a. Remove counterweight
1. Loosen the bolt (1) and (2) and, shift the clamp
(3) inward. And, shift the alternator toward the
engine.
End by :
a. Install counterweight.
3. Install the fan belt and adjust the belt tension <V2403 Engine>
properly by tightening the bolt (2) and (1).
1. Disconnect wiring harness (1) from the alternator.
4. In case of replacing the alternator belt, it needs to
remove the fan belt at first. 2. Loosen top bolt (2) and then remove belt from the
pulley.
5. To replace the alternator belt (5), loosen the bolt
(2) and the bolt (1). 3. Support the alternator. Remove bolt (3) and
washer. Remove the alternator.
6. Shift the alternator (6) toward the engine.
4. Install the alternator in the reverse order of
7. lnstall the alternator belt in the reverse order of removal.
removal.
5. Adjust the belt tension properly.
<A2300 Engine>
<D15/18/20S(C)-5>
<G15/18/20S(C)-5>
Park the lift truck on the plain ground and lift it off
the ground. Put the wooden block under the lift truck,
if drive axle needs to be removed.
11. Remove the drive axle from the frame. Put the
drive axle on the wooden block.
End By:
d. Install mast.
Mast System
Disassembly & Assembly
Testing & Adjusting
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.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index
Forks Backrest
Start By:
a. Remove forks.
b. Remove backrest.
a. Install backrest.
b. Install forks.
Disassemble Carriage
Start By:
a. Remove carriage.
3. Remove screw (5) and washer (4). * Permissible tolerance of ± 0.08 mm (.003in)
Remove two top roller bearings (6) and the shims.
Refer to carriage Adjustment in Testing & Adjusting.
4. Remove bolt (7), washer, pin-adjust (8) and
side-roller bearing (9) from the carriage.
Assemble Carriage
Start By:
a. Remove forks.
Move the truck to the place where pit is set up.
End By:
NOTICE
Place identification marks on all hydraulic
connectors and hoses to assure proper installation.
Plug and cap all hydraulic connectors and hoses to
avoid debris and contamination from entering the
system.
2. Disconnect hose(3).
WARNING
Tilt cylinders (4) can drop when pin(6) is
removed. 6. B16/18/20X-5, B15/18/20T-5
To avoid component damage or personal injury, Tilt forward mast assembly with the hoist.
support tilt cylinder (4) while removing pin(6). Remove bolts (8) from each side.
End By:
a. Install forks.
5. D,G15/18/20S(C)-5, GC15/18/20S(C)-5,
B15/18S-5, BC15/18/20S(C)-5
Tilt forward mast assembly about 8° with the
hoist.
Remove four bolts (7) from pit each side of the
base of mast assembly.
Start By:
B16/18/20X-5, B15/18/20T-5
13. Remove bearings (18) and shims from the 18. Remove bearings (22) and the shims from the
intermediate mast channel (24). stationary mast channel.
14. Remove nylon pads (19) and shims. 19. Remove nylon pads (23) and the shims.
15. Remove bearings (20) and shims from the inner 20. Remove bearings (25) and the shims from the
mast channel (21). intermediate mast channel (24).
16. Fasten nylon straps and hoist to inner channel 21. Fasten nylon straps and a hoist to the
(21). Remove inner channel. The weight of the intermediate mast channel (24). Remove
inner channel is 110 kg (243 lb). intermediate mast channel. The intermediate
mast channel weighs 112kg (247 lb).
1. Make sure all parts are clean and free of dirt and
foreign material.
A. Lower Bearing Adjustment of Intermediate 4. Find narrowest point by ruler on the stationary
Mast mast in the area where the bearings make
contact at 420 mm (16.5 in) channel lap.
NOTICE
When the correct amount of shim has been installed
behind bearings (1) there will be contact (zero
clearance) between the bearings and the inner mast
at most narrow point of mast.
17. Install shims (8) behind each pad (7) until there
is 0.80 mm (.031 in) maximum clearance (E)
between the pads and the inner and
15. Make sure stationary mast upper bearings are intermediate masts with the masts at full
properly shimmed by rolling up and down and extension. Lift by crane, and pull out
moving intermediate mast to right and left. If intermediate mast from stationary mast and
clearance between both masts can be detected, insert the shims behind each pad. In case of
pull out the intermediate mast from the standard and full free mast, the pads of
stationary mast with crane and add shim 0.5 mm stationary upper can be easily extruded by
or 1 mm to both stationary upper bearings. pulling down the inner mast from the bottom of
stationary mast.
16. In case of standard and full free mast, stationary
upper bearings can be easily extruded by pulling
down the inner mast from the bottom of
stationary mast. If intermediate mast is stuck
and cannot move by rolling up and down, there
might be excessive shim. Pull out the
intermediate mast from the stationary mast and
remove shim 0.5 mm to both stationary upper
18. Select lower bearings (3) and (4) from the chart
to obtain minimum clearance (B) between
bearing and channel leg for full channel length. 20. Lifting by crane, insert inner mast (11) into
Use same bearing on left and right side. intermediate mast (12) from the upper side.
End by:
30. Install regulator (22) to secondary cylinder and
tube ass’y (23) and bolts (24) to stationary mast. a. Install primary lift cylinder.
Carriage Adjustment
(3) Upper Bearings. (4) Shims. (5) Bolt. (6) Screw.
(7) Side-roller Bearings. (8) Lower Bearings. (9) Pin-adjust.
(10) Bolt. (A) Zero Clearance.
(B) 4.0 to 6.0 mm. (.157 to .242 in) Clearance.
(C) Minimum Clearance. (D) 4.5 ± 0.5 mm
WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2%
Inner Lift Chains or more could cause damage or injury to
(1) Chain Anchor Nuts. persons.
<STD>
D,G15/18/20S(C)-5 .....................22 mm(0.866 in)
B15/18S-5 ....................................7 mm (0.276 in)
B16/18/20X-5, GC15/18/20S(C)-5,
B15/18/20T-5, BC15/18/20S(C) -5
.................................................. -6 mm (-0.236 in)
3. Measure any drift of the carriage for a ten minute Tilt Cylinder Adjustment
period. Drift for all models shall not exceed 100.0 (1) Pivot eye. (2) Bolt. (3) Rod.
mm (4.00 in).
26
For B16/18/20X-5, B15/18/20T-5
For B15/18S-5, BC15/18/20S(C)-5,
D,G15/18/20S(C)-5, GC15/18/20S(C)-5 1. Tighten screw (1) that holds bearing (3) to hinge
bracket of stationary mast to a torque of 34±7
N•m (25±5 lb•ft)
Hydraulic Schematic
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
T MAIN CONTROL VALVE HYDRAULIC SCHEMATIC
141kgf/cm 2 2 SECTION A385000 MODEL : D15S-5, D18S-5, D20SC-5
3 SECTION A385001 G15S-5, G18S-5, G20SC-5
4 SECTION A385002
GC15S-5, GC18S-5, GC20SC-5
P/S CYLINDER B4
AUX2
D(G)15S A271264 TILT CYLINDER
A4
GC15S A251573 (A252110)
LIFT CYLINDER
AUX1 B3
STANDARD D501914
A3 PRIMARY D501986
FFT
SECONDARY D511486
PRIMARY D501865
FF
SECONDARY D511624
B2
TILT
A2
PRIMARY
SECONDARY
or STANDARD
LIFT
STEERING UNIT A1
D(G)15S A385006
GC15S A385007
PROTECTOR
220kgf/cm2 (D502539)
PROTECTOR
(D501495)
FLOW REGULATOR
P (D501493)
84kgf/cm2
PRIORITY VALVE
RELIEF PRESSURE
(A251581)
MODEL MAST Main Relief Pressure-lift Auxiliary Pressure-tilt, Attachment
Electric Schematic
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
GC15S-5, GC18S-5, GC20SC-5
ELECTRIC SCHEMATIC
MODEL : D15S-5, D18S-5, D20SC-5
(Cummins A2300)
A384001-00
ELECTRIC SCHEMATIC
MODEL : G15S/18S/20SC-5 Non-Certi & Tier-3 LP
GC15S/18S/20SC-5 Tier-3 LP
G20/25/30/32E-5 Non Certi & Tier-3 LP
GC20/25/30/32E-5 Non Certi & Tier-3 LP
(G420F(E) LP)
A404014-01
ELECTRIC SCHEMATIC
MODEL : D15S/18S/20SC-5(KUBOTA E/G V2403)
EMOUT, EMOUU
A384030-00
●Electric Schematic MODEL: G15/18S-5, G20SC-5 DF Non-Cert.
G20/25/30E-5 DF Tier-3 & Non-Cert.
(G424I(E) DF)
600123-00107
●Electric Schematic MODEL: G15/18S-5, G20SC-5 LP Tier-3 & Non-Cert.
G20/25/30E-5 LP Tier-3 & Non-Cert.
(G424I(E) LP)
600123-00108
●Electric Schematic MODEL: G15S/18S/20SC-5 Non-Certi GAS & DF
G20/25/30E-5 Tier-3 DF & Non-Certi GAS, DF
(G420F(E) Gas/DF)
A404010_0301
SB2353E04
Operation &
Maintenance Manual
FORKLIFTS
D15S-5, D18S-5, D20SC-5
G15S-5, G18S-5, G20SC-5
Original Instruction
1503
Table of Contents
Table of Contents
Operation Section
1
Information Section
Foreword
Photographs or illustrations guide the operator
Literature Information through correct procedures of checking, operation
and maintenance of the DOOSAN operator restraint
This manual should be stored in the operator's
system.
compartment in the literature holder or seat back
SAFE and EFFICIENT OPERATION of a lift truck
literature storage area.
depends to a great extent on the skill and alertness
This manual contains safety, operation,
on the part of the operator. To develop this skill the
transportation, lubrication and maintenance
operator should read and understand the Safe
information.
Driving Practices contained in this manual.
Some photographs or illustrations in this publication
Forklift trucks seldom tipover, but in the rare event
show details or attachments that can be different
they do, the operator may be pinned to the ground
from your lift truck. Guards and covers might have
by the lift truck or the overhead guard. This could
been removed for illustrative purposes.
result in serious injury or death.
Continuing improvement and advancement of
Operator training and safety awareness is an
product design might have caused changes to your
effective way to prevent accidents, but accidents
lift trucks which are not included in this publication.
can still happen. The DOOSAN operator restraint
Read, study and keep this manual with the lift truck.
system can minimize injuries. The DOOSAN
Whenever a question arises regarding your lift truck,
operator restraint system keeps the operator
or this publication, please consult your DOOSAN
substantially within the confines of the operator’s
dealer for the latest available information.
compartment and the overhead guard.
Safety This manual contains information necessary for Safe
Operation. Before operating a lift truck make sure
The Safety Section lists basic safety precautions. In that the necessary instructions are available and
addition, this section identifies the text and locations understood.
of warning signs and labels used on the lift truck.
Read and understand the basic precautions listed in Operation
the Safety Section before operating or performing
The Operation Section is a reference for the new
lubrication, maintenance and repair on this lift truck.
operator and a refresher for the experienced one.
This section includes a discussion of gauges,
Operator Restraint System (If Equipped) switches, lift truck controls, attachment controls,
transportation and towing information.
This manual contains safety, operation and
maintenance information for the DOOSAN operator Photographs and illustrations guide the operator
through correct procedures of checking, starting,
restraint system. Read, study and keep it handy.
operating and stopping the lift truck.
Operating techniques outlined in this publication are
WARNING basic. Skill and techniques develop as the operator
gains knowledge of the lift truck and its capabilities.
Your DOOSAN truck comes equipped with an
operator restraint system. Should it become
necessary to replace the seat for any reason, it
should only be replaced with another DOOSAN
operator restraint system.
2
Information Section
Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without specific
intervals are listed under “When Required” topics.
Items in the “Maintenance Intervals” chart are
referenced to detailed instructions that follow.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the “Maintenance Intervals” chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at “Every 500 Service
Hours or 3 Months”, also service those items listed
under “Every 250 Service Hours or Monthly” and
“Every 10 Service Hours or Daily”.
Environment Management
Note that DOOSAN is ISO 14001 certified which is
harmonized with ISO 9001. Periodic
ENVIRONMENTAL AUDITS & ENVIRONMENTAL
PERFORMANCE EVALUATIONS have been made
by internal and external inspection entities.
LIFE-CYCLE ANALYSIS has also been made
through out the total product life. ENVIRONMENT
MANAGEMENT SYSTEM includes DESIGN FOR
ENVIRONMENT from the initial stage of the design.
ENVIRONMENT MANAGEMENT SYSTEM
considers environmental laws & regulations,
reduction or elimination of resource consumption as
well as environmental emission or pollution from
industrial activities, energy saving,
environment-friendly product design (lower noise,
vibration, emission, smoke, heavy metal free, ozone
depleting substance free, etc.), recycling, material
cost reduction, and even environmentally oriented
education for the employee.
3
Safety Section
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”
as shown below.
WARNING
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is
used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
4
Safety Section
Safety
The safety rules and regulations in this section are
representative of some, but not all rules and Warning Signs and Labels
regulations noted under the Occupational Safety
There are several specific safety signs on your lift
and Health Act (OSHA) and are paraphrased
truck. Their exact location and description of the
without representation that the OSHA rules and
hazard are reviewed in this section. Please take the
regulations have been reproduced verbatim.
time to familiarize yourself with these safety signs.
Please refer to 1910. 178 in Federal Register Vol.
Make sure that you can read all safety signs. Clean
37, No. 202, the National Fire Protection Association
or replace these if you cannot read the words or see
No. 505 (NFPA), American National Standard, ANSI
the pictures. When cleaning the labels use a cloth,
B56. 1 Safety Standard for Low lift and High Lift
water and soap. Do not use solvent, gasoline, etc.
Trucks and subsequent revisions for a complete list
You must replace a label if it is damaged, missing or
of OSHA rules and regulations as to the safe
cannot be read. If a label is on a part that is replaced,
operation of powered industrial lift trucks. Since
make sure a new label is installed on the replaced
regulations vary from country to country outside in
part. See your dealer for new labels.
U.S.A., operate this lift truck in accordance with local
regulations.
DOOSAN lift trucks are manufactured according to Training Required To Operate or Service
the regulations and standards laid down in EU Warning
Machinery Directive 98/37/EC and EMC directive
2004/108/EC. Please refer to the Directives
89/655/EC and 89/391/EC and its amendments for
the safe use of DOOSAN lift trucks.
The most effective method of preventing serious
injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.
Do not operate a lift truck if in need of repair,
defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt
any adjustments or repairs unless trained and
authorized to do so. Located on the right of the steering wheel.
WARNING
Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DOOSAN LIFT TRUCK dealers.
5
Safety Section
6
Safety Section
WARNING
Operation without this device in place may be
No hands. Do not place hands in this area. Do hazardous.
not touch, lean on, or reach through the mast or
permit others to do so.
7
Safety Section
Packing brake
No Riders Warning
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
8
Safety Section
WARNING
WARNING
Correct adjustment is necessary to provide
adequate braking. See the MAINTENANCE section
for adjustment procedures. The lift truck may creep
at engine idle and can cause damage, injury or
death. Always apply the parking brake when leaving
the lift truck. The parking brake is NOT automatically
applied.
9
Safety Section
10
Safety Section
Operation Information
Mounting and Dismounting
Mount and dismount the lift truck carefully.
Clean your shoes and wipe your hands before
mounting.
Face the lift truck when mounting and dismounting.
Use both hands face the lift truck when mounting
and dismounting.
Use the handgrips for mounting and dismounting.
Do not try to climb on or off the lift truck when
Inspect the part of the chain that is normally carrying tools or supplies.
operated over the crosshead roller. When the chain Never get on or off a moving lift truck.
bends over the roller, the movement of the parts Do not use any controls as handholds when entering
against each other causes wear. or leaving the operator's station.
Inspect to be sure that chain link pins do not extend Never get on or off a moving lift truck. Never jump
outside of the bore hole. off the lift truck.
If any single link pin is extended beyond its Keep hands and steering wheel free of slippery
connecting corresponding link, it should be material.
suspected of being broken inside of its bore hole.
Inspect the chain anchor and the anchor links for
wear. Before Starting the Lift Truck
Do not change any factory set adjustment
values(including engine rpm setting) unless you Perform a walk-around inspection daily and at the
have both authorization and training. Especially start of each shift. Refer to the topic “Walk-around
Safety equipment and switches may not be removed Inspection” in “Every 10 Service Hours or Daily”
or adjusted incorrectly. Repairs, adjustments and section of this manual.
maintenances that are not correct can make a Adjust the seat so that full brake pedal travel can be
dangerous operating condition. obtained with the operator's back against the seat
For any checkup, repair, adjustments, maintenance back.
and all other work concerning your forklift truck, Make sure the lift truck is equipped with a lighting
please contact your DOOSAN dealer. We would like system as required by conditions.
to draw your attention to the fact that any secondary Make sure all hydraulic controls are in the HOLD
damages due to improper handling, insufficient position.
maintenance, wrong repairs or the use of other than Make sure the direction control lever is in the
original DOOSAN spare parts waive any liability by NEUTRAL position.
DOOSAN. Make sure the parking brake is engaged.
Make sure no one is standing and/or working on,
underneath or close to the lift truck before operating
the lift truck.
11
Safety Section
Operate the lift truck and controls only from the Operating the Lift Truck
operator's station.
Make sure the lift truck horn, lights, backup alarm (if Always keep the lift truck under control.
equipped) and all other devices are working Obey all traffic rules and warning signs.
properly. Never leave the lift truck with the engine operating,
Check for proper operation of mast and attachments. or with the parking brake disengaged.
Pay particular attention to unusual noises or erratic Operate the engine only in a well ventilated area.
movement which might indicate a problem. Lower mast, with or without load, before turning or
Make sure service and parking brakes, steering, and traveling. Tip over could result. Watch out for
directional controls are operational. overhead obstructions.
Make sure all personnel are clear of lift truck and Always observe floor load limits and overhead
travel path. clearance.
Refer to the topic “Lift Truck Operation” in the Start, turn, and brake smoothly, slow down for turns,
“Operation Section” of this manual for specific grades, slippery or uneven surfaces.
starting instructions.
12
Safety Section
13
Safety Section
14
Safety Section
15
Safety Section
16
Safety Section
17
Safety Section
WARNING
Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and
down.
18
Safety Section
WARNING
Your DOOSAN truck comes equipped with a
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any
reason, it should only be replaced with another
DOOSAN operator restraint system.
19
Safety Section
WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen in an accident.
WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.
Fasten the Seat Belt 3. Be sure to fasten the belt across your hips, not
across your abdomen.
