Tier Dual Fuel System (Gasoline)
Contents
1. e gt FUEL MIL o SELECT RELAY 2 a 2 1 2 o e 5 1206 314 2131124 16531156 OXYGEN SENSOR TMAP SENSOR SMART COIL ELECTRONIC THROTTLE A B4C D z SEED n n n B NC 1 1 23 C 2 FUEL SELECT SWITCH A B A B FUEL PUMP FUEL LOCK OFF FUEL TRIM VALVE FUEL INJECTOR Figure E2 G424E G430E Tier I Dual Fuel Engine 24 Electrical Connections G430E Dual Fuel Electrical Connection Ignition Switch 5 S ou Main PWR Relay Battery Zn N SECM Fuel Injector MIL D Electronic Throttle S Fuel Pump H 1 Lock Off il Distributor E ME ny Valve SS Sensor ECT Sensor Oxygen DBW Sensor Foot Pedal 5 Oil Pressure Switch ENS Figure E1 G424E G430E Tier I Dual Fuel Engine 25 Electrical Connections CAN BUS CONNECTOR FEMALE 1 z z lt lt 0 SECM CONNEC2. WHEN SWITCHING FROM ieG TO LOUD FUEL SURE THAT THERE 15 NO SPILLAGE OF FUEL FROM THE CARBURETOR FLOAT SYSTEM Fuel Select Switch ay E 2 Gasoline 3 Filter ene Gasoline Filter Electric Fuel Pump Mounting locations shown are specific to G20 25 30E 3 model G424E G430E Tier Dual Fuel Engine The pump discharge is located on the electrical terminal side of the pump Both fuel filters and fuel pump have a specific inlet orientation to fuel flow which should be noted upon installation Figure 24 System Operational Overview The fuel pressure regulator returns fuel to the tank through the return line when the fuel pressure is too great Figure 25 Figure 26 shows the fuel pressure regulator mounted near the battery tray Figure 25 A single fuel injector is controlled by the SECM and when energized meters fuel before the throttle into the mixer to throttle adapter For proper fuel atomization and delivery to the throttle a separate venturi booster section has been installed inside the mixer to throttle adapter Figure 26 WARNING AN The gasoline fuel injection system of the MI 04 system operates at a fuel pressure of 270 Kpa 39psi Pressurized fuel is present in the fuel lines when the engine is not running Safety glasses should be worn at all times when removing fuel lines or eye injury may occur Avoid directing high pressure fuel spray onto hot e
3. EXHAUST SYSTEM Cast Iron Dry VALVE CONFIGURATION 2 Valves per Cylinder DISPLACEMENT 2 350 cc 143 CID BORE 86 5 mm 3 41 in STROKE 100 mm 3 94 in COMPRESSION RATIO 8 6 1 COMPRESSION PRESSURE 1 128 kPa 163 5 psi Intake Valve 12 BTDC Open 40 ABDC Close VALVE TIMING Exhaust Valve 54 BBDC Open 6 ATDC Close FIRING ORDER 1 3 4 2 SPARK PLUGS BPR5ES 0 7 0 8 mm 0 028 0 031 in Air Gap WEIGHT 146 Kg 322 Ibs Dry ROTATION Counter Clockwise CCW when viewed from Flywheel End FUELTYPE LPG Gasoline GOVERNED SPEED 2600 25 RPM IDLE RPM 700 25 RPM for LPG 750 25 RPM for Gasoline IGNITIOIN TIMING Electronic controlled by ECM LP FUEL SYSTEM MIXER Piston Type Air Valve Assembly inside Downdraft REGULATOR Two Stage Negative Pressure Regulator FUEL FILTRATION 40 Microns Maximum GASOLINE FUEL SYSTEM FUEL FILTER PRIMARY 60 Microns FUEL PUMP Electric Fuel Pump 12V FUEL FILTER SECONDARY 10 Microns GASOLINE REGULATOR ASM Gasoline Pressure Regulator 270kPa FUEL INJECTOR ASS Y Electric Fuel Injector 12V COOLING SYSTEM WATER PUMP ROTATION V Belt Drive Clockwise CW when viewed from engine front THERMOSTAT Opening Temperature 82 C 180 F Fully Open Temperature 95 C 203 F COOLING WATER CAPACITY 3 1
4. CHAPTER 6 ELECTRICAL CONNECTIONS G424E Dual Fuel Electrical Connection Ignition Switch 7 5 Main PWR Relay 24 4 Fuel Select Switch Fuel Injector Fuel ace Throttle NE Ey Fuel Pump NU ll TMAP Sensor di Smart Coil Valve d WE Es VR Sensor ECT Sensor DBW Im Sensor Foot Pedal Oil Pressure Switch Figure E1 G424E G430E Tier I Dual Fuel Engine 23 Electrical Connections CAN BUS CONNECTOR FEMALE SECM CONNECTOR SECM CONNECTOR MALE i E 5 a 5 amp 5 z Oe 120 OHM 3 Es g ii 5 2 pee te E a a Z 8 Z ENT sa sa EES 22 ed C AA AA STR SE X D m uou 1323 5621 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 APP GNDo APP PWR a LOW 2 OIL APP1 FUEL SELECT 5 RELAY 4 N
5. Clockwise CW when viewed from engine front THERMOSTAT Opening Temperature 82 C 180 F Fully Open Temperature 96 C 205 F COOLING WATER CAPACITY 3 8 L block only LUBRICATION SYSTEM OIL PRESSURE MIN HOT 28 kPa 4 psi 700 RPM 124 kPa 18 psi 2000 RPM Upper Limit 130 C 266 F OIL TEMPERATURE Recommended 99 110 C 210 230 F Lower Limit 80 C 176 F CRANKCASE CAPACITY 3 8 L 4 0 qts OIL FILTER 0 95 L 1 qt ENGINE OIL SPECIFICATION API SJ SAE 10W30 ENGINE ELECTRICAL IGNITION TYPE Electronic Advanced by ECM IGNITION COIL 12 V operation volt DISTRIBUTOR Delco EST Distributor with ignition module STARTER MOTOR 12 Volt 2 0 kW ALTERNATOR 12 Volt 61 Amp ENGINE OIL PR S W 21 4 kPa 3 1 psi ENGINE CONTROL MODULE ECM 12 V operation volt 24 pins of I O VR SENSOR Magnetic pick up sensor assembled on Flywheel Housing TMAP Intake Air Temp amp Manifold Absolute Press Sensor PEDAL ANGLE SENSOR Installed on Accelerator Pedal OXYGEN SENSOR Heated Exhaust Gas Oxygen Sensor HEGO 12 V operation volt ECT ECM Engine Coolant Temperature Sensor for ECM G424E G430E Tier Dual Fuel Engine Engine Specification Engine Coolant Temp Sensor for GAUGE on Sel etd Instrument Panel TPS Throttle Position Sensor built in Throttle Body THROTT
6. the FTV signal wire Set the range for 4 or 40 and the MIN MAX setting to usually the default setting of the meter The multimeter will then read the Duty Cycle percentage the same as the Service Tool In order to use the Service Tool a USB Universal Serial Bus to CAN Controller Area Network communication adapter by Kavaser will be required along with a Crypt Token Figure G7 The Crypt Token acts as a security key allowing the laptop to retrieve the necessary data from the SECM Figure G8 1 Install the Crypt Token in an available USB port in the computer Figure G8 2 With the ignition key in the OFF position connect the Kavaser communication cable from a second USB port on the computer to the CAN communications cable on the engine If your laptop computer does not have a second USB port an appropriate USB Hub will need to be used G424E G430E Tier Dual Fuel Engine 3 Connect a timing light to the engine 4 Turn the ignition key to the ON position Do Not Start the Engine 5 Launch the MotoView program on your computer and open the Service Tool display 6 Start the engine you should now see the idle RPM on your Service Tool display Run Screen Figure G9 NOTE 1 Service Tool software MotoTuneViewer and the security Crypt Token is obtainable by certified technicians through authorized dealers TEST AND ADJUSTMENTS FTV DUTY CYCLE 4 02 SENSOR VOLTS MAP INTAKE MANIFOLD TEMP C
