Doosan G25P-5 Manuale di Servizio

Service ManualG424FE LP/Dual Fuel EngineG424F LP EngineG20P-5, G25P-5, G30P-5, G33P-5, G35C-5GC20P-5, GC25P-5, GC30P-5, GC33P-5SB4251E00May. 2007

G424F(FE) Service Manual Chapter 1. General Information 8Replacement Part When oil seal, O-ring, packing and gasket have been removed, b

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 98 16. Second and third connecting rod bearing attaching bolts, with a 14-mm

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 99Obs.: This procedure should be performed with protecting gloves. These procedures shou

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 100• Install the connecting rod upper shell lubricated only in the face turned toward t

G424F(FE) Service Manual Chapter 4. Engine Electrical System 101Chapter 4. ENGINE ELECTRICAL SYSTEM Specifications Ignition Coil Item Specificatio

G424F(FE) Service Manual Chapter 4. Engine Electrical System 102Ignition System Spark-ignited engines require accurate control of spark timing and s

G424F(FE) Service Manual Chapter 4. Engine Electrical System 103MISFIRES DIS problems can include many of the same ailments as other ignition system

G424F(FE) Service Manual Chapter 4. Engine Electrical System 104Spark Plug Wire Inspection Sparking plug wire integrity is vital for proper engine o

G424F(FE) Service Manual Chapter 4. Engine Electrical System 105Spark Plug Replacement Removal Remove or disconnect 1. Remove the spark plug wires

G424F(FE) Service Manual Chapter 4. Engine Electrical System 106b. Best for a loose terminal post by twisting and pulling the post. The terminal post

G424F(FE) Service Manual Chapter 4. Engine Electrical System 107• Reduced ignition system voltage output - Weak coil pack - Worn ignition wires - Inc

G424F(FE) Service Manual Chapter 1. General Information 9Precautions for catalytic Converter CAUTION If a large amount of unburned gasoline flows

G424F(FE) Service Manual Chapter 4. Engine Electrical System 108Alternators The alternators used on these engines have three phase, full-wave, recti

G424F(FE) Service Manual Chapter 4. Engine Electrical System 109Refer to the following troubleshooting table Symptom Possible cause Remedy Fuse cu

G424F(FE) Service Manual Chapter 4. Engine Electrical System 110Troubleshooting Procedure Inspection before Starting 1. Alterna

G424F(FE) Service Manual Chapter 4. Engine Electrical System 111 2. Alternator and outer terminal connection ins

G424F(FE) Service Manual Chapter 4. Engine Electrical System 112 3. Battery outer terminal inspection. Inspection after Starting

G424F(FE) Service Manual Chapter 4. Engine Electrical System 113Drop of Electric Pressure Test of Alternator Output Wire This test is to check that

G424F(FE) Service Manual Chapter 4. Engine Electrical System 1142. Turn the ignition switch OFF. 3. Disconnect the battery ground cable. 4. Disconn

G424F(FE) Service Manual Chapter 4. Engine Electrical System 115STARTING SYSTEM General Description The starting motor is used to turn the engine f

G424F(FE) Service Manual Chapter 4. Engine Electrical System 116 Diagnosis Procedure The following simplified procedure is

G424F(FE) Service Manual Chapter 4. Engine Electrical System 117The result of these switches and relays is to permit a 5 amp dash-mounted switch to t

G424F(FE) Service Manual Chapter 1. General Information 10Tightening Torque Tightening Torque Table of Standard Parts Torque (kg·m) Bolt nominal di

G424F(FE) Service Manual Chapter 4. Engine Electrical System 1185. Is voltage equal to or greater than shown in Figure1? • If the starting motor vo

G424F(FE) Service Manual Chapter 4. Engine Electrical System 119Troubleshooting Starting system problem can be classified into “Start motor is not o

G424F(FE) Service Manual Chapter 4. Engine Electrical System 120Starter Repair Removal Remove or disconnect WARNING Always disconnect the cable a