20
Safety Section
21
Safety Section
The stability of the lift truck is determined by the For the lift truck to be stable (not tip over forward or
location of its CG; or, if the truck is loaded, the to the side), the CG must stay within the area of the
combined CG of the truck and load. The lift truck lift truck stability base – a triangular area between
has moving parts and, therefore, has a CG that the front wheels and the pivot of the steer wheels. If
moves. The CG moves forward or backward as the the CG moves forward of the front axle, the lift truck
mast is tilted forward or backward. The CG moves will tip forward. If the CG moves outside of the line
up or down as the mast moves up or down. The CG on either side of the stability base, the lift truck will
and, therefore, the stability of the loaded lift truck, tip to the side.
are affected by a number of factors such as:
the size, weight, shape and position of the load
the height to which the load is lifted
WARNING
the amount of forward or backward tilt Dynamic forces (braking, acceleration, turning)
tire pressure also affect stability and can produce tipover
dynamic forces created when the lift truck is even when the CG is within the stability triangle.
accelerated, braked or turned
condition and grade of surfaces on which the lift
truck is operated
Capacity Load (Weight and Load Center)
22
Safety Section
NOTICE
1. Capacity/Nameplates originally attached to
forklifts sold by DOOSAN shall not be removed,
altered or replaced without DOOSAN’s approval.
2. DOOSAN assumes no responsibility for lift trucks
placed in service without a valid DOOSAN
Nameplate.
3. If necessary to change your specification,
contact your DOOSAN lift truck dealer.
23
Safety Section
Safety Rules
24
Safety Section
Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the
Do not let other people ride on the truck. rated capacity shown on the capacity plate.
Lift trucks are designed to carry loads, not people.
Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.
25
Safety Section
Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward.
load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards.
cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
26
Safety Section
27
Safety Section
Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully
Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in
make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and
Never overtake other vehicles. turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work..
28
Safety Section
Do not operate forklifts near flammable or An unloaded forklift may be easier to tip over than a
combustible materials. loaded truck.
To avoid the discoloration, deformation or When traveling without a load, the risk of lateral
combustion of materials (such as lumber, veneer overturn is greater.
board, paper products and other similar items),
always park at least 30 cm (12 inches) away from
them
29
Safety Section
WARNING
In the event of a tipover, the risk of serious
injury or death will be reduced if the operator is
using the operator restraint system and follows
the instructions provided.
Don’t jump.
Lean forward.
Hold on tight.
30
General Section
Declaration of Conformity
We,
Manufacturer
Doosan Corporation Industrial Vehicle
468, Injung-ro, Dong-gu, Incheon, Korea 401-010
herewith declare
that the following equipment conforms with the appropriate requirements of the Directives
2006/42/EC(Machinery Directive), 2000/14/EC as amended by 2005/88/EC(Noise Emission in
the environment by equipment for use outdoors), and 2004/108/EC (EMC Directive) based on
its design and type, as brought into circulation by us.
31
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type electric, diesel, gasoline, LPG
6 Operator type Stand-on, rider seated
7 Tires c = cushion, p = pneumatic
8 Wheels (x = driven) number, front/rear
DIMENSIONS
9 maximum fork height with rated load mm
Lift with STD
10 free lift mm
two - stage mast
11 special free lift mm
12 Fork carriage ISO class
thickness X width X length mm
13 Forks
fork spacing (minimum X maximum) mm
14 Tilt of mast forward/backward deg
15 length without forks mm
16 width mm
17 mast lowered height mm
Overall dimensions
18 mast extended height mm
19 overhead guard height mm
20 seat height mm
21 Outside turning radius mm
22 Load moment constant (from center of front wheel to fork face) mm
23 90° stacking aisle (add load length and clearance) mm
23a 90° intersecting aisle mm
PERFORMANCE
24 travel, loaded/unloaded km/h
25 Speeds lift, loaded/unloaded mm/s
26 lowering, loaded/unloaded mm/s
28 Drawbar pull at 1.6 km/h, loaded/unloaded kg
30 Gradeability at 1.6 km/h, loaded/unloaded %
31 Acceleration time traveling loaded/unloaded s
WEIGHT
32 Total weight kg
33 with load front/rear kg
Axle load
34 without load front/rear kg
CHASSIS
35 number of front/rear
36 Tires front size
size
37 rear size
38 Wheelbase mm
39 Tread front/rear mm
40 at the lowest point mm
Ground clearance loaded
41 at the center of wheelbase mm
42 Service brake
43 Parking brake
DRIVE
45 Battery voltage/capacity V/AH
49 manufacturer/model
50 rated output (at rpm) gas/LPG KW(hp)
51 Engine max. torque (at rpm) gas/LPG N·m(Ib·ft)
52 cycle/cylinders/displacement cc
53 fuel consumption l/hr
55 Type
Transmission
56 number of speeds forward/reverse
32
General Section
33
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type electric, diesel, gasoline, LPG
6 Operator type Stand-on, rider seated
7 Tires c = cushion, p = pneumatic
8 Wheels (x = driven) number, front/rear
DIMENSIONS
9 maximum fork height with rated load mm
10 Lift with STD mm
free lift
two - stage mast
11 special free lift mm
12 Fork carriage ISO class
thickness X width X length mm
13 Forks
fork spacing (minimum X maximum) mm
14 Tilt of mast forward/backward deg
15 length without forks mm
16 width mm
17 mast lowered height mm
Overall dimensions
18 mast extended height mm
19 overhead guard height mm
20 seat height mm
21 Outside turning radius mm
22 Load moment constant (from center of front wheel to fork face) mm
23 90° stacking aisle (add load length and clearance) mm
23a 90° intersecting aisle mm
PERFORMANCE
24 travel, loaded/unloaded km/h
25 Speeds lift, loaded/unloaded mm/s
26 lowering, loaded/unloaded mm/s
28 Drawbar pull at 1.6 km/h, loaded/unloaded kg
30 Gradeability at 1.6 km/h, loaded/unloaded %
31 Acceleration time traveling loaded/unloaded s
WEIGHT
32 Total weight kg
33 with load front/rear kg
Axle load
34 without load front/rear kg
CHASSIS
35 number of front/rear
36 Tires front size
size
37 rear size
38 Wheelbase mm
39 Tread front/rear mm
40 at the lowest point mm
Ground clearance loaded
41 at the center of wheelbase mm
42 Service brake
43 Parking brake
DRIVE
45 Battery voltage/capacity V/AH
49 manufacturer/model
50 rated output (at rpm) gas/LPG KW(hp)
51 Engine max. torque (at rpm) gas/LPG N·m(Ib·ft)
52 cycle/cylinders/displacement cc
53 fuel consumption l/hr
55 Type
Transmission
56 number of speeds forward/reverse
34
General Section
35
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type electric, diesel, gasoline, LPG
6 Operator type Stand-on, rider seated
7 Tires c = cushion, p = pneumatic
8 Wheels (x = driven) number, front/rear
DIMENSIONS
9 maximum fork height with rated load mm
10 Lift with STD mm
free lift
two - stage mast
11 special free lift mm
12 Fork carriage ISO class
thickness X width X length mm
13 Forks
fork spacing (minimum X maximum) mm
14 Tilt of mast forward/backward deg
15 length without forks mm
16 width mm
17 mast lowered height mm
Overall dimensions
18 mast extended height mm
19 overhead guard height mm
20 seat height mm
21 Outside turning radius mm
22 Load moment constant (from center of front wheel to fork face) mm
23 90° stacking aisle (add load length and clearance) mm
23a 90° intersecting aisle mm
PERFORMANCE
24 travel, loaded/unloaded km/h
25 Speeds lift, loaded/unloaded mm/s
26 lowering, loaded/unloaded mm/s
28 Drawbar pull at 1.6 km/h, loaded/unloaded kg
30 Gradeability at 1.6 km/h, loaded/unloaded %
31 Acceleration time traveling loaded/unloaded s
WEIGHT
32 Total weight kg
33 with load front/rear kg
Axle load
34 without load front/rear kg
CHASSIS
35 number of front/rear
36 Tires front size
size
37 rear size
38 Wheelbase mm
39 Tread front/rear mm
40 at the lowest point mm
Ground clearance loaded
41 at the center of wheelbase mm
42 Service brake
43 Parking brake
DRIVE
45 Battery voltage/capacity V/AH
49 manufacturer/model
50 rated output (at rpm) kW(hp)
51 Engine max. torque (at rpm) N·m(Ib·ft)
52 cycle/cylinders/displacement cc
53 fuel consumption l/hr
55 Type
Transmission
56 number of speeds forward/reverse
36
General Section
37
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center Ib/kg
4 Load center distance inch/mm
5 Power type electric, diesel, gasoline, LPG
6 Operator type Stand-on, rider-seated
7 Tire type c = cushion, p = pneumatic
8 Wheels (x = driven) number, front/rear
DIMENSIONS
9 Lift with STD maximum fork height with rated load inch/mm
10 two - stage mast free lift inch/mm
11 special free lift mm
12 Fork carriage ISO class
13 Forks thickness X width X length inch
fork spacing (minimum X maximum) mm
14 Tilt of mast forward/backward deg
15 length without forks inch/mm
16 width inch/mm
17 mast lowered height inch/mm
Overall dimensions
18 mast extended height inch/mm
19 overhead guard height inch/mm
20 seat height inch/mm
21 Outside turning radius inch/mm
22 Load moment constant inch/mm
(from center of front wheel to fork face)
23 90° stacking aisle (add load length and clearance) inch/mm
23a 90° intersecting aisle inch/mm
PERFORMANCE
24 travel, loaded/unloaded mph
kph
25 Speeds lift, loaded/unloaded fpm
mm/s
26 lowering, loaded/unloaded fpm
mm/s
28 Drawbar pull at 1.6 km/h, loaded/unloaded Ib/kg
30 Gradeability at 1.6 km/h, loaded/unloaded %
31 Acceleration time traveling loaded/unloaded s
WEIGHT
32 Total weight unloaded Ib/kg
33 Axle load without load, front/rear Ib
kg
34 without load, front/rear Ib
kg
CHASSIS
35 number of front/rear
36 Tires front size
size
37 rear size
38 Wheelbase inch/mm
39 Tread front/rear inch
mm
40 at the lowest point inch/mm
Ground clearance loaded
41 at the center of wheelbase inch/mm
42 service brakes
Brakes
43 parking brakes
DRIVE
45 Battery voltage/capacity V/AH
49 model
50 rated output (at rpm) kW
hp
51 Engine max. torque N·m
Ib·ft
52 cycle/cylinders/displacement cc
53 fuel consumption l/hr
55 Type
Gear shaft
56 no. of speeds forward/reverse
57 Operating pressure system/attachment bar
38
General Section
39
General Section
Specifications
CHARACTERISTICS
1 Manufacturer
2 Model
3 Capacity at rated load center Ib/kg
4 Load center distance inch/mm
5 Power type electric, diesel, gasoline, LPG
6 Operator type Stand-on, rider-seated
7 Tire type c = cushion, p = pneumatic
8 Wheels (x = driven) number, front/rear
DIMENSIONS
9 Lift with STD maximum fork height with rated load inch/mm
10 two - stage mast free lift inch/mm
11 special free lift mm
12 Fork carriage ISO class
13 Forks thickness X width X length inch
fork spacing (minimum X maximum) mm
14 Tilt of mast forward/backward deg
15 length without forks inch/mm
16 width inch/mm
17 mast lowered height inch/mm
Overall dimensions
18 mast extended height inch/mm
19 overhead guard height inch/mm
20 seat height inch/mm
21 Outside turning radius inch/mm
22 Load moment constant inch/mm
(from center of front wheel to fork face)
23 90° stacking aisle (add load length and clearance) inch/mm
23a 90° intersecting aisle inch/mm
PERFORMANCE
24 travel, loaded/unloaded mph
kph
25 Speeds lift, loaded/unloaded fpm
mm/s
26 lowering, loaded/unloaded fpm
mm/s
28 Drawbar pull at 1.6 km/h, loaded/unloaded Ib/kg
30 Gradeability at 1.6 km/h, loaded/unloaded %
31 Acceleration time traveling loaded/unloaded s
WEIGHT
32 Total weight unloaded Ib/kg
33 Axle load without load, front/rear Ib
kg
34 without load, front/rear Ib
kg
CHASSIS
35 number of front/rear
36 Tires front size
size
37 rear size
38 Wheelbase inch/mm
39 Tread front/rear inch
mm
40 at the lowest point inch/mm
Ground clearance loaded
41 at the center of wheelbase inch/mm
42 service brakes
Brakes
43 parking brakes
DRIVE
45 Battery voltage/capacity V/AH
49 model
50 rated output (at rpm) kW
hp
51 Engine max. torque N·m
Ib·ft
52 cycle/cylinders/displacement cc
53 fuel consumption l/hr
55 Type
Gear shaft
56 no. of speeds forward/reverse
57 Operating pressure system/attachment bar
40
General Section
41
General Section
D15/18S-5, D20SC-5
83 105
(W/O Cabin)
G15/18S-5, G20SC-5
80 103 0.8 0.2
G424F(E) Engine (W/O Cabin)
G15/18S-5, G20SC-5
81 104
G424I(E) Engine (W/O Cabin)
42
General Section
G15S-5
D15S-5
G18S-5
D18S-5
G20SC-5
D20SC-5
43
General Section
G15S-5
D15S-5
G18S-5
D18S-5
G20SC-5
D20SC-5
44
General Section
Serial Number
Serial Number Locations
For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.
45
General Section
46
General Section
TH - Tire Handler
CC - Carton Clamp
RC - Roll Clamp
LS - Load Stabilizer
47
Operation Section
Diesel (12V)
LPG/GAS (12V)
48
Operation Section
49
Operation Section
50
Operation Section
51
Operation Section
52
Operation Section
1. No truck moving with an operator’s absence on Before exiting the lift truck, the parking brake should
driver seat. always be applied.
.
To prevent motion of the truck without an
operator in the seated position, the OSS will shut WARNING
off the drive power immediately when an WHEN LEAVING MACHINE APPLY PARKING
operator leaves the seat..
BRAKE!
2. Hydraulic lifting and lowering locking.
PARKING BRAKE IS NOT AUTOMATICALLY
The OSS will lock the hydraulic control valve to APPLIED.
prevent lifting and lowering fork within three
seconds of operator leaving seat. In case of
key-off, hydraulic control valve will be locked Some trucks may be equipped (ask your dealer if this
immediately. applies to your truck) with an alarm that
will sound if the parking brake is not
3. Parking Brake Warning. applied when leaving the machine.
53
Operation Section
1. Forward - Push the lever forward for Inching Control Pedal - Pushing down on
FORWARD direction travel. the inching pedal, modulates the
hydraulic pressure to the clutch packs,
2. Neutral - Move the lever to center permitting disc slippage.
position for NEUTRAL. Further pushing on the pedal completely relieves
clutch pack pressure and applies the service brakes
3. Reverse - Pull the lever back for to stop and hold the lift truck.
REVERSE direction travel.
NOTE : The purpose of the inching control pedal is
to provide precise inching control at slow
travel speed, with high engine rpm. This is
used for fast hydraulic lift during load
approach, pickup or positioning.
54
Operation Section
Push DOWN on the brake pedal to slow or Pull the lever BACK to engage the parking
stop the lift truck. brake.
RELEASE the brake pedal to allow the lift Push the lever FORWARD to release the
truck to move. parking brake.
RELEASE the pedal to decrease engine 1. Lower Position - Push the lever
rpm (speed). FORWARD smoothly to lower the load.
55
Operation Section
Tilt Control
56
Operation Section
Refueling
Gasoline or Diesel Engine
Equipped
WARNING
Explosive fumes may be present during
refueling. Do not smoke in refueling areas.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to those indoors.
Stop the engine and get off the lift truck during 1. Park the lift truck only at a designated safe
refueling. location. Place the transmission in NEUTRAL.
Lower the forks to the ground. Engage the
parking brake. Stop the engine.
NOTICE
57
Operation Section
WARNING
Only trained, authorized personnel should fill or
exchange LP-Gas tanks.
Personnel engaged in filling of LP-Gas
containers should wear protective clothing such
as face shield, long sleeves and gauntlet gloves.
Do not refuel or store LP-Gas powered lift trucks
near any underground entrance, elevator shafts 2. Close the fuel shut off valve at the LP - Gas tank.
or any other place where LP-Gas could collect in Run the engine until it stops, then turn off the
a pocket causing a potentially dangerous
ignition switch and electrical disconnect the
condition. switch (if equipped).
Examine all LP-Gas containers before filling and 3. Disconnect the fuel supply line.
again before reuse, for damage to various valves,
liquid gauge, fittings and hand valve wheels.
All defective or damaged LP-Gas containers
must be removed from service.
Explosive fumes may be present during
refueling.
Do not smoke in refueling areas.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to indoor locations.
Stop the engine and get off the lift truck during
refueling. 4. Loosen the retaining clamps and remove the
The careless handling of LP-Gas containers can tank.
result in a serious accident. 5. Check the mounting to be sure the locating pin
Use extreme care when transporting containers (dowel) is not missing or broken.
to prevent damage to them.
NOTICE
1. Park the lift truck on level ground, with the
parking brake applied, the transmission in If the location pin (dowel) is missing or broken,
NEUTRAL, the forks lowered and the engine be sure the pin is replaced.
running at low idle.
58
Operation Section
WARNING
The LP-Gas tank must not extend past the
counterweight.
59
Operation Section
Typical Example
60
Operation Section
Typical Example
13.Observe the fuel level gauge after starting the
11.Measure the engine crankcase oil level with the truck. Add fuel if necessary.
dip stick. Maintain the oil level between the MAX.
and MIN., (or FULL and ADD) notches on the dip WARNING
stick.
Personal injury may occur from accidents
caused by improper seat adjustment. Always
adjust the operator's seat before starting the lift
truck engine.
Seat adjustment must be done at the beginning
of each shift and when operators change.
Typical Example
61
Operation Section
NOTICE
If the inside of engine cylinder is wet by gasoline,
the engine could not start. In this case, press
accelerator pedal fully and turn the ignition switch to
ON position for 10 seconds. The inside of cylinder
would be dry because ECM does not allow gasoline
fuel injection. Repeat it three times. Don’t press
accelerator pedal and turn the ignition switch to the
START position to start engine.
NOTICE
When you restart the engine after turning off it, wait
4 to 5 seconds and restart it to protect the starter.
62
Operation Section
NOTICE
Do not engage the starter for more than 10 seconds.
63
Operation Section
WARNING
Sparks occurring near the battery could cause
vapors to explode.
Always connect the external power source
ground cable to a point away from and below the
battery, and well clear of fuel system
components.
Typical Example
NOTICE
64
Operation Section
NOTE : The Underwriter’s Laboratory (U.L.) 5. Turn the ignition switch key to the OFF position
requires that the gasoline tank must be at and then to the START position to start the
least one - quarter full when operating on engine. Release it when the engine starts.
LP - Gas. This will allow the lift truck to be
restarted on gasoline and moved to an
approved refueling area, when operating in Changing From LP - Gas to
a hazardous area.
Gasoline
1. Park the lift truck level in an authorized refueling
1. Park the lift truck level in an authorized refueling area with the forks lowered, the parking brake
area with the forks lowered, the parking brake applied, the transmission in NEUTRAL and the
applied, the transmission in NEUTRAL and the engine running.
engine running.
2
3 4
65
Operation Section
2
3 4
Typical Example
66
Operation Section
LPG/GAS (12V)
3
8. Observe the hour meter(8) make sure it is
operating properly.