7. may not set a fault code by the Small Engine Control Module SECM Below are basic checks that should be made before referring to the Advanced Diagnostics section if engine or drivability problems are encountered Consider all parts of the ignition and mechanical systems as well as the fuel system Probable Cause Corrective Action Fuel tank empty Fill fuel container Engine Cranking The tank should be at least 1 4 full to properly but Will Not Start prime the fuel pump Gas Fuel select switch is not on GAS Clogged fuel filter Repair replace as required See Primary and Secondary Fuel Filter replacement Improper fuel supply line Check connection connection between the tank Verify correct hose connections and the fuel pump Clamps must be tight Look for kinked pinched and or collapsed hose Electric Fuel Pump malfunction Check electrical connection GAS Check Relay and fuse Turn key ON and verify pump is operating Fuel Pressure regulator Test pressure regulator operation malfunction See Tests and Adjustments Fuel Injector malfunction Test Injector operation See Tests and Adjustments Incorrect air fuel or See Advanced Diagnostics ignition spark control No VR Sensor Signal Verify the VR signal is present See Advanced Diagnostics G424E G430E Tier Dual Fuel Engine 16 Basic Troubleshooting Problem Probable Cause Corrective Action Difficult to Start Gas Fuel tank almost em
8. pressure of the system a pressure gauge and T fitting must be installed before the pressure regulator to measure fuel pump supplied pressure or after the pressure regulator to measure regulated pressure The gasoline fuel injection system of the MI 04 system operates at a fuel pressure of 270 Kpa 39psi Pressurized fuel is present in the fuel lines when the engine is not running Safety glasses should be worn at all times when removing fuel lines or eye injury may occur Avoid directing high pressure fuel spray onto hot engine components As a quick check of fuel system performance the tank return line from the regulator can be removed from the tank fitting and placed into a small empty fuel container or fuel catch If the fuel pump is supplying sufficient fuel pressure and the regulator is functioning properly the regulator will bypass fuel through the return line while the engine is running no fuel is bypassed through the return line while the engine is running insufficient fuel pressure may be the cause either from a faulty fuel pump or clogged fuel filter If the fuel pump and regulator are supplying sufficient fuel pressure to the fuel injector the fuel injector may be faulty and can be checked with a universal Noid test light FIGURE F2 Figure F2 Universal 278000 Noid Test Light G424E G430E Tier Dual Fuel Engine 32 To check for SECM signal pulses to the fuel injector si
9. vapor connection between the pressure regulator converter and the mixer Check connection Verify no holes in hose Clamps must be tight Look for kinked pinched and or collapsed hose Pressure regulator malfunction Test pressure regulator operation See Tests and Adjustments Poor High Speed Performance Gas Air Fuel Mixer malfunction Check mixer See Air Fuel mixer section Restricted exhaust system Check exhaust system Measure exhaust back pressure Incorrect ignition control Incorrect air fuel control Incorrect throttle position See Advanced Diagnostics amp Tests and Adjustments G424E G430E Tier Dual Fuel Engine 20 Basic Troubleshooting CHAPTER 5 MI 04 ADVANCED DIAGNOSTICS Fault List Definitions Several sensors in the MI 04 system have input low high faults and a sensor range fault These are the coolant temperature sensor the throttle position sensor and the pedal position sensors Signals to these sensors are converted into digital counts by the SECM A low high sensor fault is normal set when the converted digital counts reach the minimum of 0 or the maximum of 1024 1024 5 0 VDC with 204 counts per volt A sensor range fault is set if the parameter measured by the sensor is outside the normal operating range 1024 Counts Input High 0 Counts Input Low Figure F1 Injector Fault Fuel Injector Fault is normally set when the
10. 5 4192 00 Tier I Dual Fuel System Gasoline G424E G430E Tier I Dual Fuel Engine Lift Trucks G20E 3 G25E 3 G30E 3 G32E 3 with G424E Tier Dual Fuel Engine G20P 3 G25P 3 G30P 3 G32P 3 G33P 3 with G430E Tier Dual Fuel Engine 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 A WARNING Improp
11. 5 500TR AIR FUEL MIXER Installing the Mixer Throttle Assembly G424E Dual Fuel GASKET INTAKE MANIFOLD ADAPTER INTAKE MANIFOLD BRACKET TMAP BOLT TMAP BRACKET TMAP SENSOR WASHER TMAP MTG BOLT TMAP MTG BOLT ADAPTER GASKET ITB THROTTLE BODY ITB 32MM O RING O RING SPACER LP MIXER CA55 FITTING ORIFICE GASKET MIXER AIR HORN GASKET MIXER ADAPTER SCREW CAP IDLE SCREW FITTING FUEL G424E G430E Tier Dual Fuel Engine 28 20 21 INJECTOR ASSEMBLY FUEL HOSE VENTURI VENTURI SPACER APOLLO ADAPTER BOLT INJECTOR MTG WASHER SPRING SET SCREW O RING FITTING BOLT END PLUG WASHER BOLT AIR HORN ADAPTER WASHER BOLT FITTING VENTILATION COOLANT TEMP SENSOR ECM N CA55 500TR Mixer Installing the Mixer Throttle Assembly G430E Dual Fuel GASKET INTAKE MANIFOLD ADAPTER INTAKEMANIFOLD BRACKET TMAP BOLT TMAP BRACKET FITTING OUTLET FITTING INLET TMAP WASHER TMAP MTG BOLT TMAP MTG BOLT ADAPTER GASKET ITB THROTTLE BODY O RING O RING SPACER MIXER FITTING ORIFICE GASKET MIXER AIR HORN GASKET MIXER ADAPTER SCREW CAP IDLE SCREW FITTING TO CONVERTER INLET G424E G430E Tier Dual Fuel Engine 29 INJECTOR ASSEMBLY FUEL HOSE VENTURI VENTURI SPACER APOLLO ADAPTER FOR DUAL FUEL BOLT INJECTOR MTG WASHER SET SCREW O RING FITTING TO TRIM V V BOLT END PLUG BO