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 121Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS) General Information Specification

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 122Q’ty Components G424FE G424F Items Specifications Transmission Oil Temperatur

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 123LP Fuel Components Specification Q’ty Components G424FE G424F Items Specific

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 124Q’ty Components G424FE G424F Items Specifications N-2001 LP Regulator For G42

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 125Q’ty Components G424FE G424F Items Specifications CA100 Mixer For G424F None

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 126Service Standard Basic Idle rpm (After warm up) No Load 750±15 rpm Ignit

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 127Component Location Engine Control Module (SECM48) Crankshaft Position Sen

G424F(FE) Service Manual Chapter 1. General Information 11Recommended Lubricants and Capacities Recommended Lubricants Lubricant Specification Rem

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 128Pre-Catalyst Oxygen Sensor Pedal Angle Sensor Transmission Oil Temperat

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 129Electronic Throttle Body Ignition Coil N-2007 LP Regulator Fuel Trim

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 130Gasoline Injectors and fuel rail Gasoline Fuel Pump Ass'y

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 131G424FE EMS (Engine Management System) Overview General Description MI-07 c

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 132Dual Fuel System of G424FE (certified engine system) INPUT

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 133MI-07 System Components The MI-07 control system provides electronic contr

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 134Other system features include: Tamper-Resistance Special tools, equipment,

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 135pressure regulator outlet pressure changes by the same amount and in the same

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 136When an operator turns on the key switch the lock-off is opened, but if the o

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 137 Figure 6. Parts View of N-2007 Regulator Because vapor propane has now left

G424F(FE) Service Manual Chapter 1. General Information 12Engine Model and Engine Serial Number Engine Model Fuel Type Emission Regulation G424FE LP

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 138and air valve spring (6). The gas-metering valve is permanently mounted to th

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 139 Figure 12. Idle Mixture Adjustment Screw (with tamper proof cap removed)

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 140Branch-Tee Fitting A branch-tee fitting is installed in the atmospheric vent

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 141MPI Gasoline System Operation MPI (multi-point injection) system is used for

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 142Electronic Throttle System The electronic throttle system controls engine

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 143There are multiple limp-home modes available with electronic throttle control

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 144and length. There are fewer parts to malfunction on the DIS system when compa

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 145The HEGO stoichiometric air-fuel ratio voltage target is approximately 500 mV

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 146SECM General Description The Small Engine Control Module (SECM) controlle

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 147Speed Management Drive-by-wire refers to the fact that the MI-07 control sy

G424F(FE) Service Manual Chapter 1. General Information 13General Specification G424FE Engine G424F Engine GENERAL DESCRIPTION ENGINE TYPE: Water

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 148Drive-By-Wire Signal Flow Process Figure 22. Drive-By-Wire Signal Flow Proce

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 149SECM Wiring Diagrams for G424FE CAUTION—PROPER WIRING To prevent system f

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 150 Figure 21. SECM Wirin

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 151 Figure 22. SECM Wiring Diagram for G424FE

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 152G424F EMS (Engine Management System) Overview General Description MI-07

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 153LP System of G424F INPUT

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 154MI-07 System Components The MI-07 control system provides electronic contro

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 155Other system features include: Tamper-Resistance Special tools, equipment, k

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 156stage) valve closes. Unlike most other regulator/converters, the N-2001 prima

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 157imbalance on the secondary diaphragm, which overcomes the secondary spring fo

G424F(FE) Service Manual Chapter 1. General Information 14 G424FE Engine G424F Engine COOLING SYSTEM WATER PUMP ROTATION: Toothed Timing Belt Driv

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 158 Figure 9. Parts View of CA100 Mixer A pressure/force imbalance begins to bu

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 159Electronic Throttle System The electronic throttle system of G424F engine is

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 160SECM Wiring Diagrams for G424F LP Engine

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 161EMS Inspection and Repair Engine Control Module (SECM) The 48-pin Small Eng

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 162Outputs • Saturated injector drivers (4) 10A peak, 45 V max, 1 injector