67
Operation Section
The SECM makes any necessary corrections to the Even engine coolant temperature and adequate oil
air fuel ratio by controlling the inlet fuel pressure to pressure are monitored by the SECM. The SECM
the air/fuel mixer by modulating the dual fuel trim controller has full adaptive learning capabilities,
valves (FTV) connected to the regulator. Reducing allowing it to adapt control function as operating
the fuel pressure leans the air/fuel mixture and conditions change. Factors such as ambient
increasing the fuel pressure enriches the air/fuel temperature, fuel variations, ignition component
mixture. To calculate any necessary corrections to wear, clogged air filter, and other operating
the air fuel ratio, the SECM uses a number of variables are compensated.
different sensors to gain information about the
engine’s performance. Engine speed is monitored MPI (multi-point injection) is used for this system.
by the SECM through a variable reluctance (VR) or Fuel injection pressure and flow rate depend on
Hall Effect sensor. Intake manifold air temperature engine-specific fuel injection requirements. A
and absolute pressure are monitored with a TMAP variety of regulators and injectors can be used to fit
sensor. MI-07 is a drive-by-wire (DBW) system individual needs. The gasoline fuel pressure
connecting the accelerator pedal to the electronic regulator is a one-way, non-return configuration. All
throttle through the electrical harness; mechanical gasoline specific components are automotive
cables are not used. A throttle position sensor production parts and validated to strict automotive
(TPS) monitors throttle position in relation to the standards. Four (4) sequential injection channels
accelerator pedal position sensor (APP) command. are supported.
68
Operation Section
EMS (Engine management system) of G420F engine and G424I engine is an open loop LP system and/or
closed loop gasoline system. 3-way catalytic muffler is not used for this system.
LPG regulator and the mixer are operated in open loop as no mixture adjustments are made by the SECM.
Manifold pressure from the TMAP, rpm from the crank position sensor and throttle position is used by the
SECM to calculate load. Feedback from the electronic throttle is still provided to the SECM by the throttle
position sensors (TPS).
69
Operation Section
Basic Troubleshooting(LP)
The MI-07 systems are equipped with built-in fault basic checks that should be made before referring
diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or
displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
and are covered in the Advanced Diagnostics
section. Items such as fuel level, plugged fuel Locating a problem in a propane engine is done
lines, clogged fuel filters and malfunctioning exactly the same way as with a gasoline engine.
pressure regulators may not set a fault code by the Consider all parts of the ignition and mechanical
Small Engine Control Module (SECM). Below are systems as well as the fuel system.
70
Operation Section
71
Operation Section
72
Operation Section
73
Operation Section
74
Operation Section
75
Operation Section
76
Operation Section
77
Operation Section
78
Operation Section
79
Operation Section
Isolate the gasoline system by Verify LPG cylinder is full and valve is open.
Rough Idle (Gas) running the lift truck on LPG If the problem does not exist in LPG mode
proceed with the corrective action steps
below.
80
Operation Section
Foot pedal sticking or incorrect Check pedal return spring travel for binding
pedal signal
See Advanced Diagnostics
81
Operation Section
82
Operation Section
83
Operation Section
(*) Fault actions shown are default values specified by the OEM
84
Operation Section
ECT_IR_Fault TurnOnMil
Engine coolant temperature (Disabled in all
Check for coolant system problems, e.g.
171 not changing as expected software
defective or stuck thermostat
MI07SEQ062V05
and higher)
FuelSelectConflict Check fuel select switch connection for a
Conflict in fuel select signals, (1) TurnOnMil short to GND
181 normally set if both of the fuel (2) Delayed SECM (SIGNAL) Pin A12
select signals are shorted to EngineShutdown SECM (SIGNAL) Pin A15
ground SECM (Sensor GND) Pin B1
Check CAM sensor connections
CamEdgesFault SECM (SIGNAL) Pin B10 to CAM sensor
No CAM signal when engine is Pin 2
191 known to be rotating, broken None SECM (Sensor GND) Pin B1 to CAM
crankshaft sensor leads or sensor Pin 3
defective CAM sensor Switched 12V to CAM sensor Pin 1
Check for defective CAM sensor
Check CAM sensor connections
CamSyncFault
SECM (SIGNAL) Pin B10 to CAM sensor
Loss of synchronization on the
Pin 2
CAM sensor, normally due to
192 None SECM (Sensor GND) Pin B1 to CAM
noise on the signal or an
sensor Pin 3
intermittent connection on the
Switched 12V to CAM sensor Pin 1
CAM sensor
Check for defective CAM sensor
Check Crankshaft sensor connections
CrankEdgesFault
SECM (SIGNAL) Pin B5 to Crank sensor
No crankshaft signal when
Pin 3
engine is known to be rotating,
193 None SECM (Sensor GND) PIN B1 to Crank
broken crankshaft sensor
sensor Pin 2
leads or defective crank
Switched 12V to Crank sensor Pin 1
sensor
Check for defective Crank sensor
Check Crankshaft sensor connections
CrankSyncFault
SECM (SIGNAL) Pin B5 to Crank sensor
Loss of synchronization on the
Pin 3
crankshaft sensor, normally
194 None SECM (Sensor GND) Pin B1 to Crank
due to noise on the signal or
sensor Pin 2
an intermittent connection on
Switched 12V to Crank sensor Pin 1
the crankshaft sensor
Check for defective Crank sensor
(*) Fault actions shown are default values specified by the OEM.
85
Operation Section
(*) Fault actions shown are default values specified by the OEM.
86
Operation Section
TPS2AdaptHiMin
Learned WOT end of TPS2
272 None N/A
sensor range lower than
expected
TPS1AdaptLoMax
Learned closed throttle end
281 None N/A
of TPS1 sensor range higher
than expected
TPS2AdaptLoMax
Learned closed throttle end of
282 None N/A
TPS2 sensor range higher
than expected
TPS_Sensors_Conflict Check the throttle connector and pins for
TPS sensors differ by more corrosion.
than expected amount To check the TPS disconnect the throttle
NOTE: The TPS is not a connector and measure the resistance
(1) TurnOnMil
291 serviceable item and can from:
(2) CutThrottle
only be repaired by TPS Pin 2 (GND) to Pin 6 (TPS1 SIGNAL)
replacing the DV-EV throttle (0.7 Ω ± 30%)
assembly. TPS Pin 3 (PWR) to Pin 6 (TPS1 SIGNAL)
(1.4 Ω ± 30%)
Check the throttle connector and pins for
corrosion.
Check continuity between throttle body Pin
3 and SECM Pin B24 (XDPR +5Vdc)
Check continuity between throttle body Pin
TPS_Intermittent 2 and SECM Pin B1 (sensor ground)
Signal from the SECM to the Check continuity on TPS1:
292 TurnOnMil
throttle position sensor power between throttle body Pin 6 and SECM Pin
or ground is not continuous B23
Check continuity on TPS2:
between throttle body Pin 5 and SECM Pin
B4
*Note: move wires around when checking
for continuity to duplicate intermittent signal
Check TMAP connector and MAP signal
wiring for an open circuit
TMAP Pin 4 to SECM Pin B18 (signal)
MAPTimeRangeLow
TMAP Pin 1 to SECM Pin B1 (sensor GND)
Manifold Absolute Pressure TMAP Pin 3 to SECM Pin B24 (XDRP +5
sensor input is low, normally Vdc)
331 set if the TMAP pressure
TurnOnMil Check the MAP sensor by disconnecting
(33) signal wire has been the TMAP connector and measuring at the
disconnected or shorted to sensor:
ground or the circuit has
TMAP Pin 1(GND) to
opened to the SECM
Pin 4 (pressure signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to
Pin 4 (pressure signal KPA) (3.4kΩ - 8.2kΩ)
87
Operation Section
(*) Fault actions shown are default values specified by the OEM.
88
Operation Section
(*) Fault actions shown are default values specified by the OEM.
89
Operation Section
(*) Fault actions shown are default values specified by the OEM.
90
Operation Section
(*) Fault actions shown are default values specified by the OEM.
91
Operation Section
(*) Fault actions shown are default values specified by the OEM.
92
Operation Section
(*) Fault actions shown are default values specified by the OEM.
93
Operation Section
(*) Fault actions shown are default values specified by the OEM.
94
Operation Section
(*) Fault actions shown are default values specified by the OEM.
95
Operation Section
(*) Fault actions shown are default values specified by the OEM.
96
Operation Section
(1) TurnOnMil
Check FTV1 for an open wire or FTV connector
LSDFault_Dither1 (2) Disable being disconnected
Dither Valve 1 Fault, signal GasO2 Ctrl FTV1 Pin 1 (signal) to SECM Pin A1
711
has opened or shorted to (3) Disable FTV1 Pin 2 (power) to SECM (DRVP) Pin A23
(71) ground or power or defective Check FTV1 for an open coil by disconnecting
GasPost O2Ctrl
dither 1 valve (Certified Units the FTV connector and measuring the
resistance (~26Ω ± 2Ω )
Only)
(1) TurnOnMil
Check FTV1 for an open wire or FTV connector
LSDFault_Dither2 (2) Disable being disconnected or signal shorted to GND
Dither Valve 2 Fault, signal GasO2 Ctrl FTV2 Pin 1 (signal) to SECM Pin A2
712 has opened or shorted to (3) Disable FTV2 Pin 2 (power) to SECM (DRVP) Pin A23
ground or power or defective GasPost O2Ctrl Check FTV1 for an open coil by disconnecting
dither 2 valve (Certified Units the FTV connector and measuring the
resistance (~26Ω ± 2Ω )
Only)
713 LSDFault_CSValve None N/A
LSDFault_CheckEngine
Check Engine Lamp Fault, Check ‘Check Engine Lamp’ for an open wire or
714 signal has opened or shorted None
shorted to GND
to ground or power or
defective check engine lamp
LSDFault_CrankDisable
Crank Disable Fault, signal
715 has opened or shorted to None N/A
ground or power or defective
crank disable relay
Check fuel pump for an open wire or connector
being disconnected or signal shorted to GND
Fuel Pump Pin B (signal) from SECM Pin A13
LSDFault_FuelPump
Fuel Pump Pin A (power) from main relay 1 Pin
Fuel pump fault, signal has A23
716 opened, shorted to ground or TurnOnMil
Check Fuel Pump for an open coil by
power, or defective fuel
disconnecting the Fuel Pump connector and
pump measuring the resistance
(~26Ω ± 3Ω)
Check for 12V to fuel pump
Check fuel lock off valve for an open wire or
connector being disconnected or signal shorted
to GND
LSDFault_LockOff Lock off Pin B (signal) from SECM Pin A11
Fuel lock off Valve Fault,
Lock off Pin A (power) from main relay 1 Pin
717 signal has opened or shorted TurnOnMil
A23
to ground or power or Check lock off valve for an open coil by
defective Fuel lock off valve
disconnecting the lock off valve connector and
measuring the resistance (~26Ω ± 3Ω)
Check for 12V to lock off valve
LSDFault_MIL
Malfunction Indicator Lamp
718 Fault, signal has opened or None None
shorted to ground or power
or defective MIL lamp
97
Operation Section
(1) TurnOnMil
(2) Disable
GasFuelAdaptRangeLo GasO2 Ctrl Check for vacuum leaks.
721 In LPG mode, system had to Check fuel trim valves, e.g. leaking valve or
(72) adapt rich more than (3) Disable hose
expected GasPost O2Ctrl Check for missing orifice(s).
(Certified Units
Only)
GasDesEquivLo
In LPG mode, system had to
722 None N/A
adapt rich more than
expected
(*) Fault actions shown are default values specified by the OEM.
98
Operation Section
99
Operation Section
(*) Fault actions shown are default values specified by the OEM.
100
Operation Section
(*) Fault actions shown are default values specified by the OEM.
101
Operation Section
O2_PostCatRangeLow
Post-catalyst O2 sensor
912 voltage out of range low, None N/A
sensor signal shorted to
ground
102
Operation Section
FuelTempRangeLow
Fuel Temperature
Check fuel temp sensor connector and
Sensor Input is Low
wiring for a short to GND
normally set if the fuel TurnOnMil
931 SECM (signal) Pin B14 to FTS Pin 1
temperature sensor wire (Certified Units Only)
SECM (sensor GND) Pin B1 to FTS Pin 2
has shorted to chassis
SECM (system GND) Pin A16, B17
ground or the sensor
has failed.
FuelTempRangeHigh
Fuel Temperature
Check if fuel temp sensor connector is
Sensor Input is High
disconnected or for an open FTS circuit
normally set if the fuel TurnOnMil
932 SECM (signal) Pin B14 to FTS Pin 1
temperature sensor wire (Certified Units Only)
SECM (sensor GND) Pin B1 to
has been disconnected
FTS Pin 2
or the circuit has
opened to the SECM.
(*) Fault actions shown are default values specified by the OEM.
103
Operation Section
(*) Fault actions shown are default values specified by the OEM.
104
Operation Section
WARNING
Sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift truck
to tip over.
4. Select the direction of travel by pushing the
directional lever FORWARD for forward direction Stop the loaded lift truck completely, before
or by pulling the lever BACK for reverse shifting to reverse.
direction. Failure to comply could result in personal injury.
105
Operation Section
Inching
NOTE : The purpose of the inching pedal is to
provide precise lift truck inching control at
very slow travel speed and high engine
rpm. This is used for fast hydraulic lift,
during load approach, pick up or load
positioning.
106
Operation Section
WARNING
Loss of stability can occur when a lift truck
steering wheel is rotated quickly while the truck
is in motion. A steering knob will assist with
easy rotation of the steering wheel, but if a
steering knob is improperly used (e.g., rotating
the steering wheel quickly while the truck is in
motion), this can contribute to truck instability
and a tip over. A steering knob is intended for
slow travel maneuverability ONLY.
107
Operation Section
Function of Knobs
108
Operation Section
Sideshift Left - Push the knob forward The state of the finger tip system can be checked by
smoothly to shift the carriage to the left. the external warning lamp blinking..
Emergency Switch
109
Operation Section
1
2
Forward - Push the lever forward. In case that the AUX2(2) knob is not again used
The lift truck will move forward. within 10 seconds after pushing or pulling
AUX2(2) knob, the cramping motion is disable. In
Neutral - Move the lever to center position. order to make it possible to do it, push a
The lift truck should not move when lever selector switch(3) again to activate a cramping
is in neutral. motion.
.
Reverse - Pull the lever toward the
operator. The lift truck will move in
reverse..
110
Operation Section
2 2
2
1
To move the armrest up, turn the knob(2) clockwise.
111
Operation Section
Operating Techniques
Inching into Loads Lifting the Load
1. Lift the load carefully and tilt the mast back a
short distance.
Typical Example
Typical Example
Typical Example
112
Operation Section
NOTICE
Typical Example
Typical Example
Typical Example
WARNING
Typical Example
Do not tilt the mast forward with the load unless
directly over the unloading area, even if the
power is off.
2. For better vision, travel in reverse with bulky
loads.
113
Operation Section
Turning
Typical Example
Typical Example
114
Operation Section
115
Operation Section
WARNING
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.
116
Operation Section
WARNING
When adjusting the fork spread, be careful not to
pinch your hand between forks and the carriage
slot.
WARNING
Make sure the forks are locked before carrying a
load.
If the fork/locking pin is not fully engaged, the
fork could become unintentionally disengaged.
117
Operation Section
Storage Information
Cover components such as the breather and air
Before Storage cleaner which may be caught with humidity.
The machine should be operated at least once a
Before storing your lift truck, clean and inspect as
week. Fill the cooling system, if cooling water is
the following procedures.
discharged, and mount the battery. Start the engine
Wipe away grease, oil, etc. adhering to the body of
and warm up thoroughly. Move the machine a little
the truck with waste cloth, and use water, if needed.
forwards and backwards. Operate the hydraulic
While cleaning the truck, check general condition of
controls several times.
the truck. Especially check the truck body for recess
or damage and tires for wear or nails or stones in
the tread. To Operate the Lift Truck After a
Fill the fuel tank with fuel specified.
Check for leakage of hydraulic oil, engine oil, fuel, or Long Time Storage
coolant, etc. Remove covers and antirust from each of the
Apply grease, where needed. components and exposed parts.
Check for looseness of nuts and bolts, especially Drain the engine crankcase, transmission (clutch
hub nuts. type machine), differential and final reduction gear,
Check mast rollers to see that they rotate smoothly. clean the inside of them and add new oil.
Prime the oil into the lift cylinders by actuating the lift Drain off foreign matter and water from the hydraulic
lever all the way several times. oil tank and fuel tank.
Drain off coolant completely in water of cold weather, Remove the head cover from the engine cylinder.
if antifreeze is not used. Oil valves and rocker shaft and check each valve for
proper operation.
Add cooling water to the specified level.
Long Time Storage Charge the battery and mount it on the machine.
Perform the following service and checks in addition Connect the cables.
to the “Parking the lift truck” services. Perform pre-operational checks carefully. (refer to
Taking the rainy season into consideration, park the “Before Starting the Engine”)
machine at a higher and hard ground. Warm up the machine.
Avoid parking on soft grounds such as an asphalt
ground in summer.
Dismount the battery from the machine.Even though
the machine is parked indoors, if the place is hot or
humid, the battery should be kept in a dry, cool
place. Charge the battery once a month.
Apply antirust to the exposed parts which tend to
rust.
118
Operation Section
Transportation Hints
119
Operation Section
B
D
A
C
A
120
Operation Section
Towing Information
To provide sufficient control and braking when
WARNING moving a disabled lift truck downhill, a larger towing
Personal injury or death could result when lift truck or additional lift trucks connected to the rear
towing a disabled lift truck incorrectly. could be required. This will prevent uncontrolled
rolling. The different situation requirements cannot
Block the lift truck wheels to prevent movement be given, as minimal towing lift truck capacity is
before releasing the brakes. The lift truck can required on smooth level surfaces to maximum on
roll free if it is not blocked. inclines or poor surface conditions.
Follow the recommendations below, to properly Consult your DOOSAN Lift Tuck dealer for towing a
perform the towing procedure. disabled lift truck.
121
Maintenance Section
122
Maintenance Section
Repetitive Overloading
Causes of Fork Failure Repetitive cycling of loads which exceeds the
Improper Modification or Repair fatigue strength of the material can lead to fatigue
failure. The overload could be caused by loads in
Fork failure can occur as a result of a field modifi- excess of the rated fork capacity and by use of
cation involving welding, flame cutting or other sim- the forks tips as pry bars. Also, by handling loads
ilar processes which affect the heat treatment and in a manner which causes the fork tips to spread
reduces the strength of the fork. and the forks to twist laterally about their
In most cases, specific processes and techniques mountings.
are also required to achieve proper welding of the
particular alloy steels involved. Critical areas most Wear
likely to be affected by improper processing are the Forks are constantly subjected to abrasion as
heel section, the mounting components and the fork they slide on floors and loads. The thickness of
tip. the fork blade is gradually reduced to the point
where it may not be capable of handling the load
Bent or Twisted Forks for which it was designed.
Fatigue Overloading
Parts which are subjected to repeated or fluctuating Extreme overloading can cause permanent bend-
loads can fail after a large number of loading cycles ing or immediate failure of the forks. Using forks of
even though the maximum stress was below the less capacity than the load or lift truck when lifting
static strength of the part. loads and using forks in a manner for which they
The first sign of a fatigue failure is usually a crack were not designed are some common causes of
which starts in an area of high stress concentration overloading.