12. CATALYTIC MUFFLER Three way Catalyst included G424E G430E Tier I Dual Fuel Engine 6 Engine Specification Specifications G430E Dual Fuel Engine GENERAL DESCRIPTION ENGINE TYPE Water cooled Inline 4 Cycle 4 Cylinders COMBUSTION SYSTEM Naturally Aspirated 1 Venturi Intake Manifold EXHAUST SYSTEM Cast Iron Dry VALVE CONFIGURATION Pushrod Actuated Overhead Valves 2 Per Cylinder DISPLACEMENT 2 967 181 CID BORE 101 60 mm 4 00 in STROKE 91 44 mm 3 60 in COMPRESSION RATIO 9 25 1 COMPRESSION PRESSURE 690 kPa 100 psi Minimum FIRING ORDER 1 3 4 2 SPARK PLUGS AC R46TS 0 9 mm 0 035 in Air Gap WEIGHT 165 Kg 363 Ibs Dry ROTATION CCW when viewed from Flywheel FUELTYPE LPG Gasoline GOVERNED SPEED 2500 25 RPM IDLE RPM 700 25 RPM for LPG 750 25 RPM for Gasoline IGNITIOIN TIMING Electronic controlled by ECM LP FUEL SYSTEM MIXER Piston Type Air Valve Assembly inside Downdraft REGULATOR Two Stage Negative Pressure Regulator FUEL FILTRATION 40 Microns Maximum GASOLINE FUEL SYSTEM FUEL FILTER PRIMARY 60 Micron ELECTRIC FUEL PUMP Electric Fuel Pump 12V FUEL FILTER SECONDARY 10 Micron GASOLINE REGULATOR ASM Gasoline Pressure Regulator 270kPa FUEL INJECTOR ASS Y Electric Fuel Injector 12V COOLING SYSTEM WATER PUMP ROTATION V Belt Drive
13. EST Test Mode Injector Diagnostics Inactive To check the actual fuel discharge from the fuel eem injector remove the fuel injector mounting bolt from IGNITION TEST onion Diagnostics Inactive the mixer to throttle adapter and remove the fuel 5 Click to Start Test injector Place the fuel injector in an appropriate fuel FTV TEST TestMode Ready container so that any fuel spray from the injector will remain in the container during the test You can Es simply crank the engine and visually watch the fuel hil rar injector open or if available you may use the injector RPM test in the Service Tool software ENGINE STATE STALL AFR CONTROL MODE Open Loop THROTTLE TEST 0 Test Mode Diagnostics Inactive SPARK ANALOG EST 610 Unlocked SPARK ADVANCE 15 0 0 00 COIL DWELL 1 090 COOLANT TEMP 0 00 COOLANT TEMP 32 INJECTOR UNITS INJECTOR PULSE WIDTH ms LIQUID 02 INTEGRATOR 0000 mg per pulse LIQUID ADAPTIVE LEARN 0 00000 1 NRUN SCREEN rev B TEST SCREEN rev B FAULT LIST rev B Figure G3 Figure G4 NOTE 1 Take care not to lose the injector spacer when removing the fuel injector FIGURE To use the injector test in the Service Tool software G3 simply select the checkbox to the right of the INJECTOR TEST FIGURE G4 The box will change to read Enabled and the test mode w
14. L block only LUBRICATION SYSTEM OIL PRESSURE 50 kPa 7 psi Low Idle 450 kPa 65 psi Hi Idle Upper Limit 125 C 257 F OIL TEMPERATURE Recommended 99 110 C 210 230 F Lower Limit 80 C 176 F CRANKCASE CAPACITY 3 7L OIL FILTER 031 ENGINE OIL SPECIFICATION SJ SAE 10W30 or SAE 5W30 ENGINE ELECTRICAL IGNITION TYPE Electronic Advanced by ECM IGNITION COIL 12 V operation volt Ignition driver circuitry inside DISTRIBUTOR Mitsubishi Distributor STARTER MOTOR 12 Volt 1 2 kW Reduction drive ALTERNATOR 12 Volt 61 Amp ENGINE OIL PR S W 24 5 kPa 3 6 psi ENGINE CONTROL MODULE ECM 12 V operation volt 24 pins of I O VR SENSOR Magnetic pick up sensor assembled on Timing belt cover TMAP Intake Air Temp amp Manifold Absolute Press Sensor PEDAL ANGLE SENSOR Two Output Signals Installed on Accelerator Pedal OXYGEN SENSOR Heated Exhaust Gas Oxygen Sensor HEGO 12 V operation volt 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 G424E G430E Tier Dual Fuel Engine 5 Engine Specification THROTTLE BODY Electronic Throttle Body FUEL TRIM VALVE FTV 12 V operation volt LP FUEL LOCK OFF 12 V operation volt ON OFF Control by ECM EXHAUST SYSTEM
15. LE BODY Electronic Throttle Body FUEL TRIM VALVE FTV 12 V operation volt LP FUEL LOCK OFF 12 V operation volt ON OFF Control by ECM EXHAUST SYSTEM CATALYTIC MUFFLER Three way Catalyst included G424E G430E Tier Dual Fuel Engine 8 Engine Specification CHAPTER 2 DUAL FUEL SYSTEM OPERATIONAL OVERVIEW 04 General Description Woodward s MI 04 control system is designed to provide a complete fully integrated solution that will meet or exceed TIER 2 Large Spark Ignited Engines emission standards established by the California Air Research Board CARB and the Environmental Protection Agency EPA for 2004 The MI 04 is a closed loop system utilizing a catalytic muffler to reduce the emission level in the exhaust gas In order to obtain maximum effect from the catalyst an accurate control of the air fuel ratio is required A small engine control module SECM uses a heated exhaust gas oxygen sensor HEGO in the exhaust system to monitor exhaust gas content MI 04 Dual Fuel System of G424E Engine EED Fuel Line Fault Light Key switch LP Fuel Filter Fuel Lock Foot Pedal E Fuel Select Switch N d b APP 4 gt Converter Air Cleaner Fuel Pump Fuel Trim Mixer Fuel Injector al DBW Throttle Engine Oxygen Sensor N Distributor Smart Coil 4 VR Sensor amp Oil P
16. LT ITB CONN AIR HORN ADAPTER WASHER AIR HORN BOLT AIR HORN PLUG HOSE COOLANT FORMED CLAMP HOSE WATER PUMP CLAMP HOSE FITTING N CA55 500TR Mixer CHAPTER 8 TEST AND ADJUSTMENTS WARNING e LP gas is highly flammable To prevent personal injury keep fire and flammable materials away from the lift truck when work is done on the fuel system e Gas vapor may reduce oxygen available for breathing cause headache nausea dizziness and unconsciousness and lead to injury or death Always operate the forklift in a well ventilated area e Liquid propane may cause freezing of tissue or frostbite Avoid direct contact with skin or tissue always wear appropriate safety protection including gloves and safety glasses when working with liquid propane CAUTION N The regulator converter and mixer are part of a certified system complying with EPA and CARB 2004 requirements Only trained certified technicians should perform disassemble service or replacement of the regulator converter or mixer G424E G430E Tier Dual Fuel Engine 30 TEST AND ADJUSTMENTS Testing the Gasoline Fuel Delivery System Gasoline System Test Hardware 1 Universal 278000 Noid test light 2 Pinch off pliers hose clamp or Vise Grip type pliers 3 Small fuel catch container Operating fuel pressure of the gasoline system is 270 Kpa 39 psi At least 14 of the fuel tank should be filled with fuel to provide a proper fuel prime from the tan