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 163Camshaft Position Sensor (G424FE- Dual Fuel Only) Component Location Desc

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 164Installation 1. Install new O-ring on CMP sensor. 2. Lubricate O-ring with

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 165Crankshaft Position Sensor Component Location Crank Position Sensor Conne

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 166MAP (Manifold Absolute Pressure) Sensor MAP sensor The manifold absolute

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 167IAT (Intake Air Temperature) Sensor MAP sensor The intake air temperature

G424F(FE) Service Manual Chapter 1. General Information 15G424F/G424FE Engine Power and Torque G424FE G424F ENGINE MODEL unit G424FE-LP G424FE-DF(L

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 168Oxygen Sensor (Pre-Catalyst) Component Location Pre - Catalyst Oxygen Sens

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 169Oxygen Sensor (Post-Catalyst) Component Location Description The rear hea

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 170ECT (Engine Coolant Temperature) Sensor Component Location ECT Senser Des

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 171Schematic Diagram [CIRCUIT DIAGRAM] [HARNESS CONNECTORS]

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 172LP Fuel Temperature Sensor Location Description The LP Fuel Temperature S

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 173Angle Sensor-Accelerator Location Description Angle Sensor-Accelerator is

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 174Transmission Oil Temperature Switch Location Description Transmission Oil

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 175Ground Speed Limit Switch (optional) Location Description Groun

G424F(FE) Service Manual Chapter 5. Engine Management System (EMS) 176Electronic Throttle Body Location Description The MI-07 system uses ele

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 177Chapter 6. LPG FUEL DELIVERY SYSTEM G424FE LP System Inspection and Repair Remov

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 16Chapter 2. RECOMMENDED MAINTENANCE Suggested maintenance requirements for an engine

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 178Hose Connections Proper operation of the closed loop control greatly depends on th

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 179DIAGRAM NOTES Trim valves must be positioned vertically with flow arrows in positi

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 180Removal and Installation of N-2007 LP Regulator Follow the procedures below for

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 181Removal and Installation of CA100 Mixer for G424FE Follow the procedures below for

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 182NOTE : A plastic O-ring spacer and an O-ring are inside the mixer/adapter assembly.

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 183Tests and Adjustments WARNING—PROPER USE • LP gas is highly flammable. To preven

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 184 Figure 34. Secondary Stage Test Connection Pressure Test Primary S

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 185 CAUTION • LP gas is highly flammable. To prevent personal injury, keep fire and

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 186 Figure 38. KVaser Communication Adapter Figure 39. Crypt

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 187Factory Adjustment Procedure: NOTE : Be sure engine is fully warm (ECT>167°F [7

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 17Engine Oil Classification Recommended API classification: Above SJ Recommended SAE vis

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 188Field Adjustment Procedure: The idle mixture adjustment should only be necessary o

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 189Parts Description CA100 Mixer for G424FE Engine Parts List of CA100 Mixer (Cert

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 190Exploded View of CA100 Mixer (Certified)

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 191N-2007 Regulator for G424FE Engine Parts List of N-2007 Regulator (Certified) R

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 192Exploded View of N-2007 Regulator (Certified)

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 193G424F LPG System Inspection and Repair Removal and Installation WARNING – PROPE

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 194G424F Fuel System Connections NOTE: Preferred mounting of regulator is off engine.

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 195Removal and Installation of N-2001 LP Regulator/Converter Follow the procedures b

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 196Removal and Installation of CA100 Mixer for G424F Follow the procedures below for

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 197CA100 Mixer Installation Steps 1. Install the vapor fuel inlet fitting onto the

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 18Checking Engine Oil Level 1. Check that the oil level is between “MIN” an

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 198Tests and Adjustments WARNING – PROPER USE • LP gas is highly flammable. To pr

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 199Pressure Test Primary Stage Test Hardware 1. Hand vacuum pump 2. Regulator fue

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 200AVV (Air Valve Vacuum) Testing Purpose of Test Check for excessive or inadequat