This is usually in the heel section or on the fork
mounting.
As the crack progresses under repetitive load
cycling, the load bearing cross section of the
remaining metal is decreased in size until it
becomes insufficient to support the load and com-
plete failure occurs.
Fatigue failure is the most common mode of fork
failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.
123
Maintenance Section
124
Maintenance Section
125
Maintenance Section
Tire Inflation
The operating inflation pressure is based on the
weight of a ready - to - work machine without
attachments, at rated payload, and in average oper-
ating conditions. Pressures for each application may
vary and should always be obtained from your tire
supplier.
WARNING
Deflate tire before removing wheel nuts at tire
change. Typical Example
WARNING
Personal injury or death could result when tires
are inflated incorrectly.
Use a self - attaching inflation chuck and stand
behind the tread when inflating a tire.
Proper inflation equipment, and training in using
the equipment, are necessary to avoid
overinflation. A tire blowout or rim failure can
result from improper or misused equipment.
NOTICE
Set the tire inflation equipment regulator atno more
than 140 kPa (20 psi) over the recommended tire
pressure.
126
Maintenance Section
Torque Specifications
Metric Hardware Torque for Standard Bolts, Nuts,
Most of the nuts, bolts, studs, and threaded holes in and Taperlock Studs
your lift truck are metric. In this manual we provide
specifications in both metric and U.S. customary
measurement. Always replace metric hardware with NOTICE
metric hardware. See the parts books for proper
replacement. The two charts below give general torques for
bolts, nuts, and taperlock studs of SAE Grade 5
NOTE : For proper fit, use only metric tools on met- or better quality.
ric hardware. Non-metric tools might slip
and cause injury.
Torques for Bolts and Nuts With
Torque for Standard Hose Clamps Standard Threads
- Worm Drive
Standard Nut and Bolt Torque
Thread Size
Inch
NOTICE N•m
1
lb•ft
The chart below gives the torques for initial 1/4 12 + 4 9+3
5/16 25 + 7 18 + 5
installation of hose clamps on new hose and for 3/8 45 + 7 33 + 5
reassembly or retightening of hose clamps on 7/16 70 + 15 50 + 11
existing hose. 1/2 100 + 15 75 + 11
9/16 150 + 20 110 + 15
5/8 200 + 25 150 + 18
3/4 360 + 50 270 + 37
Initial Installation Torque On 7/8 570 + 80 420 + 60
New Hose 1 875 + 100 640 + 75
Clamp Width 1 1/8 1100 + 150 820 + 110
1 1 1/4 1350 + 175 1000 + 130
N•m lb•in 1 3/8 1600 + 200 1180 + 150
16 mm (.625 in) 7.5 + 0.5 65 + 5 1 1/2 2000 + 275 1480 + 200
13.5 mm (.531 in) 4.5 + 0.5 40 + 5 1
1 Newton meter (N•m) is approximately the same as 0.1
8 mm (.312 in) 0.9 + 0.2 8+2 kg.m.
Reassembly Or
127
Maintenance Section
Standard Torque
Thread Size
Metric
1
N•m lb•ft
M6 12 + 4 9+3
M8 25 + 7 18 + 5
M10 55 + 10 41 + 7
M12 95 + 15 70 + 11
M14 150 + 20 110 + 15
M16 220 + 30 160 + 22
M20 450 + 70 330 + 50
M24 775 + 100 570 + 75
M30 1600 + 200 1180 + 150
M36 2700 + 400 2000 + 300
1
1 Newton meter (N•m) is approximately the same as 0.1
kg.m.
128
Maintenance Section
NOTICE
DOOSAN recommends that the coolant mixture
contain 50% commercially available automotive
antifreeze, and 50% water.
The coolant mix with concentration of antifreeze
smaller than 30% does not provide sufficient corro-
sion protection. Concentrations over 60% adverse-
ly affect freeze protection and heat transfer rates.
Never add coolant to an overheated engine, engine
damage can result. Allow the engine to cool first.
If the machine is to be stored in, or shipped to, an
area with freezing temperatures, the cooling sys-
tem must be protected to the lowest expected out-
side (ambient) temperature.
The engine cooling system is normally protected to
-28℃(-20℉) with antifreeze, when shipped from the
factory unless special requirements are defined.
Check the specific gravity of the coolant solution
frequently in cold weather to ensure adequate pro-
tection.
129
Maintenance Section
Antifreeze Concentrations
Protection Temperature Concentration
Protection to -15°C (5°F) 30% antifreeze and 70% water
Protection to -23°C (-10°F) 40% antifreeze and 60% water
Protection to -37°C (-34°F) 50% antifreeze and 50% water
Protection to -51°C (-60°F) 60% antifreeze and 40% water
130
Maintenance Section
Fuel Specifications
• Especially in U.S.A. and Canada, Low Sulfur
General Fuel Information (300-500mglkg sulfur content) or Ultra Low Sulfur
fuel should be used.
Use only fuel as recommended in this section.
• Bio-Diesel fuels. See Bio-Diesel Fuels on next
page.
NOTICE • NEVER mix kerosene, used engine oil, or residual
fuels with the diesel fuel.
Fill the fuel tank at the end of each day of oper-
ation to drive out moisture laden air and to pre- • The water and sediment in the fuel should not
vent condensation. Maintain a constant level exceed 0.05% by volume.
near the top of the day tank to avoid drawing
moisture into the tank as the level decreases. • Keep the fuel tank and fuel-handling equipment
clean at all times.
Do not fill the tank to the top. Fuel expands as it
gets warm and can overflow.o not fill the fuel • Poor quality fuel can reduce engine performance
filters with fuel before installing them. and / or cause engine damage.
Contaminated fuel will cause accelerated wear to
the fuel system parts. • Fuel additives are not recommended. Some fuel
additives may cause poor engine performance.
131
Maintenance Section
132
Maintenance Section
Lubricant Specifications
• Gasoline/LP-Gas Engine[G420F(E)]
: API SJ or higher NOTICE
• Gasoline/LP-Gas Engine[G424I(E)]
: API SL or higher Make-up oil added to the hydraulic tanks must
• Diesel Engine: API CH-4 Grade or ACEA E5 mix with the oil already in the systems. Use only
petroleum products unless the systems are
equipped for use with special products. If the
NOTICE hydraulic oil becomes cloudy, water or air is
entering the system. Water or air in the sys- tem
Failure to follow the oil recommendations can will cause pump failure. Drain the fluid, retighten
cause shortened engine lift due to carbon all hydraulic suction line clamps, purge and refill
deposits or excessive wear. the system. Consult your DOOSAN Lift Truck
dealer for purging instructions.
133
Maintenance Section
NOTE : Multi-grade oils are not blended by DOO- Gear Oil offers maximum protection against the
SAN for use in transmissions. Multi-grade scoring and pitting of gear teeth and rolling element
oils which use high molecular weight bearings.
polymers as viscosity index improvers lose Gear Oil can also provide excellent stability under
their viscosity effectiveness by permanent high temperature conditions and has superior low
and temporary shear of the viscosity index temperature performance. It will also give protection
improver and therefore, are not against rust and corrosion.
recommended for transmission and drive
train compartments. • Oil Cooled Disc Brake (OCDB)
Select oil that meets below specifications.
NOTE : Failure to follow this recommendation can The API GL-4 specification or MIL - L2105A or E oil
cause shortened transmission life due to could be used.
material incompatibility, inadequate friction-
al requirements for disk materials and/or
excessive gear wear.
134
Maintenance Section
• Shoe Brake
Use heavy duty hydraulic brake fluid. It must be cer-
tified by the oil supplier to meet SAE J1703f latest
revision, DOT 3 or 4 specifications.
• ISO 6743/4 HM
• AFNOR NFE 48-603 HM
• DIN 51524 TEIL2 H-LP
• HAGGLUNDS DENISON HFO-HF2
• CINCINNATI P68,69,70
135
Maintenance Section
136
Maintenance Section
Maintenance Intervals
First 50-100 Service Hours or a Week
NOTICE
Engine Oil & Filter (Diesel Engine Only) - Change
Never exceed the Maintenance Intervals specified in
................................................................................. 152
the manual. Defects and/or damage to the important
Transmission Oil, Oil Filter & Strainer - Check,
functional components may be resulted in.
Clean, Change........................................................ 153
Drive Axle Oil - Change ......................................... 154
NOTICE Parking Brake - Test, Adjust.................................. 155
137
Maintenance Section
138
Maintenance Section
When Required
Air Cleaner Indicator Check 149 O
Air Intake System Change 174 O
Air Intake System Check, Clean 159 O
Battery Terminal Clean, Inspect 163 O
Belts Check, Adjust 167 O
Brake Oil Level Check 163 O
Carriage Roller Extrusion Adjust 147 O
Checking the TMAP Sensor
186 O
(G420F(E)/G424I(E) Engine Only)
Coolant Level Check, Clean 148 O
Cooling System Clean, Change 180 O
Crosshead Roller Inspect 168 O
Drive Axle Oil Change 154 O
Drive Axle Oil (Shoe Brake) Change 176 O
Drive Axle Oil Level Check 161 O
Drive Wheel Bearing Reassemble 179 O
Engine Oil & Filter Change 164 O
Engine Oil & Filter (Diesel Engine Only) Change 152 O
Engine Oil Level Check 148 O
Engine Valve Lash (Diesel Engine Only) Check, Adjust 158 O
Fork Inspect 182 O
Fuel Filter (Diesel Engine Only) Change 166 O
Fuel Filter (LP - Gas Engine Only) 177 O
Fuel Lines & Fittings Check 175 O
Fuel Tank Filler Cap and Screen (If Equipped) Clean 142 O
Fuel Trim Valve(FTV) Inspection (G420F(E)/G424I(E)
170 O
Engine Only)
Fuse & Relay (G420F(E)/G424I(E) Only) 144 O
Fuses, Bulbs and Circuit Breaker Change, Reset 143 O
Horn & Lights (If Equipped) Check 169 O
Change, Check,
Hydraulic Oil 184 O
Clean
Hydraulic Oil Level Check 161 O
Hydraulic Return Filter, Breather & Strainer Check, Change 171 O
Inching & Braking Control Shaft Lubricate 169 O
Inspect Battery System 184 O
Inspect Coolant Hoses (LP, Dual Fuel Engines Only) 175 O
139
Maintenance Section
When Required
Inspect Electrical System
170 O
(G420F(E)/G424I(E) Engine Only)
Inspect Engine for Exhaust Leaks 149 O
Inspect Engine for Fluid Leaks 148 O
Inspect Foot Pedal Operation (G420F(E)/G424I(E)
149 O
Only)
Inspect for Intake Leaks (G420F(E)/G424I(E) Engine
186 O
Only)
Inspect Ignition System (LP-Gas, Gasoline & Dual Fuel
176 O
Engines Only)
Inspect Mixer Assembly (G420F(E)/G424I(E) Engine
175 O
Only)
Inspect Throttle Assembly (G420F(E)/G424I(E) Engine
175 O
Only)
Inspect Vacuum Lines and Fittings
170 O
(G420F(E)/G424I(E) Engine Only)
Test, Check,
Lift Chains 172 O
Adjust
LP Regulator/Converter Inspection (LP, Dual Fuel
175 O
Engine Only)
Mast Channels Lubricate 151 O
Mast Hinge Pin Lubricate 168 O
Inspect,
Mast, Carriage, Lift Chains & Attachments 162 O
Lubricate
Overhead Guard Inspect 169 O
Parking Brake Test, Adjust 155 O
PCV Valve System Inspect, Clean 165 O
Priming the Fuel System (Diesel Engine Only) 141 O
Replace LP Fuel Filter Element (LP-Gas, Dual Fuel
176 O
Engine Only)
Replace Oxygen Sensor (G420F(E)/G424I(E) Engine
185 O
Only)
Replace Spark Plugs (G420F(E)/G424I(E) Engine Only) 187 O
Seat, Hood Latch & Support Cylinder Check, Lubricate 143 O
Steer Wheel Bearings Reassemble 178 O
Steering Mechanism Check, Lubricate 162 O
Test Fuel System for Leaks (LP and Dual Fuel Engines
146 O
Only)
Testing Fuel Lock-off Operation (LP-Gas Engine Only) 177 O
Check, Adjust,
Tilt Cylinders 167 O
Lubricate
Timing Belt (G420F(E) LP-Gas, Gasoline & Dual Fuel
Change 188 O
Engine Only)
Tires and Wheels Inspect, Check 146 O
Check , Clean ,
Transmission Oil, Oil Filter & Strainer 153 O
Change
Transmission Oil Level Check 151 O
Walk-Around Inspection Inspect 150 O
Wheel Bolts & Nuts Inspect 165 O
140
Maintenance Section
When Required
You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.
141
Maintenance Section
WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
142
Maintenance Section
Seat, Hood Latch & Support Fuses, Bulbs and Circuit Breaker -
Cylinder - Check, Lubricate Change, Reset
Fuses
NOTICE
143
Maintenance Section
Bulbs
Bulbs are identified as follows :
1. Bulb-head lamp halogen (12V-35W)
*2. Bulb-back up (12V-8W)
*3. Bulb-turn signal (12V-23W)
*4. Bulb-stop & tail (12V-23/8W)
Located rear side of valve mounting bracket
*OPTIONALLAMP OR LIGHT
Circuit Breaker
144
Maintenance Section
Typical Example
145
Maintenance Section
Test Fuel System for Leaks (LP Tires and Wheels - Inspect, Check
and Dual Fuel Engines Only)
WARNING
Servicing and changing tires and rims can be
dangerous and should be done only by trained
personnel using proper tools and procedures.
Deflate tire before removing wheel nuts from the
truck.
If correct procedures are not followed while ser-
vicing tires and rims, the assemblies could burst
with explosive force and cause serious physical
Check injury or death.
Points
Follow carefully the specific information provid-
ed by your tire servicing man or dealer.
1. Obtain a leak check squirt bottle or pump spray
bottle.
Check Inflation and Damage
2. Fill the bottle with an approved leak check
solution. Inspect tires for wear, cuts, gouges and foreign
objects. Look for bent rims and correct seating of
3. Spray a generous amount of the solution on the locking ring.
fuel system fuel lines and connections, starting at Check tires for proper inflation. See “Tire Inflation
the storage container. Pressures”.
To inflate tires always use a clip-on chuck with a
4. Wait approximately 15-60 seconds then perform a minimum 60 cm (24 inches) length of hose to an in-
visual inspection of the fuel system. Leaks will line valve and gauge.
cause the solution to bubble. Always stand behind the tread of the tire. NOT in
front of the rim.
5. Repair any leaks before continuing.
WARNING
Prior to any service or maintenance activity, Test Do not reinflate a tire that has been run while flat or
Fuel System for Leaks underinflated, without first checking to make sure
the rim is not damaged and is in the correct position.
When tires are changed, be sure to clean all rim
parts and, if necessary, repaint to stop detrimental
effects of corrosion. Sand blasting is recommended
for removal of rust.
146
Maintenance Section
147
Maintenance Section
Diesel Engines
Inspect Engine for Fluid Leaks
1. Start the engine and allow it to reach operating
temperatures.
Typical Example
148
Maintenance Section
3. Start and run the engine to stabilize the coolant 1. Observe the air cleaner service indicator.
level in the filler neck. If low add coolant until it
reaches the top of the filler neck. Install the radi- 2. Service the air cleaner when the RED band in
ator cap. Observe coolant level in the expansion the service indicator, lock in the visible position.
bottle. If necessary, add coolant to bring the See topic, “Air Intake System - Check, Clean” in
coolant to the appropriate line on the expansion “Every 250 Service Hours or Monthly”.
bottle.
NOTE : Service the element more frequently, as
4. Stop the engine. required, in severe dust or lint conditions.
Also, service it more frequently where the
5. Inspect the cooling system for leaks, hose cracks
operator is required to wear a respirator.
or loose connections.
3. Close hood and seat assembly.
WARNING
Inspect Foot Pedal Operation
Pressure air can cause personal injury. (G420F(E)/G424I(E) Only)
When using pressure air for cleaning, wear a 1. Verify foot pedal travel is smooth without sticking.
protective face shield, protective clothing and
protective shoes.
Maximum air pressure must be less than 205 WARNING
kPa (30 psi) for cleaning purposes.
When the acceleration pedal harness is connected
or disconnected, should be worked KEY OFF
condition.
6. Blow any dust and lint from the radiator fins.
If not, occurred malfunction, can cause the personal
injury.
149
Maintenance Section
Typical Example
150
Maintenance Section
WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.
151
Maintenance Section
152
Maintenance Section
WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.
NOTICE
153
Maintenance Section
12. Maintain the oil level between the Min and Max
marks on the dip stick/filter cap.
When the oil temperature is 40°C approximately,
the cold side mark on the dipstick is applicable.
When the oil temperature is 80°C approximately,
the hot side mark on the dipstick is applicable.
13. Check for oil leaks at the filters and drain plug”.
14. Stop the engine. Install the floor mat and floor
plate.
154
Maintenance Section
155
Maintenance Section
WARNING
To prevent personal injury, the operator MUST
be ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck
starts to move.
156
Maintenance Section
157
Maintenance Section
NOTICE
The valve clearances are to be adjusted at the times
of the following situations.
WARNING
To prevent possible injury when adjusting diesel
engines, do not use the starter motor to turn the
flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring valve clearance.
NOTICE
Measure the valve lash with the engine stopped. To
obtain an accurate measurement, allow at least 20
minutes for the engine cylinder head and block to
cool.
Valve Clearances
Engine Valve Clearance
2.3 Liter Exhaust Valves 0.2 mm(0.008 in)
(V2403)Diesel Intake Valves 0.2 mm(0.008 in)
158
Maintenance Section
NOTICE
159
Maintenance Section
Cleaning Primary Filter Elements Air-205 kPa (30 psi) Maximum Pressure
WARNING
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.
160
Maintenance Section
161
Maintenance Section
NOTICE
162
Maintenance Section
Typical Example
163
Maintenance Section
164
Maintenance Section
PCV Valve System - Inspect, Clean Wheel Bolts & Nuts - Inspect
G420F(E)/G424I(E) Gasoline, LP-GAS Inspect Tightness
and Dual Fuel Engine
Steer Wheels
G420F(E)
Typical Example
Drive Wheels
G424I(E)
2. Shake the PCV valve. If it rattles, reinstall it. If it 2. Inspect tightness of wheel nuts in a sequence
does not rattle, replace it. opposite each other to 180 N•m (133 lb•ft).
165
Maintenance Section
WARNING
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire.
Turn the disconnect switch OFF if fitted or dis-
connect the battery when changing fuel filters.
NOTICE
166
Maintenance Section
Typical Example
Typical Example
NOTICE
2. To adjust the alternator drive belt, loosen adjust- 2. Check the pivot eye pins for loose retainer bolts
ing bracket bolt and mounting bolt. Move the and wear.
alternator in or out as required. Tighten bolts.