17. OOLANT TEMP COOLANT TEMP 7 Adjust the idle mixture screw on the mixer until a reading of 25 40 is reached for the FTV Duty Cycle in Closed Loop Idle Figure G12 8 To make this adjustment you will need to adjust the idle mixture screw all the way inward If the FTV Duty Cycle measures between 25 4096 no further adjustment is necessary f the measured FTV Duty Cycle is above 40 adjust the screw outward until the duty cycle drops below 40 9 Use the accelerator pedal to increase RPM above idle momentarily Rev the engine then release the pedal to return to idle RPM The duty cycle setting should remain within the adjustment range 25 4096 Place your thumb over the adjustment port for a more accurate reading by preventing air from leaking past the mixture adjustment screw which may cause the duty cycle to decrease 10 To obtain an accurate FTV Duty Cycle reading when the tamper proof cap is not installed place your thumb over the idle screw port so that no air will leak past the screw threads 11 If the FTV Duty Cycle reading is above 40 adjust the idle adjustment screw outward and re check the duty cycle reading Continue to do this until the FTV Duty Cycle reading is within the optimum range 25 4096 DO NOT adjust the Screw so far outward that the tamper proof cap cannot be installed A duty cycle measurement at Closed Loop Idle of 40 50 is acceptable if the optimum range of 25 40 cannot be reached through adj
18. TOR SECM CONNECTOR MALE 2 1 2 E a E 2 RO1 5 8 Qu E 120 Dee Gee ELE E Be 8 3 5 2 EE tae zu a 8 X B Saa a TO DE CY BEE EER EK IE RS OUE DEE EP lt OUTA SA PO UO UV EX Ot t OUS E Os 1 2 3 4 5 6 7 819110 111 12113 14 15116117 18 19 20 21 22 23 24 APP GNDo APP PWR LOW APP20 OIL APP1 FUEL SELECT 5 RELAY 1 N N 2 1 1 FUEL MIL SELECT RELAY 2 Im a N z o N 1 3 seel 1 E o 12VDC A 1 2 3 4 2 344 5 OXYGEN SENSOR TMAP SENSOR GM MODULE COIL PWR ELECTRONIC THROTTLE AB CD cue G Doo 7 123 FUEL SELECT SWITCH A B A B FUEL PUMP FUEL LOCK OFF FUEL TRIM VALVE FUEL INJECTOR Figure E2 G424E G430E Tier Dual Fuel Engine 26 Electrical Connections Resistance Checks NOTE Gi All resistive checks are made with the sensor or device disconnected from the harness CONNECTOR POINT TO POINT EXPECTED RANGE INJ FUEL INJECTOR INJ PIN A SIGNAL TO PIN B 120 4 20 PWR CONNECTOR POINT TO POINT EXPECTED RANGE FUEL PUMP GAS PUMP HOUSING TO CHASSIS 0Q Pump housing should be isolated from chassis ground CONNECTOR POINT TO POINT EXPECTED RANGE VR SENSOR VR PIN 1 TO PIN 2 3200 G424E G430E Tier I Dual Fuel Engine 27 Electrical Connections CHAPTER 7 N CA5
19. ally hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment NOTE provides other helpful information that does not fall under the warning or caution categories gt gt This manual shows just Dual fuel Engine and engine control system for TIER I Gasoline Engine so regarding other ares please refer to the separate manual of SB4136E for G424E TIER I LP Engine and SB4137E for G430E TIER I LP Engine and SB2215E for G424 Engine Basic and SB4005E for G430 Engine Basic G424E G430E Tier Dual Fuel Engine 2 Table of Contents Index CHAPTER 1 ENGINE SPECIFICATION Indication of Engine Serial Number 4 Specifications G424E Dual Fuel Engine 5 Specifications G430E Dual Fuel Engine 7 CHAPTER 2 DUAL FUEL SYSTEM OPERATIONAL OVERVIEW MI 04 General Description 9 04 Dual Fuel Gasoline Delivery System 11 MI 04 Gasoline Fuel Injection 13 CHAPTER 3 MAINTENANCE SCHEDULE RECOMMENDED MAINTENANCE SCHEDULE14 Replace Gasoline Primary and Secondary Fuel Filter 14 Inspect the Fuel Pump Insulated Mounting Clamps rm 15 Maintenance 15 CHAPTER 4 BASIC TROUBLESHOOTING Basic Troubles
20. ar the electric fuel pump running e After 5 seconds the pump should stop running e pump continues to run check the rubber insulation on the electric fuel pump mounting clamps e the housing of the pump makes contact with the engine chassis a ground path be created causing the pump to run anytime the ignition key is in the ON position and the fuel select switch is in GAS position causing pre mature pump failure e clamp insulation is damaged replace the clamp with new insulated clamp Maintenance Schedule Interval Hours Eve Eve Eve Evo CHECK POINT Every Every 500 4000 1000 1500 2500 Daily 250hrs or Hours or Hours a month 3 months Hours or Hours or Hours or or 2 6 months 9months 15 months years Fuel Lock Off Fuel Filter Section LPG amp Gasoline Replace Primary Gasoline X fuel filter Replace Secondary X Gasoline fuel filter Inspect fuel pump X insulated retaining clamps G424E G430E Tier Dual Fuel Engine 15 System Operational Overview CHAPTER 4 BASIC TROUBLESHOOTING Basic Troubleshooting Gasoline The MI 04 systems are equipped with built in fault diagnostics Detected system faults can be displayed by the Malfunction Indicator Lamp MIL and are covered in the Advanced Diagnostics section Items such as fuel level plugged fuel lines clogged fuel filters and malfunctioning pressure regulators
21. el System of G430E Engine Fault Light gm L 9 d LP Fuel Line LP Fuel Filter gt Key switch Fuel Lock Main Foot Pedal PWR bey Fuel Select Relay Converter Air Cleaner i Fuel Trim Valve 59 Mixer Fuel Pump Fuel Injector DBW Throttle Oxygen Sensor r Distributor VR Sensor Oil Pressure Switch Coolant Temp Sensor Catalytic Muffler Figure 10 G424E G430E Tier Dual Fuel Engine 10 System Operational Overview 04 Dual Fuel Gasoline Delivery System A manual fuel select switch enables the forklift operator to choose between LPG or Gasoline operation When the select switch is in the Gasoline position an electric fuel pump supplies the fuel and generates the injection pressure The fuel is pumped through a Primary 60 micron filter to the pump Figure 23 The pump then discharges the fuel at an increased pressure through a Secondary 10 micron filter to a pressure regulator The pressure regulator incorporates a spring loaded diaphragm with no bias signal connected maintaining a constant operating fuel pressure at the metering orifice 270 Kpa regardless of the amount of fuel being injected The electric fuel pump incorporates a G Rotor pumping element driven by an electric motor with permanent magnets an internal check valve to prevent back flow and is mounted external from the fuel tank CAUTION FIRE HAZARD