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 201 Figure 40. Opening the Service Tool Display Idle Mixture Adjustment N

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 202Power Valve Adjustment 1. The power valve should only be adjusted after the idle s

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 203Parts Description CA100 Mixer for G424F Engine Refer to Figure 45 exploded view o

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 204Exploded View CA100 Mixer Figur

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 205CA100 Disassembly and Service (1) BODY (2)

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 206 4. Clean the heavy end deposits from the mixer body with solvent. Be s

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 207N-2001 Regulator for G424F Engine Refer to Figure 47 exploded view on facing page.

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 193. Refill with engine oil filter. 1) Clean and install the oil drain plug with a new g

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 208Exploded View N-2001-RSA Regulator

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 209N2001 Regulator Disassembly Steps: 1. Remove the six

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 210 Turn the regulator body over with the rear

G424F(FE) Service Manual Chapter 6. LPG FUEL DELIVERY SYSTEM 211N2001 Disassembled Service 1. Clean the primary and secondary valves with soap

G424F(FE) Service Manual 212 Chapter 7. MPI Gasoune Fuel Delivery System Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM Specification Items Specif

G424F(FE) Service Manual 213 Chapter 7. MPI Gasoune Fuel Delivery System Components Location 1. Fuel Tank 2. Fuel Pump (Including full pressure

G424F(FE) Service Manual 214 Chapter 7. MPI Gasoune Fuel Delivery System Fuel Pressure Test Release The Internal Pressure 1. Disconnect the fu

G424F(FE) Service Manual 215 Chapter 7. MPI Gasoune Fuel Delivery System Inspect Fuel Leakage On Connection 1. Connect the battery negative (-) t

G424F(FE) Service Manual 216 Chapter 7. MPI Gasoune Fuel Delivery System Remove Service Tool And Connect the Fuel Line 1. Disconnect the Fuel Pre

G424F(FE) Service Manual 217 Chapter 7. MPI Gasoune Fuel Delivery System Injector Inspection Operation check Operation Sound Check 1. Using a

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 20Cooling System Maintenance Coolant Recommendation The engine cooling system is provid

G424F(FE) Service Manual 218 Chapter 7. MPI Gasoune Fuel Delivery System Inspection 1. Measure the resistance of the injectors between the termin

G424F(FE) Service Manual 219 Chapter 7. MPI Gasoune Fuel Delivery System Fuel Pump Removal (Including Fuel Filter And Fuel Pressure Regulator)

G424F(FE) Service Manual 220 Chapter 8. Basic Troubleshooting Chapter 8. BASIC TROUBLESHOOTING Preliminary Checks MI-07 systems are equipped wit

G424F(FE) Service Manual 221 Chapter 8. Basic Troubleshooting Basic Troubleshooting Guide Customer Problem Analysis Sheet 1. Forklift Informatio

G424F(FE) Service Manual 222 Chapter 8. Basic Troubleshooting Basic Inspection Procedure Measuring Condition Of Electronic Parts Resistance Th

G424F(FE) Service Manual 223 Chapter 8. Basic Troubleshooting Connector Inspection Procedure Handling of Connector 1. Never pull on

G424F(FE) Service Manual 224 Chapter 8. Basic Troubleshooting Checking Point for Connector 1. While the connector is connected: Hold the connec

G424F(FE) Service Manual 225 Chapter 8. Basic Troubleshooting Electrical Circuit Inspection Procedure ● Check Open Circuit 1. Procedures for

G424F(FE) Service Manual 226 Chapter 8. Basic Troubleshooting ● Check Short Circuit 1. Test Method for Short to Ground Circuit • Continuity

G424F(FE) Service Manual 227 Chapter 8. Basic Troubleshooting Symptom Troubleshooting Guide Chart for MPI Gasoline System Engine Is Not Starting

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 21Checking coolant leaks 1. After the coolant temperature drops below 38°C loosen the ra