167
Maintenance Section
Typical Example
168
Maintenance Section
1 2
169
Maintenance Section
Visually inspect vacuum lines and fittings for 1. Check for loose, dirty or damaged connectors
physical damage such as bittleness, cracks and and wires on the harness including: Fuel
kinks. Repair/replace as required. lock-off, TMAP sensor, O2 sensor, Electronic
throttle, Control Relays, Fuel Trim Valve, Foot
Slovent or oil damage may cause vacuum lines to Pedal, and crank sensor.
become soft resulting in a collapsed line while
the engine is running.
2. Repair and/or replace as necessary.
If abnormally soft lines are detected, replace as
necessary.
170
Maintenance Section
171
Maintenance Section
WARNING
Personal injury can be caused by sudden move-
ment of the mast and carriage. Keep hands and
feet clear of any parts that can move.
Typical example
**Chain Pitch for G15/18S-5, G20SC-5, D15/18S-5, If the tension is not the same on both chains, take
D20SC-5 = 15.88mm(0.63 in) the procedure as follows.
172
Maintenance Section
3. Make adjustment anchor nut(1),(2) for equal 1. Lift the inner mast and put blocks under the inner
chain tension. mast to release the tension from the lift chains.
2. Loosen nut(3) and adjust nut(4) to make inner
mast rail flush with outer mast rail bottom.
173
Maintenance Section
NOTICE
174
Maintenance Section
Inspect Coolant Hoses (LP, Dual Fuel Lines & Fittings - Check
Fuel Engines Only) Visually inspect fuel lines and fittings for physical
1. Visually inspect coolant hoses and clamps. damage. Replace as required.
Remember to check the two coolant lines that
connect to the pressure regulator/converter.
1 2
2. Replace any hose that shows signs of swelling,
cracking, abrasion or deterioration.
2
(1) Fuel line
1 (2) LP mixer
(3) Throttle Assembly
175
Maintenance Section
G420F(E) Engine 1
(1) screws
176
Maintenance Section
Fuel Filter (LP - Gas Engine Only) Testing Fuel Lock-off Operation
(LP-Gas Engine Only)
Disassembly
1. Start engine.
4 2
1 2. Locate the electrical connector for the fuel lock
7
5. Turn the ignition key switch off and re-connect the
fuel lock-off connector.
1. Remove top cover (2), magnet (3), spring (4), and
filter element (7) from bottom cover (5). NOTE : The length of time the engine runs on
trapped fuel vapor increases with any
2. Replace the filter element (7). increase in distance between the fuel
lock-off and the pressure
3. Check bottom cover O-ring seal (6) for damage. regulator/converter.
Replace if necessary.
177
Maintenance Section
Park the lift truck level with the forks lowered, park-
ing brake engaged, transmission in NEUTRAL and
the engine stopped.
178
Maintenance Section
179
Maintenance Section
WARNING
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the filler cap is cool enough to
touch with your bare hand.
V2403 Diesel Engine
Remove the filler cap slowly to relieve pressure.
Coolant is included antifreeze for forbidding
corrosion. Avoid contact with the skin and eyes
to prevent personal injury.
Use all cleaning solution with care.
1. Turn the radiator cap slowly to relieve the G420F(E) 2.0L LPG/Gasoline Engine
pressure, and then remove the cap.
180
Maintenance Section
NOTICE
Inject the coolant additionally into below specific port
of G424I(E) engine besides the radiator if needs
more coolant while clean & change the cooling
system.
10
NOTICE
Hold the drain port when the radiator drain valve is
turned because the tank and the drain port are
separated.
181
Maintenance Section
182
Maintenance Section
5. Check the fork blade (J) and shank (H) for wear
with special attention to the heel (G). The fork
should be withdrawn from service if the thickness
is reduced to 90 percent or less of the original
thickness.
Fork blade length may also be reduced by wear,
especially on tapered forks and platens. Remove 8. Check fork markings (N) for legibility. Renew
the forks from service when the blade length is markings as required to retain legibility.
no longer adequate for the intended loads.
9. a. Lift the mast and operate the tilt control lever,
until the top surface of the forks is parallel with
the floor. Place two straight bars that are the
same width as the carriage, across the forks
as shown.
b. Measure the distance from the bottom of each
end of the two bars to the floor. The forks must
be parallel within 3 mm (.12 in) for Full
Tapered and Polished (FTP) forks, all other
forks 6.4 mm (.25 in), for their complete length.
183
Maintenance Section
Hydraulic Oil - Change, Check, 5. Start the engine and operate the hydraulic con-
Clean trols, and the steering system, through a few
cycles to fill the lines. Look for oil leaks.
WARNING
6. Stop the engine and check the oil level. With all
Hot oil and components can cause personal cylinders retracted, maintain the oil level to the
injury. Do not allow hot oil or components to FULL mark on the breather/dip stick.
contact skin.
Park the lift truck level with the forks lowered, park-
ing brake engaged, transmission in NEUTRAL and Inspect Battery System
the engine stopped.
1. Clean battery outer surfaces with a mixture of
baking soda and water.
184
Maintenance Section
WARNING
When assembling the filters, check the arrow
mark on the filter surface.
The arrow mark position is same as fuel flow
direction.
G420I(E) Engine
185
Maintenance Section
G420F(E)
G424I(E)
186
Maintenance Section
WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.
(1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug
187
Maintenance Section
WARNING
G420F(E) is dual over-head CAM engine. If
timing belt is not replaced on time, engine could
be damaged.
188
Index Section
189
Index Section
Every 1500 Service Hours or 9 Months ................176 Horn & Lights (If Equipped) - Check ..................... 169
Every 2000 Service Hours or Yearly .....................178 How to Fix Forklift to a Carrier............................... 120
Every 250 Service Hours or Monthly.....................159 How to Survive in a Tipover..................................... 30
Every 2500 Service Hours or 15 Months ..............184 Hydraulic Oil - Change, Check, Clean .................. 184
Every 3000 Service Hours or 18 Months ..............188 Hydraulic Oil (HYDO) ............................................. 133
Every 500 Service Hours or 3 Months ..................167 Hydraulic Oil Level - Check ................................... 161
Hydraulic Return Filter, Breather & Strainer - Check,
Change.................................................................... 171
F
Fatigue.....................................................................123 I
Finger Tip (Option) .................................................108
Fire or Explosion Prevention.................................... 15 Identification, Lift Capacity and Attachment Plate . 46
First 250 Service Hours or a Month ......................158 If Optional Suspension Seat (Weight Adjusting
First 50-100 Service Hours or a Week ..................152 Type) Equipped ........................................................ 18
First Installation.......................................................124 Important Safety Information ..................................... 4
Fluid Penetration....................................................... 14 Improper Modification or Repair ............................ 123
Foreword ..................................................................... 2 Inching & Braking Control Shaft - Lubricate ......... 169
Fork - Inspect ..........................................................182 Inching into Loads .................................................. 112
Fork Inspection .......................................................124 Inching..................................................................... 106
Fuel Filter (Diesel Engine Only) - Change ............166 Index........................................................................ 189
Fuel Filter (LP - Gas Engine Only) ........................177 Inspect Battery System .......................................... 184
Fuel Lines & Fittings - Check .................................175 Inspect Coolant Hoses (LP, Dual Fuel Engines Only)
Fuel Selector Switch (If Dual Fuel Equipped)......... 52 ................................................................................. 175
Fuel Specifications .................................................131 Inspect Electrical System (G420F(E)/G424I(E)
Fuel Tank Filler Cap and Screen (If Equipped) - Engine Only) ........................................................... 170
Clean .......................................................................142 Inspect Engine for Exhaust Leaks ........................ 149
Fuel Trim Valve(FTV) Inspection Inspect Engine for Fluid Leaks .............................. 148
(G420F(E)/G424I(E) Engine Only) ........................170 Inspect Foot Pedal Operation (G420F(E)/G424I(E)
Fuse & Relay (G420F(E)/G424I(E) Only) .............144 Only)........................................................................ 149
Fuse.........................................................................144 Inspect for Intake Leaks (G420F(E)/G424I(E)
Fuses, Bulbs and Circuit Breaker - Change, Reset Engine Only) ........................................................... 186
.................................................................................143 Inspect Ignition System (LP-Gas, Gasoline & Dual
Fuel Engines Only)................................................. 176
Inspect Mixer Assembly (G420F(E) /G424I(E)
G Engine Only) ........................................................... 175
Inspect Throttle Assembly (G420F(E)/G424I(E)
G420F Engine and G424I Engine ........................... 69 Engine Only) ........................................................... 175
G420F(E)/G424I(E) Gasoline, LP-GAS and Dual Inspect Tightness ................................................... 165
Fuel Engine .............................................................165 Inspect Vacuum Lines and Fittings
G420F/G424I Dual Fuel System (If Equipped)....... 65 (G420F(E)/G424I(E) Engine Only)........................ 170
G420FE Engine and G424IE Engine ...................... 68 Inspection, Maintenance and Repair of Lift Truck
Gasoline and LP-Gas Engines ..............................148 Forks ....................................................................... 122
Gasoline Engine ....................................................... 62 Instrument Panel ...................................................... 48
Gasoline or Diesel Engine Equipped ...................... 57
Gasoline Specifications ..........................................132
Gasoline, LP-Gas Engine Crankcase ...................164 L
General Fuel Information .......................................131
General Hazard Information .................................... 10 Lift Chain Adjustment ............................................. 172
General Warnings to Operator .................................. 6 Lift Chain Wear Test .............................................. 172
Lift Chains - Test, Check, Adjust........................... 172
Lift Control knob ..................................................... 108
H Lift Control................................................................. 55
Lift Fork Adjustment ............................................... 117
Hand Placement Warning .......................................... 7 Lift Truck Capacity Rating ....................................... 46
Hook-on type Fork ..................................................117 Lift Truck Controls .................................................... 54
Lift Truck Operation................................................ 105
190
Index Section
N S
No Riders Warning ..................................................... 8 Safety Rules ............................................................. 24
No Standing On Forks Warning, No Standing Under Safety ....................................................................... 2,5
Forks Warning............................................................. 7 Seat Adjustment ....................................................... 18
Noise and Vibration .................................................. 42 Seat Switch System ................................................. 53
Seat ........................................................................... 52
Seat, Hood Latch & Support Cylinder - Check,
O Lubricate ................................................................. 143
Serial Number Locations ......................................... 45
Operating in Hot Weather ......................................115 Serial Number........................................................... 45
Operating Techniques ............................................112 Service Brake Pedal................................................. 55
Operating the Lift Truck............................................ 12 Servicing Filter Element......................................... 159
Operation Information............................................... 11 Sideshift Attachment Control (If Equipped) ............ 56
Operation..................................................................... 2 Specifications ...................................... 32,34,36,38,40
Operator's Station and Monitoring Systems ........... 48 Stability and Center of Gravity................................. 22
191
Index Section
Unloading ................................................................113
192
SB2354E03
Operation &
Maintenance Manual
FORKLIFTS
GC15S-5, GC18S-5, GC20SC-5
Original Instruction
1503
Table of Contents
Table of Contents
General Section
Index Section
Declaration of Conformity .......................................32
Specifications ...........................................................33 Index ...................................................................... 150
Noise and Vibration .................................................36
Serial Number ..........................................................37
Operator's Warning and Identification Plate ..........38
Operation Section
Operator's Station and Monitoring Systems ..........40
Seat Switch System (If Equipped) ..........................43
Lift Truck Controls ...................................................46
Refueling ..................................................................49
Before Starting the Engine ......................................51
Starting the Engine ..................................................53
After Starting the Engine .........................................56
Lift Truck Operation .................................................84
Operating Techniques .............................................87
Parking the Lift Truck ..............................................91
Lift Fork Adjustment.................................................92
Storage Information .................................................93
Transportation Hints ................................................94
Towing Information ..................................................96
1
Information Section
Foreword
Literature Information Photographs or illustrations guide the operator
through correct procedures of checking, operation
This manual should be stored in the operator's and maintenance of the DOOSAN operator restraint
compartment in the literature holder or seat back system.
literature storage area.
SAFE and EFFICIENT OPERATION of a lift truck
This manual contains safety, operation, transportation, depends to a great extent on the skill and alertness
lubrication and maintenance information. on the part of the operator. To develop this skill the
operator should read and understand the Safe
Some photographs or illustrations in this publication Driving Practices contained in this manual.
show details or attachments that can be different
from your lift truck. Guards and covers might have Forklift trucks seldom tipover, but in the rare event
been removed for illustrative purposes. they do, the operator may be pinned to the ground
by the lift truck or the overhead guard. This could
Continuing improvement and advancement of result in serious injury or death.
product design might have caused changes to your
lift trucks which are not included in this publication. Operator training and safety awareness is an
Read, study and keep this manual with the lift truck. effective way to prevent accidents, but accidents
can still happen. The DOOSAN operator restraint
Whenever a question arises regarding your lift truck, system can minimize injuries. The DOOSAN
or this publication, please consult your DOOSAN operator restraint system keeps the operator
dealer for the latest available information. substantially within the confines of the operator’s
compartment and the overhead guard.
2
Information Section
Maintenance
The Maintenance Section is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without
specific intervals are listed under “When Required”
topics. Items in the “Maintenance Intervals” chart
are referenced to detailed instructions that follow.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Environment Management
Note that DOOSAN VHEICLE B.G. is ISO 14001
certified which is harmonized with ISO 9001.
Periodic ENVIRONMENTAL AUDITS &
ENVIRONMENTAL PERFORMANCE EVALUATIONS
have been made by internal and external inspection
entities. LIFE-CYCLE ANALYSIS has also been
made through out the total product life.
3
Safety Section
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”
as shown below.
WARNING
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is
used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
4
Safety Section
Safety
The safety rules and regulations in this section are Warning Signs and Labels
representative of some, but not all rules and
regulations noted under the Occupational Safety Warning Signs and Labels
and Health Act (OSHA) and are paraphrased There are several specific safety signs on your lift
without representation that the OSHA rules and truck. Their exact location and description of the
regulations have been reproduced verbatim. hazard are reviewed in this section. Please take the
time to familiarize yourself with these safety signs.
Please refer to 1910. 178 in Federal Register Vol. Make sure that you can read all safety signs. Clean
37, No. 202, the National Fire Protection or replace these if you cannot read the words or
Association No. 505 (NFPA), American National see the pictures. When cleaning the labels use a
Standard, ANSI B56. 1 Safety Standard for Low lift cloth, water and soap. Do not use solvent, gasoline,
and High Lift Trucks and subsequent revisions for a etc.
complete list of OSHA rules and regulations as to You must replace a label if it is damaged, missing
the safe operation of powered industrial lift trucks. or cannot be read. If a label is on a part that is
Since regulations vary from country to country replaced, make sure a new label is installed on the
outside in U.S.A., operate this lift truck in replaced part. See your dealer for new labels.
accordance with local regulations.
Training Required To Operate or
DOOSAN lift trucks are manufactured according to
the regulations and standards laid down in EU
Service Warning
Machinery Directive 98/37/EC and EMC directive
2004/108/EC. Please refer to the Directives
89/655/EC and 89/391/EC and its amendments for
the safe use of DOOSAN lift trucks.
5
Safety Section
General Warnings to Operator 9. Do not allow anyone to stand or pass under the
elevated portion of any machine.
3. Put directional control or shift lever in neutral 18. Observe safety rules when handling fuel for
before “ON - OFF” switch is turned on. engine powered machine and when changing
batteries for electric machines.
4. Start, turn and brake smoothly. Slow down for
turns, slippery or uneven surfaces. Extremely 19. Avoid overuse of the inching pedal as this may
poor surfaces should be repaired. Avoid cause the automatic transmission oil to
running over loose objects or holes in the overheat or the clutch to slip. Do not use as a
roadway surfaces. Use extreme caution when footrest or for long periods of time.
turning on inclines.
20. If user operates continuously pushing work or
5. Travel with load as low as possible and tilted both brake pedal and accelerator pedal were
back. If load interferes with visibility, travel with depressed at the same time, it may cause the
load trailing. automatic transmission oil to overheat or the
clutch to slip.
6. On grade operations travel with load up grade.
6
Safety Section
WARNING
Operation without this device in place may be
hazardous.
No hands. Do not place hands in this area. Do
not touch, lean on, or reach through the mast or
permit others to do so.
7
Safety Section
Packing brake
Located on the Overhead Guard.
No Riders Warning
WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.
8
Safety Section
WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied. Alarm
will sound if parking brake is not applied.
WARNING
Correct adjustment is necessary to provide
adequate braking. See the MAINTENANCE section
for adjustment procedures. The lift truck may creep
at engine idle and can cause damage, injury or
death. Always apply the parking brake when
leaving the lift truck. The parking brake is NOT
automatically applied.
9
Safety Section
General Hazard Information Always use the overhead guard. The overhead
guard is intended to protect the lift truck operator
from overhead obstructions and from falling objects.
Attach a “Do Not Operate” or similar warning tag to Do not raise loads any higher than necessary and
start switch or controls before servicing or repairing never raise a load higher than 1830 mm (72 in) with
the lift truck. the overhead guard removed.
Do not start or service the lift truck when a “DO Always use load backrest extension when the carriage
NOT OPERATE” or similar warning tag is attached or attachment does not fully support the load. The
to the start switch or controls. load backrest extension is intended to prevent the
load or any part of the load from falling backwards
Wear a hard hat, protective glasses and other into the operator's station.
protective equipment as required by job conditions.
When operation the lift truck, do not depend only on
Know the width of your attachments so proper flashing lights or back-up alarm (if equipped) to
clearance can be maintained when operating near warn pedestrians.
fences, boundary obstacles, etc.
Always be aware of pedestrians and do not proceed
Do not wear loose clothing or jewelry that can catch until the pedestrians are aware of your presence
on controls or other parts of the lift truck. and intended actions and have moved clear of the
lift truck and/or load.
Keep the lift truck, especially the deck and steps,
free of foreign material such as debris, oil tools and Do not drive lift truck up to anyone standing in front
other items which are not part of the lift truck. of an object.
Secure all loose items such as lunch boxes, tools Obey all traffic rules and warning signs.
and other items which are not part of the lift truck.
Keep hands, feet and head inside the operator
Know the appropriate work-site hand signals and station. Do not hold onto the overhead guard while
who gives them. Accept signals from one person operating the lift truck. Do not climb on any part of
only. the mast or overhead guard or permit others to do
so.
10
Safety Section
Inspect the part of the chain that is normally Never get on or off a moving lift truck.
operated over the crosshead roller. When the chain
bends over the roller, the movement of the parts Do not use any controls as handholds when
against each other causes wear. entering or leaving the operator's station.
Inspect to be sure that chain link pins do not extend Never get on or off a moving lift truck. Never jump
outside of the bore hole. off the lift truck.
If any single link pin is extended beyond its connecting Keep hands and steering wheel free of slippery
corresponding link, it should be suspected of being material.
broken inside of its bore hole.
Inspect the chain anchor and the anchor links for Before Starting the Lift Truck
wear. Perform a walk-around inspection daily and at the
start of each shift. Refer to the topic “Walk-around
Do not change any factory set adjustment values Inspection” in “Every 10 Service Hours or Daily”
(including engine rpm setting) unless you have both section of this manual.
authorization and training. Especially Safety equipment
and switches may not be removed or adjusted Adjust the seat so that full brake pedal travel can be
incorrectly. Repairs, adjustments and maintenances obtained with the operator's back against the seat
that are not correct can make a dangerous operating back.
condition.