22. er 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 WARNING Read this entire manual and all other publications pertaining to the work to be performed before in
23. fy that the distributor rotor is lined up with number 1 cylinder on the distributor cap Figure G2 Internal VR Sensor Signal Rotor 3 Remove the distributor rotor and dust cover so that the internal VR sensor and signal rotor gear are visible Figure G3 The internal VR sensor inside the distributor is not used by the SECM for a speed reference with the G420E G424E engine and it s wiring harness does not connect to the system The distributors internal VR sensor is only used as an alignment reference point for setting the correct distributor position Figure G1 G424E G430E Tier I Dual Fuel Engine 34 TEST AND ADJUSTMENTS Signal rotor Incorrect Alignments Flat Side of Shaft 4 Loosen the distributor hold down nut and rotate the distributor so that the signal rotor gear tooth of the 1 cylinder tooth opposite the flat side of the distributor shaft lines up with the sensor pickup Figure G4 Correct Alignment Figure G5 5 To correctly set the distributor align the center of the 1 cylinder tooth with the leading edge of the VR sensor pickup Figure G5 Keep in mind that the distributor rotates in a clockwise direction 6 Once the proper alignment is obtained lock the distributor in place by tightening the hold down nut to the specified torque value and re install the rotor dust cover and rotor cap WARNING AN Improper alignment of the distributor may cause system ignition problems resu
24. hooting Gasoline 16 CHAPTER 5 MI 04 ADVANCED DIAGNOSTICS Fault List 0 22 21 Table a MI 04 Diagnostic Fault Codes Flash Codes a ER DAE DEE SERE ANS 22 CHAPTER 6 ELECTRICAL CONNECTIONS G424E Dual Fuel Electrical Connection 23 G430E Dual Fuel Electrical Connection 25 Resistance Checks 27 G424E G430E Tier Dual Fuel Engine CHAPTER 7 N CA55 500TR AIR FUEL MIXER Installing the Mixer Throttle Assembly G424E Dual 28 Installing the Mixer Throttle Assembly G430E AE EE N 29 CHAPTER 8 TEST AND ADJUSTMENTS Testing the Gasoline Fuel Delivery System 31 Timing Adjustment G424E LP and Dual Fuel AAR 34 Ignition Timing Adjustment 34 Timing Adjustment G430E Dual Fuel Engine 37 Idle Mixture 40 CHAPTER 9 SERVICE TOOL KIT Table of Contents CHAPTER 1 ENGINE SPECIFICATION Indication of Engine Serial Number G424E Dual Fuel Engine G424E G430E Tier Dual Fuel Engine 4 Engine Specification Specifications G424E Dual Fuel Engine GENERAL DESCRIPTION ENGINE TYPE Water cooled Inline 4 Cycle 4 Cylinders COMBUSTION SYSTEM Naturally Aspirated 1 Venturi Intake Manifold Semi spherical Combustion chamber
25. ill go active This will pulse the injector for 7 seconds when the engine is not running CAUTION Running the injector test with the injector installed in the throttle adapter will discharge raw gasoline into the intake manifold and could result in excessive engine wear through misfire or loss of lubrication G424E G430E Tier I Dual Fuel Engine 33 TEST AND ADJUSTMENTS Timing Adjustment G424E 1 Using the timing indicator on the crankshaft pulley set the engine on 0 degrees Top Dead Center LP and Dual Fuel Engine TDC of number 1 cylinder Figure G1 Distributor with Rotor Cap Removed Ignition Timing Adjustment With the MI 04 system both mechanical and vacuum advance are no longer inside the distributor All ignition timing advance is controlled by the SECM The only timing adjustment that can be made by a technician is the mechanical alignment of the distributor The SECM uses a 40 degree timing window from 5 degrees BTDC to 35 degrees BTDC Because of this an accurate adjustment cannot be made with a standard timing light since the SECM will maintain the correct timing even if the distributor is moved as long as the distributor setting remains within the 40 degree window Therefore the ignition timing setting of the distributor becomes very important and is described in the following steps Timing Wheel at 0 degrees TDC Firing Order 1 3 4 2 Figure G2 2 Remove the distributor rotor cap and veri
26. injector driver signal is open due to the connector becoming disconnected Low Oil Pressure Low Oil Pressure the oil pressure switch has closed or become failed normally indicating a low oil condition in the engine G424E G430E Tier Dual Fuel Engine 21 Advanced Diagnostics Table a Probable Fault Action 04 Diagnostic Fault Codes Flash Codes Corrective Action First Check Injector Fault Stored Fault Code MIL Disable Adaptive learns Check Injector INJ for an open wire or injector connector being disconnected INJ PIN A SIGNAL TO PIN B PWR Check INJ for an open coil by disconnecting the INJ connector and measuring the coil resistance 12Q 20 INJ PIN A SIGNAL TO PIN B PWR Low Oil Pressure Low Engine Oil Pressure Delayed Engine Shutdown Check engine oil level Check electrical connection to the oil pressure switch SECM PIN 23 to Oil Pressure Switch Running Reset G424E G430E Tier Dual Fuel Engine Stored Fault Code Reset Counter to be incremented 22 Check to ensure that proper grounding of the harnessing has been achieved Check to ensure that there are no intermittent connections in the electrical harness or associated connections Check for interruptions in Vbatt supply to the SECM Check to ensure that the ignition system distributor coil cap rotor plugs and high tension leads is operating normally Advanced Diagnostics