G424F(FE) Service Manual 228 Chapter 8. Basic Troubleshooting Irregular Idling Or Engine Is Suddenly Stopped

G424F(FE) Service Manual 229 Chapter 8. Basic Troubleshooting Engine Hesitation Or Insuffient Accelelation

G424F(FE) Service Manual 230 Chapter 8. Basic Troubleshooting

G424F(FE) Service Manual 231 Chapter 8. Basic Troubleshooting Troubleshooting Guide for MPI Gasoline System • The following number represents ins

G424F(FE) Service Manual 232 Chapter 8. Basic Troubleshooting

G424F(FE) Service Manual 233 Chapter 8. Basic Troubleshooting Basic Troubleshooting Intermittents An intermittent fault is the most difficult

G424F(FE) Service Manual 234 Chapter 8. Basic Troubleshooting Surges and/or Stumbles Engine power varies under steady throttle or cruise. Feels l

G424F(FE) Service Manual 235 Chapter 8. Basic Troubleshooting Engine Cranking but Will Not Start / Difficult to Start Engine cranks OK, but does

G424F(FE) Service Manual 236 Chapter 8. Basic Troubleshooting Engine Cranking but Will Not Start / Difficult to Start (cont’d.) PROBABLE CAUSE C

G424F(FE) Service Manual 237 Chapter 8. Basic Troubleshooting Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During Acc

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 22Checking and Adjusting Drive Belt 1. Checking tension 1) Press the middle

G424F(FE) Service Manual 238 Chapter 8. Basic Troubleshooting Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During Acc

G424F(FE) Service Manual 239 Chapter 8. Basic Troubleshooting Detonation / Spark Knock A mild to severe ping, usually worse under acceleration.

G424F(FE) Service Manual 240 Chapter 8. Basic Troubleshooting Backfire Fuel ignites in intake manifold or in exhaust system, making loud popping

G424F(FE) Service Manual 241 Chapter 8. Basic Troubleshooting Rough, Unstable, Incorrect Idle, or Stalling Engine cranks OK, but does not start f

G424F(FE) Service Manual 242 Chapter 8. Basic Troubleshooting Rough, Unstable, Incorrect Idle, or Stalling (cont’d.) PROBABLE CAUSE CORRECTIVE A

G424F(FE) Service Manual 243 Chapter 8. Basic Troubleshooting Cuts Out, Misses Steady pulsation or jerking that follows engine speed, usually mor

G424F(FE) Service Manual 244 Chapter 8. Basic Troubleshooting Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell Fuel economy, as m

G424F(FE) Service Manual 245 Chapter 8. Basic Troubleshooting High Idle Speed Engine idles above the range of 750-1100 rpm. PRELIMINARY CHECKS P

G424F(FE) Service Manual 246 Chapter 8. Basic Troubleshooting Excessive Exhaust Emissions or Odors Vehicle has high CO emissions. NOTE: Excessi

G424F(FE) Service Manual 247 Chapter 8. Basic Troubleshooting Diagnostic Aids for Rich / Lean Operation SERVICE TOOL ITEM RICH LEAN Pre-catalys

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 23Ignition System Maintenance Inspect Battery System • Clean battery outer surfaces wi

G424F(FE) Service Manual 248 Chapter 8. Basic Troubleshooting Chart T-1 Restricted Exhaust System Check Proper diagnosis for a restricted exhaust

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 249Chapter 9. ADVANCED DIAGNOSTICS MI-07 systems are equipped with built-in fault diagn

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 250Fault Action Descriptions Each fault detected by the SECM is stored in memory (FIFO)

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 251Table 1. Fault List Definitions FAULT DESCRIPTION CODE (MI04 CODE) APP1AdaptHiMax Le

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 252Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) CamEdge

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 253Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) EST1_Op

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 254Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) ETCS

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 255Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) GasF

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 256Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) Hbri

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 257Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE)LSDFa

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 24Inspection of Spark Plug Inspection and clean 1) Ignition cable 2) Igniti

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 258Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) LiqPost