Make sure the lift truck is equipped with a lighting
For any checkup, repair, adjustments, maintenance system as required by conditions.
and all other work concerning your forklift truck,
please contact your DOOSAN dealer. We would like to Make sure all hydraulic controls are in the HOLD
draw your attention to the fact that any secondary position.
damages due to improper handling, insufficient
maintenance, wrong repairs or the use of other than Make sure the direction control lever is in the
original DOOSAN spare parts waive any liability by NEUTRAL position.
DOOSAN.
Make sure the parking brake is engaged.
11
Safety Section
Operate the lift truck and controls only from the Operating the Lift Truck
operator's station.
Always keep the lift truck under control.
Make sure the lift truck horn, lights, backup alarm (if
equipped) and all other devices are working Obey all traffic rules and warning signs.
properly.
Never leave the lift truck with the engine operating,
Check for proper operation of mast and or with the parking brake disengaged.
attachments. Pay particular attention to unusual
noises or erratic movement which might indicate a Operate the engine only in a well ventilated area.
problem.
Lower mast, with or without load, before turning or
Make sure service and parking brakes, steering, traveling. Tip over could result. Watch out for
and directional controls are operational. overhead obstructions.
Make sure all personnel are clear of lift truck and
travel path. Always observe floor load limits and overhead
Refer to the topic “Lift Truck Operation” in the clearance.
“Operation Section” of this manual for specific
starting instructions. Start, turn, and brake smoothly, slow down for turns,
grades, slippery or uneven surfaces.
Before Operating the Lift Truck Do not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plate
Test brakes, steering controls, horn and other devices on the lift truck. Use extreme caution when handing
for proper operation. Report faulty performance. Do
suspended, long, high or wide load.
not operate lift truck until repaired.
12
Safety Section
Always use overhead guards except where z Park the lift truck level, with the forks lowered
operation conditions do not permit. Do not operate and the mast tilted forward until the fork tips
lift truck in high stacking areas without overhead touch the floor.
guards. z Move the direction control lever to NEUTRAL.
When stacking, watch for falling objects. Use load z Engage the parking brake.
backrest extension and overhead guard. z Turn the key switch off and remove the key.
Refer to the topic “Operation Techniques” in the z Turn the disconnect switch to OFF and remove
“Operation Section” of this manual. the key (if equipped).
z Block the drive wheels when parking on an
incline.
13
Safety Section
z Park the lift truck in authorized areas only. Do not use a kinked or frayed wire rope cable.
Wear gloves when handling the wire rope cable.
z Park the lift truck level, with the forks lowered
and the mast tilted forward until the fork tips
Retainer pins, when struck with force, can fly out
touch the floor.
and injure nearby persons. Make sure the area is
z Place the transmission controls in neutral. clear of people when driving retainer pins.
z Engage the parking brake.
Wear protective glasses when striking a retainer pin
z Stop the engine. to avoid injury to your eyes.
z Remove the start switch key and turn the
disconnect switch OFF (if equipped). Chips or other debris can fly off objects when struck.
Make sure no one can be injured by flying debris
z Block the drive wheels when parking on an before striking any object.
incline.
Falling Objects Protective Structure(FOPS)
14
Safety Section
Hot oil and components can cause personal injury. Clean and tighten all electrical connections. Check
Do not allow hot oil or components to contact the daily for loose or frayed electrical wires. Have all
skin. At operation temperature, the hydraulic tank is loose or frayed electrical wires tightened, repaired
hot and can be under pressure. or replaced before operation the lift truck.
Remove the hydraulic tank fill cap only after the Keep all fuels and lubricants stored in properly
engine has been stopped and the fill cap is cool marked containers and away from all unauthorized
enough to remove with your bare hand. persons.
Remove the hydraulic tank fill cap slowly to relieve Store all oily rags or other flammable material in a
pressure. protective container, in a safe place.
Relieve all pressure in air, oil fuel or cooling Do not weld or flame cut on pipes or tubes that
systems before any lines, fittings or related items contain flammable fluids. Clean them thoroughly
are disconnected or removed. with nonflammable solvent before welding or flame
cutting on them.
Batteries
Remove all flammable materials such as fuel, oil
Batteries give off flammable fumes which can and other debris before they accumulate on the lift
explode. truck.
Do not smoke when observing the battery electrolyte Do not expose the lift truck to flames, burning brush,
levels. etc., if at all possible.
Electrolyte is an acid and can cause personal injury Shields, which protect hot exhaust components
if it contacts skin or eyes. from oil or fuel spray in the event of a line, tube or
seal failure, must be installed correctly.
Always wear protective glasses when working with
batteries. Do not operate in areas where explosive gases
exist or are suspected.
15
Safety Section
16
Safety Section
Dry nitrogen(N2) gas is recommended for inflation Operator Restraint System (If
of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure. Equipped)
Nitrogen mixes properly with air.
Warning Signs and Labels
Nitrogen inflated tires reduce the potential of a tire Your DOOSAN lift truck has the following tipover
explosion, because nitrogen does not support warning decals.
combustion. Also, nitrogen helps prevent oxidation
and the resulting deterioration of rubber and Make sure that you can read all safety signs. Clean
corrosion of rim components. or replace these if you cannot read the words or
see the pictures. When cleaning the labels use a
Proper nitrogen inflation equipment and training in cloth, water and soap. Do not use solvent, gasoline,
its use are necessary to avoid overinflation. A tire etc. You must replace a label if it is damaged,
blowout or rim failure can result from improper or missing or cannot be read. If a label is on a part
misused equipment. that is replaced, make sure a new label is installed
on the replaced part. See you DOOSAN Lift Truck
Stand behind the tread and use a self-attaching dealer for new labels.
chuck when inflation a tire.
The most effective method of preventing serious
Servicing, changing tires and rims can be dangerous injury or death to yourself or others is to familiarize
and should be done only by trained personnel using yourself with the proper operation of the lift truck, to
proper tools and procedures. If correct procedures be alert, and to avoid actions or conditions which
are not followed while servicing tires and rims, the can result in an accident.
assemblies could burst with explosive force and
cause serious personal injury or death. Follow
carefully the specific information provided by your WARNING
tire or rim servicing personnel or dealer.
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.
17
Safety Section
WARNING
Seat Adjustment
18
Safety Section
Backrest Inclination
19
Safety Section
Seat Belt
The Operator Restraint System, Prevents the
operator from jumping from the operator's
compartment in the event of forward or side tipover.
The system is designed to keep the operator on the
seat and in the operator's compartment in the event
of tipover.
Inspection
WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.
WARNING
Your DOOSAN truck comes equipped with a 1. Grip the plate (connector) of the belt and insert
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any the plate into the slot of the buckle until a snap
reason, it should only be replaced with another is heard. Adjust the belt to fit snugly acreoss
DOOSAN operator restraint system. your hips. Pull on the belt to confirm it is latched.
20
Safety Section
21
Safety Section
22
Safety Section
Lift Truck Stability Base Remember that, unless otherwise indicated, the
capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
mast, and having no special-purpose attachment. In
addition, the capacity load assumes that the load
center is no further from the top of the forks than it
is from the face of the backrest. If these conditions
do not exist, the operator may have to reduce the
safe operating load because the truck stability may
be reduced. The lift truck should not be operated if
its capacity/nameplate does not indicate capacity
load.
23
Safety Section
Safety Rules
24
Safety Section
Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the
Do not let other people ride on the truck. rated capacity shown on the capacity plate.
Lift trucks are designed to carry loads, not people. Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.
25
Safety Section
Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward.
load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards.
cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.
Look out for overhead obstructions when raising or Do not jump off if your truck starts to tip over.
stacking loads. Do not travel with a raised load. Do Stay in your seat to survive.
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.
26
Safety Section
Do not stack or turn on ramps. Do not drive in forward direction when loads restrict
Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to
the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
an incline.
27
Safety Section
Do not operate your truck close to another truck. Mop up spilt fuel and do not forget to close the fuel
Always keep a safe distance from other trucks and tank before restarting the engine.
make sure there is enough distance to stop safely. Park your lift truck in authorized areas only. Fully
Never overtake other vehicles. lower the forks to the floor, put direction lever in
NEUTRAL position, engage the parking brake, and
turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work.
28
Safety Section
Do not operate forklifts near flammable or An unloaded forklift may be easier to tip over than a
combustible materials. loaded truck.
To avoid the discoloration, deformation or When traveling without a load, the risk of lateral
combustion of materials (such as lumber, veneer overturn is greater.
board, paper products and other similar items),
always park at least 30 cm (12 inches) away from
them.
carrying loads.
Avoid uneven bumps, pot holes and other hazards
whenever possible.
29
Safety Section
WARNING
Hold on tight.
DON’T jump.
30
Safety Section
Lean forward.
31
General Section
Declaration of Conformity
We,
Manufacturer
Doosan Corporation Industrial Vehicle
468, Injung-ro, Dong-gu, Incheon, Korea 401-010
herewith declare
that the following equipment conforms with the appropriate requirements of the Directives
2006/42/EC(Machinery Directive) based on its design and type, as brought into circulation by
us.
32
General Section
Specifications
CHARACTERISTICS
1 Manufacturer DOOSAN DOOSAN DOOSAN
2 Model GC15S-5(TIER-3) GC18S-5(TIER-3) GC20SC-5(TIER-3)
3 Capacity at rated load center lb/kg 3000/1500 3500/1750 4000/2000
4 Load center distance inch/mm 24/500 24/500 24/500
5 Power type electric, diesel, gasoline, lp-gas LP LP LP
6 Operator type stand-on, rider-seated Rider - seated Rider - seated Rider - seated
7 Tire c=cushion, p=pneumatic C C C
8 Wheels(x=driven) number, front/rear X 2/2 X 2/2 X 2/2
DIMENSIONS
9 Lift with STD maximum fork height with rated load inch/mm 118/3000 118/3000 118/3000
10 two-stage mast free lift inch/mm 5.1/130 5.1/130 5.3/135
11 special free lift mm
12 Fork carriage ISO class ll II II
thickness X width X length inch 1.4 x 4 x 41 1.4 x 4 x 41 1.6 x 4 x 41
13 Forks
mm 35x100x1050 35x100x1050 40x100x1050
14 Tilt of mast forward/backward deg 6/8 6/8 6/8
15 length without forks inch/mm 80.8/2051.5 82.9/2106.5 84.1/2138.5
16 width inch/mm 37/940 39/991 39/991
17 Overall mast lowered height inch/mm 78/1980 78/1980 78/1980
18 dimensions mast extended height inch/mm 159/4045 159/4045 159/4050
19 overhead guard height inch/mm 81/2060 81/2060 81/2060
20 seat height inch/mm 39.3/1000 39.3/1000 39.3/1000
21 Outside turning radius inch/mm 73.1/1857 75/1905.5 76/1932
22 Load moment constant inch/mm 15.5/394 15.5/394 15.7/399
23 90° stacking aisle inch/mm 88.6/2251 90.5/2299.5 91.7/2331
23a 90° intersecting aisle inch/mm 63.1/1603 64.7/1643 65.1/1653
PERFORMANCE
24 travel, loaded/unloaded mph 11.3/11.6 11.3/11.6 11.3/11.6
kph 18.0/18.5 18.0/18.5 18.0/18.5
25 lift, loaded/unloaded fpm 118.1/128 118.1/128 118.1/128
Speeds
mm/s 600/650 600/650 600/650
26 lowering, loaded/unloaded fpm 98.4/88.6 98.4/88.6 98.4/88.6
mm/s 500/450 500/450 500/450
28 Drawbar pull at 1.0 mph, loaded lb/kg 3086/1400 3064/1390 3042/1380
30 Gradeability at 1.6 mph, loaded % 35.5 30.5 28
31 Acceleration traveling loaded/unloaded s
WEIGHT
32 Total weight unloaded lb/kg 5940/2695 6510/2955 6800/3085
33 Axle load with loaded, front/rear lb 7840/1100 8345/1450 9400/1400
kg 3685/510 4035/670 4435/650
34 without loaded, front/rear lb 2370/3570 2190/4320 2095/4695
kg 1075/1620 995/1960 955/2130
CHASSIS
35 number of front/rear 2/2 2/2 2/2
36 Tires front size inch 18 X 6 X 12.12 18 X 7 X 12.12 18 X 7 X 12.12
37 rear size inch 14 X 5 X 10 14 X 5 X 10 14 X 5 X 10
38 Wheel base inch/mm 48.2/1225 48.2/1225 48.2/1225
39 Tread front/rear inch 31/31 32/31 32/31
mm 787/787 813/787 813/787
40 at loaded, the lowest point inch/mm 3/75 3/75 3/75
Ground clearance
41 at loaded, the center of wheelbase inch/mm 4.3/110 4.3/110 4.3/110
42 Service brake foot/hydraulic foot/hydraulic foot/hydraulic
43 Parking brake hand/mech hand/mech hand/mech
DRIVE
45 Battery voltage/capacity V/AH 12 / 45 12 / 45 12 / 45
49 manufacturer/model G420FE G420FE G420FE
50 rated output (at rpm) hp/rpm 45@2400 45@2400 45@2400
ps/rpm 46@2400 46@2400 46@2400
51 Engine max. torque lb-ft 108@1600 108@1600 108@1600
kg.m/rpm 15@1600 15@1600 15@1600
52 cycle/cylinders/displacement cc 1975 1975 1975
53 fuel consumption l/hr
55 type Powershift Powershift Powershift
Transmission
56 no. speeds forward/reverse 1/1 1/1 1/1
33
General Section
CHARACTERISTICS
1 Manufacturer DOOSAN DOOSAN DOOSAN
2 Model GC15S-5(TIER-3) GC18S-5(TIER-3) GC20SC-5(TIER-3)
3 Capacity at rated load center lb/kg 3000/1500 3500/1750 4000/2000
4 Load center distance inch/mm 24/500 24/500 24/500
5 Power type electric, diesel, gasoline, lp-gas LP LP LP
6 Operator type stand-on, rider-seated Rider - seated Rider - seated Rider - seated
7 Tire c=cushion, p=pneumatic C C C
8 Wheels(x=driven) number, front/rear X 2/2 X 2/2 X 2/2
DIMENSIONS
9 Lift with STD maximum fork height with rated load inch/mm 118/3000 118/3000 118/3000
10 two-stage mast free lift inch/mm 5.1/130 5.1/130 5.3/135
11 special free lift mm
12 Fork carriage ISO class ll II II
thickness X width X length inch 1.4 x 4 x 41 1.4 x 4 x 41 1.6 x 4 x 41
13 Forks
mm 35x100x1050 35x100x1050 40x100x1050
14 Tilt of mast forward/backward deg 6/8 6/8 6/8
15 length without forks inch/mm 80.8/2051.5 82.9/2106.5 84.1/2138.5
16 width inch/mm 37/940 39/991 39/991
17 Overall mast lowered height inch/mm 78/1980 78/1980 78/1980
18 dimensions mast extended height inch/mm 159/4045 159/4045 159/4050
19 overhead guard height inch/mm 81/2060 81/2060 81/2060
20 seat height inch/mm 39.3/1000 39.3/1000 39.3/1000
21 Outside turning radius inch/mm 74/1882 76/1930 77/1956
22 Load moment constant inch/mm 15.5/394 15.5/394 15.7/399
23 90° stacking aisle inch/mm 89.5/2276 91.5/2324 92.5/2355
23a 90° intersecting aisle inch/mm 63.1/1603 64.7/1643 65.1/1653
PERFORMANCE
24 travel, loaded/unloaded mph 11.3/11.6 11.3/11.6 11.3/11.6
kph 18.0/18.5 18.0/18.5 18.0/18.5
25 lift, loaded/unloaded fpm 118.1/128 118.1/128 118.1/128
Speeds
mm/s 600/650 600/650 600/650
26 lowering, loaded/unloaded fpm 98.4/88.6 98.4/88.6 98.4/88.6
mm/s 500/450 500/450 500/450
28 Drawbar pull at 1.0 mph, loaded lb/kg 3196/1450 3174/1440 3152/1430
30 Gradeability at 1.6 mph, loaded % 36.5 31.5 29
31 Acceleration traveling loaded/unloaded s
WEIGHT
32 Total weight unloaded lb/kg 5940/2695 6510/2955 6800/3085
33 Axle load with loaded, front/rear lb 7840/1100 8345/1450 9400/1400
kg 3685/510 4035/670 4435/650
34 without loaded, front/rear lb 2370/3570 2190/4320 2095/4695
kg 1075/1620 995/1960 955/2130
CHASSIS
35 number of front/rear 2/2 2/2 2/2
36 Tires front size inch 18 X 6 X 12.12 18 X 7 X 12.12 18 X 7 X 12.12
37 rear size inch 14 X 5 X 10 14 X 5 X 10 14 X 5 X 10
38 Wheel base inch/mm 50.6/1285 50.6/1285 50.6/1285
39 Tread front/rear inch 31/31 32/31 32/31
mm 787/787 813/787 813/787
40 at loaded, the lowest point inch/mm 3/75 3/75 3/75
Ground clearance
41 at loaded, the center of wheelbase inch/mm 4.3/110 4.3/110 4.3/110
42 Service brake foot/hydraulic foot/hydraulic foot/hydraulic
43 Parking brake hand/mech hand/mech hand/mech
DRIVE
45 Battery voltage/capacity V/AH 12 / 45 12 / 45 12 / 45
49 manufacturer/model G424IE G424IE G424IE
50 rated output (at rpm) hp/rpm 45.5@2450 45.5@2450 45.5@2450
ps/rpm 46.1@2450 46.1@2450 46.1@2450
51 Engine max. torque lb-ft 109@1600 109@1600 109@1600
kg.m/rpm 15.1@1600 15.1@1600 15.1@1600
52 cycle/cylinders/displacement cc 2359 2359 2359
53 fuel consumption l/hr
55 type Powershift Powershift Powershift
Transmission
56 no. speeds forward/reverse 1/1 1/1 1/1
34
General Section
35
General Section
GC15/18S-5, GC20SC-5
G420FE & G424IE 82 1.8 0.5
Engine (W/O Cabin)
36
General Section
Serial Number
Serial Number Locations
For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.
37
General Section
38
General Section
NOTE : When only a mast-type is listed on the SWS - Swing Shift, Sideshift
Nameplate, a standard carriage and forks
are used. RAM - Ram or Boom
TH - Tire Handler
CC - Carton Clamp
RC - Roll Clamp
LS - Load Stabilizer
39
Operation Section
Diesel (12V)
LPG/GAS (12V)
40
Operation Section
41
Operation Section
12. Front Floodlights - Push down on the Electrical Disconnect Switch (If
switch(17), to the first step, to turn the
front floodlights on. Equipped)
Front and Rear Floodlights - Push down on the
switch(17), to the second step, to turn both the front
and rear floodlights on. The floodlights are optional.
13. Transmission Neutral Position Light
- Indicates the neutral position of
transmission.
42
Operation Section
NOTICE
1. Prior to operating the lift truck, be sure to
understand and check the SEAT SWITCH
SYSTEM.