27. ition timing advance is controlled by the SECM The only timing adjustment that can be made by a technician is the mechanical alignment of the distributor The SECM uses a 40 degree timing window from 5 degrees BTDC to 35 degrees BTDC Because of this an accurate adjustment cannot be made with a standard timing light since the SECM will maintain the correct timing even if the distributor is moved as long as the distributor setting remains 4 within the 40 degree window Therefore the ignition es timing setting of the distributor becomes very 4 NEN important and is described in the following steps ET X b f di Bes N _ N E Proper Distributor Alignment Rotor Alignment i Arrow Figure G1 Module Housing Arrow 1 Using the timing indicator on the crankshaft pulley set the engine on 0 degrees Top Dead Center TDC of number 1 cylinder Figure G1 2 Remove the distributor rotor cap and verify that the distributor rotor is lined up with number 1 cylinder on the distributor cap Figure G2 3 The internal distributor alignment arrows are now visible Figure G3 The internal crank signal from the GM ignition module is not used by the SECM for a speed reference with the 3 0L engine The distributors internal alignment arrows are only used as an alignment reference point for setting the correct distributor position within the timing window 4 Loosen the distributor hold do
28. k pick up tube to the fuel pump anything less may cause the pump to cavitate allowing air into the fuel system A primary 100 micron fuel filter is used inline before the electric fuel pump and a 10 micron secondary fuel filter is used between the fuel pump and the fuel pressure regulator The regulator does not use a bias control signal on the diaphragm and always supplies a constant pressure When fuel pressure is too high the regulator routes excessive fuel through the return line back to the fuel tank Regulated fuel pressure is supplied from the regulator outlet exits to the fuel injector The fuel lines from the fuel pump to the injector are under pressure even when the engine is not running and care should be taken when disconnecting these fuel lines as pressurized fuel will be discharged Fuel Tank Outlet 1 Filter to Pump Pump to 2 Filter Regulator Inlet Return to Tank Fuel Tank Outlet Figure F1 NOTE 1 Pump filter regulator mounting locations as shown specific to G20 25 30E 3 lift trucks G424E G430E Tier I Dual Fuel Engine 31 TEST AND ADJUSTMENTS The return line from the regulator to the fuel tank is not under pressure and can safely be removed without pressurized fuel spray Verify that the Fuel Selector Switch is in the Gasoline position before performing the following tests A fuel pressure tap is not provided the MIO4 gasoline system In order to check the operating fuel
29. l Engine 18 Test Injector operation See Tests and Adjustments Basic Troubleshooting Problem Probable Cause Corrective Action Will Not Accelerate Hesitation During Acceleration or Engine Stalls Gas Throttle butterfly valve not opening or sticking Foot Pedal signal incorrect or intermittent Incorrect air fuel or ignition control See Advanced Diagnostics Engine Mechanical See Engine Manufacturers Service Manual Rough Idle Gas Isolate the gasoline system by running the lift truck on LPG Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in LPG mode then the root cause is most likely to be something other than the fuel system See Advanced Diagnostics amp Tests and Adjustments Pressure regulator malfunction Test pressure regulator operation See Tests and Adjustments Clogged fuel filter Repair replace as required See Primary and Secondary Fuel Filter replacement Pressure regulator malfunction Test pressure regulator operation See Tests and Adjustments Fuel Injector malfunction Test Injector operation See Tests and Adjustments Vacuum leak G424E G430E Tier Dual Fuel Engine 19 Check for vacuum leaks Between mixer and throttle body Between throttle body and intake manifold Between i
30. lting in ignition misfires or backfires G424E G430E Tier I Dual Fuel Engine 35 TEST AND ADJUSTMENTS Figure G8 7 After you have completed setting the distributor alignment you will need to adjust the VR sensor used by the SECM for speed reference This sensor is mounted near the crankshaft pulley Using a feeler gauge Figure G8 loosen the sensor retaining bolts and adjust the gap between the sensor and the gear tooth from 1 25mm to 1 5mm Re tighten the sensor retaining bolts wheel Figure G6 when complete 10 Rotate the crankshaft pulley 180 degrees and align a timing gear tooth in the center of the VR sensor pickup as you did in step 8 Verify that the sensor gap is still within 1 25mm to 1 5mm This step is to check timing gear run out and insures proper speed signal amplitude 1 the VR sensor gap is not within the specification repeat steps 9 amp 10 and continue adjusting the sensor gap until you are within tolerance This completes setting ignition timing and sets the center of the SECM ignition control range at 15 Figure G7 a degrees BTDC 8 Rotate the crankshaft pulley so that one of the gear teeth on the timing wheel aligns in the center of the VR sensor Figure G7 G424E G430E Tier I Dual Fuel Engine 36 TEST AND ADJUSTMENTS Timing Adjustment G430E Dual Fuel Engine ENGINE With the 04 system both mechanical and vacuum advance are no longer inside the distributor All ign
31. mply disconnect the electrical harness from the fuel injector and connect the Noid test light to the end of the harness in place of the injector Crank the engine with the ignition key and you will see the Noid light flash every time the SECM sends a signal to the fuel injector to open and spray fuel If SECM pulses are not present at the injector and a DFC code 51 Injector Fault has not been set the Fuel Select Relay 1 may be at fault When the Fuel Select Switch is placed in the Gas position a low or ground signal is supplied through the switch to PIN 8 of the SECM This ground signal informs the SECM that the lift truck should operate in Gasoline mode When the SECM PIN 8 input is low the SECM PIN 21 output becomes low supplying the ground signal to the coil of both the 1 and 2 Fuel Select Relays Voltage 12 VDC is supplied to one side of the coil for both the 1 and 2 Fuel Select Relays when the key switch is in the ON position When the 1 Fuel Select Relay coil is energized the relay will switch SECM PIN 12 output from the FTV to the fuel injector The SECM PIN 12 output signal supplies the fuel injector with the correct drive pulses NOTE Refer to Electrical Connections for the system wiring schematic of the Fuel Select Relays TEST AND ADJUSTMENTS If the Noid light shows valid signals from the SECM to the injector a final visual check of the fuel injector can be made TESTS T Disapied INJECTOR T