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 259Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) SensVol

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 260Table 1. Fault List Definitions (cont’d.) FAULT DESCRIPTION CODE (MI04 CODE) TPS2

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 261Table 2. Diagnostic Fault Codes (Flash Codes) DFC PROBABLE FAULT FAULT ACTION* COR

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 262Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 263Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTI

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 264Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 265Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT AC

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 266Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 267Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTIO

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 25Spark Plugs 5. Install the spark plug and tighten it to the specified torque. Take car

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 268Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACTIO

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 269Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 270Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 271Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 272Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 273Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 274Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 275Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 276Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 277Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 26Fuel System Maintenance Replace LP Fuel Filter Element Park the lift truck in an auth

G424F(FE) Service Manual Chapter 9. Advanced Diagnostics 278Table 2. Diagnostic Fault Codes (Flash Codes) cont’d. DFC PROBABLE FAULT FAULT ACT

G424F(FE) Service Manual 279 Appendix Appendix Service Tool Software (MotoView) Introduction The MI-07 Service Tool is a graphic interface to the

G424F(FE) Service Manual 280 Appendix A334071 Extension Cable (L=200 cm) A334082 Extension Cable (L=20 cm) Connection of the Service

G424F(FE) Service Manual 281 Appendix MotoView Display Screens Service Screen Tab The first screen displayed when connecting to the SECM-48 is the

G424F(FE) Service Manual 282 Appendix AFR (Air Fuel Ratio) Control The AFR Control category is divided into two separate sections, one for LP and a

G424F(FE) Service Manual 283 Appendix Faults Screen Tab The second available screen in the service tool display is the Fault screen. All ten stor

G424F(FE) Service Manual 284 Appendix Ground Speed Screen Tab The Ground Speed screen displays parameters for the ground speed option. The Engi

G424F(FE) Service Manual 285 Appendix DFC 12-353 Screen Tab Figure 10. Diagnostic Fault Codes 12-43 Screen D

G424F(FE) Service Manual 286 Appendix DFC 371-641 Screen Tab Figure 11. Diagnostic Fault Codes 371-641 Screen

G424F(FE) Service Manual 287 Appendix DFC 642-995 Screen Tab Figure 12. Diagnostic Fault Codes 642-995 Screen

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 27Pressure Regulator/Converter Inspection • Visually inspect the pressure regulator/con

G424F(FE) Service Manual 288 Appendix Signal I/O Screens 1-4 There are four Signal I/O (Inputs & Outputs) screens available to assist in tr

G424F(FE) Service Manual 289 Appendix Manual Override Screens 1 & 2 There are two manual override screens available for the technician to t

G424F(FE) Service Manual 290 Appendix Switched Components To override a switched state component such as the LP lock-off, enter the desired ON/OF

G424F(FE) Service Manual 291 Appendix Manual Spark Advance To override the ignition spark advance place your mouse pointer over the Lock Spark Ad

G424F(FE) Service Manual 292 Appendix Manual Override Screen 2 Components that can be overridden on override screen 2 include the Low Oil Pressure

G424F(FE) Service Manual 293 Appendix SECM field update with Service Tool SECM controllers can be upgraded in the field using MotoUpdate software.

G424F(FE) Service Manual 294 Appendix STEP 2 - CONNECT THE COMPUTER Prior to launching the MotoUpdate software, a valid Criptoken must be installed

G424F(FE) Service Manual 295 Appendix The next screen will provide a list of all of the available software upgrades available for the current engine

G424F(FE) Service Manual 296 Appendix STEP 4 - PROGRAM THE MODULE Once the desired upgrade is located and highlighted, select Next to upgrade ithe

G424F(FE) Service Manual 297 Appendix Ground Speed Limits (Option) The maximum allowable speed of Doosan forklifts is an optional feature that can

1 Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rul

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 28Maintenance Schedule NOTE: The MI-07 fuel system was designed for use with LPG fuel th

G424F(FE) Service Manual 298 Appendix How to Set New Speed Limit Maximum RPM for both the NEUTRAL state (Normal) and IN-GEAR state (Speed Limiting)