43
Operation Section
44
Operation Section
Seat
NOTE : Seat arrangements may vary. Basic
operation will be similar.
45
Operation Section
46
Operation Section
Push DOWN on the brake pedal to slow Pull the lever BACK to engage the parking
or stop the lift truck. brake.
RELEASE the brake pedal to allow the lift Push the lever FORWARD to release the
truck to move. parking brake.
RELEASE the pedal to decrease engine 1. Lower Position - Push the lever
rpm (speed). FORWARD smoothly to lower the load.
47
Operation Section
48
Operation Section
Refueling
WARNING Changing LP-Gas Tanks
1. Park the lift truck on level ground, with the
Only trained, authorized personnel should fill or parking brake applied, the transmission in
exchange LP-Gas tanks. NEUTRAL, the forks lowered and the engine
running at low idle.
Personnel engaged in filling of LP-Gas containers
should wear protective clothing such as face
shield, long sleeves and gauntlet gloves.
Stop the engine and get off the lift truck during
refueling.
NOTICE
49
Operation Section
WARNING
The LP-Gas tank must not extend past the
counterweight.
50
Operation Section
Typical Example
51
Operation Section
Typical Example
13. Observe the fuel level gauge after starting the
11. Measure the engine crankcase oil level with the truck. Add fuel if necessary.
dip stick. Maintain the oil level between the MAX.
and MIN., (or FULL and ADD) notches on the
dip stick.
WARNING
Personal injury may occur from accidents
caused by improper seat adjustment. Always
adjust the operator's seat before starting the lift
truck engine.
Seat adjustment must be done at the beginning
of each shift and when operators change.
Typical Example
52
Operation Section
NOTICE
If the inside of engine cylinder is wet by gasoline,
the engine could not start. In this case, press
accelerator pedal fully and turn the ignition switch
to ON position for 10 seconds. The inside of
cylinder would be dry because ECM does not allow
gasoline fuel injection. Repeat it three times. Don’t
press accelerator pedal and turn the ignition switch
2. Lift trucks equipped with electrical disconnect to the START position to start engine.
switches ; the engine will not start unless the
disconnect switch is in the ON (closed) position.
Before starting, turn the disconnect switch to the
OFF (open) position.
NOTICE
When you restart the engine after turning off it, wait
4 to 5 seconds and restart it to protect the starter.
53
Operation Section
NOTICE
Do not engage the starter for more than 10
seconds.
54
Operation Section
WARNING
Sparks occurring near the battery could cause
vapors to explode.
Always connect the external power source
ground cable to a point away from and below
the battery, and well clear of fuel system
components.
Typical Example
NOTICE
Do not reverse battery cables. It can cause
damage to the alternator.
Always connect the external power source
cables in parallel with the lift truck battery
cables : POSITIVE(+) to POSITIVE(+) and
NEGATIVE(-) to NEGATIVE(-).
Attach ground cable last, remove first. All lift
trucks equipped with DOOSAN built internal
combustion engines are NEGATIVE(-) ground.
55
Operation Section
8
5 6 7
LPG/GAS (12V)
56
Operation Section
The SECM makes any necessary corrections to the pressure are monitored by the SECM. The SECM
air fuel ratio by controlling the inlet fuel pressure to controller has full adaptive learning capabilities,
the air/fuel mixer by modulating the dual fuel trim allowing it to adapt control function as operating
valves (FTV) connected to the regulator. Reducing conditions change. Factors such as ambient
the fuel pressure leans the air/fuel mixture and temperature, fuel variations, ignition component
increasing the fuel pressure enriches the air/fuel wear, clogged air filter, and other operating
mixture. To calculate any necessary corrections to variables are compensated.
the air fuel ratio, the SECM uses a number of
different sensors to gain information about the MPI (multi-point injection) is used for this system.
engine’s performance. Engine speed is monitored Fuel injection pressure and flow rate depend on
by the SECM through a variable reluctance (VR) or engine-specific fuel injection requirements. A
Hall Effect sensor. Intake manifold air temperature variety of regulators and injectors can be used to fit
and absolute pressure are monitored with a TMAP individual needs. The gasoline fuel pressure
sensor. MI-07 is a drive-by-wire (DBW) system regulator is a one-way, non-return configuration. All
connecting the accelerator pedal to the electronic gasoline specific components are automotive
throttle through the electrical harness; mechanical production parts and validated to strict automotive
cables are not used. A throttle position sensor standards. Four (4) sequential injection channels
(TPS) monitors throttle position in relation to the are supported.
accelerator pedal position sensor (APP) command.
Even engine coolant temperature and adequate oil
57
Operation Section
Basic Troubleshooting(LP)
The MI-07 systems are equipped with built-in fault basic checks that should be made before referring
diagnostics. Detected system faults can be to the Advanced Diagnostics section, if engine or
displayed by the Malfunction Indicator Lamp (MIL) drivability problems are encountered.
and are covered in the Advanced Diagnostics
section. Items such as fuel level, plugged fuel Locating a problem in a propane engine is done
lines, clogged fuel filters and malfunctioning exactly the same way as with a gasoline engine.
pressure regulators may not set a fault code by the Consider all parts of the ignition and mechanical
Small Engine Control Module (SECM). Below are systems as well as the fuel system.
58
Operation Section
59
Operation Section
60
Operation Section
61
Operation Section
62
Operation Section
63
Operation Section
64
Operation Section
65
Operation Section
(*) Fault actions shown are default values specified by the OEM.
66
Operation Section
ECT_IR_Fault TurnOnMil
Engine coolant temperature (Disabled in all
Check for coolant system problems, e.g.
171 not changing as expected software
defective or stuck thermostat
MI07SEQ062V05 and
higher)
FuelSelectConflict Check fuel select switch connection for a
Conflict in fuel select signals, (1) TurnOnMil short to GND
181 normally set if both of the fuel (2) Delayed SECM (SIGNAL) Pin A12
select signals are shorted to EngineShutdown SECM (SIGNAL) Pin A15
ground SECM (Sensor GND) Pin B1
Check CAM sensor connections
CamEdgesFault SECM (SIGNAL) Pin B10 to CAM sensor
No CAM signal when engine is Pin 2
191 known to be rotating, broken None SECM (Sensor GND) Pin B1 to CAM
crankshaft sensor leads or sensor Pin 3
defective CAM sensor Switched 12V to CAM sensor Pin 1
Check for defective CAM sensor
Check CAM sensor connections
CamSyncFault
SECM (SIGNAL) Pin B10 to CAM sensor
Loss of synchronization on the
Pin 2
CAM sensor, normally due to
192 None SECM (Sensor GND) Pin B1 to CAM
noise on the signal or an
sensor Pin 3
intermittent connection on the
Switched 12V to CAM sensor Pin 1
CAM sensor
Check for defective CAM sensor
Check Crankshaft sensor connections
CrankEdgesFault
SECM (SIGNAL) Pin B5 to Crank sensor
No crankshaft signal when
Pin 3
engine is known to be rotating,
193 None SECM (Sensor GND) PIN B1 to Crank
broken crankshaft sensor
sensor Pin 2
leads or defective crank
Switched 12V to Crank sensor Pin 1
sensor
Check for defective Crank sensor
Check Crankshaft sensor connections
CrankSyncFault
SECM (SIGNAL) Pin B5 to Crank sensor
Loss of synchronization on the
Pin 3
crankshaft sensor, normally
194 None SECM (Sensor GND) Pin B1 to Crank
due to noise on the signal or
sensor Pin 2
an intermittent connection on
Switched 12V to Crank sensor Pin 1
the crankshaft sensor
Check for defective Crank sensor
(*) Fault actions shown are default values specified by the OEM.
67
Operation Section
TPS2AdaptLoMin
Learned closed throttle end of
242 None N/A
TPS2 sensor range lower than
expected
TPS1AdaptHiMax
Learned WOT end of TPS1
251 sensor range higher than None N/A
(25) expected
TPS2AdaptHiMax
Learned WOT end of TPS2
252 sensor range higher than None N/A
expected
TPS1AdaptHiMin
Learned WOT end of TPS1
sensor range lower than
271 None N/A
expected
(*) Fault actions shown are default values specified by the OEM.
68
Operation Section
69
Operation Section
(*) Fault actions shown are default values specified by the OEM.
70
Operation Section
(*) Fault actions shown are default values specified by the OEM.
71
Operation Section
(*) Fault actions shown are default values specified by the OEM.
72
Operation Section
(*) Fault actions shown are default values specified by the OEM.
73
Operation Section
(*) Fault actions shown are default values specified by the OEM.
74
Operation Section
(*) Fault actions shown are default values specified by the OEM.
75
Operation Section
(*) Fault actions shown are default values specified by the OEM.
76
Operation Section
(*) Fault actions shown are default values specified by the OEM.
77
Operation Section
(*) Fault actions shown are default values specified by the OEM.
78
Operation Section
(1) TurnOnMil
Check FTV1 for an open wire or FTV connector
LSDFault_Dither1 (2) Disable being disconnected
Dither Valve 1 Fault, signal GasO2 Ctrl FTV1 Pin 1 (signal) to SECM Pin A1
711
(71) has opened or shorted to (3) Disable FTV1 Pin 2 (power) to SECM (DRVP) Pin A23
ground or power or defective GasPost O2Ctrl Check FTV1 for an open coil by disconnecting
dither 1 valve (Certified Units the FTV connector and measuring the
resistance (~26Ω ± 2Ω )
Only)
(1) TurnOnMil Check FTV1 for an open wire or FTV connector
LSDFault_Dither2 (2) Disable being disconnected or signal shorted to GND
Dither Valve 2 Fault, signal GasO2 Ctrl FTV2 Pin 1 (signal) to SECM Pin A2
712 has opened or shorted to (3) Disable FTV2 Pin 2 (power) to SECM (DRVP) Pin A23
ground or power or defective GasPost O2Ctrl Check FTV1 for an open coil by disconnecting
dither 2 valve (Certified Units the FTV connector and measuring the
Only) resistance (~26Ω ± 2Ω )
713 LSDFault_CSValve None N/A
LSDFault_CheckEngine
Check Engine Lamp Fault,
714 signal has opened or shorted None Check ‘Check Engine Lamp’ for an open wire or
shorted to GND
to ground or power or
defective check engine lamp
LSDFault_CrankDisable
Crank Disable Fault, signal
715 has opened or shorted to None N/A
ground or power or defective
crank disable relay
Check fuel pump for an open wire or connector
being disconnected or signal shorted to GND
LSDFault_FuelPump Fuel Pump Pin B (signal) from SECM Pin A13
Fuel pump fault, signal has Fuel Pump Pin A (power) from main relay 1 Pin A23
716 opened, shorted to ground or TurnOnMil Check Fuel Pump for an open coil by
power, or defective fuel disconnecting the Fuel Pump connector and
pump measuring the resistance
(~26Ω ± 3Ω)
Check for 12V to fuel pump
Check fuel lock off valve for an open wire or connector
being disconnected or signal shorted to GND
LSDFault_LockOff Lock off Pin B (signal) from SECM Pin A11
Fuel lock off Valve Fault,
Lock off Pin A (power) from main relay 1 Pin A23
717 signal has opened or shorted TurnOnMil
Check lock off valve for an open coil by
to ground or power or disconnecting the lock off valve connector and
defective Fuel lock off valve measuring the resistance (~26Ω ± 3Ω)
Check for 12V to lock off valve
LSDFault_MIL
Malfunction Indicator Lamp
718 Fault, signal has opened or None None
shorted to ground or power
or defective MIL lamp
(1) TurnOnMil
(2) Disable
GasFuelAdaptRangeLo Check for vacuum leaks.
GasO2 Ctrl
721 In LPG mode, system had to (3) Disable Check fuel trim valves, e.g. leaking valve or
(72) adapt rich more than GasPost O2Ctrl hose
expected Check for missing orifice(s).
(Certified Units
Only)
GasDesEquivLo
722 In LPG mode, system had to None N/A
adapt rich more than expected
(*) Fault actions shown are default values specified by the OEM.
79
Operation Section
(1) TurnOnMil
GasO2FailedLean (2) DisableGas Check for vacuum leaks.
Pre-catalyst O2 sensor O2Ctrl Check dual dither valves, e.g. leaking valve or
751 (3) Disable
indicates extended lean GasPost O2Ctrl hose.
operation on LPG (Certified Units Check for missing orifice(s).
Only)
Correct other faults that may contribute to 752
(e.g. faults pertaining to dither valves, Pre-Cat
GasPostO2FailedLean (1) TurnOnMil O2, Post Cat O2 sensor)
Pre-catalyst O2 sensor (2) DisableGasPost Check for vacuum leaks
752 Check for leaks in exhaust, catalytic converter,
indicates extended lean O2Ctrl
operation on LPG (Certified Units Only) HEGO sensors; repair leaks.
Check all sensor connections (see fault 742
corrective actions).
(1) TurnOnMil
GasO2FailedRich (2) DisableGas
O2Ctrl Check dual dither valves, e.g. plugged valve or
771 Pre-catalyst O2 sensor (3) DisableGasPost hose.
(77) indicates extended rich O2Ctrl
operation on LPG Check for plugged orifice(s).
(Certified Units
Only)
(*) Fault actions shown are default values specified by the OEM.
80
Operation Section
(*) Fault actions shown are default values specified by the OEM.
81
Operation Section
O2_PostCatRangeLow
Post-catalyst O2 sensor
912 voltage out of range low, None N/A
sensor signal shorted to
ground
(*) Fault actions shown are default values specified by the OEM.
82
Operation Section
(*) Fault actions shown are default values specified by the OEM.
83
Operation Section
WARNING
Sudden reversal of a loaded lift truck traveling
forward can cause the load to fall or the lift
truck to tip over.
Stop the loaded lift truck completely, before
4. Select the direction of travel by pushing the shifting to reverse.
directional lever FORWARD for forward Failure to comply could result in personal injury.
direction or by pulling the lever BACK for
reverse direction.
NOTE : Where conditions permit, directional
changes can be made under full power at
speeds up to 8 km/h (5 mph). A speed of 8
km/h (5 mph) is a fast walk. Directional
shift changes at speeds above 8 km/h (5
mph) are considered abusive. Bring the lift
truck to a complete stop where load
stability or other factors prevent safe
operation under full power shifts safe
operation under full power shifts.
84
Operation Section
Inching
NOTE : The purpose of the inching pedal is to
provide precise lift truck inching control at
very slow travel speed and high engine
rpm. This is used for fast hydraulic lift,
during load approach, pick up or load
positioning.
85
Operation Section
WARNING
Loss of stability can occur when a lift truck
steering wheel is rotated quickly while the truck
is in motion. A steering knob will assist with
easy rotation of the steering wheel, but if a
steering knob is improperly used (e.g., rotating
the steering wheel quickly while the truck is in
motion), this can contribute to truck instability
and a tip over. A steering knob is intended for
slow travel maneuverability ONLY.
86
Operation Section
Operating Techniques
Inching into Loads Lifting the Load
1. Lift the load carefully and tilt the mast back a
short distance.
87
Operation Section
NOTICE
WARNING
Do not tilt the mast forward with the load unless
directly over the unloading area, even if the
2. For better vision, travel in reverse with bulky
power is off.
loads.
88
Operation Section
Turning
89
Operation Section
90
Operation Section
3. Engage the parking brake. 7. Block the drive wheels if parking on an incline.
4. Lower the forks to the ground.
WARNING
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.
91
Operation Section
WARNING
When adjusting the fork spread, be careful not
to pinch your hand between forks and the
carriage slot.
WARNING
Make sure the forks are locked before carrying
a load.
If the fork/locking pin is not fully engaged, the
fork could become unintentionally disengaged.
92
Operation Section
Storage Information
Before Storage • The machine should be operated at least once a
week. Fill the cooling system, if cooling water is
Before storing your lift truck, clean and inspect as discharged, and mount the battery. Start the
the following procedures. engine and warm up thoroughly. Move the
machine a little forwards and backwards.
• Wipe away grease, oil, etc. adhering to the body Operate the hydraulic controls several times.
of the truck with waste cloth, and use water, if
needed.
To Operate the Lift Truck after a
• While cleaning the truck, check general
condition of the truck. Especially check the truck Long Time Storage
body for recess or damge and tires for wear or • Remove covers and antirust from each of the
nails or stones in the tread. components and exposed parts.
• Fill the fuel tank with fuel specified. • Drain the engine crankcase, transmission
• Check for leakage of hydraulic oil, engine oil, (clutch type machine), differential and final
fuel, or coolant, etc. reduction gear, clean the inside of them and add
new oil.
• Apply grease, where needed.
• Drain off foreign matter and water from the
• Check for looseness of nuts and bolts, especial- hydraulic oil tank and fuel tank.
ly hub nuts.
• Remove the head cover from the engine
• Check mast rollers to see that they rotate smoothly. cylinder. Oil valves and rocker shaft and check
• Prime the oil into the lift cylinders by actuating each valve for proper operation.
the lift lever all the way several times. • Add cooling water to the specified level.
• Drain off coolant completely in water of cold • Charge the battery and mount it on the machine.
weather, if antifreeze is not used. Connect the cables.
• Perform pre-operational checks carefully. (refer
Long Time Storage to “Before Starting the Engine”)
Perform the following service and checks in • Warm up the machine.
addition to the “Parking the lift truck” services.
93
Operation Section
Transportation Hints
Lift Truck Shipping Machine Lifting and Tiedown
Check travel route for overpass clearances. Make Information
sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
overhead guard or cab. NOTICE
To prevent the lift truck from slipping while loading Improper lifting or tiedowns can allow load to
or shifting in transit, remove ice, snow or other shift and cause injury and/or damage.
slippery material from the loading dock and the
truck bed before loading.
1. Weight and instructions given herein apply to
lift trucks as manufactured by DOOSAN.
NOTICE 2. Use proper rated cables and slings for lifting.
Position the crane for level lift truck lift.
Obey all state and local laws governing the
weight, width and length of a load. 3. Spreader bar widths should be sufficient to
Observe all regulations governing wide loads. prevent contact with the lift truck.
4. Use the tiedown locations provided for lift truck
tiedown.
NOTICE
Check the state and local laws governing weight,
Remove ice, snow or other slippery material width and length of a load.
from the shipping vehicle and the loading dock.
Contact your DOOSAN Lift Truck dealer for
shipping instructions for your lift truck.
94
Operation Section
B
D
A
C
A
95
Operation Section
96
Maintenance section
97
Maintenance section
98
Maintenance section
99
Maintenance section
Most repairs or modifications should be done Check the fork arm before and after the second
only by the original manufacturer of the forks or application of the test load. It shall not show
an expert knowledgeable of the materials, any permanent deformation.
design, welding and heat treatment process.
Consult the fork manufacturer for further infor-
2. The following repairs or modifications SHOULD mation as may be applicable to the specific fork
NOT be attempted. involved.
• Flame cutting holes or cutouts in fork Testing is not required for repairs to the
blades. positioning lock or the markings.
• Welding on brackets or new mounting
hangers.
• Repairing cracks or other damage by
welding.
• Bending or resetting.