32. nal The larger the gap between the sensor and the flywheel the smaller the amplitude of the speed signal If the gap is too small the VR sensor will make contact with the flywheel and become damaged during operation Therefore it is necessary to adjust the VR sensor for proper operation TEST AND ADJUSTMENTS 9 With the engine timing still at 0 degrees TDC the VR sensor will align between the machined timing marks the flywheel Figure G8 Loosen the VR sensor locknut and adjust the sensor inward toward the flywheel until the sensor makes contact with the flywheel Flywheel surfa between the timing marks 10 Once the VR sensor makes contact with the flywheel back the sensor outwards 1 turn and tighten down the sensor locknut This should adjust the sensor signal strength within the proper range This completes setting ignition timing and sets the center of the SECM ignition control range WARNING Improper assemble of VR sensor may cause VR sensor failure G424E G430E Tier I Dual Fuel Engine 39 TEST AND ADJUSTMENTS Idle Mixture Adjustment P Figure G7 The method for making the idle mixture adjustment to a running engine is to use the Service Tool software by connecting a laptop computer to the SECM If you do not have the Service Tool a multimeter capable of measuring Duty Cycle such as a Fluke 87 can be used Connect the meter positive lead to between battery positive and the meter negative to
33. ngine components G424E G430E Tier I Dual Fuel Engine 12 System Operational Overview 04 Gasoline Fuel Injection A single Seimens high flow fuel injector is used to inject fuel into the LPG mixer to throttle adapter Intake air to the engine continues to flow through the LPG mixer however propane is not supplied to the mixer while in gasoline operation A booster venturi Figure 27 inside the adapter receives the fuel from the injector and distributes it into the air stream before the throttle valve The VR signal from the 30 5 timing wheel located on the crankshaft pulley is used by the SECM as an engine position reference for correct operation of the injector The SECM uses the measured air fuel ratio from the oxygen sensor to control the amount of fuel delivered by the injector Figure 27 A view of a separate injector venturi used in a two piece throttle adapter is shown in Figure 28 for a clearer description The MI 04 dual fuel throttle adapter uses a single piece adapter where the venturi cannot be removed Figure 28 G424E G430E Tier Dual Fuel Engine 13 In Figure 29 the fuel injector is shown out of the throttle body adapter A spacer is used on the tip of the injector to properly seat the injector with the venturi o ring Figure 29 System Operational Overview CHAPTER 3 MAINTENANCE SCHEDULE RECOMMENDED MAINTENANCE SCHEDULE Suggested maintenance requirements for an engine equipped wi
34. ntake manifold and cylinder head Basic Troubleshooting Problem Probable Cause Corrective Action Rough Idle Gas Incorrect Idle speed control Incorrect timing or spark control See Advanced Diagnostics amp Tests and Adjustments Engine Mechanical See Engine Manufacturers Service Manual High Idle Speed Gas Incorrect Idle speed control Throttle sticking See Advanced Diagnostics amp Tests and Adjustments Foot pedal sticking or incorrect pedal signal Check pedal return spring travel for binding See Advanced Diagnostics Poor High Speed Performance Gas Isolate the gasoline system by running the lift truck on LPG Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in LPG mode then the root cause is most likely to be something other than the fuel system See Advanced Diagnostics amp Tests and Adjustments Clogged fuel filter Repair replace as required See Fuel Filter replacement Plugged fuel line Remove obstruction from the fuel line Close liquid fuel valve Using caution disconnect the fuel line some propane may escape Clear obstruction with compressed air Re connect fuel line Slowly open liquid fuel valve amp Leak test Air filter clogged Check air filter Clean replace as required Faulty
35. pty Fuel Pump Cavitations The tank should be at least full to properly prime the fuel pump Fuel select switch is not on GAS Clogged fuel filter Repair replace as required See Primary and Secondary Fuel Filter replacement Electric Fuel Pump malfunction GAS Check electrical connection Check Relay and fuse Turn key ON and verify pump is operating See Tests and Adjustments Pressure regulator malfunction Test pressure regulator operation See Tests and Adjustments Fuel Injector malfunction Test Injector operation See Tests and Adjustments Air filter clogged Check air filter Clean replace as required Incorrect air fuel or ignition control See Advanced Diagnostics Engine Mechanical See Engine Manufacturers Service Manual Will Not Run Continuously Gas Isolate the gasoline system by running the lift truck on LPG Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in LPG mode then the root cause is most likely to be something other than the fuel system See Advanced Diagnostics Fuel tank almost empty Fuel Pump Cavitations The tank should be at least full to properly prime the fuel pump Clogged fuel filter G424E G430E Tier Dual Fuel Engine 17 Repair replace as required See Primary and Secondary F
36. ressure Switch Coolant Temp Sensor Catalytic Muffler Figure 10 G424E G430E Tier Dual Fuel Engine 9 System Operational Overview The SECM makes any necessary corrections to the air fuel ratio by controlling the inlet fuel pressure to the air fuel mixer by modulating the fuel trim valve FTV connected to the regulator Reducing the fuel pressure leans the air fuel mixture and increasing the fuel pressure enriches the air fuel mixture To calculate any necessary corrections to the air fuel ratio the SECM uses a number of different sensors to gain information about the engines performance Engine speed is monitored by the SECM through a variable reluctance VR sensor Intake manifold air temperature and absolute pressure is monitored with a TMAP sensor The MI 04 is a drive by wire DBW system connecting the accelerator pedal to the electronic throttle through the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle position in relation to the accelerator pedal position sensor APP feedback Even engine coolant temperature and adequate oil pressure is monitored by the SECM The SECM controller has full adaptive learning capabilities allowing it to adapt control function as operating conditions change Factors such as ambient temperature fuel variations ignition component wear clogged air filter and other operating variables are compensated 04 Dual Fu