G424F(FE) Service Manual 299 Appendix LPG And LPG Fuel Tanks LPG Fuel Supply Liquefied petroleum gas (LPG) consists mainly of propane, propylene,

G424F(FE) Service Manual 300 Appendix LPG Fuel Tanks The two styles of LPG storage containers available for industrial use and lift truck applicati

G424F(FE) Service Manual 301 Appendix Fuel Gauge In figure 5 a visual fuel gauge is used to show the fuel level in the tank. A mechanical float mec

G424F(FE) Service Manual 302 Appendix Most liquid service valves have an internal hydrostatic relief valve and are usually labeled “LIQUID WITH INTE

G424F(FE) Service Manual 303 Appendix Regulatory Compliance EPA / CARB Emissions Certification When properly applied and calibrated, ’s MI-07 c

G424F(FE) Service Manual 304 Appendix Abbreviations ACFM AFR BHP Bi-Fuel CTS CNG Dual Fuel ECM FPP FPV FTS FTV GPM HEGO LAT LPG MAP MAT MIL M

G424F(FE) Service Manual Chapter 2. Recommended Maintenance 29

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 30Chapter 3. ENGINE MECHANICAL SYSTEM General Information Engine Outline

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 31Technical Specifications CRANKSHAFT Maximum saddle taper...

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 32CYLINDER HEAD Valve seat angle (all) ...

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 33Shells Selection Table MAIN BEARINGS – STANDARD SIZE (*)

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 34 MAIN BEARINGS – 0.50 UNDERSIZE (*)

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 35 CONNECTING ROD BEARINGS CONNECTING ROD BEARINGS 0.25 UNDERSIZE

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 36Recommended Torque Values nuts N•m Starter to cylinder block 45 Exhaust manifold

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 37bolts N•m Oil pan to cylinder block 18-22 Con–rod bearing cap to con–rod 30-40+

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 38Troubleshooting Symptom Possible cause Remedy Low compression Cylinder head gasket

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 39Engine Exploded View (1 of 2) 1) RING KIT

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 40Engine Exploded View (2 of 2) 1) ENGINE 3)

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 41Intake manifold and gasket Components 1)

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 42Removal Remove or Disconnect 1. Relieve of fuel line pressure: • Fuel-off solenoid

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 43Installation Install or connect 1. Coolant pipe attaching bolt with cylinder block i

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 4414. Connect wiring to the injectors. 15. Connect the PCV hose between PCV and fitting

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 45Exhaust Manifold and Gasket Components 1) Gas

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 46Removal Remove or disconnect 1. Spark plug cable terminals; 2. Exhaust manifold hea

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 47Timing Belt Components 1) Cover 2) Bolt

G424F(FE) Service Manual Index 3Index Chapter 1. GENERAL INFORMATION Precautions before Service...7 Tightening Torque

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 48Removal Remove or disconnect 1. Crankshaft pulley; see “Crankshaft Pulley – Removal”

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 49Description Specification 1. Back side rubber is hardened Glossy back side. Due to

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 50Installation Install or connect Important • Align the camshaft timing pulley mark w

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 51Timing Belt Tensioner Removal Remove or disconnect 1. Timing belt; see instructions

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 52PCV Valve Outline and Operation Principle Engine condition No

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 53Crankcase Ventilation CamCarrierCylinderHeadEngineB

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 54Service Procedure REMOVAL 1. After disconnecting the vacuum hose (A), r

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 55Camshaft Timing Pulley and/or Seal Removal Remove or disconnect 1. Timing belt; see

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 56 Crankshaft Front Seal Removal Remove or disconnect 1. Ti

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 57Camshaft Case Cover and Gasket Removal Remove or disconnect 1. Spark plug cables fr

G424F(FE) Service Manual Index 4Crankshaft Accessory Pulley... 57 Timing Belt Rear Cover ...