100
Maintenance section
1/2 100 + 15 75 + 11
Initial Installation Torque On New
Clamp Width Hose 9/16 150 + 20 110 + 15
N•m1 lb•in 5/8 200 + 25 150 + 18
16 mm (.625 in) 7.5 + 0.5 65 + 5 3/4 360 + 50 270 + 37
101
Maintenance section
3/8 35 + 5 26 + 4
Original fasteners removed from the lift truck should
7/16 45 + 10 33 + 7 be saved for reassembly whenever possible. If new
fasteners are needed, they must be of the same size
1/2 65 + 10 48 + 7 and grade as the ones that are being replaced.
5/8 110 + 20 80 + 15
The material strength identification is usually shown
3/4 170 + 30 125 + 22 on the bolt head by numbers (8.8, 10.9, etc.). This
chart gives standard torques for bolts and nuts with
7/8 260 + 40 190 + 30 Grade 8.8.
1 400 + 60 300 + 45
NOTE : Metric hardware must be replaced with
1 1/8 500 + 700 370 + 50 metric hardware. Check parts book.
M8 25 + 7 18 + 5
M10 55 + 10 41 + 7
M12 95 + 15 70 + 11
102
Maintenance section
103
Maintenance section
PH 5.5 to 9.0
ppm = parts per million
104
Maintenance section
Fuel Specifications
LP-Gas Specifications z Bio-Diesel fuels. See Bio-Diesel Fuels on next
page.
LP-Gas is “Liquefied Petroleum Gas”. The exact
composition of LP-Gas varies slightly between
z NEVER mix kerosene, used engine oil, or residual
different parts of the country and different refineries.
fuels with the diesel fuel.
HD5 is recommended for DOOSAN forklift trucks.
Remember LP-Gas is heavier than air and will sink
to the lowest spot possible. Avoid areas near floor z The water and sediment in the fuel should not
drains or lubrication pits where escaped fuel may exceed 0.05% by volume.
collect.
z Keep the fuel tank and fuel-handling equipment
Composition of HD5 clean at all times.
Propane (C3H8) 90.0 %
z Poor quality fuel can reduce engine performance
Propylene up to 5 % and / or cause engine damage.
Butane (C4H10) 2.0 %
z Fuel additives are not recommended. Some fuel
iso-Butane 1.5 %
additives may cause poor engine performance.
Methane (CH4) 1.5 %
105
Maintenance section
Lubricant Specifications
Lubricant Information Hydraulic Oil (HYDO)
Certain abbreviations follow Society of Automotive The following commercial classifications can be
Engineers (SAE) J754 nomenclature and some used in the hydraulic system.
classifications follow SAE J183 abbreviations.
• ISO 6743/4 HM
The MILspecifications are U.S.A. Military • AFNOR NFE 48-603 HM
Specifications. • DIN 51524 TEIL 2 H-LP
• HAGGLUNDS DENISON HFO-HF2
The recommended oil viscosities can be found in the • CINCINNATI P68,69,70
Lubricant Viscosities chart in this publication.
Viscosity : ISO VG32
Grease is classified by the National Lubricating
Grease Institute (NLGI) based on ASTM D217-68 Industrial premium hydraulic oils that have passed
Worked Penetration characteristics which are given the Vickers vane pump test (35VQ25).
a defined consistency number. These oils should have antiwear, antifoam, antirust
and antioxidation additives for heavy duty use as
Engine Oil (DEO and EO) stated by the oil supplier. ISO viscosity grade of 32
would normally be selected.
The following oil specifications provide guidelines for
the selection of commercial products :
NOTICE
• LP-Gas Engine : API SJ or higher
Make-up oil added to the hydraulic tanks must
mix with the oil already in the systems. Use only
petroleum products unless the systems are
NOTICE
equipped for use with special products.
Failure to follow the oil recommendations can
If the hydraulic oil becomes cloudy, water or air is
cause shortened engine lift due to carbon
deposits or excessive wear. entering the system. Water or air in the system
will cause pump failure. Drain the fluid, retighten all
hydraulic suction line clamps, purge and refill
the system. Consult your DOOSAN Lift Truck
Consult the EMA Lubricating Oils Data Book for a
dealer for purging instructions.
listing of oil brands.
106
Maintenance section
107
Maintenance section
• Shoe Brake
Use heavy duty hydraulic brake fluid. It must be
cer- tified by the oil supplier to meet SAE J1703f
latest revision, DOT 3 or 4 specifications.
• ISO 6743/4 HM
• AFNOR NFE 48-603 HM
• DIN 51524 TEIL2 H-LP
• HAGGLUNDS DENISON HFO-HF2
• CINCINNATI P68,69,70
108
Maintenance section
109
Maintenance section
Maintenance Intervals
Every 250 Service Hours or Monthly
110
Maintenance section
111
Maintenance section
When Required
You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.
NOTICE
1. Check the operation of the seat adjuster rod. Check the fuses. Use a flashlight, if necessary.
Make sure that the seat slides freely on its track.
Lightly oil the seat slider tracks if necessary.
Typical Example
2. Pull the latch to raise the hood and seat Fuses are identified as follows :
assembly. Make certain the support cylinder
will hold the hood open. 1. Horn - 10 amp.
3. Lightly oil the hood latch mechanism and the 2. Head Lamp, Clearance Lamp, Tail Lamp. - 15 amp.
rod for the hood support cylinder. 3. Lamp Relay Coil, Fwd/Rev Solenoid, Rear Lamp
/Alarm - 10 amp
4. Instrument Panel, Hour Meter, Preheat Controller,
Fuel Shut-off Solenoid - 15 amp
5. Stop Lamp, Turn Signal Lamp, Strobe Lamp - 15 amp
6. Starter Relay - 10 amp
112
Maintenance section
Relays
Typical Example
113
Maintenance section
Check
Points
WARNING
114
Maintenance section
-6 11 11
115
Maintenance section
116
Maintenance section
1. Raise the hood and seat assembly. Remove the fill cap slowly to relieve pressure.
G420FE Engine
G424IE Engine
117
Maintenance section
2. Remove the radiator cap. Fill radiator to the top Air Intake System - Check
of the filler neck. Inspect radiator cap. Replace
if damaged. Install the radiator cap. Checking Service Indicator
3. Start and run the engine to stabilize the coolant 1. Observe the air cleaner service indicator.
level in the filler neck. If low add coolant until it 2. Service the air cleaner when the RED band in
reaches the top of the filler neck. Install the the service indicator, lock in the visible position.
radiator cap. Observe coolant level in the See topic, “Air Intake System - Check, Clean” in
expansion bottle. If necessary, add coolant to “Every 250 Service Hours or Monthly”.
bring the coolant to the appropriate line on the
expansion bottle.
NOTE : Service the element more frequently, as
4. Stop the engine. required, in severe dust or lint conditions.
5. Inspect the cooling system for leaks, hose Also, service it more frequently where the
cracks or loose connections. operator is required to wear a respirator.
118
Maintenance section
WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.
119
Maintenance section
Park the lift truck level, with the forks lowered, park-
ing brake engaged, transmission in NEUTRAL and
the engine stopped.
Component is shown removed from the lift truck for
illustrative purposes.
IPMO060I
3. Engage the parking brake. Slowly release the 3. Remove the filler cap. Fill the compartment with
service brake. oil. See “Refill Capacities”. Install the dip
stick/filler cap.
4. The parking brake should hold the lift truck. If
the lift truck starts to move, immediately apply 4. Start the engine.
the service brakes. Have the parking brake
5. With the service brake applied and engine at
adjusted.
low idle, shift the transmission to forward and
reverse to fill the clutches.
120
Maintenance section
Drive Axle Oil - Change 5. Allow the oil to drain completely out. Discard the
old oil according to federal, state, and local
Park the lift truck on a level surface. Apply the regulations.
parking brake. Place the directional control lever in
NEUTRAL. 6. Clean and reinstall the drain plug.
7. Add sufficient fresh oil through the level/fill
opening until it reaches the bottom of the hole.
See the section Lubricant Viscosities and
Refill Capacities for the type and amount of oil
to use.
8. Clean and reinstall the level/fill plug.
9. Remove the wood blocking and lower the
carriage.
10. Operate the lift truck for a few minutes and
check oil level again. See the topic, “Drive Axle
Oil Level - Check” in “Every 250 Service Hours
1. Raise the carriage high enough to access the or Monthly” section.
drain plug and level/fill plug.
2. Block the bottom of the mast with a block of
wood to hold the carriage in the raised position.
3. Turn the ignition switch OFF.
4. Place an appropriate container under the axle to
catch the oil as it drains. Remove the drain plug
and the level/fill plug.
121
Maintenance section
NOTICE
Never service filter with the engine running.
122
Maintenance section
Cleaning Primary Filter Elements Air-205 kPa (30 psi) Maximum Pressure
WARNING
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.
123
Maintenance section
124
Maintenance section
NOTICE
Lubricate chains more frequently than normal in
applications where the lift truck is operating in a
atmosphere which could cause corrosion of
components or when lift truck must work in
rapid lift cycles.
125
Maintenance section
Typical Example
126
Maintenance section
Engine Oil Filter - Change 7. Before installing a new filter element, apply a
small amount of clean engine oil to the filter
1. Operate lift truck a few minutes to warm oil.
element gasket.
Park the lift truck with the forks lowered,
parking brake applied, transmission in neutral 8. Install the new filter element. When the gasket
and the engine stopped. contacts the base, tighten it 3/4 of a turn more.
Do not overtighten.
2. Raise rear of lift truck off ground and block
securely. 9. Raise the lift truck, remove the blocking and
lower the lift truck.
10. Fill the crankcase. See Refill Capacities.
WARNING 11. Start the engine and allow the oil to fill the filter
and passages.
Hot oil and components can cause personal
12. Check for oil leaks
injury. Do not allow hot oil or components to
contact skin.
127
Maintenance section
Typical Example
Typical Example
NOTICE
Failure to loosen the alternator mounting bolt
will cause excessive stress and break the alter-
nator mounting ear.
1. Lubricate two fittings for the mast pivot eyes,
one on each side of the mast.
2. To adjust the alternator drive belt, loosen
adjusting bracket bolt and mounting bolt. Move 2. Check the pivot eye pins for loose retainer bolts
the alternator in or out as required. Tighten bolts. and wear.
128
Maintenance section
129
Maintenance section
1. Lubricate three fittings for the inching and brake 3. Check all lights such as warning, directional,
pedal control shaft. backup, driving and flood lights for correct
operation. Replace all burned out bulbs. Have
repairs made if needed.
Drive Axle Oil (OCDB) - Change
See topic, “Drive Axle Oil - Change” in the “First 50 Overhead Guard - Inspect
- 100 Service Hours”.
2
1
130
Maintenance section
131
Maintenance section
Hydraulic Return Filter, Breather 4. Remove the return filter from tank top plate
assembly.
& Strainer - Check, Change
5. Change the return filter.
6. Remove the suction strainer from the tank.
WARNING
7. Install a new strainer by hand.
Hot oil and components can cause personal
injury. Do not allow hot oil or components to 8. Install the tank top plate assembly and fasten
contact skin. the bolt.
9. Start the engine and operate the hydraulic con-
Park the lift truck level with the forks lowered, trols, and the steering system, through a few
parking brake engaged, transmission in NEUTRAL cycles to fill the lines. Look for oil leaks.
and the engine stopped. 10. Stop the engine and check the oil level. With all
cylinders retracted, maintain the oil level to the
FULLmark on the dip stick/filler cap assembly.
132
Maintenance section
Chain wear test is a measurement of wear of the Lift the carriage and the mast high enough for get-
chain links and pins. Take the following steps to ting tension on lift chains. Check the chains, and
check chain wear. make sure the tension is the same. Lift chains are
required to check for equal tension about every
1. Lift the mast and carriage enough for getting 1,000 service hours or 6 months.
tension on lift chains.
WARNING
Personal injury can be caused by sudden
movement of the mast and carriage.
Keep hands and feet clear of any parts that can
move.
**Chain Pitch for GC15/18S-5, GC20SC-5 If the tension is not the same on both chains, take
= 15.88mm(0.63 in) the procedure as follows.
133
Maintenance section
Carriage Chain Adjustment 4. Set the mast vertical and raise the carriage and
check equal chain tension. If not equal, repeat
Make sure that carriage height is correct. If correct, the same procedure as step 1 through step 3.
adjust the chain for equal tension. If not, adjust the
5. Put LOCTITE No. 242 Tread lock on the
chain for correct carriage height by adjusting
threads of the anchor nuts(1),(2) after the
anchor nuts(1),(2).
adjustment is completed.
NOTE : See the previous section, “Carriage Roller
Extrusion” in “When Required”. for proper Mast Chain Adjustment - FF,FFT Mast
height of carriage.
134
Maintenance section
135
Maintenance section
Inspect Coolant Hoses (LP, Dual Fuel Lines & Fittings - Check
Fuel Engines Only) Visually inspect fuel lines and fittings for physical
1. Visually inspect coolant hoses and clamps. damage. Replace as required.
Remember to check the two coolant lines that
connect to the pressure regulator/converter.
1 2
2. Replace any hose that shows signs of swelling,
cracking, abrasion or deterioration.
2
(1) Fuel line
1 (2) LP mixer
(3) Throttle Assembly
136
Maintenance section
1
G420F(E) Engine
(1) screws
G424I(E) Engine
137
Maintenance section
Fuel Filter (LP - Gas Engine Only) Testing Fuel Lock-off Operation
(LP-Gas Engine Only)
Disassembly
1. Start engine.
4 2 1
5 2. Locate the electrical connector for the fuel lock
3
6 3. Disconnect the electrical connector.
7
4. The engine should run out of fuel and stop within
a short period of time.
1. Check bottom cover O-ring seal (6) for damage. NOTE: The length of time the engine runs on
Replace if necessary. trapped fuel vapor increases with any
increase in distance between the fuel lock-
2. Re-assemble the filter assembly aligning the off and the pressure regulator/converter.
scribe lines on the top and bottom covers.
138
Maintenance section
1. Raise the steer wheels off the ground. Block 18. Raise the lift truck and remove the blocking.
the lift truck up with blocking under the frame Lower the lift truck to the ground.
and steer axle.
2. Remove the hub cap.
3. Straighten the lockwasher tangs.
4. Remove the locknut, lockwasher and flat washer.
5. Remove the outer wheel bearing.
6. Remove the wheel assembly.
139
Maintenance section
WARNING
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine
has been stopped and the filler cap is cool
enough to touch with your bare hand.
Remove the filler cap slowly to relieve pressure. G420F(E) 2.0L LPG/Gasoline Engine
Coolant is included antifreeze for forbidding
corrosion. Avoid contact with the skin and eyes
to prevent personal injury.
Use all cleaning solution with care.
NOTICE
Hold the drain port when the radiator drain valve is
turned because the tank and the drain port are
separated.
140
Maintenance section
NOTICE
Inject the coolant additionally into below specific
port of G424I(E) engine besides the radiator if
needs more coolant while clean & change the
cooling system.
10
141
Maintenance section
Fork - Inspect
142
Maintenance section
5. Check the fork blade (J) and shank (H) for wear
with special attention to the heel (G). The fork
should be withdrawn from service if the
thickness is reduced to 90 percent or less of the
original thickness.
143
Maintenance section
Hydraulic Oil - Change, Check, 5. Start the engine and operate the hydraulic con-
trols, and the steering system, through a few
Clean cycles to fill the lines. Look for oil leaks.
WARNING 6. Stop the engine and check the oil level. With all
Hot oil and components can cause personal cylinders retracted, maintain the oil level to the
injury. Do not allow hot oil or components to FULL mark on the breather/dip stick.
contact skin.
Park the lift truck level with the forks lowered, park-
ing brake engaged, transmission in NEUTRAL and
the engine stopped.
144
Maintenance section
G424I(E) Engine
145
Maintenance section
WARNING
When assembling the filters, check the arrow
mark on the filter surface.
The arrow mark position is same as fuel flow
direction.
146
Maintenance section
2. If the TMAP is found to be loose, remove the Replace PCV Valve and breather
TMAP retaining screw and the TMAP sensor
from the manifold adapter.
element (LP-Gas, Gasoline and Dual
Fuel Engines) - Change
3. Visually inspect the TMAP O-ring seal for
damage. Replace as necessary.
G420F(E)
G424I(E)
147
Maintenance section
WARNING
DO NOT OVERTIGHTEN THE SPARK PLUGS.
(1) Ignition wiring harness (2) Ignition Coil Assy (3) Spark plug
148
Maintenance section
149
Index Section
Index
# Cooling System – Clean, Change ....................... 140
Cooling System Specifications............................. 103
12 Months Inspection ........................................... 100 Crosshead Roller - Inspect................................... 129
Crushing or Cutting Prevention.............................. 14
Cylinder Rod Extension-Adjust ............................ 129
A
150
Index Section
151
Index Section
Mast, Carriage, Lift Chains & Attachments - Inspect, Replace Oxygen Sensor ...................................... 149
Lubricate................................................................ 125 Replace PCV Valve and breather element (LP-Gas,
Metric Hardware ................................................... 101 Gasoline and Dual Fuel Engines) - Change ....... 147
Mounting and Dismounting .....................................11 Replace Spark Plugs (G420F(E)/G424I(E) Engine
Moving Fan Warning .................................................8 Only) ...................................................................... 148
N S
T
P
Table of Contents...................................................... 1
Packing brake ............................................................8 Test Fuel System for Leaks ................................. 114
Parking Brake - Test, Adjust ......................... 120,130 Test Operation ...................................................... 120
Parking Brake Lever ................................................47 Testing Fuel Lock-off Operation (LP-Gas Engine
Parking the Lift Truck ..............................................91 Only) ...................................................................... 138
Power Shift Transaxle .............................................84 Tilt Control ............................................................... 48
Power Shift Transaxle(PTA18) ............................ 120 Tilt Cylinders - Check, Adjust, Lubricate ............. 128
Pressure Air .............................................................14 Tilting Steering Column .......................................... 45
Pressure Warning ......................................................7 Timing Belt - Change ............................................ 149
Prestart Conditions ..................................................53 Timing Belt for Counterbalance Shaft - Change . 149
Tire and Wheels - Inspect, Check ....................... 113
To Operate the Lift Truck after a Long Time
R Storage .................................................................... 93
Torque for Metric Fasteners ................................. 102
Reading Diagnostic Fault Codes ............................65 Torque for Standard Bolts, Nuts, and Taperlock
Refill Capacities .................................................... 109 Studs ...................................................................... 101
Refueling ..................................................................49 Torque for Standard Hose Clamps - Worm Drive
Relays.................................................................... 113 ............................................................................... 101
Replace LP Fuel Filter Element (LP-Gas, Dual Fuel Torque Specifications ........................................... 101
Engine Only) ......................................................... 137 Torques for Bolts and Nuts With Standard Threads
............................................................................... 101
Replace Oxygen Sensor (G420F(E)/G424I(E) Torques for Taperlock Studs ................................ 102
Engine Only) ......................................................... 145 Towing Information ................................................. 96
152
Index Section
U
Unloading .................................................................88
W
Walk-Around Inspection – Inspect....................... 116
Walk-Around Inspection ..........................................51
Warning Signs and Labels .................................. 5,17
Wheel Bolts - Inspect ........................................... 115
When Required ..................................................... 112
153