37. stalling operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage The engine or other type of prime mover should be equipped with an over speed over temperature or overpressure where applicable shutdown device s that operates totally independently of the prime mover control device s to protect against runaway or damage to the engine or other type of prime mover with possible personal injury or loss of life should the mechanical hydraulic governor s or electric control s the actuator s fuel control s the driving mechanism s the linkage s or the controlled device s fail CAUTION To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards e Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS WARNING indicates a potenti
38. th an MI 04 fuel system are contained in this section The owner should however develop his own maintenance schedule using the requirements listed in this section and any other requirements listed by the engine manufacturer G424E G430E Tier I Dual Fuel Engine Replace Gasoline Primary and Secondary Fuel Filter Elements Gasoline Filter Park the lift truck in an authorized refueling area with the forks lowered parking brake applied and the transmission in Neutral 1 Place the fuel select switch in the Gasoline position Remove the fuel select relay 2 for the electric fuel pump Start and run the engine until the fuel in the system runs out of fuel and the engine stops 2 Turn off the ignition switch 3 Replace the fuel filter taking care to install the new filter with flow in the proper direction When replacing the Primary fuel filter use a hose clamp between the tank and the filter to prevent fuel from spilling during replacement 4 Prefilling the primary gasoline filter with fuel will greatly reduce the cranking time necessary to prime the pump anytime the primary gasoline filter or pump is drained for service 5 Re install the fuse for the pump and crank the engine several times before attempting a start to prime the fuel pump System Operational Overview Inspect the Fuel Pump Insulated Mounting Clamps e the ignition key to the ON position without cranking the engine you should he
39. uel Filter replacement Basic Troubleshooting Problem Probable Cause Corrective Action Will Not Run Continuously Gas Electric Fuel Pump malfunction GAS Check electrical connection Check Relay and fuse Turn key ON and verify pump is operating See Tests and Adjustments Pressure regulator malfunction Test pressure regulator operation See Tests and Adjustments Fuel Injector malfunction Test Injector operation See Tests and Adjustments Incorrect idle speed or ignition problem See Advanced Diagnostics Engine Mechanical See Engine Manufacturers Service Manual Will Not Accelerate Hesitation During Acceleration or Engine Stalls Gas Isolate the gasoline system by running the lift truck on LPG Verify LPG cylinder is full and valve is open If the problem does not exist in LPG mode proceed with the corrective action steps below If the problem also exists in LPG mode then the root cause is most likely to be something other than the fuel system See Advanced Diagnostics Fuel tank almost empty Fuel Pump Cavitations The tank should be at least full to properly prime the fuel pump Clogged fuel filter Repair replace as required See Primary and Secondary Fuel Filter replacement Pressure regulator malfunction Test pressure regulator operation See Tests and Adjustments Fuel Injector malfunction G424E G430E Tier Dual Fue
40. ustment If the FTV Duty Cycle cannot be adjusted below 50 the mixer is faulty and should be replaced 12 Turn the ignition key to the OFF position to shut down the engine G424E G430E Tier Dual Fuel Engine 41 Idle Mixture Screw Tamper Proof Cap Figure 29 13 Install the tamper proof cap on the idle mixture screw adjustment port so that no further adjustments can be made Figure 29 NOTE If the FTV Duty Cycle reading is cannot be adjusted between 25 40 check for possible vacuum leaks manifold leaks or a faulty mixer TEST AND ADJUSTMENTS CHAPTER 9 SERVICE TOOL KIT A343079 USB Universal Serial Bus to CAN Controller Area Network Converter Assembly A343080 Service Tool Software includes CD and Crypt Token License Dongle A334071 Extension Cable L 200cm A334082 Extension Cable L 20cm G424E G430E Tier Dual Fuel Engine 42 Service Tool Kit
41. wn bolt and rotate the distributor so that the module housing arrow aligns with the rotor arrow as shown in Figure G3 G424E G430E Tier I Dual Fuel Engine 37 TEST AND ADJUSTMENTS 5 Once the alignment arrows are adjusted as shown in Figure G3 the outside corner of the distributor housing should not align with the distributor reference mark on the engine block and should resemble the alignment as shown in Figure G4 Once the proper alignment is obtained lock the distributor in place by tightening the hold down nut to the specified torque value and re install the distributor rotor cap Figure G4 WARNING Improper alignment of the distributor may cause system ignition problems resulting in ignition misfires or backfires G424E G430E Tier I Dual Fuel Engine 38 7 After you have completed setting the distributor alignment you will need to adjust the VR sensor used by the SECM for speed reference This sensor is mounted in the bell housing of the flywheel at the bottom of the engine Circular timing reference marks have been precisely machined into the surface of the flywheel Figure G6 The MI 04 VR sensor will use these machined marks for speed reference Figure G6 Magnetic Eines Of Machined Timing Mark Permanent Flywheel Magnet Housing 8 Figure G7 shows a functional diaghram of the VR sensor and the principle of operation The sensor will detect each timing mark in the flywheel and output a sig
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