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 58Timing Belt Rear Cover Removal Remove or disconnect 1. Timing belt; See “Timing Bel

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 59Rocker Arms, Linkage, Valve Lifters With Cylinder Head and Engine Removal Remove or

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 60Cooling System General Description Cooling System Schematic

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 61 The thermostat housing has two outlet ports. Upper outlet p

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 62Testing and Adjusting Adhere to the following warnings when performing any tests or a

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 63Pressure Cap Test Pressure Cap Diagram (A) Sealing surface of cap and

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 64Thermostat The thermostat is the wax pellet type. A jiggle valve (which improves a

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 65NOTE: Another condition that can cause heat problems is the ignition timing. Retarded

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 66Make proper antifreeze additions. Adding pure antifreeze as a makeup solution for coo

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 67 Water Pump Removal Remove or disconnect 1. Drain the coolant loosening

G424F(FE) Service Manual Index 5EMS Inspection and Repair... 161 Engine Control Module (SECM) ... 161 Camsha

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 68Lubrication System General Description

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 69Testing and Adjusting Adhere to the following warnings when performing any tests or a

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 70Too Much Oil Consumption • Engine outside oil leakage Check for leakage at the se

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 71Oil Pan Removal Remove or disconnect 1. Drain the oil on a proper container, removi

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 72Oil Pump Removal Remove or disconnect 1. Timing pulley rear cover; see “Timing Pull

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 73Important • The Tensioner roller lug (1) should be positioned in the guide housing (2

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 74Tighten • Switch: 30 – 50 N·m (22 – 36,7 lb·ft) 10. Install the oil pump; see “Oil P

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 75 8. Camshaft cover-to-cylinder block breather hose, with special clamp pli

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 76 28. Attach the camshaft case on a vise. Obs.: Use protecting jaws in the

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 77 11. With a Torx T-55 or 19-mm socket wrench, according to th

G424F(FE) Service Manual Index 6Acceleration... 237 Detonation / Spark Knock...

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 78Tighten • Bolt: 18 – 28 N·m (13 – 20.5 lb·ft.) 26. With a 15-mm socket wrench and to

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 79Tighten • Nuts: 18 – 22 N·m (13 – 16 lb·ft.) Obs.: Tighten the intake manifold nut

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 80Important • If the lash is out of the specification, which is 0.015 – 0.042 mm (inta

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 81 Engine Disassembly Removal Remove or disconnect 1. Engine

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 82 22. Spark plugs, with a proper wrench. 23. Clutch assembly

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 8334. Install two flywheel attaching bolts in the crankshaft, to rotate the latter and e

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 84

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 85Important: • Whenever the crankshaft is removed, it should be positioned standing up

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 86 8. Connecting rod cap with the lower shell lubricat

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 87 21. Camshaft case. 22. New cylinder head attac

G424F(FE) Service Manual Chapter 1. General Information 7Chapter 1. GENERAL INFORMATION Precautions before Service Removal and Disassembly

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 88Tighten • Bolts: 6 – 10 N·m (4.4 – 7 lb·ft.). • Nut: 6 – 8 N·m (4.4 – 5.8 lb·ft.).

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 89 39. Timing pulley front cover and attaching bol

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 9054. Engine assembly; see “Engine Assembly – Installation”, in this section. Cylinder

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 91 Crankshaft Removal Re

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 92• Note the trunnions and journals maximum concentricity, which could be 0.005 mm. •

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 935. Tighten the main bearing attaching bolts, with a Torx E12 wrench, extension and tor

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 949. Connecting rod cap bolts, without fully tightening, with a 14-mm socket wrench and

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 9522. New cylinder head attaching bolts, in the indicated sequence, with a Torx E55 wren

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 96Tighten • Bolts: 4 – 10 N·m (3 – 7 lb·ft.). 38. Timing belt. Important • Timing

G424F(FE) Service Manual Chapter 3. Engine Mechanical System 9747. A new seal ring in the crankcase phase and reference sensor. 48. Crankshaft phase